Case Study: San Francisco Bay Bridge Retrofit Impacted by Cable Supplier Delays (2019)

Project Overview
• Name: San Francisco Bay Bridge Seismic Retrofit
• Location: San Francisco, California
• Year: 2019
• Project Size: $550 million
• Scope: Seismic retrofit of major suspension bridge including cable replacement
• Lead Agencies/Contractors: Caltrans /

Category of the Issue, Problem, or Challenge
• Supply Chain Disruption
• Structural Cable Procurement

Summary of the Issue, Problem, or Challenge
Replacement cable deliveries were delayed due to raw material shortages and production bottlenecks at specialized cable manufacturing facilities, leading to schedule setbacks.

Root Cause Analysis

• Single-source supplier dependency for high-strength bridge cables.
• Production capacity constraints and raw material price spikes.
• Inadequate early supplier engagement to confirm delivery timelines.
• Lack of contractual clauses for supply risk mitigation.

Impacts Due to the Issue, Problem, or Challenge
• 6-month delay in cable installation phases.
• Cost increases due to rush orders and alternate sourcing (~$8 million).
• Impact on overall bridge reopening and public perception.

Corrective Actions Taken

1. Established relationships with backup cable suppliers.
2. Revised contracts to include supply risk and penalty clauses.
3. Enhanced early procurement and delivery tracking processes.

Lessons Learned

• High-risk single-source suppliers must be supplemented with alternatives.
• Early and continuous supplier engagement is critical.
• Contracts should clearly address supply risks and remedies.

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

• Are critical material suppliers diversified and capacity vetted?
• Are contracts aligned with risk mitigation for supply delays?
• Is supplier communication and delivery tracking robust?