Case Study: Subcontractor Delay in Utility Relocation Causes Overall Project Hold-Up in New Jersey (2019)

Project Overview
• Name: NJ Turnpike Expansion
• Location: Newark, New Jersey
• Year: 2019
• Project Size: $600 million
• Scope: Highway expansion with complex utility relocations
• Lead Agencies/Contractors: New Jersey DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Scheduling & Coordination

Summary of the Issue, Problem, or Challenge
Utility relocation subcontractor underestimated the complexity and time required, leading to a critical path delay of 7 weeks and disruption of follow-on construction.

Root Cause Analysis

  • Inadequate initial utility survey and planning.
  • Poor project management and progress tracking by subcontractor.
  • Insufficient communication with utility owners and prime contractor.
  • Lack of contingency planning for unexpected utility conflicts.

Impacts Due to the Issue, Problem, or Challenge

  • Extended project schedule and increased overhead costs.
  • Penalties and strained relationships among project stakeholders.
  • Increased risk of cascading delays in other trades.

Corrective Actions Taken

  1. Enhanced utility survey and mapping procedures.
  2. Increased project management oversight and regular progress reporting.
  3. Improved communication protocols with utility owners and prime contractor.
  4. Established contingency plans for unforeseen utility issues.

Lessons Learned

  • Detailed upfront utility surveys are critical to accurate scheduling.
  • Strong project management and communication reduce delay risks.
  • Contingency planning mitigates impact of unknown conditions.

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

  • Are utility surveys comprehensive and verified?
  • Is subcontractor project management actively monitoring progress?
  • Are communication and contingency protocols established and followed?
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