Case Study: Skilled Trades Shortage Delays Ohio River Bridge Pile Driving (2019)

Project Overview
• Name: Ohio River Bridge Replacement
• Location: Cincinnati, Ohio
• Year: 2019
• Project Size: $375 million
• Scope: Replacement of a major river crossing including deep foundation pile driving and superstructure erection
• Lead Agencies/Contractors: Ohio DOT /

Category of the Issue, Problem, or Challenge
• Skilled Trades Shortage
• Workforce Planning

Summary of the Issue, Problem, or Challenge
Pile driving crews with specialized rig operators and laborers certified for marine and deep foundation work were in short supply. High demand in the Midwest region caused crew shortages that delayed foundation completion.

Root Cause Analysis

• Limited certified pile driving operators regionally available due to concurrent projects.
• Contractor’s labor forecasting underestimated specialized crew requirements.
• Training pipeline for marine foundation trades was insufficient to meet demand.
• Delayed vendor equipment mobilization compounded labor scheduling challenges.

Impacts Due to the Issue, Problem, or Challenge
• Delay of 4 months on foundation works, impacting critical path.
• Increased costs related to labor overtime and equipment standby fees (~$3.8 million).
• Re-sequencing of subsequent superstructure works required.

Corrective Actions Taken

1. Contracted supplemental crews from other states with relocation support.
2. Developed accelerated training programs for foundation laborers and rig operators.
3. Adjusted project schedule to allow overlapping non-dependent activities during pile delays.

Lessons Learned

• Deep foundation trades require specialized labor forecasting and early recruitment.
• Training and certification pathways need to be developed regionally for niche trades.
• Project schedules must be flexible to absorb specialized labor shortages.

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

• Has the labor demand for specialized trades been accurately forecasted?
• Are training and certification programs available or planned for niche trades?
• Does the schedule accommodate delays due to specialized labor shortages?