Case Study: Denver FasTracks Rail Expansion Design-Construction Interface Issues (2015)

Project Overview
• Name: Denver FasTracks Rail Expansion
• Location: Denver, Colorado
• Year: 2015
• Project Size: $2.3 billion
• Scope: Expansion of regional commuter rail network including stations, tracks, and bridges
• Lead Agencies/Contractors: Regional Transportation District (RTD) /

Category of the Issue, Problem, or Challenge
• Design
• Design-Build Coordination

Summary of the Issue, Problem, or Challenge
During track and station construction, design inconsistencies between the preliminary engineering documents and final construction plans caused misalignment of track geometry and platform elevations. This led to costly on-site adjustments and delays.

Root Cause Analysis

• Incomplete integration of design documents between design and construction teams.
• Lack of a formal design freeze point before construction mobilization.
• Insufficient communication during transition from design to construction phases.
• Overlapping roles and unclear responsibilities in design-build setup.

Impacts Due to the Issue, Problem, or Challenge
• Project delays of 4 months due to rework and realignment.
• Additional costs estimated at $6 million.
• Stakeholder dissatisfaction and negative public perception.

Corrective Actions Taken

1. Instituted a formal design freeze protocol prior to construction start.
2. Improved collaboration between design and construction teams with joint workshops.
3. Clarified roles and responsibilities in the design-build contract documents.
4. Adopted 3D modeling to align design and construction planning more effectively.

Lessons Learned

• Clear cut-off points for design changes reduce risks of field rework.
• Early and frequent collaboration between design and construction teams is crucial.
• Design-build projects require clear contract terms defining responsibilities.
• Use of 3D BIM tools improves design-construction alignment.

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

• Is there a formal design freeze before construction mobilization?
• Are design and construction teams collaborating continuously?
• Are contract roles and responsibilities clearly defined for design-build projects?
• Are 3D models used to verify design and construction alignment?