Conflicts
Where the customer said one thing, the PM said another, and the plan says nothing. Each one shows every side with evidence, why it matters, what it costs you if it's wrong, and what to do — work the expensive ones first.
$222,200–$347,700
still at risk · 11 open
$0
recovered · 0 closed
Drawing Revision Conflict — Rev B vs. Rev C
Harborline Tower — Architectural Railing Package
The customer approved Rev C while the shop folder marks Rev B as active, and a PM status report claims 70% fabrication complete — likely from the superseded drawing.
Customer Approval Email — May 9
Approved — please proceed with Drawing Rev C as attached. Rev C revises the top-rail profile and adds two intermediate posts per run.
Shop Folder (SharePoint)
MetalWorks_Harborline_Railing_Rev_B.pdf — marked ACTIVE in the shop folder.
PM Status Report — May 5
Railing fabrication is approximately 70% complete.
Cost of being wrong
$29,100 – $51,100
Rework $12,900–$18,700 · margin erosion $16,200 · +9 days
Drivers: fabricated to superseded drawing
Why it matters
Fabrication is likely proceeding from an outdated drawing, risking rework on completed assemblies, a schedule slip, and a disputed change order with the GC.
Recommended action
Pause work, make Rev C the single active revision, and issue a priced change order for the delta.
Install Date Promised on Superseded Revision
Harborline Tower — Architectural Railing Package
The PM committed a May 27 install date based on Rev B progress. Rev C adds posts and revises the top rail, changing labor and material.
PM Email — May 5
Install is locked for May 27 based on current fabrication progress.
Customer Approval Email — May 9
Rev C revises the top-rail profile and adds two intermediate posts per run.
Cost of being wrong
$20,600 – $34,100
Rework $9,800–$14,300 · margin erosion $10,800 · +5 days
Drivers: fabricated to superseded drawing · material refabrication
Why it matters
A committed install date built on superseded scope is a likely customer escalation with the GC.
Recommended action
Re-baseline the install date against Rev C and communicate proactively before the GC plans crews.
Change Order Not Raised for Rev C Delta
Harborline Tower — Architectural Railing Package
Rev C increases the material take-off (added posts) but no change order has been raised; the contract value still reflects Rev B.
Customer Approval Email — May 9
Two added intermediate posts per run across all guardrail runs.
Shop Folder (SharePoint)
No change-order document present in the job folder.
Cost of being wrong
$10,500 – $18,200
Rework $5,100–$7,400 · margin erosion $5,400 · +3 days
Drivers: fabricated to superseded drawing · material refabrication
Why it matters
Unbilled scope erodes margin and weakens the position if a dispute arises later.
Recommended action
Quantify the Rev C delta and raise a change order before proceeding.
Weld Spec — Verbal Call vs. Drawing Callout
Beacon Plaza — Monumental Stair Fabrication
The May 6 Teams call note cites one weld spec; the approved shop drawing callout cites another. The EOR has not confirmed either in writing.
Teams Transcript — May 6
EOR (verbal): "go with the full-pen detail on the stringer connections."
Approved Shop Drawing
Connection callout: fillet weld per detail 4/S-301.
Cost of being wrong
$29,700 – $44,100
Rework $12,100–$17,500 · margin erosion $17,600 · +5 days
Drivers: structural rework · fabricated to superseded drawing
Why it matters
Welding to the wrong spec on a monumental stair risks rejection at inspection and full rework.
Recommended action
Obtain written EOR confirmation of the governing weld spec before structural welds proceed.
Special Inspection Requirement Unconfirmed
Beacon Plaza — Monumental Stair Fabrication
If full-penetration welds govern, special inspection may be required and is not currently scheduled.
Teams Transcript — May 6
No mention of special inspection scheduling for the stair welds.
Approved Shop Drawing
General notes reference special inspection per IBC where applicable.
Cost of being wrong
$11,600 – $18,300
Rework $2,800–$4,100 · margin erosion $8,800 · +3 days
Drivers: rework + schedule exposure
Why it matters
Missing a required special inspection can halt the job and require destructive testing.
Recommended action
Confirm inspection requirements with the EOR alongside the weld spec.
