Case Study: Denver Airport Expansion Delayed by Electrical Cable Shortages (2020)
Project Overview
• Name: Denver International Airport Expansion Phase II
• Location: Denver, Colorado
• Year: 2020
• Project Size: $450 million
• Scope: Terminal expansion including extensive electrical and communications systems
• Lead Agencies/Contractors: Denver Airport Authority /
Category of the Issue, Problem, or Challenge
• Supply Chain Disruption
• Electrical Materials Procurement
Summary of the Issue, Problem, or Challenge
Electrical cable deliveries were delayed due to global raw material shortages and increased demand, causing work stoppages and re-sequencing of construction activities.
Root Cause Analysis
- Global copper shortages impacting cable manufacturing.
- High demand for electrical components across multiple infrastructure projects.
- Lack of early procurement and supply chain risk planning.
- Limited supplier base for specialty cable types.
Impacts Due to the Issue, Problem, or Challenge
• 3-month delay in electrical systems installation.
• Increased costs from rush orders and schedule compression (~$3.8 million).
• Impact on commissioning and airport operation timelines.
Corrective Actions Taken
- Developed multi-supplier sourcing strategies for critical electrical materials.
- Advanced procurement timelines with contractual commitments.
- Implemented supply chain risk monitoring and early alert systems.
Lessons Learned
- Specialty electrical material supply requires early and diversified sourcing.
- Global raw material markets must be monitored continuously.
- Supply risk management must be integral to project planning.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are electrical material suppliers diversified and lead times validated?
- Are global commodity market trends incorporated in supply risk plans?
- Is early procurement prioritized for specialty components?