Case Study: Subcontractor Inadequate Concrete Mix Quality Causes Pavement Cracking in New York (2020)

Project Overview
• Name: I-87 Pavement Rehabilitation
• Location: Albany, New York
• Year: 2020
• Project Size: $220 million
• Scope: Highway pavement rehabilitation including concrete overlays
• Lead Agencies/Contractors: New York State DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Materials Quality Control

Summary of the Issue, Problem, or Challenge
Concrete subcontractor’s failure to adhere to mix design specifications resulted in early cracking and reduced pavement durability, requiring partial removal and replacement.

Root Cause Analysis

• Deviation from specified mix proportions and curing procedures.
• Lack of adequate batch testing and quality monitoring.
• Poor communication of mix design changes with project engineers.
• Inadequate subcontractor quality control processes.

Impacts Due to the Issue, Problem, or Challenge

• Rework and replacement of affected pavement sections.
• Schedule delays and increased material costs.
• Potential long-term durability and maintenance issues.

Corrective Actions Taken

1. Enforced strict compliance with mix design and curing protocols.
2. Instituted more frequent batch sampling and testing.
3. Improved communication channels with engineering and quality teams.
4. Implemented subcontractor QC audits and corrective training.

Lessons Learned

• Strict adherence to concrete mix specifications is critical for durability.
• Continuous testing prevents acceptance of substandard materials.
• Open communication and documentation avoid misunderstandings.

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

• Are mix designs strictly followed and verified?
• Is concrete quality continuously monitored during production?
• Are changes in mix design properly approved and documented?