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Civil and Precast Construction · Question
Short answer
Most overruns come from a handful of causes: design that was incomplete when pricing began, ground conditions that differ from assumptions, owner changes during construction, delays that raise overheads and financing cost, and material price movement. Quotes that omit items also create surprises later. Careful early planning and disciplined change control reduce, though never remove, the risk.
Overruns rarely come from one dramatic event. They build from small gaps that were visible at the start.
Incomplete design is the largest source. If drawings and specifications are unfinished when the contractor quotes, the price rests on assumptions, and every clarification becomes a cost question later. Ground is the second: foundations designed without a proper soil study can change once the excavation shows what is really there.
Owner changes come next. A revised layout, an upgrade in finish or an added floor mid-way costs more than the same item planned at the start, because completed work may have to be undone.
Delay does its own damage. A late start, slow approvals, shortage of labour or poor sequencing extends the time that site costs, supervision and interest on borrowed money keep running. When the project is financed, delay also pushes back the start of repayment-supporting income.
Materials, especially steel and cement, move in price. A contract that does not allow for this passes the risk to the contractor, who may protect itself with a higher quote or, in difficult cases, slow the work.
Finally, there are thin or incomplete budgets. Owners forget to include approval costs, utility connections, site development, contingency and professional fees, then find the real total is higher.
A warehouse that grew
A hypothetical owner approves a simple shed, then adds a mezzanine and a heavier floor after construction starts. Because the foundation is already cast, strengthening it costs far more than designing for the load at the outset.
Practical protections include finishing design before tendering, commissioning soil tests early, allowing a sensible contingency, controlling variations in writing and agreeing a clear approach to price movement in the contract.
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