Case Study: Subcontractor Safety Protocol Lapses Cause Work Stoppage on Texas Highway Project (2019)

Project Overview
• Name: SH 130 Expansion
• Location: Austin, Texas
• Year: 2019
• Project Size: $450 million
• Scope: Highway widening and interchange upgrades
• Lead Agencies/Contractors: Texas DOT /

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

Summary of the Issue, Problem, or Challenge
A subcontractor’s failure to enforce safety protocols led to a serious on-site injury, triggering a regulatory investigation and a temporary work stoppage.

Root Cause Analysis

• Subcontractor’s safety training programs were inadequate.
• Lack of enforcement of PPE usage and safety procedures among crews.
• Insufficient supervision and safety audits by subcontractor and prime contractor.
• Communication gaps regarding safety responsibilities between subcontractor and prime contractor.

Impacts Due to the Issue, Problem, or Challenge

• Work halted for 3 weeks pending investigation and corrective actions.
• Increased insurance premiums and potential penalties.
• Negative impact on project schedule and worker morale.

Corrective Actions Taken

1. Subcontractor revamped safety training with mandatory certifications.
2. Prime contractor increased frequency of on-site safety audits.
3. Instituted clear safety roles and communication protocols.
4. Implemented incident reporting and near-miss tracking systems.

Lessons Learned

• Safety lapses by subcontractors can halt entire projects.
• Continuous training and enforcement of safety protocols are essential.
• Open communication and clear roles improve safety accountability.

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

• Is the subcontractor’s safety training program comprehensive?
• Are safety audits conducted regularly and documented?
• Are safety responsibilities clearly defined and communicated?