How Design-Build is Changing the Way We Approach Concrete Repair and Rehabilitation

When dealing with aging infrastructure, repairs can be unpredictable and complex.  The progressive design/build process offers a streamlined and effective solution for project delivery. Design/build integrates the evaluation, design and construction phases under a single entity, fostering collaboration, efficiency, and innovation. This is distinct from the traditional design/bid/build process, where separate entities handle design and construction, often leading to miscommunication, project delays, and higher costs.

Key Advantages of Design/Build in Extending the life of Existing Concrete Structures

Single-Source Responsibility & Risk Reduction

Traditional concrete repair projects often involve separate design and construction contracts.  This can, unfortunately, lead to change orders and delays when unexpected conditions arise. With the progressive design/build approach, a single team is responsible for the assessment, design, and execution of repairs, ensuring that decisions are made efficiently and accountability is maintained.

Image source: https://www.cogram.com/blog/design-build-construction

“In traditional Design/Bid/Build, you aren’t sure of the project cost until it is done. These days, especially, you're going to be over budget most likely. The cost of disputes and litigation on more traditional delivery methods is higher in general. With more use of progressive design-build, you can have some of the cost certainty early in the project and fewer disputes, which results in overall lower costs.” – FMI Design Build Study Final Report 2025

 

Real-Time Problem Solving & Adaptability

Concrete rehabilitation often uncovers hidden issues, such as moisture ingress, deeper-than-expected or more widespread concrete spalling, or outdated reinforcement details. The design/build model allows for immediate collaboration, enabling teams to modify repair plans in real time without project stoppages.

Studies conducted by FMI show Design/Build projects are completed up to 102% faster than traditional Design/Bid/Build - DBIA Data Sourcebook 2025.

 

Innovative Techniques & Materials for Long-Lasting Repairs

Design-build fosters innovation in concrete repair, seamlessly integrating advanced materials and techniques, such as:

• Advanced non-destructive testing (NDT) methods to assess damage with minimal disruption.
• High-performance materials (fiber-reinforced polymers, corrosion-resistant coatings, specialized repair mortars).
• Innovative rehabilitation techniques, such as FRP rebar, electrochemical treatments and cathodic protection to extend structure lifespan.

 

Cost-Effective & Efficient Execution

By integrating design and construction, teams can optimize repair strategies early, ensuring that materials and techniques are selected for both performance and cost-effectiveness, ultimately leading to a more positive project experience for everyone involved.

Every dollar counts! Design-build projects see 3.8% LESS cost growth compared to traditional Design/Bid/Build methods (DBIA Data Sourcebook 2025).

Minimizing Disruptions

Traffic congestion, facility downtime, and public inconvenience are major concerns in concrete repair projects. The design/build model ensures smoother scheduling and faster execution, reducing disruptions to operations.

Check out how a Design/Build Model was the key to repair and extending the
service life while minimizing downtime at this Cargill Salt Dome Facility! 

The Future of Concrete Repair with Design/Build

As infrastructure ages and repair demands grow, design/build is proving to be the most efficient and reliable approach for addressing complex concrete rehabilitation challenges. From bridges and parking structures to industrial facilities, this method allows for faster problem-solving, cost-effective repairs, and greater repair durability.

Want to see design/build in action? Watch our webinar on Design/Build Construction below to see how this approach is transforming the industry.

 

Additional Resources

• Cargill Salt Dome ICRI Submission
• DBIA - Design-Build Institute of America
• Canadian Design-Build Institute (CDBI)

For more insights on design-build for concrete rehabilitation, contact us today to discuss how this approach can benefit your next concrete repair project.