Case Study: Cost Overrun Due to Construction Delay on Pennsylvania Bridge Replacement (Pittsburgh, PA, 2014)

Project Overview
• Name: Pittsburgh Bridge Replacement Project
• Location: Pittsburgh, Pennsylvania
• Year: 2014
• Project Size: $350 million
• Scope: Replacement of aging steel bridge with modern multi-span structure
• Lead Agencies/Contractors: Pennsylvania Department of Transportation (PennDOT) /

Category of the Issue, Problem, or Challenge
• Construction Delay
• Cost Management

Summary of the Issue, Problem, or Challenge
Extended construction delays due to contractor performance issues and weather interruptions led to substantial cost overruns.

Root Cause Analysis

• Contractor Resource Shortages: Inadequate labor and equipment availability slowed progress.
• Adverse Weather: Prolonged wet conditions reduced work days and productivity.
• Inadequate Scheduling: Ineffective schedule management and failure to mitigate delays.
• Communication Breakdowns: Delayed decision-making and issue resolution.

Impacts Due to the Issue, Problem, or Challenge

• Cost overruns estimated at 20%.
• Project completion delayed by nearly eight months.
• Increased liquidated damages risk and stakeholder dissatisfaction.

Corrective Actions Taken

1. Imposed stricter contractor performance monitoring and penalties.
2. Developed detailed weather contingency and recovery plans.
3. Enhanced project schedule controls with regular progress assessments.
4. Improved communication protocols and escalation procedures.

Lessons Learned

• Contractor resource planning is critical to meet schedules.
• Weather impacts require robust mitigation strategies.
• Strong project controls and communication reduce delay risks.

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

• Are contractor resources sufficient and monitored?
• Are weather risks accounted for in scheduling?
• Are communication and escalation protocols effective?