Early project delivery in Mega-Projects is a reality: How FYLD stops delays before they start

“Ferrovial delivered 3 months early on a 2-year Mega-Highway project. Here’s how: time back on tools, early intervention to delays & zero guesswork.”

Projects delays and overspend in mega-projects are often seen as inevitable. But Ferrovial proved otherwise.

On a £2.2 billion Texas highway upgrade, they didn’t just meet their deadline—they beat it by three full months on a 2-year project. No overstaffing. No re-scheduling. No luck. Just smart field execution, real-time oversight, and the right technology in the hands of their crews.

That technology? FYLD.

Outdated processes drain your schedule—and lead to costly overruns

If your daily site reports still live on clipboards, you're not leading a major project—you’re babysitting paperwork.

Ferrovial’s task was to widen I-35W, one of the busiest highways in Texas, with minimal disruption and maximum speed. It spanned 12 miles, involved thousands of workers, and required absolute precision. But on day one, their teams were stuck in the same trap as every other big job:

• Paper-based safety processes  went unread and were filed away - missed opportunity to spot delays and safety issues before they arise.

• Language barriers between subcontractors (mostly Spanish-speaking) and managers (primarily English-speaking) slowed down site communication.

• Minimal visibility  into daily job blockers across a sprawling 12-mile site resulted in delays to critical schedule items

Each of these added friction, slowed decision-making, and increased risk of both delays and incidents.

Sound familiar?

These aren’t just operational headaches. They’re compounding risks—every delay and misstep increases costs, damages reputation, and chips away at your profit margins. HS2 delay costs are estimated at a staggering £50m per day!!

Turn frontline input into fast, actionable decisions

Your gangs know what’s happening in the field. But unless you can see what they see—and act on it—you’re flying blind.

Ferrovial stopped relying on after-the-fact updates and gave their workforce a voice. Instead of more paperwork and pred-tape, they rolled out frontline intelligence technology that teams on the ground and in the back office could use to connect, communicate, and operate.

With FYLD, crews recorded video site-assessments in their own language. AI reviewed them in real time, flagged potential hazards, and suggested fixes on the spot. Instant translation made cross-team communication frictionless. Supervisors and projects leaders could watch these videos from anywhere. No waiting. No driving up and down the site to get updates. No crossed wires between field and office.

Now, managers weren’t reacting to yesterday’s issues. They were prioritising today’s risks in real time—and preventing tomorrow’s delays.

The result? A step change in both safety and productivity, with gangs spending more time delivering, and less time blocked, from their daily work critical to the schedule.

If your current process can’t do that, it’s not a system—it’s a liability.

Cut time-wasting admin. Increase productivity without adding headcount.

Think you need more boots on the ground to speed up delivery? Ferrovial didn’t. They made better use of the ones they already had. FYLD was rolled out to over 1,000 users, around 85% of the workforce, in under two months. Once embedded, the benefits stacked up quickly:

• Time spent completing site-assessments dropped by 75%

• Site compliance improved from 16% to 100%

• Over 75,000 potential delays were detected and acted on

• Supervisors regained hours previously lost to paperwork and driving the site

• More than 1,000 safety and productivity interventions captured in the final month alone

They didn’t scale headcount—they scaled insight, efficiency, and execution. This combination of visibility, speed, and control helped Ferrovial do what few mega projects achieve: finish significantly ahead of schedule. Three. Months. Early.

If your teams are buried in forms, chasing verbal updates, or stuck reacting to problems instead of preventing them, it’s time to rethink how you operate. 

“Before FYLD, our processes were just paper in a file cabinet. Now, gangs are being heard—and people are listening.”

 — Chad Reynolds, Project Leader, Ferrovial

Time isn’t money. It’s margin, reputation, and your next contract.

Think you have to sacrifice safety to hit deadlines? FYLD didn’t just help Ferrovial speed up delivery, they also improved their safety performance:

• Recordable Incident Rate dropped 73% below the national construction average.

• FYLD’s system helped drive consistent safety engagement across thousands of shifts.

• Conversations around risk became part of daily team routines. 

The financial impact followed:

• 3-month early finish on a £2.2 billion project.

• Early toll lane opening accelerated revenue and reduced project costs.

• Lower incident rates led to potential insurance premium reductions.

• Stronger reputation with the Department of Transportation for future project bids.

Stronger safety culture. Faster delivery. Fewer claims. That’s what happens when safety data becomes visible, usable, and real-time. If you're leading a major project, here's the takeaway:

Every day you’re late costs you money. But every day you're not making data-driven, field-led decisions? That’s costing you even more.

What’s the cost of being 3 months late?

Every delayed day costs money. But what’s costing you more is not knowing what’s happening until it’s too late. In major projects, every delayed day means lost revenue, stalled progress, and reputational damage.

Ferrovial’s success wasn’t about doing more—it was about doing things differently. They used FYLD to unlock visibility, act faster, and remove blockers before they turned into problems.

That’s what intelligent and connected fieldwork looks like.

Learn how to cut delay risk, increase productivity, and win back time on your next big build.  Steal the FYLD playbook - let’s talk