Case Study: Quality Control Issues with Asphalt Paving on Miami Expressway Project (Florida, 2020)

Project Overview
• Name: Miami Expressway Widening
• Location: Miami, Florida
• Year: 2020
• Project Size: $350 million
• Scope: Widening and resurfacing of a major expressway
• Lead Agencies/Contractors: Florida Department of Transportation (FDOT) /

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

Summary of the Issue, Problem, or Challenge
Substandard asphalt mix and poor compaction resulted in surface irregularities and early rutting, requiring partial removal and repaving during construction.

Root Cause Analysis

• Inadequate quality control of asphalt mix design and production.
• Insufficient field compaction monitoring and testing.
• Poor communication of specifications to paving crews.
• Lack of real-time quality documentation and corrective action protocols.

Impacts Due to the Issue, Problem, or Challenge

• Delay of 3 months due to repaving and additional testing.
• Increased project costs and resource usage.
• Reduced pavement lifespan and increased maintenance risk.

Corrective Actions Taken

1. Revised asphalt mix designs and supplier quality audits.
2. Increased compaction testing frequency and enforcement.
3. Enhanced training and supervision of paving crews.
4. Implemented digital documentation and immediate corrective response system.

Lessons Learned

• Rigorous QC in asphalt production and placement is critical.
• Real-time testing and documentation improve quality outcomes.
• Training ensures crews meet project specifications consistently.

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

• Are asphalt mix and compaction thoroughly tested and monitored?
• Is quality documentation maintained in real time?
• Are paving crews properly trained and supervised?