The Hidden Cost of Fastener Delays in Industrial Projects
Meeting project deadlines is tough enough when all goes as planned. But when fasteners don’t arrive on schedule your project can suffer. Bolts, nuts, screws, washers, and other fasteners that are backordered, delayed in shipping, ordered too late due to lack of planning, and incorrect specifications resulting in reordering - all can bring entire projects to a screeching halt.
For example, a project may be ready for installation, crews scheduled and equipment on site - only to discover a single fastener type was ordered incorrectly. It must now be reordered with a long lead time.
The problem is that fasteners are often an afterthought because they’re small and relatively inexpensive. To illustrate the impact, consider a $.50 bolt can stall a $5 million project. Their absence can create wildly disproportionate damage.This often happens when fasteners are treated as standard items late in the planning process or specified without accounting for lead times or approved alternates.
In addition, the cost of having a crew sitting around waiting can add up to thousands of dollars a day any time a fastener is delayed. When a structural steel crew of 15 workers sits idle for two days waiting for anchor bolts at $65/hour, that's $15,600 in direct labor costs alone. Not to mention equipment rental fees that continue accruing and the additional cost of shipping due to rush orders. Add penalties for missing project deadlines and you have a project that now costs double what it should’ve been.
At that point, project managers are left with poor choices: send crews home, pay overtime later, rush-ship replacement fasteners, or attempt substitutions that may not pass inspection.
Unseen costs
Not every hidden cost is easy to determine. For example, less obvious impacts like cascading schedule delays - when one trade is delayed, it pushes back subsequent trades - can have devastating effects. Teams may be reassigned mid-project, only to be pulled back again once materials arrive.
Overtime wages will also catch up once fasteners arrive. Not to mention the breaking down of relationships with clients and contractors. Any damage to your reputation may affect future bids. Plus, if teams over-order to prevent future delays, inventory carrying costs may increase. In addition, constantly putting out fires rather than working systematically results in lost productivity.
Real-world context - where fastener delays hit hardest
The impact of fastener delays can be most clearly seen in the real world. Consequences vary somewhat within various industries. Here are examples of some of those industries.
Structural and steel projects
Missing anchor bolts or structural fasteners can delay erection, inspections, and downstream trades. This often happens when crews and equipment are already on site.
OEM and equipment manufacturing
Final assembly can stall when a single fastener is unavailable. This delays shipment and pushes back customer delivery schedules.
Energy and infrastructure projects
Specialty fasteners with coatings, certifications, or compliance requirements often have long lead times and limited substitution options.
The solution
Reliable fastener partnerships play a major role as risk management. Benefits of partnering with Melfast, for instance, provide you with expertise and advice for maintaining inventory depth, technical expertise, and being assured of established supply chains that prevent delays. For questions, custom orders, or advice on selecting the best fastener for your projects, reach out to us - we’re here to help.
