Related to Structural Steel Construction
Case Study: San Francisco Bay Area Steel Beam Splice Failure (2018)
Project Overview
- Name: Bay Bridge Eastern Span Replacement
- Location: San Francisco, California
- Year: 2018
- Project Size: $6.4 billion
- Scope: Structural steel beam splicing for long-span bridge sections
- Lead Agencies/Contractors: Caltrans /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Welding and Bolting
- Joint Failures
Summary of the Issue, Problem, or Challenge
A critical beam splice joint was found defective after discovery of incomplete bolt installation and weld undercuts, triggering emergency repairs and inspection of all splice joints.
Root Cause Analysis
| Factor | Details |
| Incomplete Bolt Installation | Several bolts were missing or inadequately torqued. |
| Poor Welding Quality | Weld undercuts and cracks detected at splice welds. |
| Lack of Final QA Verification | Insufficient post-installation inspection of splice joints. |
Impacts Due to the Issue, Problem, or Challenge
- Emergency repair work causing schedule disruption
- Increased inspection and testing costs
- Heightened safety risk during construction
Corrective Actions Taken
- Mandatory torque testing and bolt verification at all splice joints
- Enhanced weld procedure qualifications and welder certification checks
- Implementation of third-party QA inspections for all critical joints
Lessons Learned
- Bolting and welding must be equally scrutinized in splice connections
- Comprehensive QA inspections prevent critical joint failures
- Proper documentation and enforcement of installation procedures are essential
Case Study: Atlanta Steel Girder Camber Adjustment Failure (2016)
Project Overview
- Name: I-285 Perimeter Highway Widening
- Location: Atlanta, Georgia
- Year: 2016
- Project Size: $350 million
- Scope: Structural steel girder camber adjustment and erection
- Lead Agencies/Contractors: Georgia DOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Camber Correction
- Field Adjustment
Summary of the Issue, Problem, or Challenge
Field camber adjustments on steel girders were performed without engineering oversight, resulting in over-cambering that compromised beam fit-up with deck forms.
Root Cause Analysis
| Factor | Details |
| Lack of Engineering Guidance | Adjustments performed without structural engineer approval. |
| Insufficient Field Measurements | No verification of camber during adjustments. |
| Poor Communication | Disconnection between design team and field crew. |
Impacts Due to the Issue, Problem, or Challenge
- Beam modifications and replacement requirements
- Project delays and increased labor costs
- Potential structural serviceability issues
Corrective Actions Taken
- Required engineering sign-off for all camber adjustments
- Use of laser measurement tools for real-time camber verification
- Improved field-to-design communication protocols
Lessons Learned
- Camber modifications must be engineered and measured accurately
- Real-time verification tools prevent costly rework
- Coordination between field and design teams is crucial
Case Study: Miami Structural Steel Beam Corrosion Under Temporary Coating (2020)
Project Overview
- Name: Miami Urban Expressway Expansion
- Location: Miami, Florida
- Year: 2020
- Project Size: $480 million
- Scope: Steel beam fabrication, coating, and erection
- Lead Agencies/Contractors: Florida DOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Corrosion Protection
- Coating Failures
Summary of the Issue, Problem, or Challenge
Temporary protective coatings on steel beams failed to prevent corrosion during prolonged storage in high-humidity conditions, requiring costly recoating.
Root Cause Analysis
| Factor | Details |
| Inadequate Temporary Coatings | Coatings were not rated for tropical humidity exposure. |
| Extended Storage Duration | Beams stored longer than anticipated without re-coating. |
| Lack of Monitoring | No periodic inspection of coating condition during storage. |
Impacts Due to the Issue, Problem, or Challenge
- Increased costs for cleaning and recoating
- Delays in beam installation schedule
- Potential long-term durability concerns
Corrective Actions Taken
- Selection of coatings designed for tropical environments
- Scheduling and limiting storage duration for coated materials
- Regular inspections and maintenance of protective coatings
Lessons Learned
- Temporary coatings must match environmental exposure
- Storage planning must consider weather and duration
- Monitoring is essential for corrosion protection management
Case Study: Pittsburgh Arch Rib Erection Alignment Issues (2018)
Project Overview
- Name: Three Rivers Arch Bridge Replacement
- Location: Pittsburgh, Pennsylvania
- Year: 2018
- Project Size: $400 million
- Scope: Erection of steel arch ribs and installation of spandrel columns
- Lead Agencies/Contractors: Pennsylvania DOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Erection and Alignment
- Arch Rib and Spandrel Columns
Summary of the Issue, Problem, or Challenge
During erection, arch ribs were found misaligned by several inches due to inadequate surveying and temporary support adjustment, causing complications in spandrel column installation.
