Case Study: Skilled Concrete Finisher Shortage Delays Denver Light Rail Expansion (2022)
Project Overview
• Name: Denver RTD FasTracks Light Rail Expansion
• Location: Denver, Colorado
• Year: 2022
• Project Size: $580 million
• Scope: Construction of new light rail lines including extensive concrete work for tracks and stations
• Lead Agencies/Contractors: Regional Transportation District (RTD) /
Category of the Issue, Problem, or Challenge
• Skilled Trades Shortage
• Concrete Finishing
Summary of the Issue, Problem, or Challenge
The project was slowed when a shortage of skilled concrete finishers led to delays in track slab and station platform pours. High demand in the booming Denver construction market pulled labor towards residential projects.
Root Cause Analysis
- Rapid residential construction increased competition for concrete finishers.
- Insufficient early workforce planning and trade-specific recruitment.
- Limited training and apprenticeship programs for finishers in the region.
- Owner’s aggressive schedule left little flexibility for labor fluctuations.
Impacts Due to the Issue, Problem, or Challenge
• 3-month delay in concrete pours critical to track installation.
• Increased labor and rework costs (~$2.3 million).
• Subsequent delays in systems installation and commissioning phases.
Corrective Actions Taken
- Expanded recruitment efforts targeting skilled finishers from neighboring states.
- Partnered with trade schools to boost apprenticeship and training slots.
- Allowed schedule flexibility and phased pours to optimize labor use.
Lessons Learned
- Skilled trades shortages can cascade into critical path delays.
- Early labor market analysis and partnerships with training providers are essential.
- Schedule buffers for labor fluctuations improve resilience.
Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation
- Is there sufficient supply of skilled concrete finishers?
- Are apprenticeship and training programs aligned with project needs?
- Does the schedule allow for labor market fluctuations?