Case Study: New Jersey Turnpike Widening – Design-Bid-Build Delivery Issues (2012)
Project Overview
• Name: New Jersey Turnpike Widening
• Location: New Jersey
• Year: 2012
• Project Size: $2.2 billion
• Scope: Widening and reconstruction of a major interstate highway using Design-Bid-Build
• Lead Agencies/Contractors: New Jersey Turnpike Authority /
Category of the Issue, Problem, or Challenge
• Project Delivery Method
• Design-Bid-Build
Summary of the Issue, Problem, or Challenge
Sequential design and bidding phases led to long delays and cost overruns as design errors and constructability issues emerged only after contract award, requiring redesigns and change orders during construction.
Root Cause Analysis
- Lack of constructability reviews during design phase.
- Disconnected communication between design engineers and contractors.
- Design errors not identified until after contract award.
- Change orders generated from unresolved design and site condition issues.
Impacts Due to the Issue, Problem, or Challenge
• Project delay of 10 months due to redesign and rework.
• Cost overruns approaching $40 million.
• Reduced contractor confidence and productivity due to scope changes.
Corrective Actions Taken
- Incorporated constructability reviews in subsequent projects.
- Improved pre-bid design quality control and error checking.
- Enhanced communication between design and construction teams.
- Considered alternative delivery methods for complex future projects.
Lessons Learned
- Design-Bid-Build can lead to late discovery of design issues impacting schedule and cost.
- Early constructability input is essential to minimize redesign risk.
- Effective communication between designers and contractors improves project outcomes.
- Delivery method choice must consider project complexity and risk profile.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are constructability reviews embedded in the design process?
- How are design-construction communications managed before bid?
- Are risks of design errors addressed prior to contract award?
- Has the project delivery method been evaluated against project complexity?