Case Study: Welding Quality Control Failures on New York Harbor Bridge Construction (New York, 2014)

Project Overview
• Name: New York Harbor Bridge Replacement
• Location: New York
• Year: 2014
• Project Size: $1.1 billion
• Scope: Replacement of key bridge spans with complex steel structures
• Lead Agencies/Contractors: New York State Department of Transportation (NYSDOT) /

Category of the Issue, Problem, or Challenge
• Quality Control
• Structural
• Project Delay

Summary of the Issue, Problem, or Challenge
Non-compliance with welding procedures and lack of qualified weld inspectors resulted in defective welds requiring partial demolition and re-welding.

Root Cause Analysis

• Welders lacked up-to-date certification for specific welding procedures.
• Welding procedure specifications (WPS) were not adequately followed or enforced.
• Insufficient supervision and inspection during welding operations.
• Poor record-keeping on weld inspections and repairs.

Impacts Due to the Issue, Problem, or Challenge

• Delay of 6 months due to demolition and corrective welding.
• Significant cost overruns related to rework and inspection.
• Heightened scrutiny from regulatory agencies and stakeholders.

Corrective Actions Taken

1. Re-certified all welders on applicable procedures.
2. Strengthened enforcement of welding procedure compliance.
3. Increased frequency and rigor of welding inspections.
4. Implemented improved documentation and traceability of weld quality.

Lessons Learned

• Welding quality control is critical for structural safety.
• Certified personnel and strict adherence to procedures prevent defects.
• Accurate documentation supports accountability and traceability.

Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation

• Are welders certified and procedures strictly enforced?
• Are welding inspections frequent and rigorous?
• Is weld documentation complete and accessible?