Common Inspection Failures: Top 20 and How to Avoid Them

In all of the custom home builds, I've seen these failures repeatedly.

Learn from others' expensive mistakes and pass your inspections on the first try.

⚠️Warning

Every failed inspection costs you:

  • Time: 3-7 days minimum (corrections + re-inspection scheduling)
  • Money: Re-inspection fees ($50-150) + contractor callbacks + your time
  • Cascade delays: Each phase delay pushes everything back
  • Stress and frustration: Significant

One failed framing inspection can delay your entire project by a week and cost $500-$1,000 in holding costs alone.

Top 20 Inspection Failures

1. Missing or Incorrect Joist Hangers

What it is: Joist hangers missing, wrong size, or improperly nailed

Why it fails: Structural connection critical for load transfer

Code reference: IRC R502.6, R802.3

How I see it happen:

How to avoid:

Cost to fix: $200-500 (carpenter callback to replace hangers)

This fails inspections more than almost anything else.

2. Improper Bearing for Beams

What it is: Beams don't have adequate bearing on posts or walls

Why it fails: Beam could slip off bearing surface under load

Code reference: IRC R502.6 - minimum 1.5" bearing for sawn lumber, 3" for beams

How I see it happen:

How to avoid:

Cost to fix: $300-800 (structural modifications)

3. Missing Fire Blocking

What it is: Required fire blocking not installed in walls or floor/ceiling assemblies

Why it fails: Fire code requirement to slow vertical fire spread

Code reference: IRC R302.11

How I see it happen:

Where required:

How to avoid:

Cost to fix: $200-400 (cutting drywall to access, installing, repairing)

This is especially annoying because it's often caught after drywall is up.

4. Incorrect Stair Dimensions

What it is: Rise or run outside code requirements

Why it fails: Safety - inconsistent stairs cause falls

Code reference: IRC R311.7.5

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $800-2,000 (rebuild stairs)

This is expensive when it fails because stairs often need to be rebuilt entirely.

5. Missing AFCI or GFCI Protection

What it is: Required Arc Fault or Ground Fault protection not installed

Why it fails: Electrical safety code requirement

Code reference: NEC 210.12 (AFCI), 210.8 (GFCI)

Where required:

How I see it happen:

How to avoid:

Cost to fix: $150-400 (breaker replacements, outlet replacements)

6. Improper Plumbing Venting

What it is: Drain/waste/vent system doesn't meet code

Why it fails: Prevents proper drainage, allows sewer gas entry

Code reference: IRC P3104-P3111

How I see it happen:

How to avoid:

Cost to fix: $500-1,500 (cutting walls, re-piping)

This is expensive to fix because walls are often closed.

7. Wrong Wire Size for Circuit

What it is: Wire gauge doesn't match circuit breaker size

Why it fails: Fire hazard - wire overheats

Code reference: NEC 240.4

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $200-1,000 (rewiring circuits)

8. Inadequate Egress Windows

What it is: Bedroom windows don't meet egress requirements

Why it fails: Life safety - need escape route in fire

Code reference: IRC R310

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $800-3,000 (new window, framing changes)

Plan this early - fixing after framing is expensive.

9. Missing Lateral Bracing on Beams

What it is: Beams not properly braced to prevent rotation/buckling

Why it fails: Structural stability requirement

Code reference: IRC R502.8, R802.8

How I see it happen:

Where required:

How to avoid:

Cost to fix: $200-500 (adding bracing)

10. Improper Notching of Structural Members

What it is: Joists, rafters, or studs notched beyond code limits

Why it fails: Reduces structural capacity

Code reference: IRC R502.8 (floors), R602.6 (walls), R802.7 (roofs)

Limits:

How I see it happen:

How to avoid:

Cost to fix: $300-1,000 (sistering members, structural repairs)

11. Electrical Boxes Not Flush

What it is: Outlet/switch boxes recessed or protruding from wall surface

Why it fails: Code requirement for proper device installation

Code reference: NEC 314.20

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $100-300 (box extenders or remounting)

12. Missing Handrail or Guards

What it is: Required handrails or guardrails not installed

Why it fails: Fall protection safety requirement

Code reference: IRC R311.7.8 (handrails), R312 (guards)

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $500-2,000 (building and installing rails)

13. Inadequate Ventilation

What it is: Attic or crawl space ventilation insufficient

Why it fails: Moisture control, energy code requirement

Code reference: IRC R806 (attic), R408 (crawl space)

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $500-1,500 (adding vents)

14. Shower Pan Flood Test Failure

What it is: Shower pan doesn't hold water during flood test

Why it fails: Leak will damage structure

Code reference: IRC P2709

Test requirements:

How I see it happen:

How to avoid:

Cost to fix: $500-3,000 (depends if tile is installed yet)

Test early - fix is much cheaper before tile.

15. Tempered Glass Not Installed Where Required

What it is: Regular glass used where safety glass required

Why it fails: Life safety requirement

Code reference: IRC R308.4

Where tempered glass required:

How I see it happen:

How to avoid:

Cost to fix: $400-2,000 (replacing glass)

16. Insulation Gaps and Voids

What it is: Insulation not completely filling cavities

Why it fails: Energy code requirement

Code reference: IRC N1102 (energy code)

How I see it happen:

How to avoid:

Cost to fix: $200-800 (adding insulation)

Inspectors use thermal cameras - gaps show clearly.

17. Drain Lines with Improper Slope

What it is: Horizontal drain pipes don't slope correctly

Why it fails: Won't drain properly

Code reference: IRC P3005.3

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $300-1,000 (re-piping sections)

18. Smoke and CO Detectors Missing

What it is: Required detectors not installed

Why it fails: Life safety requirement

Code reference: IRC R314, R315

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $200-500 (adding detector locations)

19. Wood-to-Concrete Contact

What it is: Wood members in direct contact with concrete without protection

Why it fails: Moisture will rot wood

Code reference: IRC R317

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $500-2,000 (replacing lumber)

20. Service Disconnect Missing

What it is: No accessible disconnect for AC or heat pump

Why it fails: Safety requirement for servicing

Code reference: NEC 440.14

Requirements:

How I see it happen:

How to avoid:

Cost to fix: $150-400 (installing disconnect)

Patterns in Failures

Failed Because Work Wasn't Complete

Don't call for inspection until actually ready:

Failed Because Didn't Match Plans

Build what's on approved plans:

Failed Because Contractor Didn't Know Code

This is on you to manage:

Failed Because Inspector Was Having a Bad Day

Reality: This happens

Prevention Strategy

Before You Build

During Construction

Before Inspection

During Inspection

Quick Reference Checklist

Before Calling for ANY Inspection

The Bottom Line

90% of inspection failures are preventable by:

  1. Knowing the code
  2. Building carefully
  3. Checking your work
  4. Being prepared

The other 10% you'll learn from and fix quickly.

Every failed inspection is a lesson. Don't repeat the same mistake twice.

**Detailed guides for each inspection type