Case Study: Chicago Expressway Rehabilitation Faces Steel Plate Delivery Delays (2022)
Project Overview
• Name: Chicago I-90 Expressway Rehabilitation
• Location: Chicago, Illinois
• Year: 2022
• Project Size: $275 million
• Scope: Rehabilitation of expressway bridges and overpasses including steel plate repairs
• Lead Agencies/Contractors: Illinois DOT /
Category of the Issue, Problem, or Challenge
• Supply Chain Disruption
• Structural Steel Materials
Summary of the Issue, Problem, or Challenge
Delays in delivery of critical steel plates for bridge repairs occurred due to supplier production backlogs and disruptions in raw steel supply chains caused by trade tariff impacts and domestic mill constraints.
Root Cause Analysis
- Tariff-driven volatility impacting raw steel imports and mill output.
- Limited domestic mill production capacity amid high demand.
- Late procurement decisions and inadequate supplier lead time assessments.
- Lack of alternate qualified steel plate suppliers.
Impacts Due to the Issue, Problem, or Challenge
• 3.5-month delay in bridge repair schedule.
• Increased costs from expedited steel sourcing and schedule acceleration (~$2.7 million).
• Risk of compromised quality due to rushed fabrication.
Corrective Actions Taken
- Engaged additional steel suppliers and verified quality standards.
- Advanced procurement with contractual delivery guarantees.
- Monitored trade and tariff impacts as part of supply risk management.
Lessons Learned
- Steel supply chain can be highly sensitive to trade policies and market dynamics.
- Early procurement and multi-supplier engagement mitigate risks.
- Quality assurance must remain rigorous despite schedule pressures.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are steel suppliers diversified and delivery commitments enforceable?
- Is procurement aligned with market and policy risks?
- Are quality controls maintained under schedule pressures?