not missed or skipped and in another set to make sure that everyone talks through and resolves all the hard and unexpected problems.
“The biggest cause of serious error in this business is a failure of communication,” O’Sullivan told me.
In the Citicorp building, for example, the calculations behind the designs for stabilizing the building assumed the joints in those giant braces at the base of the building would be welded. Joint welding, however, is labor intensive and therefore expensive. Bethlehem Steel, which took the contract to erect the tower, proposed switching to bolted joints, which are not as strong. They calculated that the bolts would do the job. But, as a
New Yorker
story later uncovered, their calculations were somehow not reviewed with LeMessurier. That checkpoint was bypassed.
It is not certain that a review would have led him to recognize a problem at the time. But in 1978, a year after the building opened, LeMessurier, prompted by a question from a Princeton engineering student, discovered the change. And he found it had produced a fatal flaw: the building would not be able to withstand seventy-mile-an-hour winds—which, according to weather tables,would occur at least once every fifty-five years in New York City. In that circumstance, the joints would fail and the building would collapse, starting on the thirtieth floor. By now, the tower was fully occupied. LeMessurier broke the news to the owners and to city officials. And that summer, as Hurricane Ella made its way toward the city, an emergency crew worked at night under veil of secrecy to weld two-inch-thick steel plates around the two hundred critical bolts, and the building was secured. The Citicorp tower has stood solidly ever since.
The construction industry’s checklist process has clearly not been foolproof at catching problems. Nonetheless, its record of success has been astonishing. In the United States, we have nearly five million commercial buildings, almost one hundred million low-rise homes, and eight million or so high-rise residences. We add somewhere around seventy thousand new commercial buildings and one million new homes each year. But “building failure”—defined as a partial or full collapse of a functioning structure—is exceedingly rare, especially for skyscrapers. According to a 2003 Ohio State University study, the United States experiences an average of just twenty serious “building failures” per year. That’s an annual avoidable failure rate of less than 0.00002 percent. And, as Joe Salvia explained to me, although buildings are now more complex and sophisticated than ever in history, with higher standards expected for everything from earthquake proofing to energy efficiency, they take a third less time to build than they did when he started his career.
The checklists work.
4. THE IDEA
There is a particularly tantalizing aspect to the building industry’s strategy for getting things right in complex situations: it’s that it gives people power. In response to risk, most authorities tend to centralize power and decision making. That’s usually what checklists are about—dictating instructions to the workers below to ensure they do things the way we want. Indeed, the first building checklist I saw, the construction schedule on the right-hand wall of O’Sullivan’s conference room, was exactly that. It spelled out to the tiniest detail every critical step the tradesmen were expected to follow and when—which is logical if you’re confronted with simple and routine problems; you want the forcing function.
But the list on O’Sullivan’s other wall revealed an entirely different philosophy about power and what should happen to itwhen you’re confronted with complex, nonroutine problems—such as what to do when a difficult, potentially dangerous, and unanticipated anomaly suddenly appears on the fourteenth floor of a thirty-two-story skyscraper under construction. The philosophy is that