Case Study: Subcontractor Delay in Steel Fabrication Impacts Bridge Construction in Washington State (2019)

Project Overview
• Name: Tacoma Narrows Bridge Expansion
• Location: Tacoma, Washington
• Year: 2019
• Project Size: $580 million
• Scope: Bridge widening with major steel components
• Lead Agencies/Contractors: Washington DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Scheduling & Supply Chain

Summary of the Issue, Problem, or Challenge
The steel fabrication subcontractor missed critical delivery dates due to production bottlenecks and material shortages, causing a 5-week delay in bridge erection.

Root Cause Analysis

• Insufficient capacity planning and scheduling by subcontractor.
• Delays in steel supply due to vendor issues.
• Poor communication between subcontractor and prime contractor.
• Lack of contingency planning for production disruptions.

Impacts Due to the Issue, Problem, or Challenge

• Schedule slippage impacting overall project timeline.
• Increased labor and equipment rental costs.
• Contractual disputes and penalty exposure.

Corrective Actions Taken

1. Revised production scheduling and capacity planning.
2. Diversified steel suppliers to reduce material risk.
3. Improved communication protocols and progress reporting.
4. Developed contingency plans for supply chain disruptions.

Lessons Learned

• Accurate production and supply planning prevent delays.
• Strong supplier relationships reduce material risks.
• Transparent communication between all parties is essential.

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

• Are subcontractor fabrication schedules realistic and monitored?
• Are material suppliers vetted and alternatives prepared?
• Is communication proactive and frequent?