Case Study: Miami Port Tunnel Design Modifications Impact Schedule and Costs (2010)
Project Overview
• Name: Miami Port Tunnel
• Location: Miami, Florida
• Year: 2010
• Project Size: $667 million
• Scope: Design and construction of a deep-bore tunnel connecting the Port of Miami to the interstate highway system
• Lead Agencies/Contractors: Florida DOT /
Category of the Issue, Problem, or Challenge
• Design
• Tunnel Engineering
Summary of the Issue, Problem, or Challenge
Mid-construction design changes to accommodate unforeseen underground utilities and updated ventilation requirements resulted in significant scope expansion. The changes caused delays and increased costs due to re-design and additional construction work.
Root Cause Analysis
- Incomplete underground utility mapping prior to design completion.
- Late integration of updated environmental and safety ventilation standards.
- Insufficient contingency planning for utility conflicts.
- Delayed coordination between design teams and utility providers.
Impacts Due to the Issue, Problem, or Challenge
• Schedule delays of 6 months.
• Cost overruns approximated at $18 million.
• Disruptions in utility service and stakeholder dissatisfaction.
Corrective Actions Taken
- Enhanced subsurface utility engineering (SUE) investigations during design.
- Established formal coordination processes with utility companies.
- Included contingency buffers in schedule and budget for design changes.
- Upgraded ventilation system design early with stakeholder input.
Lessons Learned
- Comprehensive subsurface investigations reduce utility conflict risks.
- Early and ongoing coordination with utility providers is critical.
- Contingency planning for design changes is essential in complex environments.
- Regulatory and safety standards updates must be integrated promptly.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Has a thorough subsurface utility investigation been completed?
- Are utility providers engaged early in the design process?
- Are contingency buffers included for potential design changes?
- Are ventilation and safety standards updated and incorporated timely?