Project cost overruns are rarely caused by a single issue—they build up through overlooked details, misaligned teams, and poor change control. For glass distributors, early missteps in scoping, budgeting, and coordination can lead to expensive rework and strained client relationships.
The Scenario: Facade Redesign After Initial Budget Approval
A commercial tower project budgeted for high-performance glass units with integrated shading. However, mid-project, the design team requested larger lites and a different shading interlayer. The distributor quoted the updated spec, but approval was delayed, and fabrication had already begun based on the original design.
The redesign was ultimately accepted—but came at a 22% cost increase, all of which was charged to the distributor for “lack of alignment.”
What Went Wrong
No freeze on design changes after final budget sign-off.
No protocol for formally documenting mid-project scope shifts.
Fabrication began without written reconfirmation from the GC.
Cost Overrun Breakdown
Re-fabrication of 37 oversized units.
Installation delays due to shipping and site adjustments.
Extended labor hours and change order disputes.
Process Improvements
Implemented design change lock-in windows with explicit client sign-off.
Required written budget confirmation tied to final shop drawing approval.
Introduced change order alerts linked to project margin calculators.
Cost overruns are not just about money—they’re about trust and control. Distributors that tighten design-to-fabrication workflows avoid the downstream chaos of misaligned decisions.
