Case Study: Houston Flood Control Project Delayed by Concrete Admixture Shortages (2023)

Project Overview
• Name: Houston Bayou Flood Control System
• Location: Houston, Texas
• Year: 2023
• Project Size: $320 million
• Scope: Construction of floodwalls, pump stations, and stormwater infrastructure
• Lead Agencies/Contractors: Harris County Flood Control District /

Category of the Issue, Problem, or Challenge
• Supply Chain Disruption
• Concrete Materials – Admixtures

Summary of the Issue, Problem, or Challenge
The project faced delays when key concrete admixtures used for high-performance concrete mixes were unavailable due to supply interruptions from chemical manufacturers impacted by raw material shortages and transportation bottlenecks.

Root Cause Analysis

• Raw chemical shortages at primary admixture suppliers.
• Transportation delays due to regional weather events and driver shortages.
• Lack of diversified supplier base for admixtures.
• Inadequate early procurement planning and risk assessment.

Impacts Due to the Issue, Problem, or Challenge
• 2.5-month delay in critical concrete pours for floodwall segments.
• Increased costs due to sourcing from alternate, more expensive suppliers (~$1.5 million).
• Schedule ripple effects impacting subsequent mechanical and electrical work.

Corrective Actions Taken

1. Developed multiple supply contracts for chemical admixtures.
2. Increased inventory buffers and early procurement of concrete additives.
3. Established real-time supply chain monitoring with suppliers.

Lessons Learned

• Critical chemical admixtures require supply chain risk management equivalent to major structural materials.
• Early supplier engagement and multi-sourcing reduce risk.
• Supply chain visibility is key to proactive mitigation.

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

• Are admixture suppliers diversified and capacity vetted?
• Are supply chain risks regularly reviewed and contingency plans in place?
• Is there sufficient inventory to cover schedule fluctuations?