Case Study: Skilled Asphalt Paving Crew Shortage Slows Phoenix Highway Rehabilitation (2019)
Project Overview
• Name: Phoenix I-10 Highway Rehabilitation
• Location: Phoenix, Arizona
• Year: 2019
• Project Size: $180 million
• Scope: Highway surface rehabilitation including asphalt paving and milling
• Lead Agencies/Contractors: Arizona Department of Transportation (ADOT) /
Category of the Issue, Problem, or Challenge
• Skilled Trades Shortage
• Asphalt Paving and Surfacing
Summary of the Issue, Problem, or Challenge
The project was delayed due to difficulty securing enough experienced asphalt paving crews during peak construction season. Labor demand surged regionally, impacting crew availability.
Root Cause Analysis
- Seasonal labor demand peaks strained paving labor availability.
- Limited local pool of skilled paving operators and finishers.
- Inadequate early recruitment planning for peak seasons.
- Owner’s tight project timeline with minimal schedule flexibility.
Impacts Due to the Issue, Problem, or Challenge
• 2.5-month delay in paving and surfacing activities.
• Increased costs for overtime and premium labor rates (~$1.9 million).
• Pressure on project closeout and quality assurance phases.
Corrective Actions Taken
- Developed labor-sharing agreements with nearby projects to optimize crew allocation.
- Enhanced recruitment and retention incentives for paving crews.
- Adjusted schedule to better align paving work with labor availability.
Lessons Learned
- Peak season labor demand requires proactive resource planning.
- Inter-project labor coordination can mitigate shortages.
- Schedule flexibility reduces risk from labor market fluctuations.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Has labor demand been forecast to account for seasonal peaks?
- Are labor-sharing or crew pooling agreements feasible?
- Is the project schedule aligned with labor availability?