Root Cause Analysis
| Factor | Details |
| Insufficient Surveying | Lack of frequent, precise measurement of arch rib position. |
| Temporary Support Instability | Supports allowed movement during welding and bolting. |
| Coordination Deficiencies | Poor communication between field engineers and erection crews. |
Impacts Due to the Issue, Problem, or Challenge
- Rework on alignment caused significant project delays
- Increased labor and equipment rental costs
- Potential impact on long-term structural performance
Corrective Actions Taken
- Enhanced use of laser scanning and real-time monitoring during erection
- Reinforced temporary support bracing to prevent movement
- Daily coordination meetings between surveying, engineering, and field teams
Lessons Learned
- Continuous alignment checks critical during arch erection
- Stable temporary supports prevent costly misalignment
- Strong field coordination minimizes errors and delays
Case Study: Houston Spandrel Column Base Plate Corrosion (2020)
Project Overview
- Name: Houston Inner Loop Expansion
- Location: Houston, Texas
- Year: 2020
- Project Size: $380 million
- Scope: Installation of spandrel columns and steel arch ribs
- Lead Agencies/Contractors: Texas DOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Corrosion Protection
- Spandrel Column Base Plates
Summary of the Issue, Problem, or Challenge
Spandrel column base plates showed early-stage corrosion due to inadequate surface preparation and delayed application of protective coatings after fabrication.
Root Cause Analysis
| Factor | Details |
| Delayed Coating Application | Protective coatings applied late, after exposure to weather. |
| Poor Surface Preparation | Insufficient cleaning and rust removal before coating. |
| Storage Conditions | Base plates stored outdoors without shelter or protection. |
Impacts Due to the Issue, Problem, or Challenge
- Additional cost and schedule impact due to cleaning and recoating
- Reduced durability and increased risk of long-term corrosion damage
- Need for revised storage and handling protocols
Corrective Actions Taken
- Accelerated coating application immediately post-fabrication
- Improved surface preparation standards and inspections
- Revised storage procedures to protect components from weather
Lessons Learned
- Timely application of protective coatings critical in humid climates
- Proper surface prep essential for coating adhesion and longevity
- Storage environment can significantly impact steel durability
Case Study: Denver Arch Rib Fabrication Weld Deficiencies (2022)
Project Overview
- Name: Denver River Crossing Bridge
- Location: Denver, Colorado
- Year: 2022
- Project Size: $350 million
- Scope: Fabrication and erection of steel arch ribs and spandrel columns
- Lead Agencies/Contractors: Colorado DOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Welding Deficiencies
- Fabrication
Summary of the Issue, Problem, or Challenge
Post-fabrication inspections revealed incomplete weld penetration and porosity in critical arch rib welds, requiring extensive rework before shipment to site.
Root Cause Analysis
| Factor | Details |
| Welding Procedure Deviation | Welders deviated from approved welding parameters. |
| Insufficient Welder Training | Some welders lacked adequate training on complex weld joints. |
| Inadequate Quality Inspections | Quality control failed to detect defects early during fabrication. |
Impacts Due to the Issue, Problem, or Challenge
- Delayed shipment of steel components
- Increased fabrication costs due to rework
- Rescheduling of field erection activities
Corrective Actions Taken
- Implementation of stricter welding procedure compliance monitoring
- Additional welder training and certification programs
- Enhanced NDT inspections throughout fabrication
Lessons Learned
- Strict enforcement of welding procedures prevents costly rework
- Early detection of defects reduces schedule impact
- Skilled workforce is essential for complex weld joints
Case Study: San Francisco Spandrel Column Erection Stability Issues (2017)
Project Overview
- Name: Bay Area Arch Bridge Project
- Location: San Francisco, California
- Year: 2017
- Project Size: $500 million
- Scope: Erection of steel arch ribs and spandrel columns
- Lead Agencies/Contractors: Caltrans /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Erection Stability
- Spandrel Columns
Summary of the Issue, Problem, or Challenge
During spandrel column erection, temporary supports failed to provide adequate lateral stability, resulting in minor column movement and safety concerns.
