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BETTESWORTHConstruction

Structural Design Errors During Construction: What to Do First

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A possible structural design error found during construction needs prompt documentation and review—not an improvised repair. If a member or area may be unstable, keep people clear and follow the site’s safety and emergency procedures; then notify the responsible project parties and route the issue to the appropriate engineer through the contract process. A discrepancy may come from design documents, field conditions, coordination, sequencing, fabrication, or installation, and it does not by itself prove a design failure or negligence.

What should you do first when you find a possible structural error?

Protect people, report the condition, and preserve the facts. Do not direct a structural change based only on a field observation; the right response depends on the actual condition, design intent, construction stage, contract, and applicable requirements.

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  1. Assess whether there may be an immediate hazard. If a structure or element appears unstable, keep people away from the affected area and alert the site lead and responsible safety personnel. Use the project’s safety and emergency procedures. This is a prudent safety response, not a universal site-specific emergency plan.
  2. Notify the responsible parties. Report what appears wrong, where it is, when it was found, what work is affected, and whether work or access may pose an immediate risk. Follow the project’s communication and escalation procedures, which may involve the contractor, owner, site manager, design team, and safety staff.
  3. Record the condition before it changes. If it is safe to do so, take photographs and appropriate measurements. Note the exact location and component, date and time, drawing numbers and revisions, people present, relevant conversations, and any follow-up. Preserve related RFIs, submittals, inspection records, delivery information, and field notes.
  4. Submit the issue through the project’s formal process. Use the RFI, nonconformance report, or other route required by the contract. Give the responsible engineer enough information to assess the design intent, observed condition, loads and construction stage, and any alternatives being proposed.
  5. Wait for a documented disposition before making a design-affecting change. The engineer’s response may require revised documents, a repair design, replacement, testing, or acceptance as suitable for intended use. The correct choice cannot be determined from a general checklist.
  6. Verify completion and close out the record. Carry out the approved disposition under the project’s inspection and quality procedures. Document completion and required testing, distribute revised instructions to affected trades, and close the issue only when the required work and records are complete.

If a condition seems urgent, safety action should not wait for routine document processing. At the same time, an urgent observation is not authority for an unreviewed repair. Escalate promptly and use the site’s established emergency and stop-work procedures as applicable.

What counts as a structural design error?

A field discrepancy is a condition that appears not to match the contract documents, approved submittals, design intent, or applicable requirements. It may be a design omission or conflict, but it can also result from changed field conditions, coordination gaps, construction sequencing, fabrication, installation, or a misunderstanding about which document revision governs.

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Examples can include a member or connection that does not appear to match its approved detail, a conflict between drawings and specifications, an unexpected condition that changes the assumptions behind the design, or a construction-stage stability concern. These are reasons to ask for review, not enough information to diagnose the cause or prescribe a fix.

ASCE cautions that “the existence of a drawing discrepancy, omitted detail, specification conflict, or subsequent design revision does not by itself establish negligence.” Whether a professional met the applicable standard of care depends on the circumstances, scope, information available at the time, causation, and consequences. A change order, cost impact, or revision alone does not settle that question. See ASCE’s discussion of design errors and the professional standard of care.

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How should you document a suspected discrepancy?

Make the record factual, dated, and specific enough that someone who was not present can understand what was observed and what happened next. A record is useful for technical evaluation, coordination, and closeout; it is not a substitute for an inspection or an engineering judgment.

  • Identify the location: project area, level, grid or other location reference, and the specific member or component if known.
  • Describe what you observed: distinguish visible facts from interpretation. For example, record what appears different from the drawing rather than asserting an unconfirmed cause.
  • Reference the governing information: drawing number, revision, specification section, approved submittal, or prior RFI, where applicable.
  • Record timing and context: date and time, work underway, construction stage, conditions relevant to the observation, and who was present or notified.
  • Preserve suitable supporting material: photographs, measurements, inspection reports, delivery or fabrication records, and related communications, when available and safe to collect.
  • Track the decision: record the question submitted, the response and its author, any revised documents or instructions, implementation, verification, and closeout.

