How Early Can Construction Starts

Starting a construction project isn’t as simple as breaking ground and getting to work. There are critical steps that need to be taken to ensure the project will run smoothly from start to finish. In this blog, I’ll walk you through the key parameters and mindset you need to adopt when deciding when to begin your construction project. We’ll explore what you need before starting, why it’s crucial not to begin prematurely, and how to think strategically about phased design.

The Importance of Flow and Full Kit

One of the core principles for success in construction is maintaining flow. The more you limit work fronts and focus on completing one stage fully before moving on to the next, the smoother the overall project will be. This concept is also tied to the idea of having a full kit—a term that refers to ensuring everything needed to complete a specific task is ready and available before starting.

This principle comes from Goldratt’s rules of flow. In an insightful interview with Dr. Ephrat Goldratt, I learned about the importance of limiting work in progress and how it helps create seamless flow on a construction project. Do not start a phase unless you have a full kit. This approach minimizes delays, cost overruns, and project derailments.

Phased Design Construction: Getting It Right

Phased design is often viewed as a way to accelerate timelines, but starting a project without a full kit, even for just one phase, can lead to significant problems down the road. For example, if you’re planning to begin construction on foundations and superstructure, it’s not enough to just have the design for that part of the project ready. You need to consider aspects like design loads for the central plant, MEP (Mechanical, Electrical, Plumbing) locations, and coordination under the slab before breaking ground.

Phased design, when done correctly by top professionals, ensures each segment of the project is completed before moving on. However, if rushed, incomplete designs can cause project delays, confusion, and increased costs.

When Should You Start?

When determining the best time to start your project, it’s crucial to work backward from the desired completion date, using Takt planning, risk analysis, and forecasting. This will help you determine how long each phase of the project will take and when you need to begin to finish on time. Before starting, you must ensure you have completed the following critical tasks:

1. Design: The project design must be fully completed for either the entire project or for the specific phase you’re working on. An incomplete design will inevitably lead to delays and extra costs.
2. Procurement and Buyout: All materials and contractors should be lined up and ready to go before construction begins. Long lead items need to be secured in advance to avoid disruptions.
3. Permissions: Make sure that all permits and approvals are obtained. Failure to do this can halt construction and create significant delays.
4. Full Kit: Ensure that everything is in place to start and complete the phase or project at hand. This includes people, plans, resources, and any necessary buffers for unanticipated risks.

The Role of Buffers in Construction Success

Buffering is another critical element in successful construction projects. By building in buffers at different stages, such as commissioning or final completion, you ensure the project can absorb any unforeseen delays or issues without completely derailing your timeline. This is especially important for projects with tight schedules, as these buffers give you the flexibility to adjust without missing deadlines.

The Value of Repeated Planning and Risk Forecasting

To achieve success in construction, your project plan should be reviewed, revised, and validated multiple times before you start. Just as Pixar reviews and revises its films multiple times before release, your construction plan should go through a similar iterative process to ensure it’s robust. Ideally, the plan should be reviewed at least three times, focusing on identifying risks and ensuring that the project duration is realistic based on previous similar projects.

Merging Supply and Demand

Finally, successful projects merge supply and demand by balancing the owner’s expectations with realistic production schedules. Todd Zabel’s book, Built to Fail, emphasizes the importance of simulating a production rhythm that aligns with end dates and project milestones. By simulating this rhythm, you can ensure that the project starts on solid ground and that production flows smoothly from one phase to the next.

Conclusion

In summary, never start a construction project without a full kit—this means having your design complete, contractors and materials ready, permissions in place, and a solid plan in hand. Successful projects are built on preparation, proper sequencing, and a thorough understanding of the risks involved. By following these guidelines, you can ensure your project stays on time, on budget, and on track to meet your goals.