Case Study: QC Issues in Concrete Pouring on Miami Port Expansion (Florida, 2020)

Project Overview
• Name: Port Miami Tunnel and Expansion
• Location: Miami, Florida
• Year: 2020
• Project Size: $1.3 billion
• Scope: Tunnel construction and concrete structural works
• Lead Agencies/Contractors: Florida Department of Transportation (FDOT) /

Category of the Issue, Problem, or Challenge
• Quality Control
• Materials
• Structural

Summary of the Issue, Problem, or Challenge
Poor concrete curing and inconsistent slump resulted in reduced strength and surface defects requiring partial removal and re-pouring.

Root Cause Analysis

• Lack of strict monitoring and enforcement of curing procedures.
• Inconsistent batching and mixing leading to variable slump and workability.
• Inadequate training of concrete placement crews.
• Insufficient quality checks during and after concrete placement.

Impacts Due to the Issue, Problem, or Challenge

• Delay of 3 months due to removal and re-pouring.
• Increased costs for materials, labor, and schedule extension.
• Potential durability issues if left unaddressed.

Corrective Actions Taken

1. Implemented strict curing protocols with continuous monitoring.
2. Standardized batching and mixing procedures with tighter controls.
3. Provided targeted training for concrete crews on placement and curing.
4. Increased quality inspections during and post-pour phases.

Lessons Learned

• Consistent curing is critical for concrete strength and durability.
• Standardized batching reduces variability in concrete quality.
• Training and monitoring improve QC outcomes.

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

• Are curing procedures strictly enforced and monitored?
• Is batching standardized and quality tested?
• Are concrete crews trained in proper placement and curing?