Case Study: Delay Due to Material Shortages on Ohio River Bridge Construction (Ohio/Kentucky, 2014)
Project Overview
• Name: Ohio River Bridge Replacement
• Location: Ohio/Kentucky Border
• Year: 2014
• Project Size: $750 million
• Scope: Construction of a new major highway bridge over the Ohio River
• Lead Agencies/Contractors: Ohio Department of Transportation (ODOT), Kentucky Transportation Cabinet /
Category of the Issue, Problem, or Challenge
• Material Supply
• Project Delay
Summary of the Issue, Problem, or Challenge
Shortages of structural steel delayed key fabrication and erection phases.
Root Cause Analysis
- Global Steel Market Volatility: Price spikes and limited supply affected procurement.
- Single Supplier Reliance: Limited vendor options delayed orders.
- Contractual Timing: Late procurement contracts without buffer stock.
- Lack of Alternative Material Planning: No contingency sourcing plans were in place.
Impacts Due to the Issue, Problem, or Challenge
- Delay of 6 months.
- Increased costs from expedited freight and premium pricing.
- Impact on contractor cash flow and scheduling.
Corrective Actions Taken
- Diversified steel suppliers and developed long-term procurement contracts.
- Incorporated material market risk analysis in planning.
- Created on-site buffer stock for critical materials.
- Monitored global market trends to anticipate disruptions.
Lessons Learned
- Material market conditions can critically impact schedule.
- Proactive procurement and supplier diversification mitigate risk.
- Buffer inventories protect against supply chain shocks.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are supplier markets monitored and alternative sources identified?
- Is there on-site inventory for critical materials?
- Are procurement contracts timed to account for market volatility?