Case Study: Quality Control Breakdown on Philadelphia Highway Reconstruction (Pennsylvania, 2021)

Project Overview
• Name: I-95 Reconstruction
• Location: Philadelphia, Pennsylvania
• Year: 2021
• Project Size: $500 million
• Scope: Reconstruction of highway pavement and bridges
• Lead Agencies/Contractors: Pennsylvania Department of Transportation (PennDOT) /

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

Summary of the Issue, Problem, or Challenge
Non-compliance with asphalt mix specifications led to premature pavement failure requiring removal and replacement.

Root Cause Analysis

• Poor communication of mix design changes to contractors.
• Inconsistent material testing and acceptance criteria enforcement.
• Lack of independent verification of mix quality.
• Inadequate training on QC requirements for paving crews.

Impacts Due to the Issue, Problem, or Challenge

• Delay of 4 months due to removal and repaving.
• Increased project costs and resource use.
• Reduced pavement durability and increased maintenance liability.

Corrective Actions Taken

1. Clarified and enforced mix design specifications rigorously.
2. Increased frequency of independent material testing and acceptance.
3. Provided targeted training for paving crews and QC staff.
4. Implemented real-time testing and documentation systems.

Lessons Learned

• Consistent specification enforcement prevents premature failures.
• Independent testing enhances QC reliability.
• Training improves adherence to quality standards.

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

• Are mix designs clearly communicated and enforced?
• Is independent testing part of the QC process?
• Are paving crews adequately trained and supervised?