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Rising Costs Are Not Force Majeure: Why Estimation Tools and Generic ERPs Fail Project-Based Industries

Over the past few years, the global project landscape has fundamentally changed.

 

  • Steel, cement, and key construction materials have experienced double-digit volatility. In certain regions, spikes exceeded 30–50%.
  • Energy and fuel costs, driven by geopolitical instability, have surged unpredictably. In turn, this directly affects transportation, machinery, and production costs.
  • Global supply chains remain fragile. Meanwhile, delays, shortages, and re-routing have become the norm rather than the exception.
  • Labor markets are unstable, as skilled workers abandon project sites because of conflict, economic pressure, or repatriation. Consequently, productivity losses are severe.
  • Equipment and logistics costs have also escalated sharply, driven by fuel, maintenance, and limited availability.

 

In short, what used to be manageable fluctuations are now systemic disruptions.

 

For contractors executing large-scale projects, this creates a perfect storm. That is especially true under Lump Sum (LS) or fixed-price contracts:

 

👉 Costs are rising across every resource category

 

👉 Productivity is declining

 

👉 Timelines are slipping

 

👉 Margins are evaporating

 

And suddenly, what many hoped to classify as force majeure shows its true nature: commercial risk.

 

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The Problem: You Cannot Claim What You Cannot Prove

 

To support claims, negotiations, or contract adjustments, contractors must prove how costs have escalated across all project dimensions. Moreover, they must do so through structured, auditable data.

 

  • Procurement: Material price increases, supplier volatility
  • Labor: Wage inflation, productivity drops, workforce disruptions
  • Machinery: Utilization shifts, fuel cost spikes, maintenance and logistics escalation
  • Subcontractors: Repricing, claims, renegotiations
  • Finally, indirect costs: Overheads tied to time delays and resource inefficiencies

 

However, here’s where most systems fail.

 

Estimation tools are disconnected from reality

 

First, they stop at bidding.

 

Generic ERPs lack construction DNA

 

Similarly, they capture financials—but not project truth.

 

Construction management tools rely on fragmented ecosystems

 

In addition, they depend on third-party ERPs, spreadsheets, and manual reconciliation.

 

So what is the result?

 

There is no single version of truth and no defensible claim. As a result, there is no leverage in negotiations.

 


 

The Reality: Cost Escalation Happens Across the Entire Project Lifecycle

 

Construction cost escalation is not a snapshot. Instead, it’s a continuous, cross-functional phenomenon.

 

Therefore, to prove it, contractors must connect:

 

  • What the team estimated (BoQ)
  • What the team planned (WBS)
  • What actually happened (real-time costs)

 

Only then can they demonstrate cause, effect, and impact.

 

This is exactly where most systems collapse. After all, their vendors never designed them to integrate these dimensions.

 


 

The Shift: From Estimation to Evidence-Based Cost Control

 

In other words, what contractors need today is not another tool.

 

Instead, they need a system of record that captures reality as it unfolds.

 

For example, a system that:

 

  • Tracks procurement price escalation in real time
  • Links labor costs directly to productivity and project activities
  • Monitors machinery utilization, maintenance, and logistics costs continuously
  • Integrates subcontractor commitments and variations dynamically
  • Captures indirect costs as part of resource allocation

 

Above all, it:

 

👉 Associates everything with BoQ, WBS, and Cost Codes—simultaneously

 

That is because, without this trilateral linkage, cost escalation remains an assumption—not evidence.

 


 

Why ProjectVIEW ERP Changes the Game

 

ProjectVIEW ERP is not just another ERP. Instead, it is a construction-specific operating system. Its purpose is to capture, validate, and prove cost evolution across the entire project lifecycle.

 

At its core lies a unique principle:

 

👉 BoQ ↔ WBS ↔ Cost Codes integration

 

In short, this is not a feature. Rather, it’s the foundation of truth.

 

In practice, it enables:

 

  • Real-time comparison of Actual vs Budgeted Costs
  • Full traceability of every cost deviation
  • Automated documentation of escalation across all resources
  • Immediate visibility into financial impact per activity, resource, and contract line

 

As a result, this integrated logic ensures that every cost movement is:

 

✔ Captured ✔ Structured ✔ Justified ✔ Defensible

 

And that’s exactly what contractors need when they enter negotiations or claims.

 

As documented, ProjectVIEW ERP acts as a centralized cost control and project performance management system, integrating all processes across office and site while enabling real-time analytics and decision-making

 

Moreover, its ability to link BoQ, WBS, and Cost Codes lets all project stakeholders monitor actual vs budgeted costs continuously.

 


 

Real-Life Scenario

 

For example, a contractor operating under a fixed-price infrastructure contract faces:

 

  • 35% increase in steel prices
  • 20% rise in fuel costs
  • Labor shortages causing productivity loss
  • Delayed equipment mobilization due to geopolitical constraints

 

Without an integrated system, however:

 

  • Claims stay fragmented
  • Data remains inconsistent
  • Consequently, negotiations become defensive

 

By contrast, with ProjectVIEW ERP:

 

  • Every cost increase links to procurement transactions
  • Labor inefficiencies connect to specific WBS activities
  • The system tracks machinery costs with utilization and maintenance logs
  • The project budget automatically reflects indirect costs

 

👉 In short, the contractor doesn’t argue. 👉 Instead, the contractor proves.

 

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Beyond Construction: A Universal Need Across Capital-Intensive Industries

 

However, this challenge is not limited to construction.

 

It also applies equally to:

 

 

In fact, any industry where:

 

  • Projects are complex
  • Resources are dynamic
  • Costs evolve in real time

 

…therefore requires a system that captures reality—not assumptions.

 

In the era of uncertainty, cost control is no longer about budgeting. Instead, it’s about proving the truth of execution. So when parties challenge, extend, or renegotiate contracts: 👉 The winner is not the one with the best argument 👉 Rather, it’s the one with the best data

George Tsolakis

About the author

George Tsolakis

Chief ERP Architect, DANAOS Projects

George (Georgios) Tsolakis is Chief ERP Architect at DANAOS Projects and a subject-matter expert in construction ERP architecture, engineering economics, cost accounting and construction cost control. With more than 30 years of experience building construction-specific enterprise technology, he conceived ProjectVIEW ERP and remains its principal architect and lead developer, directing business analysis, product architecture, advisory, implementation and support for project-based…