ASCE recommends that an engineer’s site-visit record include the time, observations, people spoken with, discussions, areas visited, and follow-up. Its guidance also makes clear that an engineer’s site role is generally observation of conformance within the actual contract scope—not necessarily continuous inspection or supervision. Read ASCE’s guidance on documenting decisions and field visits.

Who should evaluate and approve a structural change?

The project’s contract, jurisdiction, design responsibilities, and delegated-design arrangements determine who has authority. Route design-affecting questions to the responsible design professional—often the engineer of record for the affected design—and do not assume that every project gives that engineer the same construction-phase role.

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Use the contract’s RFI and change-management procedures so the question, technical response, approvals, and revised documents are traceable. ASCE recommends retaining the engineer of record during construction for changes affecting facility function. It also warns that reviewers of submittals or other parties who issue design changes without the engineer’s involvement can create responsibility and performance problems. The project team should confirm the relevant scope and authority rather than infer them from job titles. See ASCE’s construction-phase guidance on retaining the engineer of record.

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In structural steel work, the AASHTO/NSBA shop-detail drawing guideline says errors or discrepancies in contract plans should be conveyed to the owner and contractor for corrective action. It also distinguishes drawing markups from actual construction changes: a markup is not, by itself, authorization to build differently. Follow the project’s required approval and change process, and make sure affected shop drawings and construction documents are updated. The guideline is available as AASHTO/NSBA G1.1, Shop Detail Drawing Review/Approval Guidelines.

Written direction matters. Dan Becker, M.ASCE, of ASCE’s Committee on Claims Reduction and Management, notes: “Many contracts state that only written directions can change the contract documents, however some contractors will take verbal direction in the same light.” Treat informal conversations as conversations, not as a reliable substitute for a required written disposition. Confirm important technical direction in the form the contract requires. See ASCE’s discussion of documenting decisions and field visits.

Can a crew repair or modify the condition in the field?

Not on the basis of an unreviewed observation or an informal instruction. A repair, replacement, field modification, or acceptance-as-is decision must be evaluated for the particular component and project, then authorized through the applicable engineering and contract process.

For U.S. steel erection, OSHA’s interpretation of 29 CFR 1926.755(b) reproduces the requirement: “Anchor rods (anchor bolts) shall not be repaired, replaced or field-modified without the approval of the project structural engineer of record.” OSHA also says the erector must receive written notice of completed modifications. This is a specific U.S. steel-erection requirement; confirm current rules and project requirements for the work at hand. See OSHA’s anchor-rod modification interpretation.

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For structural steel fabrication deviations, the American Institute of Steel Construction says the structural engineer of record should evaluate the deviation; major work requires an agreed corrective plan. The specific disposition depends on the condition and intended performance. A general article cannot establish whether a particular component should be repaired, replaced, tested, or accepted. See AISC’s guidance on general fabrication.

When the responsible engineer evaluates options, useful considerations include structural capacity and stability, temporary conditions during construction, durability and intended function, code and contract compliance, inspectability and verification, effects on connected work, schedule and cost, and approval and record requirements. These factors help frame the decision; they do not produce a universal ranking or substitute for a project-specific evaluation.

Why must temporary construction conditions be checked?

A structure that is adequately designed for its prescribed completed-state loads can still be unstable during erection if temporary bracing or sequencing is inadequate. The construction-stage condition must be considered, not assumed to be safe because the final design is adequate.

OSHA’s investigation of a November 8, 2021, roof-truss collapse during construction of a Dollar General in Orange City, Florida, reported one worker fatality and two injuries. OSHA concluded that inadequate temporary bracing allowed 70-foot trusses to buckle out of plane during erection. The agency found the trusses were properly designed for prescribed loads but unstable as erected; it also reported that the erector had not consulted an engineer for temporary bracing design, as industry practice called for trusses longer than 60 feet. These are facts about that incident, not universal bracing specifications or a formula for another project. The OSHA incident investigation illustrates why temporary states need their own competent evaluation.