Root Cause Analysis
| Factor | Details |
| Inadequate Temporary Bracing | Temporary supports were undersized for lateral load conditions. |
| Poor Erection Sequence Planning | Erection sequence did not consider cumulative stability effects. |
| Lack of Field Monitoring | Insufficient real-time monitoring of column movement during erection. |
Impacts Due to the Issue, Problem, or Challenge
- Halted erection activities until supports were reinforced
- Increased labor and equipment rental costs
- Heightened safety risk for field personnel
Corrective Actions Taken
- Redesigned temporary bracing with greater lateral capacity
- Revised erection sequence to improve structural stability during construction
- Installed monitoring devices to detect movement in real-time
Lessons Learned
- Temporary supports must be designed for all load conditions, including lateral forces
- Proper erection sequencing is critical for stability
- Continuous field monitoring enhances safety and reduces risk
Case Study: Atlanta Arch Rib Corrosion Protection Failure (2020)
Project Overview
- Name: Atlanta Riverfront Arch Bridge
- Location: Atlanta, Georgia
- Year: 2020
- Project Size: $320 million
- Scope: Steel arch rib fabrication and spandrel column installation
- Lead Agencies/Contractors: Georgia DOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Corrosion Protection
- Arch Ribs and Spandrel Columns
Summary of the Issue, Problem, or Challenge
Steel arch ribs and spandrel columns exhibited early signs of rust and coating failure after prolonged exposure due to delays in installation.
Root Cause Analysis
| Factor | Details |
| Extended On-Site Storage | Components stored outdoors without adequate protection. |
| Delayed Installation | Construction schedule delays extended exposure time. |
| Incomplete Surface Preparation | Surface contamination prior to coating application. |
Impacts Due to the Issue, Problem, or Challenge
- Need for abrasive cleaning and recoating on site
- Additional costs and delays for rework
- Increased risk of long-term corrosion damage
Corrective Actions Taken
- Improved storage protocols with covered, climate-controlled areas
- Accelerated installation schedule coordination to minimize exposure
- Implemented rigorous surface prep inspection before coating
Lessons Learned
- Proper storage critical to preserving steel integrity
- Scheduling should minimize time between fabrication and installation
- Surface prep is essential for durable corrosion protection
Case Study: New York Arch Rib and Spandrel Column Dimensional Issues (2016)
Project Overview
- Name: East River Arch Bridge Replacement
- Location: New York City, New York
- Year: 2016
- Project Size: $450 million
- Scope: Fabrication and erection of steel arch ribs and spandrel columns
- Lead Agencies/Contractors: NYSDOT /
Category of the Issue, Problem, or Challenge
- Structural Steel
- Dimensional Control
- Fabrication and Erection
Summary of the Issue, Problem, or Challenge
During assembly, several arch rib segments and spandrel columns failed to fit as designed due to dimensional inaccuracies exceeding tolerances.
Root Cause Analysis
| Factor | Details |
| Lack of Precision in Fabrication | Fabrication shops lacked precise measurement controls. |
| Insufficient Field Verification | Dimensional checks before erection were inadequate. |
| Poor Documentation | As-built fabrication data did not match design specifications. |
Impacts Due to the Issue, Problem, or Challenge
- Extensive field modifications and rework required
- Project delays and cost increases
- Compromised construction sequencing
Corrective Actions Taken
- Adoption of tighter fabrication quality control and measurement standards
- Increased use of 3D modeling and verification before shipment
- Enhanced field verification protocols during erection
Lessons Learned
- Precision in fabrication critical for complex arch structures
- Field verification essential to catch deviations early
- Up-to-date documentation streamlines erection process
Case Study: Houston Bridge Bearing Pad Deformation (2019)
Project Overview
- Name: Houston Bayou Bridge Replacement
- Location: Houston, Texas
- Year: 2019
- Project Size: $280 million
- Scope: Replacement of bearings and expansion joints on a multi-span bridge
- Lead Agencies/Contractors: TxDOT /
Category of the Issue, Problem, or Challenge
- Bridge Bearings
- Materials Engineering
- Structural Performance
Summary of the Issue, Problem, or Challenge
Shortly after bearing pads were installed, deformation and uneven compression were observed, leading to uneven load distribution and concerns about potential long-term damage.
