Even in well-coordinated projects, design intent can get lost in translation between drawings, submittals, and final fabrication. This blog explores a field failure where misinterpreted elevations and hardware prep led to rework, conflict, and client mistrust.
The Incident: Glass Doors Prepped for the Wrong Hardware Offset
A glass distributor supplied doors for a tech company’s campus interior. The architect’s elevation drawings specified a non-standard centerline for the lock prep—offset to accommodate a branded handle system. However, the fabricator used default prep dimensions from standard templates, assuming the drawings contained an error.
The misalignment became evident at installation. New holes could not be drilled due to tempering, requiring full replacement of all affected units.
Where the Breakdown Occurred
Elevation notes were not flagged for special review
The fabricator proceeded without RFI (Request for Information) clarification
The architect never received a physical hardware compatibility drawing for sign-off
Impact
$85,000 in rework and rush delivery
Architect excluded the distributor from future design-build proposals
GC required additional documentation checkpoints in all future orders
Corrective Measures
Hardware Prep Exception Flagging
Any non-standard offsets, cutouts, or dimensions are now flagged by estimators and routed to engineering before sign-off.
RFI Discipline Reinforced
When drawing notes conflict with fabrication norms, RFIs are mandatory and tracked in project timelines.
Design Validation Templates Introduced
Hardware shops and elevation layouts are reviewed together and signed by all parties before fabrication begins.
Final Insight
Design errors aren’t always in the drawings—they’re often in the assumptions. Treat every deviation as a risk to be clarified, not corrected after the fact.
