I recently found two presentations, one from 2017, the other from earlier this week, both underscoring the importance of in-house expertise for efficient construction. This is layered on top of interviews Eric and I did for our Boston case study and a few additional interviews I did in other American and European cities. It is my professional opinion that agencies that engage in major capital projects, even if they involve rolling stock acquisition rather than the construction of new lines, ought to hire in-house, and make sure to have long-term capital programs.
Both presentations concern rolling stock. The one from 2017 is by Stadler, regarding the challenges of the American market. On slide 32, it mentions that Caltrain was a demanding customer, with all expertise outsourced and yet managers engaging in micromanagement. The micromanagement is in line with what we’ve heard from contractors for other capital expansions, like Second Avenue Subway, especially contractors with experience in both the US, where this practice is common, and Europe, where it isn’t.
Thanks to the factors mentioned by Stadler as well as the Buy America requirement to set up a new factory with a new supply chain for a midsize order, the cost is $551 million/96 cars, or $5.74 million/car; the typical cost of a KISS is 300 million €/90 cars, and the €:$ ratio is not 1.72, far from it.
The other presentation, from this week, concerns the MBTA’s slow approach to electrifying its commuter rail network. It wishes to begin with a pilot on the already-electrified Providence Line, but is running against the problem of having no in-house expertise, just as Caltrain does not. The presentation on this says, on slide 3, that it takes 6-9 months to onboard consultants, and another 6-9 to develop performance requirements for a kind of vehicle that is completely standard in high-performance regional rail networks in Europe.
Instead of hiring experienced professionals (who must come from Europe or East Asia and not the US), the MBTA plans to piggyback on either the overpriced Caltrain order, or an obsolete-technology order by New Jersey Transit. The Caltrain order, moreover, is stretched for the generous loading gauge of the Western US, but does not fit the catenary height on the East Coast, even though European KISSes would easily and are around 13 cm lower than existing MBTA rolling stock.
Prior Northeastern examples
This combination of political and managerial micromanagement with outsourcing of technical expertise to consultants is common enough in the United States. In the Boston report on the Green Line Extension, we were told by multiple sources that the MBTA only has 5-6 engineers doing design review. Thus, they have the capacity to handle small projects but not large ones.
Small-scale projects like building a new infill station or taking an existing low-platform commuter rail station and converting it to an accessible high-platform one usually have limited cost premium: in Berlin, infill stations are 10 million € outside the Ring, whereas in Boston, infill stations and high-platforming projects (which are very similar in scope) are around $20-25 million – and Boston platforms are longer. This is also the case in Philadelphia, where headline costs are lower because the stations are smaller, but overall the unit costs are comparable to those of Boston.
But large projects are beyond the ability of a 6-person team. The required permanent staffing level is likely in the teens for a team whose job is just to score design and construction contracts. This choked the original Green Line Extension, leading to bottlenecks in design and contributing to the project’s extreme cost. The restarted version is still extremely expensive – it’s getting some good press this week for running slightly under a $2.3 billion/6.3 km budget, but said budget, $360 million/km, is well above the international norm for a subway, let alone trenched light rail. The current project has sunk costs from the previous ones, and a combination of in-house and consultant design about whose efficacy we’ve heard conflicting reports, but the team is much larger now.
In areas that don’t even have the skeletal design review staff of Boston, costs are high even for small projects. Connecticut deserves especial demerit: its department of transportation relies exclusively on consultants for rail design (perhaps also road design but I do not know), and infill stations cost not $20-25 million but $50+ million. The Hartford Line, compromised from the start, even displays this state-by-state difference: the one Massachusetts project, a single high platform in Springfield, cost $10 million/100 meters, a fraction of comparable projects in Connecticut. Larger Connecticut stations, such as those for Metro-North, have seen extreme scope creep, amounting to a $106 million total cost.
Consultants and design
American agencies speak of design-bid-build contracts, in which design and construction are separate, and design-build ones, where they are combined into a single contract. Design-bid-build is superior. But really, contracts in low-cost countries are often neither of those, but just build contracts, with design done mostly in-house. A procurement official in Stockholm explained to me that Swedish contracts tend to be build contracts; design-bid-build can sometimes be used with supplemental consultants helping with design, but it’s not the norm. Moreover, in Oslo, the use of design consultants instead of in-house design has not been good: consultants tend to engage in defensive design because of how Norway structures risk allocation, leading to overbuilding.
In Spain and (I believe) Italy, contracts are design-bid-build. But there’s so much in-house involvement in design that it’s more accurate to call these build contracts. The in-house design teams are not huge but they’re enough to work with private design firms and score proposals for technical merit. In Istanbul, the system is somewhat different: preliminary design at the 60% level is contracted out separately from the combination of final design and construction, which may possibly be called des-bid-ign-build, but the design part is extensively scored on technical merit, at 60-80% of the total weight. The construction contracts in Istanbul are lowest-bid, but contractors can be disqualified, and since Turkey has so much infrastructure construction, contractors know that they need to behave well to get future work.
Unfortunately, American consultants believe the opposite: they believe in the superiority of design-build and are not even aware of pure build, only design-bid-build. Sources from that world that I generally think highly of have told me that directly. But that is because the sort of projects that they are most likely to be involved in are ones that use consultants, which definitionally are not build contracts. The ongoing expansion projects in Stockholm, Madrid, Barcelona, Milan, Rome, and Berlin have no use for international consultants, so international consultants are not familiar with them, and end up knowing only about high-cost examples like London or the occasional medium-cost one like Paris. In effect, to rely on consultants is to ascertain one largely learns worst industry practices, not best ones.
The alternative to paying consultants is to obtain public-sector expertise. Agencies are obligated to hire sufficient-size teams, and pay them competitively. Engineers in Italy and Spain have a lot of social prestige, much as in France and Germany; even in medium- rather than low-cost countries in Europe, like France, we were told by UITP planners that the people planning metro systems are hired from the engineering elite (in France, this would be Grandes Ecoles graduates), and paid appropriately.
In the US, there is no such prestige. Humanities professors speak of STEM privilege routinely, but by Continental and East Asian standards, the US and UK have no STEM privilege: the elites are generalist and are not expected to know the specific industrial fields they oversee. The public sector thus treats the planner and the engineer as a servant to the political appointee. Senior management routinely ignores the advice of younger planners who are more familiar with present-day research.
The pay, too, is deficient. In absolute numbers, planners at American transit agencies get paid better than their European counterparts – but American white-collar wages are generally higher than European ones. The MBTA pays project managers $106,000 a year as of a few years ago, which is a nice wage, but the Boston private sector pays $140,000 in transportation and more in other fields. The public sector, through budget-cutting officials, sends a clear price signal: we do not want you to work for us.
There is another way, but it requires letting go of the idea that private consultants are better than long-term in-house experts. It is obligatory to hire in-house at competitive wages to grow the design review teams, and listen to them when they say something is desirable, difficult, or impossible. Instead of onboarding consultants, agencies should immediately staff up in-house with plans for long-term investments. Moreover, senior management should back the planners and engineers when they engage in value engineering, even if it annoys politicians and local activists. The role of elected politicians is to review those in-house plans and decide whether there is room in the budget for the megaprojects they recommend, and not to micromanage. This way, and only this way, can the United States shrink its procurement costs to typical Continental European levels.