“There’s never enough time to do it right, but there’s always enough time to do it again.” This quote says a lot about human nature, the construction process and the corniness level found in the industry. It’s true, though – no large project will be without “rework”. Rework is work onsite that must be redone, the causes for which are varied and plentiful. While every contractor has experienced rework on their project at some point, none of them want to do it again. Rework affects the schedule, our reputations and of course, the bottom line. In an effort to be preventative, this article is all about avoiding rework in construction, along with 10 common causes and solutions for each!
How Much Money Is Lost On Construction Rework?
According to BisNow, billions of dollars are wasted on construction rework each year. That’s a lot of missed profit. Clearly, nobody wants to have any part of rework, yet that figure is absolutely massive.
Luckily, the best medicine is preventative. Let’s review 10 common causes of rework and also discuss avoiding rework in construction going forward!
Avoiding Rework In Construction: 10 Common Causes & Solutions
Here are some common causes of rework on construction projects. These causes include on-paper mistakes, procurement of material, safety measures and even the weather.
- Uncoordinated Project Documents
- Using The Incorrect Material
- Deviating From Project Documents
- Proceeding Without Approval
- Improper Planning & Coordination
- Defective Materials
- Poor / Improper Working Conditions
- Portions Of Work Are Built Out Of Tolerance
- Insufficient Site Protection
- Incorrect Survey Marks
Below is an in-depth look at each of these causes of rework, along with how they can be avoided in the future.
1. Uncoordinated Project Documents
We’ve previously written about the many types of documents commonly found in construction, including Architectural drawings, Structural Drawings, Shop Drawings, Specifications, Etc. Rework in construction often arises when there are discrepancies between them!
By following the directive of one document, contractors may violate what another document says, which results in work onsite being redone. Rework due to uncoordinated project documents can be the fault of any party – the Contractor themselves or the Design Team.
Here are a few ways we can avoid rework in construction due to uncoordinated project documents:
- Thoroughly review all project documents at the time of bid, as well as once the project is awarded.
- Should any discrepancies be found, notify ownership or design team and request their input on proceeding.
- Make sure documents are approved before referencing them onsite.
Read Next: Construction RFI: Meaning, Purpose & Tips (FREE Excel Template)
2. Using The Incorrect Material
Speaking of project documents, the construction specifications dictate the type of materials that must be used, in accordance with the design requirements of the project.
Specifications outline the types of materials required, how a material must perform and oftentimes manufacturers/models will be listed, too.
When the wrong material is installed onsite, it SHOULD get removed. Materials must match what is specified by the Design Team, because they perform in a manner necessary for the project’s quality requirements. This can include structural integrity, weather sensitivity and so on.
Here are a couple ways we can avoid rework in construction due to installing improper materials:
- Always submit documents related to construction materials for approval prior to purchasing or using them.
- Submit physical samples for approval, when possible.
- Provide your vendors with the exact approved submittal and/or written specifications to help pick the right product.
Read Next: The Construction Submittal Log: 5 Best Practices (FREE Excel Template)
3. Deviating From Project Documents
When contractors perform work that deviates from the approved drawings, they’ll surely be redoing it. Rightly so!
Contractors that don’t follow what the drawings say will almost certainly make a mistake of some kind. The easiest way to avoid this is to formally request clarification on how to proceed, should an unknown or discrepancy pop up. This keeps contractors in the clear and gives the Design Team and Owner time to review.
Here are a couple of other ways we can avoid rework in construction due to deviating from the project documents:
- Review documents with the Design Team (Architects, Engineers, Etc) on the jobsite prior to commencing new work.
- Perform a thorough survey of the site relative to the drawings; relate your work to benchmarks, gridlines and dimensions prior to starting.
- Make sure field crews have a clear path for proceeding onsite.
Read Next: How Do You Read Blueprints? Our Step-By-Step Guide With Examples!
4. Proceeding Without Approval
Most contractual agreements in construction include some form of this statement: “Contract shall not perform any work or begin a new phase of work without having received written direction, consent and/or approval from the Owner or Owner’s Representative.“
This clause covers many topics, and one of them is Design Team approval of Contractor-supplied documentation. Contractors that don’t submit drawings for approval or perform work without them are at high risk of having to redo the work. In fact, they’re legally bound to!
There’s not too much else to say – the best way to avoid rework in this scenario is to submit as much information / documentation as you can for approval and hold off performing the work until it’s approved.
Read Next: Our Comprehensive List Of 25 Ways Contractors Lose Money
5. Improper Planning & Coordination
Construction projects can be fast-moving and chaotic. Within these aspects of construction arise coordination issues – sometimes the cart is put before the horse in haste.