RFI-Driven Scope Not in Schedule
Midtown Exchange — Commercial Handrail Install
Three RFIs answered by Outlook changed the anchor layout and sequence; the PM schedule is unchanged for 23 days.
RFI-014 Response — May 12
Proceed with revised anchor layout per attached sketch. This supersedes the original detail.
PM Schedule Export — May 14
Last modified Apr 21. No RFI tasks present in the schedule.
Cost of being wrong
$21,600 – $33,600
Rework $6,800–$9,800 · margin erosion $14,800 · +5 days
Drivers: anchorage / inspection failure
Why it matters
Field crews may install to a stale sequence, causing rework and friction with the GC.
Recommended action
Reconcile RFI outcomes into the schedule and confirm the sequence with the superintendent.
Anchor Type Discrepancy
Midtown Exchange — Commercial Handrail Install
RFI-014 sketch shows an epoxy anchor where the approved submittal shows a mechanical anchor.
RFI-014 Response — May 12
Revised detail indicates adhesive (epoxy) anchors at slab edge.
Approved Submittal
Submittal specifies mechanical expansion anchors at slab edge.
Cost of being wrong
$10,900 – $17,900
Rework $3,500–$5,100 · margin erosion $7,400 · +3 days
Drivers: anchorage / inspection failure
Why it matters
Wrong anchor type at the slab edge is a safety and inspection failure.
Recommended action
Confirm anchor type and update the submittal before procurement.
Balcony Live-Load Rating Mismatch
Foundry Lofts — Structural Stair & Balcony
The customer requirements PDF states 60 psf; the structural sketch annotates 100 psf. Detailing should not proceed until frozen.
Requirements PDF
Juliet balconies designed for 60 psf live load.
Structural Sketch (SharePoint)
Balcony framing annotated 100 psf live load.
Cost of being wrong
$39,100 – $54,700
Rework $14,700–$21,300 · margin erosion $24,400 · +5 days
Drivers: structural rework · re-engineering / re-detail
Why it matters
A 40 psf difference changes member sizes and connections — building the wrong one is a full re-detail.
Recommended action
Freeze the governing rating with Anvil's EOR before releasing detailing.
Coating System Conflict
Lakeside Pavilion — Steel Canopy & Trellis
Spec PDF calls for hot-dip galvanizing only; the kickoff email says galvanize then powder coat.
Spec PDF
All exposed steel hot-dip galvanized per ASTM A123.
Kickoff Email
We want it galvanized and then powder coated in the bronze color.
Cost of being wrong
$7,800 – $14,700
Rework $3,200–$4,700 · margin erosion $4,600 · +3 days
Drivers: recoat after delivery
Why it matters
Powder over galvanizing requires extra prep and lead time; missing it means recoating after delivery.
Recommended action
Confirm the governing coating system with the architect before blasting.
Material Substitution vs. Approved Submittal
Northgate Mall — Storefront Metal Cladding
A lighter gauge was discussed on the May 9 call to hold budget, but the approved submittal still specifies the heavier gauge.
Teams Transcript — May 9
Customer: "can we drop to the lighter gauge to keep the budget?"
Approved Submittal
Cladding panels: heavier gauge aluminum, approved as submitted.
Cost of being wrong
$17,800 – $30,000
Rework $7,000–$10,200 · margin erosion $10,800 · +5 days
Drivers: material refabrication
Why it matters
Fabricating to an unapproved substitution risks rejection and a forced refabrication at cost.
Recommended action
Issue a formal substitution request and get written approval before cutting.
Shop Drawing vs. Customer Dimension Update
Apex Logistics — Industrial Pipe Handrail
The customer's May 11 email gives loading-dock dimensions that differ from the current shop drawing set.
Customer Email — May 11
The dock handrail runs are 11'-4", not 10'-8" as previously drawn.
Shop Drawing Set (SharePoint)
Dock handrail runs dimensioned 10'-8" on current set.
Cost of being wrong
$23,500 – $31,000
Rework $4,700–$6,800 · margin erosion $18,800 · +3 days
Drivers: fabricated to superseded drawing · cut-to-length scrap
Why it matters
Fabricating to the old dimension means cut-to-length scrap and field rework.
Recommended action
Reconcile the May 11 dimensions into the shop set and confirm the active revision.