Case Study: Quality Control Lapses on Houston Flood Control Channel Construction (Texas, 2019)
Project Overview
• Name: Houston Flood Control Channel Improvements
• Location: Houston, Texas
• Year: 2019
• Project Size: $400 million
• Scope: Construction of stormwater channels and levees
• Lead Agencies/Contractors: Harris County Flood Control District /
Category of the Issue, Problem, or Challenge
• Quality Control
• Structural Integrity
• Project Delay
Summary of the Issue, Problem, or Challenge
Inspection failures allowed improperly compacted embankments and substandard concrete pours, compromising channel stability and causing remediation delays.
Root Cause Analysis
- Gaps in soil compaction testing protocols.
- Insufficient inspection frequency during concrete pours.
- Poor communication between QC inspectors and field crews.
- Inadequate corrective action procedures for detected deficiencies.
Impacts Due to the Issue, Problem, or Challenge
- Delay of 5 months for rework and additional testing.
- Increased project costs from remediation and extended oversight.
- Potential risk to flood protection performance if issues were not corrected.
Corrective Actions Taken
- Revised and increased testing protocols for soil and concrete.
- Improved inspector training and authority to halt work on quality concerns.
- Established clear communication channels and immediate corrective action workflows.
- Instituted third-party audits to supplement in-house QC.
Lessons Learned
- Quality control is crucial for infrastructure safety and longevity.
- Inspector authority and communication improve issue resolution.
- Third-party audits provide valuable independent assurance.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Are inspection and testing protocols comprehensive and followed?
- Do inspectors have clear authority to stop work for quality concerns?
- Is there an effective system for immediate corrective actions?