Development of inspection framework for mitigating risks in highway construction projects with limited workforce

Purpose The increasing complexity of highway construction projects in the USA and reduced funding have led to fewer inspectors, raising the risk of poor-quality materials and workmanship. This study proposes a framework to lower inspection risks and reduce the number of inspectors required. Design/methodology/approach A framework was developed using a qualitative research design that combined a comprehensive literature review, subject matter expert input, and thematic analysis. Data were collected through three rounds of interviews with 15 experts from state departments of transportation (DOTs) in the USA, as well as analysis of policy and operational documents, to ensure the framework’s relevance and practical applicability for reducing highway inspection workloads. Findings The developed framework includes four key strategies targeting 71 critical construction inspection items to mitigate inspection risks in highway projects: prioritizing inspections, optimizing inspection frequency, optimizing inspection documentation and considering inspector experience. Inspection risk levels are significantly associated with these strategies. As the risk level of a construction item increases, greater inspection frequency and the involvement of more experienced inspectors are required to reduce the likelihood of quality shortfalls. Originality/value This study offers a framework that empirically links inspection risk with inspection frequency, documentation requirements and inspector experience – relationships previously underexplored. Unlike prior studies that focus on isolated strategies, this research provides a holistic decision-making tool featuring 71 critical inspection items. It enables highway agencies to scientifically optimize resource allocation and mitigate risks by aligning inspection intensity and inspector expertise directly with the risk level of construction activities.