Root Cause Analysis
| Factor | Details |
| Improper Bearing Selection | Bearing pads selected did not match load and movement specifications. |
| Installation Errors | Bearing pads were installed with misalignment and inadequate seating. |
| Lack of Pre-Installation Inspection | Insufficient pre-installation verification of bearing surfaces. |
Impacts Due to the Issue, Problem, or Challenge
- Halted construction to reassess bearing condition
- Additional costs for removal and replacement of bearing pads
- Project delays due to reordering and reinstallation
Corrective Actions Taken
- Re-evaluation of bearing pad design parameters and material selection
- Implemented rigorous installation supervision and alignment checks
- Introduced pre-installation inspection protocol for bearing seating surfaces
Lessons Learned
- Proper bearing selection based on accurate load and movement data is essential
- Installation precision critical to avoid uneven stress distribution
- Pre-installation inspections can prevent costly rework
Case Study: Seattle Expansion Joint Leakage and Seal Failure (2020)
Project Overview
- Name: Seattle Downtown Bridge Rehabilitation
- Location: Seattle, Washington
- Year: 2020
- Project Size: $190 million
- Scope: Replacement of expansion joints and sealing systems on an aging highway bridge
- Lead Agencies/Contractors: Washington State DOT /
Category of the Issue, Problem, or Challenge
- Expansion Joints
- Waterproofing and Sealant Failures
Summary of the Issue, Problem, or Challenge
Shortly after installation, expansion joints exhibited water leakage through the seals, causing corrosion to adjacent structural elements and undermining deck integrity.
Root Cause Analysis
| Factor | Details |
| Incorrect Sealant Application | Sealant applied outside manufacturer’s recommended conditions. |
| Inadequate Joint Design | Joint design did not accommodate expected thermal and traffic movements. |
| Insufficient Quality Control | Lack of proper inspection during and after installation. |
Impacts Due to the Issue, Problem, or Challenge
- Water infiltration led to steel corrosion and concrete spalling
- Need for premature joint replacement and repairs
- Extended traffic disruptions and increased costs
Corrective Actions Taken
- Redesign of expansion joint system to meet movement and load demands
- Adoption of manufacturer-certified installers and strict QC procedures
- Periodic inspection and maintenance schedule established for joints
Lessons Learned
- Expansion joint design must be compatible with site-specific movement profiles
- Correct sealant application crucial to joint durability
- Quality control during installation prevents early failures
Case Study: Chicago Bridge Bearing Seat Concrete Cracking (2018)
Project Overview
- Name: Chicago River Bridge Replacement
- Location: Chicago, Illinois
- Year: 2018
- Project Size: $400 million
- Scope: Construction of new bearing seats and installation of elastomeric bearings
- Lead Agencies/Contractors: Illinois DOT /
Category of the Issue, Problem, or Challenge
- Bridge Bearings
- Concrete Quality Control
Summary of the Issue, Problem, or Challenge
Concrete bearing seats cracked during curing and early load transfer, jeopardizing bearing stability and alignment.
Root Cause Analysis
| Factor | Details |
| Improper Concrete Mix Design | Mix had insufficient strength and was prone to shrinkage cracking. |
| Poor Curing Conditions | Ambient temperatures and moisture control were not adequately maintained. |
| Inadequate Formwork Support | Formwork movement caused stress concentrations in concrete seats. |
Impacts Due to the Issue, Problem, or Challenge
- Delays for repair and reinforcement of bearing seats
- Increased cost for remedial measures
- Risk of bearing misalignment and structural issues
Corrective Actions Taken
- Revised concrete mix to improve strength and reduce shrinkage
- Implemented strict curing protocols with temperature and moisture monitoring
- Strengthened formwork design to prevent movement during placement
Lessons Learned
- Bearing seat concrete must meet stringent durability and strength criteria
- Proper curing is essential to prevent early-age cracking
- Formwork stability affects concrete quality significantly
Case Study: Miami Expansion Joint Modular Failure (2021)
Project Overview
- Name: Miami Coastal Highway Bridge Project
- Location: Miami, Florida
- Year: 2021
- Project Size: $360 million
- Scope: Installation of modular expansion joints in a coastal bridge environment
- Lead Agencies/Contractors: Florida DOT /
Category of the Issue, Problem, or Challenge
- Expansion Joints
- Modular Systems
- Corrosion and Durability
Summary of the Issue, Problem, or Challenge
Within months of installation, modular expansion joints experienced premature wear and corrosion due to saltwater exposure, causing joint misalignment and surface roughness.
Root Cause Analysis
| Factor | Details |
| Insufficient Corrosion Protection | Protective coatings inadequate for marine environment. |
| Poor Material Selection | Materials used were not fully resistant to saltwater corrosion. |
| Inadequate Maintenance Planning | Lack of immediate post-installation maintenance protocols. |
Impacts Due to the Issue, Problem, or Challenge
- Increased maintenance costs and traffic interruptions
- Early replacement of expansion joint modules required
- Reduced overall service life and performance
Corrective Actions Taken
- Specification updates to require corrosion-resistant materials and coatings
- Enhanced maintenance and inspection schedule post-installation
- Use of marine-grade materials and sealants for future projects
Lessons Learned
- Coastal and marine environments demand special materials and coatings
- Maintenance planning must start during construction phase
- Material selection drives longevity in harsh conditions
Case Study: Portland Bridge Elastomeric Bearing Failure (2017)
Project Overview
- Name: Willamette River Bridge Replacement
- Location: Portland, Oregon
- Year: 2017
- Project Size: $350 million
- Scope: Replacement of elastomeric bearings on a major river crossing bridge
- Lead Agencies/Contractors: Oregon DOT /
Category of the Issue, Problem, or Challenge
- Bridge Bearings
- Material Defects
- Structural Integrity
Summary of the Issue, Problem, or Challenge
During bearing installation, several elastomeric pads exhibited premature deformation and delamination, causing uneven load transfer and alignment issues.
