Early soil testing can cut construction cost overruns, geotechnical engineer says

One in three engineering and construction projects face major cost overruns, and poor soil data is a common culprit, according to industry research cited by NewTech Engineering. Geotechnical engineer Kerry Cooper says early site investigations can help developers avoid redesigns, delays and safety risks before construction starts.

Why it matters: - Construction budgets are under pressure, and unexpected ground conditions can quickly turn into redesigns, delays and higher costs. - Early geotechnical work can reduce uncertainty before contracts are finalized and help teams design for actual site conditions instead of assumptions. - In the Carolinas, where soil conditions can change sharply over short distances, site-specific testing can be the difference between a stable foundation and a costly surprise.

What happened: - NewTech Engineering highlighted research from Bentley Systems and Oxford Global Projects showing that about one in three engineering and construction projects experience significant cost overruns. - The company said unforeseen ground conditions are among the most common contributors to those overruns. - Kerry Cooper, owner of NewTech Engineering, said every construction project starts with the ground beneath it. - Cooper said small assumptions about soil conditions can become expensive problems once construction is underway.

The details: - Geotechnical investigations assess soil composition, groundwater conditions, bearing capacity, settlement potential and other underground factors that shape foundation design. - Poor soil data can leave projects exposed to unstable soils, excessive settlement, hidden fill, high groundwater levels or unsuitable bearing conditions. - Unexpected subsurface conditions can force foundation redesigns, additional material imports, project delays and higher construction costs. - Inadequate site investigations can also trigger equipment downtime, permitting delays, extra excavation, material changes and schedule extensions that affect multiple contractors. - The Federal Highway Administration says geotechnical engineering is critical to managing construction risk because subsurface conditions are often one of the largest unknowns in project planning. - A typical investigation can include soil borings, laboratory testing, groundwater evaluation and engineering recommendations for foundations, pavement design, retaining walls and site preparation.

Between the lines: - The message is shifting from geotechnical work as a checkbox to geotechnical work as risk management. - As construction costs rise and schedules tighten, project owners appear to be valuing better site data earlier in the process. - The Carolinas add complexity because projects may encounter expansive clay, loose sands, weathered rock, high groundwater, uncontrolled fill or residual soils from bedrock. - Cooper said neighboring properties can have completely different subsurface conditions, so relying on nearby projects instead of testing a specific site creates unnecessary risk. - The American Society of Civil Engineers says understanding subsurface conditions early helps project teams reduce uncertainty before contracts are finalized.

What's next: - Developers, architects, municipalities and contractors are expected to keep putting more emphasis on early site investigations as budgets tighten. - NewTech Engineering said more project owners are treating geotechnical engineering as an investment that can prevent expensive surprises later in construction. - The broader industry focus is likely to stay on better planning and more reliable site data to improve predictability.

The bottom line: - The cost of learning about bad soil after construction starts is usually much higher than paying for a thorough investigation upfront.