If you’ve ever managed a commercial fit-out, you’ll know budgets can shift quickly. What starts as a carefully planned project can grow in cost because of small oversights made early in the process.
At Chest Constructions, we’ve seen these surprises play out across offices, retail spaces, and medical suites — often with the same root causes. Here’s a closer look at the most common hidden costs and how to plan ahead to reduce the risk.
1. Design Revisions and Late Changes
A well-defined design brief isn’t just about aesthetics; it determines cost accuracy and build efficiency. Incomplete drawings or late design changes can trigger cascading expenses such as re-engineering, material wastage, or even new compliance submissions.
Moving a single internal wall might require electrical rerouting or a new fire-rating assessment. Industry data shows that around 35% of fit-out variations come from design amendments made after approval.
💡 Tip: Finalise your design before tendering and ensure all details meet code and landlord criteria.
2. Compliance and Approvals
Compliance isn’t just paperwork. Fit-outs must meet Building Code of Australia (BCA) standards, accessibility requirements (AS1428), and fire safety regulations.
Small issues, such as non-compliant exits or incorrect sprinkler placement, can lead to rework and additional approval fees.
💡 Tip: Engage a builder or certifier early to identify potential compliance issues before quoting. This step can save weeks in approvals and thousands in rework.
3. Services Relocation (Electrical, Plumbing, HVAC)
Many tenancies conceal outdated or undocumented services behind ceilings and walls. Once demolition begins, surprises like non-compliant ductwork or misaligned plumbing can force design changes mid-build. Relocating an electrical board or mechanical vent can easily add $5,000–$15,000 to your budget.
💡 Tip: Always request a preliminary site inspection with your builder and consultants before the final quote. This helps uncover hidden conditions and prevents “discovery costs” after work begins.
4. Project Delays and Variations
Delays impact far more than the schedule. They can eat into rent-free periods, staff relocation plans, and operational budgets. Common causes include late material procurement, prolonged approvals, or scope creep. Industry data suggests that each week of delay can increase total project cost by 2–3%.
💡 Tip: Work with a builder who provides a transparent project schedule, clear communication, and a defined process for managing variations as they arise.
5. Fit-Out Certification and Hand-Over Adjustments
Even after completion, small compliance issues can hold up occupancy certificates. Missing documentation, non-compliant emergency lighting, or incorrect accessibility rail heights can delay handover and increase holding costs.
💡 Tip: Choose a contractor who manages end-to-end certification and liaises directly with building certifiers to ensure a smooth practical completion and handover.
Closing Thought
Fit-outs rarely go exactly to plan, but thorough preparation and early collaboration reduce uncertainty. Understanding where hidden costs appear allows you to manage expectations, allocate contingency wisely, and keep your project on track.
If you have a construction, renovation, or fit-out project you’d like to discuss, don’t hesitate to get in touch. Simply reply to this email, fill out the form on our website, or give us a call at 0403 464 064.