Case Study: Subcontractor Welding Quality Issues Cause Structural Delays in Oregon (2019)

Project Overview
• Name: Portland Bridge Rehabilitation
• Location: Portland, Oregon
• Year: 2019
• Project Size: $230 million
• Scope: Bridge deck and structural steel rehabilitation
• Lead Agencies/Contractors: Oregon DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Quality Control – Welding

Summary of the Issue, Problem, or Challenge
Welding subcontractor produced welds that did not meet strength and inspection criteria, requiring extensive repairs and rework, delaying the project.

Root Cause Analysis

• Insufficient welder certification and oversight.
• Inconsistent adherence to welding procedures.
• Lack of timely non-destructive testing during fabrication and erection.
• Poor communication between subcontractor QC and prime contractor inspectors.

Impacts Due to the Issue, Problem, or Challenge

• 8-week delay due to weld repairs and retesting.
• Increased costs for labor, materials, and inspection.
• Potential risk to structural integrity if uncorrected.

Corrective Actions Taken

1. Re-certified all welders and enforced strict procedure compliance.
2. Increased frequency of non-destructive testing.
3. Strengthened communication channels between subcontractor QC and prime contractor.
4. Engaged third-party inspectors for independent verification.

Lessons Learned

• Welding quality is critical to structural safety and schedule adherence.
• Continuous inspection and testing during construction prevent costly rework.
• Clear communication between QC teams improves issue detection and resolution.

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

• Are welders properly certified and monitored?
• Is NDT performed regularly and documented?
• Are QC teams from subcontractor and prime contractor effectively communicating?