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What Should You Do If Build Costs Come In Higher Than Expected?

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One of the most confronting moments in a development project can come when the builder’s quotes start arriving, and the numbers are higher than you expected.

It’s not an uncommon situation. Even with the best planning, construction costs can shift due to labour shortages, material price changes, site-specific challenges, or simply because early feasibility assumptions didn’t fully capture the real scope of works.

When this happens, many developers feel an immediate sense of panic. Has the project failed? Should you pull out? Is all the work done so far wasted?

The reality is that higher-than-expected build costs don’t automatically mean the deal is dead. What they do mean is that you need to step back, reassess the numbers, and decide which path forward makes the most sense.

​​​​​​​Ideally, This Should Never Be a Surprise

In a perfect world, construction pricing shouldn’t come as a shock. A well-prepared feasibility should include realistic cost estimates and a buffer for unexpected variations.

More importantly, every development project should have multiple pathways built into the strategy from the very beginning.

Think of them as Plan A, Plan B, Plan C, and sometimes even Plan D. Maybe even Plan Z!

Plan A is your preferred outcome. The strategy you expect to execute if everything goes according to plan. But experienced developers understand that projects rarely unfold perfectly. That’s why alternate scenarios should always exist.

For example:
  • Plan A: Build and sell
  • Plan B: Build and hold as a rental
  • Plan C: Sell the site with development approval
  • Plan D: Exit the project early if numbers change significantly

And the list goes on.

If your entire project relies on a single “perfect” outcome, then the plan needs to be extremely robust. But most seasoned developers prefer to build flexibility into their projects so they have options if circumstances change.

First Step: Determine Whether the Increase Is Material

Not every cost increase is cause for alarm.

If the difference between your feasibility estimate and the builder’s quote is relatively small, say $10,000 to $20,000 on a project with a total construction cost of several hundred thousand dollars, the answer is usually straightforward. You proceed with Plan A and absorb the additional cost.

Small variations are simply part of doing development.

Where things become more complex is when the increase is significant. A $100,000 jump in build costs, for example, could dramatically change the profitability of the project.

At that point, it’s time to go back to the feasibility and run the numbers again.

Revisit the Feasibility

Your feasibility is the decision-making tool that should guide you through moments like this.

Update the construction costs with the real numbers from builders and reassess the project’s profitability. Look carefully at:
  • Projected end values
  • Finance costs
  • Holding costs
  • Sales costs
  • Contingency allowances
  • Developer profit

The key question is simple: Is the project still profitable?

If the answer is yes, then the next question becomes whether the reduced profit still justifies the time, risk, and effort involved.

Sometimes the numbers won’t be as attractive as originally projected, but they may still represent a reasonable outcome.

Consider How Far Into the Project You Are

Another critical factor is how far down the development pathway you’ve already travelled.

Early in the process, before town planning approvals, detailed design work, or finance arrangements, it’s relatively easy to pivot to another strategy.

However, the further along the project progresses, the harder it becomes to change course.

If you’ve already obtained development approval, paid consultants, secured finance, and incurred months of holding costs, abandoning Plan A becomes far more expensive.

In those circumstances, switching to Plan B may mean writing off a substantial amount of sunk costs.

This is one of the most difficult decisions developers face. Sometimes continuing with the original plan, even with reduced profitability, may be the most sensible way to recover the investment already made.

Understand the “Point of No Return”

Development projects often involve stages where the property temporarily loses value before it gains value again.

For example, if you’re undertaking a renovation and completely gut the house, the property may no longer be considered habitable. That can affect bank valuations and reduce the property’s market appeal until the renovation is completed.

Similarly, demolishing an existing house removes the income potential and resale value of the original dwelling before the new development has been built.

These are sometimes referred to as “point of no return” decisions.

Once you cross that threshold, the project can temporarily become “underwater,” meaning the current value of the site is lower than what you’ve invested into it so far.

That’s why experienced developers establish decision points, or “tollgates”, throughout the process. Before committing to each major step, they pause, reassess the numbers, and confirm that the project still makes sense.

​​​​​​​Revisit Your Alternate Strategies

If the revised feasibility shows the project is no longer viable under Plan A, it’s time to seriously evaluate the alternate strategies you prepared earlier.

These might include:

Changing the development strategy: Perhaps the original plan was to build and sell, but the numbers now make more sense if you build and retain the property as a rental.

Adjusting the design or specifications: Sometimes cost savings can be achieved by simplifying the design, changing materials, or revising finishes without materially affecting the end value.

Seeking alternative builders or construction methods: Quotes can vary significantly between builders, particularly if some specialise in the type of product you’re delivering.

Selling the site with development approval: This is an option many developers overlook. A site with approved plans can often command a premium compared to an unapproved site, particularly if the planning risk has already been removed.

Depending on market conditions, you may be able to exit the project with a modest profit or minimal loss.

Sometimes the Best Outcome Isn’t Perfect

Developers often begin projects with optimistic expectations. However, property development is a business, and like any business venture, outcomes don’t always unfold exactly as planned.

The goal is not perfection - it’s good decision-making.

If a project still produces a profit, even if it’s smaller than originally anticipated, it may still be worth completing. Walking away from a project too early can sometimes lead to larger losses than pushing through to completion.

On the other hand, recognising when a project no longer makes sense is also a valuable skill.

The Real Lesson

Perhaps the most important takeaway is that successful developers think about these scenarios BEFORE they happen.

By building multiple strategies into your feasibility, setting decision points throughout the project, and regularly revisiting the numbers, you give yourself the flexibility to respond intelligently when circumstances change.

Construction costs may rise, markets may shift, and unexpected challenges will inevitably arise.

But with a clear process for evaluating your options, higher build costs don’t have to derail your development, they simply become another decision point along the journey.
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