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Can I rely on cure time instead of doing such a test?

No general answer applies to every test or project. OSHA’s steel-erection inspection policy uses this question in a specific context; cure time alone should not be treated as a substitute for a test or verification that an applicable requirement calls for. Check the governing provision, approved project documents, and the responsible engineer’s direction rather than inferring acceptance from elapsed time.

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The policy is guidance for OSHA enforcement of U.S. steel-erection standards, not a blanket rule for every concrete, anchor, or structural test. The correct test, timing, and acceptance criteria depend on the requirement that applies to the work. Consult OSHA’s steel-erection inspection policy and the project’s technical documents.

What should happen before the issue is closed?

Closeout means more than completing physical work. Confirm that the approved disposition was implemented, the required inspection or testing is complete, affected parties have the current instructions, and the record shows what was decided and verified.

  • Confirm that the written disposition identifies the affected work and the authorized resolution.
  • Make sure revised drawings, specifications, or shop details are distributed to the people who need them and superseded information is not mistaken for current direction.
  • Complete inspection, testing, or other verification specified by the disposition and project quality procedures.
  • Record who performed and verified the work, when it was completed, and any outstanding conditions or follow-up.
  • Close the RFI or nonconformance only when the required technical resolution and supporting records are in place.

For steel shop-drawing discrepancies, formal conveyance to the owner and contractor and implementation of corrective action are central parts of the AASHTO/NSBA process. Project-specific contracts may add their own approval, record, and closeout steps.

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Does finding a discrepancy mean someone was negligent?

No. A discrepancy can require correction without establishing negligence, and a change or cost impact alone does not establish fault. The technical question—what condition exists and what response is safe and compliant—should be addressed separately from any later determination of responsibility.

ASCE describes standard-of-care analysis as dependent on circumstances, professional scope, information available when the work was performed, causation, and consequences. Keep records factual and preserve the project communications; do not turn an unresolved field observation into a liability conclusion. For broader context, see ASCE’s explanation of why not every design error is negligence.

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What should you avoid doing?

  • Do not treat a photo, field observation, or informal opinion as a complete structural inspection.
  • Do not move, cut, drill, weld, reinforce, replace, or otherwise alter structural work based on an unapproved field fix.
  • Do not assume a drawing markup, verbal conversation, or submittal review changes the contract documents.
  • Do not assume the completed-state design proves the structure is stable at every stage of construction.
  • Do not generalize one OSHA case, anchor-rod rule, or steel fabrication recommendation to components or jurisdictions it does not cover.
  • Do not label the issue a design failure or negligence before the technical facts, scope, and applicable standard have been evaluated.

Requirements vary by jurisdiction, contract, material, and assigned project role. OSHA sources cited here concern U.S. construction requirements; consult current regulations and the governing project documents for the particular work.

Frequently Asked Questions

What if the engineer and contractor disagree about a proposed disposition?

Keep the issue open and document each position through the project’s required channels. Refer to the contract’s escalation, dispute-resolution, and decision-authority provisions; if an immediate safety concern remains, use the site’s safety escalation process rather than waiting for a commercial resolution.

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Should a site visit by the engineer be treated as an inspection of every component?

Not automatically. The engineer’s construction-phase role depends on the contract scope, and a visit may involve general observation rather than continuous inspection or verification of every installed item. Confirm what the visit covered and what additional inspection is required.

Do building-code requirements determine who pays for a correction?

Code compliance and cost responsibility are separate questions. The governing contract and project records, along with the circumstances and cause of the condition, inform responsibility; a code issue alone does not establish who bears the cost.

What if the discrepancy is found in a shop drawing rather than in installed work?

Identify whether the drawing is approved and which contract-document revision it references, then submit the conflict through the shop-drawing/RFI process. Do not treat a reviewer’s markup as authorization for a fabrication or construction change unless the contract process makes it an approved direction.

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