Case Studies and Preconstruction Practices
From cost estimating to project scheduling, and other project control discussions.
Project Controls
- What are construction case studies, and how valuable are they?
- Have you or your team ever incorporated the review of relevant case studies into your preconstruction practices?
- Would access to over 300 case studies of actual heavy civil construction issues, problems, or challenges be of any value to you?
Case studies are utilized in the medical field, business management, manufacturing, the construction industry, and many other areas. There are also various formats of case studies.
A case study on construction issues, problems, and challenges can be created as a one-pager that construction students and professionals can read and understand in 10 minutes or less.
We have compiled over 300 heavy civil construction case studies, each just a page long, containing relevant sections that make them easy to incorporate into construction program classrooms and to use by construction professionals in the field.
The case studies are one-pagers based on actual heavy civil construction projects. They include sections such as project stats, a summary of the issue, root cause analysis, impacts, lessons learned, corrective measures, and audit and prevention questions.
Our case study format can be used for critical thinking exercises in educational settings or as a knowledge base for construction professionals.
Our goal in adding heavy civil construction case studies to our webbook is to show readers real issues, problems, or challenges that happen on heavy civil projects. We want to raise awareness of what can go wrong in heavy civil projects, help readers learn from these situations, and avoid making the same mistakes. We believe that using heavy civil construction case studies will encourage reflective practice.
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Below are a few of the case studies from the catalog of heavy civil construction case studies.
Case Study Related to Differing Site Condition
Case Study: Unforeseen Glacial Till Layers Impact Highway Foundation in Minnesota (2017)
Project Overview
• Name: I-94 Expansion Project
• Location: Minneapolis, Minnesota
• Year: 2017
• Project Size: $350 million
• Scope: Highway widening with deep foundation systems
• Lead Agencies/Contractors: Minnesota DOT, contractors
Category of the Issue, Problem, or Challenge
• Geotechnical
• Differing Site Conditions
Summary of the Issue, Problem, or Challenge
Unexpected thick layers of dense glacial till with high shear strength were encountered, complicating excavation and pile driving efforts.
Root Cause Analysis
- Preliminary borings underestimated thickness and density of glacial till.
- Limited use of cone penetration tests (CPT) for soil profiling.
- Contract lacked provisions for dealing with hard, abrasive soils.
Impacts Due to the Issue, Problem, or Challenge
- Schedule delay of 4 months due to slower excavation and pile installation.
- Increased equipment wear and replacement costs.
- Additional costs for specialized drilling techniques and tooling.
Corrective Actions Taken
- Conducted detailed CPT and geophysical surveys for better soil characterization.
- Utilized specialized heavy-duty drilling rigs and wear-resistant drill bits.
- Revised project schedule and contract terms to accommodate subsurface challenges.
- Implemented enhanced contractor communication on soil variability risks.
Lessons Learned
- Accurate characterization of glacial till requires advanced geotechnical tools like CPT.
- Contracts must address hard soil conditions to allocate risks fairly.
- Equipment selection should consider abrasive soil impact.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Have CPT or similar profiling tests been performed?
- Are drilling equipment and tooling suitable for hard soils?
- Do contracts address differing site conditions such as glacial till?
Case Study Related to Subcontract Work
Case Study: Subcontractor Welding Quality Issues Cause Structural Delays in Oregon (2019)
Project Overview
• Name: Portland Bridge Rehabilitation
• Location: Portland, Oregon
• Year: 2019
• Project Size: $230 million
• Scope: Bridge deck and structural steel rehabilitation
• Lead Agencies/Contractors: Oregon DOT, prime contractor, welding subcontractor
Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Quality Control – Welding
Summary of the Issue, Problem, or Challenge
Welding subcontractor produced welds that did not meet strength and inspection criteria, requiring extensive repairs and rework, delaying the project.
Root Cause Analysis
- Insufficient welder certification and oversight.
- Inconsistent adherence to welding procedures.
- Lack of timely non-destructive testing during fabrication and erection.
- Poor communication between subcontractor QC and prime contractor inspectors.
Impacts Due to the Issue, Problem, or Challenge
- 8-week delay due to weld repairs and retesting.
- Increased costs for labor, materials, and inspection.
- Potential risk to structural integrity if uncorrected.
Corrective Actions Taken
- Re-certified all welders and enforced strict procedure compliance.
- Increased frequency of non-destructive testing.
- Strengthened communication channels between subcontractor QC and prime contractor.
- Engaged third-party inspectors for independent verification.
Lessons Learned
- Welding quality is critical to structural safety and schedule adherence.
- Continuous inspection and testing during construction prevent costly rework.
- Clear communication between QC teams improves issue detection and resolution.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are welders properly certified and monitored?
- Is NDT performed regularly and documented?
- Are QC teams from subcontractor and prime contractor effectively communicating?