Case Study: Subcontractor Safety Protocol Failure Leads to Crane Incident in Texas (2020)

Project Overview
• Name: I-35 Expansion Project
• Location: Austin, Texas
• Year: 2020
• Project Size: $320 million
• Scope: Highway widening including bridge construction and utility relocation
• Lead Agencies/Contractors: Texas DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Safety & Operations

Summary of the Issue, Problem, or Challenge
A subcontractor’s crane operator failed to follow established safety protocols, resulting in a boom collapse that damaged partially constructed bridge components and halted work.

Root Cause Analysis

• Subcontractor’s insufficient safety training and oversight.
• Lack of effective communication and supervision from prime contractor.
• Subcontractor failed to enforce weight limits and operational guidelines for crane use.
• Inadequate subcontractor prequalification and performance monitoring processes.

Impacts Due to the Issue, Problem, or Challenge

• Project delay of 2 months due to equipment repair and rework.
• Cost overruns for damaged materials and additional safety inspections.
• Safety risk to workers, triggering OSHA investigation and fines.

Corrective Actions Taken

1. Prime contractor strengthened subcontractor prequalification and safety training requirements.
2. Implemented daily safety briefings and enhanced supervision of subcontractor crews.
3. Enforced stricter operational limits and equipment inspection routines.
4. Established clear communication channels between prime and subcontractors.

Lessons Learned

• Prime contractors must rigorously vet subcontractors’ safety capabilities.
• Continuous supervision and communication are critical to enforce protocols.
• Subcontractor failures can have major schedule and safety impacts.

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

• Are subcontractors’ safety training and certifications verified before work?
• How are subcontractors supervised and monitored daily?
• Are operational limits and equipment conditions regularly enforced?