An extremely simple example: an exterior concrete wall must be waterproofed before a brick siding is installed. In a rush, the mason begins installing brick before the wall gets waterproofed. In this instance, all of the brick that’s installed must be removed so the wall can get waterproofed.
Again, this is an extremely simple example but it illustrates the point.
The good news? Work can be coordinated and sequenced ahead of time! Here are a couple ways we can avoid rework in construction due to improper planning and coordination:
- Before commencing a new phase of work, hold a coordination meeting between all relevant contractors to discuss as a group.
- Create a written sequence plan for your work, which includes a phasing of steps and how risk will be mitigated.
Read Next: What Are The Basics Of Project Scheduling? 9 Essential CPM Steps
6. Defective Materials
This one’s short and sweet. If the material installed is not in new, unused condition, it should not be used or installed. Not only will the material not perform to the level required by the design, but it’s most likely in violation of the contract!
Avoid rework in construction by using materials that are new and have been stored properly.
Read Next: The Difference Between Construction Managers And General Contractors
7. Poor / Improper Working Conditions
One of the keys to avoiding rework in construction is to work in proper field conditions. Many construction materials and methods require specific environmental conditions for the work to come out right.
Factors such as heat, cold, precipitation, humidity, sun exposure (UV) and ventilation can all affect the installation and performance of various construction materials.
For example, concrete must be kept at a specific water-content when it’s setting up – if it evaporates too quickly, the concrete can crack and dry out. Plastic must be put over the concrete soon after it’s poured in order to ‘trap’ water inside the concrete. This prevents the concrete from drying out too fast. When this ISN’T done, there’s a greater risk of having to remedy the concrete later, or redo it completely!
Avoiding rework in construction due to environmental factors simply requires Contractors to have a firm understanding of what each material requires. This includes the manufacturer’s directions as well as the written project specs.
Read Next: What Is A Project Safety Plan? Free Construction Safety Plan Template!
PROMOTION
8. Portions Of Work Are Built Out Of Tolerance
In construction, design requirements dictate that various components of the work are built ‘to a certain tolerance’. What does this mean? It means that the variance in as-built dimensions of a particular component must be within a specific dimensional range.
For example, consider a concrete building with singular, individual windows (as opposed to continuous glass curtainwall). The Architect who designed the building chose a specific window manufacturer for the project. Their windows are manufactured and supplied in specific sizes.
In turn, the Architect specifies that the concrete must be built within a 1/2-inch tolerance. This means that the width of the window openings in the concrete cannot vary more than 1-inch in width (1/2-in. per side) from where the window sill will be vs. where the window header will go. This will allow the window system to fit and get installed properly.
When trying to avoid rework, it’s essential that contractors understand the dimensional tolerances specified for their portion of work, along with the allowable tolerances for work adjacent/underneath/on top of theirs.
Read Next: Does Weather Affect Construction? 10 Ways Your Project Will Be Impacted
9. Insufficient Site Protection
Nothing makes a construction project sour quite like good work getting ruined. Such is the story for finished work that is not properly protected once it’s done!
Site protection is extremely broad, but also simple: keep the finished work from getting damaged in any way.
Here are a few examples of how unprotected work can be quickly ruined:
- A finished floor or wall is damaged by construction equipment.
- Glass getting shattered by adjacent work taking place.
- The site isn’t protected from rain or snow and finished work gets soaked.
Want to avoid rework? Protect your finished work! It’s like taking out an insurance policy – it costs a little extra, but pays back dividends if it’s ever needed.
Read Next: Basic Jobsite Safety For Project Managers In Construction
10. Incorrect Survey Marks
Rounding off our list of causes for construction rework is…incorrect survey marks!
Marks on the job site provided by professional, licensed surveyors should be ‘right on the mark’ (terrible joke), with benchmarks representing the accurate sea-level elevation and grid lines falling precisely where they should relative to the drawings. Most of the time, they are.
Like all humans, surveyors are prone to make mistakes on occasion. Or, contractors may misinterpret the marks and proceed incorrectly in turn. Regardless of whose fault it is, a common cause of rework in construction is building based on incorrect marks on site.
Here are a couple ways we can avoid rework in construction due to incorrect marks or layout:
- Contractors can double check elevation benchmarks using apps or handheld devices.
- Contractors should perform a thorough layout of their own work prior to beginning. This will flush out discrepancies with any benchmarks or site gridlines.
Read Next: Change Order Best Practices: What Contractors & Clients Need To Know
Avoiding Rework In Construction: In Summary
At the end of the day, we’re all human. Even the most organized, well-planned construction projects will encounter issues and mistakes along the way. By understanding the 10 common site issues discussed above, contractors will be a lot better at avoiding rework in the future! I hope this article has helped you, and thanks a lot for reading.
