Well, I was working with a soprano a couple of days ago, and when she belted out her top C I can confirm that it was loud enough to bring a rush of blood to my head, if you know what I mean - exciting, in other words - but from approx 3 feet away it wasn't too uncomfortable on the ear (I didn't ask her to do it any closer!) That was in a room in my house.
Another time, last year, I was rehearsing with a baritone in a dance studio, and from a few feet away the sound was sometimes really, uncomfortably loud. This led me to believe that quite a large proportion of the sound one hears is actually reflected, rather than direct. The dance studio, which had a very bright acoustic, seemed to emphasise the higher frequencies caused by the vibrato, so the voice may not have been too loud, but the reflections certainly were in that space. On the stage, therefore, I think the voice up close may not in actual fact be as loud as it might
seem to be from the auditorium, where it benefits from all the reflections of the sound. That's my theory, anyway. Also, in theatres that are not particularly well designed for opera (like the Royal Lyceum in Edinburgh for example) a lot of the voice is absorbed by the surfaces of the theatre (and the bodies of the audience) rather than reflected, so that the sound does not project so well.
I second Reiner's comments about opera production, by the way.