Case Study: Houston I-69 Expansion Design Conflicts Delay Construction (2018)

Project Overview
• Name: I-69 Corridor Expansion
• Location: Houston, Texas
• Year: 2018
• Project Size: $1.2 billion
• Scope: Widening and reconstruction of interstate highway segments
• Lead Agencies/Contractors: Texas DOT /

Category of the Issue, Problem, or Challenge
• Design
• Highway Engineering

Summary of the Issue, Problem, or Challenge
Conflicting design standards between state DOT and federal requirements led to multiple redesigns of interchange layouts and drainage systems during construction, causing schedule impacts and cost increases.

Root Cause Analysis

• Inadequate harmonization of design standards at project outset.
• Overlapping jurisdictional requirements not fully reconciled.
• Delayed identification of conflicting criteria during design phase.
• Lack of proactive stakeholder engagement in design decisions.

Impacts Due to the Issue, Problem, or Challenge
• Project delays of 5 months.
• Cost increases estimated at $14 million.
• Increased administrative burden and coordination complexity.

Corrective Actions Taken

1. Established a design standards reconciliation committee.
2. Enhanced communication protocols between state and federal agencies.
3. Introduced early multi-agency design review workshops.
4. Integrated conflict resolution mechanisms into project governance.

Lessons Learned

• Early alignment of design standards avoids costly mid-construction changes.
• Multi-agency cooperation is critical for regulatory compliance.
• Proactive stakeholder engagement prevents oversight of conflicting requirements.
• Structured governance supports timely resolution of design conflicts.

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

• Are all applicable design standards identified and reconciled early?
• Are state and federal agencies actively collaborating during design?
• Are multi-agency design reviews embedded in the process?
• Are mechanisms for conflict resolution clearly defined and enforced?