8 Engineering Pains for General Contractors

Part 1: Key Challenges in the Construction Engineering Industry Impacting General Contractors and Construction Companies

General contractors and construction companies face numerous challenges that can significantly affect their ability to deliver projects on time, within budget, and to the required quality. These challenges often stem from issues within the engineering design and planning phases, which have downstream effects during construction. Below, we outline some of the most critical challenges that contractors encounter, particularly when working on public and private sector projects across commercial, industrial, and infrastructure sectors.

1. Incomplete Design Packages at the Tender Stage

One of the most persistent issues contractors face is receiving incomplete design packages at the tender stage. It is common for tender documents to only include 50–60% of the final design, leaving contractors to fill in the blanks when pricing their bids. This often results in significant assumptions that can lead to disputes, change orders, and cost overruns during the project. For general contractors, these uncertainties can make it difficult to provide accurate estimates, ultimately leading to financial strain when additional scope or unforeseen complexities arise later in the construction process.

Incompleteness, whether in scope or in sufficient details, costs project budet and schedule as much as 15% of a contract value.

2. Incomplete Designs Issued for Construction

Even as projects move into the construction phase, contractors frequently encounter design packages that are not fully developed, often being only 80–90% complete. Missing detailed engineering elements, such as connection designs, leave contractors without the crucial information they need to proceed. This results in delays while waiting for final designs, or, worse, contractors may be forced to make on-site decisions based on incomplete information, increasing the risk of rework and compromising quality.

3. Poor Quality of Engineering Drawings

Another issue that plagues contractors is the poor quality of engineering drawings. In many cases, drawings are not organized or detailed in a way that is practical for those on the ground, such as construction managers and foremen. Rather than having all relevant information consolidated on the same page or within the same sheet, key details are spread across multiple pages, forcing the reader to flip back and forth. This inefficiency not only wastes time but also increases the likelihood of errors, as critical information can be missed or misunderstood. Quality engineering drawings should be intuitive and structured in a way that supports the flow of construction, but too often, insufficient thought is put into making them user-friendly for construction professionals.

4. Insufficient Constructability Considerations

A major disconnect between design and construction occurs when engineers fail to properly account for constructability. Designs may appear sound on paper, but when it comes to the practicalities of building them on-site, unforeseen challenges often arise. For example, multiple critical paths in a project may intersect, creating bottlenecks that slow down progress. These bottlenecks are often the result of poor sequencing or a lack of understanding of how construction teams need to move through the phases of a build. Additionally, designs that do not factor in material availability or the logistics of working in remote or challenging environments can cause delays and budget overruns.

5. Delays in Finalizing Design Details and Schedule Slip

A common source of frustration for contractors is the delay in finalizing design details, which frequently leads to schedule slippage. When the engineering team is late in delivering finalized designs or changes, it creates ripple effects throughout the project. Construction teams are left waiting for critical information, which can stall multiple areas of work simultaneously. This domino effect not only delays the schedule but also increases costs, as labor, equipment, and materials sit idle or are underutilized during these waiting periods.

6. Specification of Materials Not Readily Available

Design specifications sometimes call for materials that are not readily available in the local market, leading to procurement delays and inflated costs. When contractors are forced to source specialized materials that require long lead times or are difficult to procure, it disrupts the project timeline and can strain relationships with clients. Furthermore, substitute materials may not always be viable, particularly if the design has not allowed for any flexibility in material selection.

7. Non-Standard Connection Designs and Specialized Labor Requirements

Another challenge arises when engineers specify non-standard connection designs or details that require specialized training for field labor. While these designs may theoretically improve structural performance, they often complicate the construction process by requiring additional training or skill sets that the local workforce may not possess. This increases labor costs and can slow down the project as contractors must invest time and resources into upskilling their workforce or bringing in specialized subcontractors. Moreover, non-standard details limit the opportunity for value-engineering, as contractors are bound by rigid specifications that may not lend themselves to more efficient or innovative construction methods.

8. Lack of Flexibility in Construction Methodologies

Many projects are designed with rigid construction methodologies that leave little room for contractor-led innovation or value-engineering. While these methodologies might meet the design intent, they can be inefficient from a constructability perspective. Contractors are often bound to follow traditional, less efficient methods that stifle opportunities to optimize processes, save time, or reduce costs.

When contractors are not incentivized or allowed to introduce their own innovations, it limits their ability to add value and achieve better project outcomes.

The construction engineering industry faces several challenges that directly impact general contractors and construction companies. From incomplete design packages and poor quality drawings to insufficient constructability considerations and material procurement issues, these problems can lead to delays, increased costs, and inefficiencies on the job site. These challenges are not just technical issues; they affect the entire project lifecycle, from tendering to final completion, creating risks that contractors must navigate carefully.

In Part 2, we will explore risk mitigation strategies that contractors can adopt to address these issues and reduce their exposure to project risks, improving both project outcomes and client satisfaction.

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