Case study
How Hensel Phelps Digitized Construction Progress Tracking and Avoided $340K+ in Field Costs Using Track 3D
Project Objectives
- Digitize progress tracking and eliminate labor-intensive documentation
- Increase coordination across 26 trades on a tight jobsite
- Avoid costly rework from missed installations or design changes
- Improve transparency during pay apps, QA/QC, and commissioning
Project Background
At San Francisco International Airport, a new $300 million, six-story office and operations center was being built between Terminals 2 and 3. With no laydown space, active passenger traffic, and progressive design-build delivery, Hensel Phelps faced daily challenges coordinating work across 6 floors and 26 trades. Site walks were time-consuming, photo documentation was inconsistent, and late-stage design changes risked expensive rework. To solve this, Hensel Phelps adopted Track 3D during the interior buildout.
Track 3D in Action
- Capture 360° site imagery twice weekly across all floors
- Track progress by linear feet and square footage
- Visually overlay as-built conditions against the BIM model
- Validate trade sequencing zone-by-zone
- Detect missing or mislocated components before rework became necessary
Use Cases in the Field
1. Missing Fire Protection Pipes
During a visual review using Track 3D, the superintendent discovered that three rooms on Level 3 were missing fire protection piping, despite being reported as 100% complete. The Track 3D dashboard clearly identified that the sprinkler heads and lines had not been installed. The issue was addressed before ceiling closure, avoiding costly rework, inspection failure, and a delay in commissioning. Estimated savings: $5,626.
2. Misaligned Ductwork
On Level 6, a 10-foot section of ductwork was routed incorrectly and incompletely, potentially obstructing ceiling rough-ins and lighting placement. The misalignment was caught using Track 3D’s model overlay tool. The duct was rerouted prior to ceiling framing, avoiding rework, project delay, and preserving layout accuracy. Estimated savings: $2,600.
3. Omitted VAV Boxes
Track 3D’s progress data highlighted a discrepancy in mechanical installation: two Variable Air Volume (VAV) units were missing. These units had been added in a late-stage design change. The visual timeline from Track 3D revealed the gap before ceiling installation, allowing teams to complete the work without demolition. This proactive catch protected the project from schedule and inspection delays.
4. Trade Sequencing & Zone Control
The team used Track 3D’s zone-based tracking to confirm that each trade had fully completed their scope before the next one mobilized. In one instance, framing was reported as finished in a quadrant, but leftover materials and image analysis revealed incomplete work. The electrical team was paused, and the framer was held accountable, preventing overlap, double handling of materials, and lost time.
5. Pay App Validation & Office Review
uperintendents and office engineers used Track 3D to verify claimed percent completions during monthly pay applications. Instead of walking every floor, they reviewed up-to-date imagery, helping prevent overbilling, improve accuracy, and save hours of administrative field time.
6. Quality Control Documentation & Commissioning
Track 3D’s time-stamped photo history allowed QC teams to verify in-wall blocking, valve installations, and above-ceiling components after close-in. This eliminated the need to open walls, speeding up commissioning, reducing owner punch list items, and preserving finishes.
The Outcomes
Outcome | Value |
Total Hours Saved | 2,964 hours |
Labor Cost Savings | $342,426.00 |
Rework Avoidance | $8,226 (on just 2 issues) |
Time Saved per Week | 40+ hours |
Job Walks Consolidated | 20+ down to 1 |
Sub Trades Coordinated | 26 across 6 floors |
What Made the Difference
- Verified Percent Complete for pay apps
- Reduced QC/Commissioning Delays by pulling historical imagery
- Remote Collaboration: Eliminated unnecessary field walks
- Increased Trade Accountability with visual evidence
What’s Next
Track 3D is now being emplemented by Hensel Phelps across all current and future projects where rework, trade stacking, or lack of visual control puts timelines or costs at risk.
Project Snapshot
Project: SFO Executive Offices & IOC
Value: ~$300M
Floors: 6
Size: 75,000–110,000 sq. ft.
Trades: 26
Duration: Nov 2023 – May 2025
About Track 3D
Track 3D is a construction tech platform that transforms 360° image capture into actionable insights. It enables visual progress tracking, BIM comparisons……
Learn more
https://track3d.ai
Contact
info@track3d.ai
“We don't just track what’s done - we prove it.”
Hensel Phelps Superintendent
“Track 3D turned a 20-hour weekly grind into a one-hour exercise.”
Hensel Phelps Superintendent
“We were paying for 100% sprinkler completion, but three rooms had nothing. Track 3D saved us from paying twice.”
Hensel Phelps Superintendent
“It’s our visual source of information quickly accesible across field, office, and owner meetings.”
Hensel Phelps Superintendent
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Case study Project Objectives Digitize progress tracking and eliminate labor-intensive documentation Increase coordination across 26
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