Case Study: Subcontractor Incomplete Asphalt Testing Causes Pavement Failure in Texas (2017)

Project Overview
• Name: Houston Beltway Expansion
• Location: Houston, Texas
• Year: 2017
• Project Size: $450 million
• Scope: Highway pavement construction and widening
• Lead Agencies/Contractors: Texas DOT /

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

Summary of the Issue, Problem, or Challenge
The paving subcontractor failed to conduct comprehensive asphalt mix testing, leading to premature pavement cracking and rutting soon after placement, requiring costly repairs.

Root Cause Analysis

• Insufficient sampling frequency and test variety.
• Lack of adherence to mix design specifications.
• Delays in test reporting causing untimely corrective actions.
• Limited oversight by prime contractor QC personnel.

Impacts Due to the Issue, Problem, or Challenge

• Early pavement distress leading to rework.
• Additional material and labor costs.
• Temporary lane closures affecting traffic flow.
• Reputational damage for contractors involved.

Corrective Actions Taken

1. Increased asphalt sampling frequency and expanded testing parameters.
2. Enforced stricter adherence to mix design specifications.
3. Implemented faster turnaround times for lab results.
4. Enhanced collaboration between subcontractor and prime contractor QC teams.

Lessons Learned

• Rigorous materials testing is critical to pavement durability.
• Quick test result feedback allows timely corrections.
• Strong QC partnerships between subcontractors and prime contractors reduce failures.

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

• Are materials tested frequently and comprehensively?
• Are mix designs strictly followed and documented?
• Is test reporting timely and communicated effectively?