Case Study: QC Failures in Precast Concrete Panel Installation on Seattle Viaduct Replacement (Washington, 2019)

Project Overview
• Name: Alaskan Way Viaduct Replacement
• Location: Seattle, Washington
• Year: 2019
• Project Size: $3.3 billion
• Scope: Precast concrete panel installation for elevated highway segments
• Lead Agencies/Contractors: Washington State Department of Transportation (WSDOT) /

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

Summary of the Issue, Problem, or Challenge
Misalignment and surface damage to precast panels during installation caused rework and project delays.

Root Cause Analysis

• Insufficient pre-installation inspection and handling protocols.
• Lack of coordination between lifting crews and installation teams.
• Inadequate training on panel handling to prevent damage.
• Poor documentation of QC checks during installation.

Impacts Due to the Issue, Problem, or Challenge

• Delay of 4 months due to rework and replacement of damaged panels.
• Increased costs for repairs, labor, and schedule impacts.
• Risk of structural integrity issues if damaged panels were accepted.

Corrective Actions Taken

1. Developed comprehensive handling and installation procedures for precast panels.
2. Enhanced coordination between lifting and installation crews.
3. Provided targeted training on safe handling and damage prevention.
4. Increased inspection and documentation during installation phases.

Lessons Learned

• Careful handling and inspection prevent costly damage to precast elements.
• Clear communication between crews is essential for quality installation.
• Documentation supports accountability and corrective action.

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

• Are handling and installation procedures clearly defined and followed?
• Is there effective coordination between all involved crews?
• Are inspection results documented thoroughly?