Case Study: I-405 Sepulveda Pass Improvement Project – Design-Build Delivery Coordination Failures (2018)

Project Overview
• Name: I-405 Sepulveda Pass Improvement
• Location: Los Angeles, California
• Year: 2018
• Project Size: $1.9 billion
• Scope: Widening and express lanes addition on a heavily trafficked corridor using Design-Build delivery
• Lead Agencies/Contractors: California Department of Transportation (Caltrans), Design-Build JV

Category of the Issue, Problem, or Challenge
• Project Delivery Method
• Design-Build

Summary of the Issue, Problem, or Challenge
During construction, poor integration between design and construction teams led to misaligned schedules, rework, and cost increases. The aggressive timeline and complex urban environment exacerbated coordination challenges, causing project delays.

Root Cause Analysis

• Lack of early and continuous collaboration between designers and constructors.
• Insufficient integration of project management systems and data sharing.
• Aggressive schedule without adequate buffers for urban constraints.
• Ineffective communication channels for rapid issue resolution.

Impacts Due to the Issue, Problem, or Challenge
• Delays totaling 7 months.
• Cost overruns exceeding $40 million.
• Increased field rework and disruption to traffic.

Corrective Actions Taken

1. Implemented integrated project delivery (IPD) practices to improve collaboration.
2. Adopted shared project management platforms for real-time data sharing.
3. Adjusted schedules to include realistic buffers for urban impacts.
4. Established rapid-response communication protocols.

Lessons Learned

• Early and ongoing collaboration between design and construction is essential.
• Integrated technology platforms enhance coordination.
• Realistic scheduling considering project context reduces delays.
• Clear, rapid communication minimizes disruptions.

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

• Are design and construction teams collaborating continuously?
• Is there an integrated project management system in place?
• Are schedules realistic with buffers for known constraints?
• Are communication protocols clear and fast?