Root Cause Analysis
| Factor | Details |
| Material Manufacturing Defect | Rubber compounds had impurities, reducing elasticity and durability. |
| Handling and Storage Issues | Bearings were exposed to UV and extreme temperature fluctuations on site. |
| Insufficient QA Testing | Lack of batch testing before installation to catch defective units. |
Impacts Due to the Issue, Problem, or Challenge
- Suspension of bearing installation work
- Additional procurement delays and costs to replace defective pads
- Temporary bridge load restrictions due to uneven load distribution
Corrective Actions Taken
- Instituted rigorous supplier QA audits and batch testing protocols
- Improved on-site storage procedures to protect elastomeric materials
- Enhanced training for construction personnel on proper handling
Lessons Learned
- Elastomeric bearing quality control at manufacturing stage is critical
- Proper material storage onsite prevents premature degradation
- Early batch testing avoids costly installation of defective components
Case Study: Atlanta Expansion Joint Concrete Deck Spalling (2018)
Project Overview
- Name: Downtown Connector Bridge Rehab
- Location: Atlanta, Georgia
- Year: 2018
- Project Size: $230 million
- Scope: Replacement of expansion joints and deck rehabilitation on a busy urban bridge
- Lead Agencies/Contractors: Georgia DOT /
Category of the Issue, Problem, or Challenge
- Expansion Joints
- Concrete Durability
- Construction Quality
Summary of the Issue, Problem, or Challenge
Within weeks after expansion joint replacement and concrete deck pouring, significant spalling was observed adjacent to the joints, weakening the deck and exposing reinforcement.
Root Cause Analysis
| Factor | Details |
| Poor Joint-Deck Interface | Improper detailing led to stress concentration at joint edges. |
| Inadequate Concrete Mix | Low-quality concrete mix with insufficient air entrainment. |
| Improper Curing | Accelerated drying caused shrinkage cracking near joints. |
Impacts Due to the Issue, Problem, or Challenge
- Early deck repairs required, impacting traffic and project schedule
- Increased costs due to repair materials and labor
- Risk of reinforcement corrosion and reduced deck lifespan
Corrective Actions Taken
- Revised joint detailing to better distribute stresses
- Improved concrete mix design focusing on durability and air content
- Implemented strict curing regime including moisture retention methods
Lessons Learned
- Joint-deck transition areas require special attention in design and construction
- Concrete mix design impacts durability near high-stress zones
- Proper curing critical to prevent early-age damage
Case Study: New York Bridge Bearing Corrosion During Construction (2020)
Project Overview
- Name: Hudson River Bridge Replacement
- Location: New York, New York
- Year: 2020
- Project Size: $450 million
- Scope: Installation of steel bridge bearings on a large river crossing
- Lead Agencies/Contractors: NY DOT /
Category of the Issue, Problem, or Challenge
- Bridge Bearings
- Corrosion Protection
- Construction Environment
Summary of the Issue, Problem, or Challenge
Steel bearings stored onsite without adequate protection began showing early signs of corrosion due to exposure to rain and humid conditions.
Root Cause Analysis
| Factor | Details |
| Inadequate Onsite Protection | Bearings lacked protective coverings during storage. |
| Delayed Installation | Bearings stored longer than planned due to schedule delays. |
| Insufficient QA Procedures | Lack of regular inspection of stored components. |
Impacts Due to the Issue, Problem, or Challenge
- Costly cleaning and repainting of corroded bearings
- Schedule impacts due to need for remediation before installation
- Increased risk of future bearing deterioration if not properly treated
Corrective Actions Taken
- Established strict storage and protection protocols for steel components
- Implemented routine onsite inspections for corrosion
- Coordinated installation schedule to minimize storage times
Lessons Learned
- Steel bearings require immediate protection upon delivery
- Storage conditions can significantly impact component durability
- Scheduling should consider material handling and protection needs