Case Study: Subcontractor Surveying Errors Cause Rework on Bridge Alignment in Ohio (2018)

Project Overview
• Name: Ohio River Bridge Replacement
• Location: Cincinnati, Ohio
• Year: 2018
• Project Size: $380 million
• Scope: Bridge replacement including substructure and superstructure
• Lead Agencies/Contractors: Ohio DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Surveying & Layout Errors

Summary of the Issue, Problem, or Challenge
The surveying subcontractor provided inaccurate alignment data, resulting in misplacement of key bridge elements and extensive rework during the construction phase.

Root Cause Analysis

• Use of outdated surveying equipment and software.
• Insufficient training of subcontractor field personnel.
• Inadequate verification and cross-checking of survey data.
• Limited oversight from prime contractor survey management.

Impacts Due to the Issue, Problem, or Challenge

• Two-month project delay due to re-surveying and reconstruction.
• Additional labor and material costs for correcting misalignment.
• Disruption of construction sequencing and workflows.

Corrective Actions Taken

1. Upgraded surveying equipment and software for accuracy.
2. Provided additional training and certification for subcontractor staff.
3. Established a verification protocol with redundant surveys.
4. Increased prime contractor supervision and auditing of subcontractor data.

Lessons Learned

• Accurate surveying is critical for infrastructure alignment and fit.
• Technology and training investments reduce surveying errors.
• Independent verification safeguards against costly misalignments.

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

• Are subcontractor survey teams properly equipped and trained?
• Is survey data independently verified before construction?
• Is prime contractor oversight adequate to catch errors early?