Case Study: Delay in Georgia Dam Rehabilitation Due to Equipment Delivery Issues (2019)
Project Overview
• Name: Lake Lanier Dam Rehabilitation
• Location: Gainesville, Georgia
• Year: 2019
• Project Size: $150 million
• Scope: Structural rehabilitation of aging dam including heavy machinery and concrete work
• Lead Agencies/Contractors: U.S. Army Corps of Engineers /
Category of the Issue, Problem, or Challenge
• Supply Chain Disruption
• Equipment and Materials Logistics
Summary of the Issue, Problem, or Challenge
The project encountered delays caused by late delivery of critical heavy equipment, including specialized concrete pumps and cranes, due to manufacturing backlogs and transport logistics challenges.
Root Cause Analysis
- Single-source suppliers with long lead times and limited equipment inventory.
- Transportation delays due to oversized equipment permits and route restrictions.
- Insufficient project planning to account for lead times and permit processes.
- Lack of proactive communication with suppliers regarding delivery status.
Impacts Due to the Issue, Problem, or Challenge
• 2.5-month delay in major construction activities dependent on heavy equipment.
• Increased costs for equipment rental extensions and expedited shipping (~$1.8 million).
• Schedule compression impacting subsequent contractor activities.
Corrective Actions Taken
- Established agreements with alternative equipment suppliers for backup.
- Improved logistics planning including early permit application for transport.
- Enhanced supplier communication protocols and tracking.
Lessons Learned
- Heavy equipment procurement requires early planning with realistic lead times.
- Transportation logistics can significantly impact equipment availability.
- Redundant sourcing and improved communication reduce delivery risks.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are lead times for critical equipment fully incorporated into schedules?
- Are logistics permits and route planning done proactively?
- Is supplier communication robust and real-time?