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What Engineers Should Know About Design Errors and Liability

November 24, 2025 by CI Solutions

Engineers Reviewing Construction Documents and Plans to Avoid Design ErrorsEssential Takeaways

  • Professional liability insurance protects engineering firms from financial damages caused by design mistakes, inspection errors, and professional service failures.
  • Recent market data shows 94% of insurers raising E&O rates, with structural and civil engineering experiencing the highest claim severity.
  • Coverage extends beyond basic mistakes to include legal defense costs, pollution incidents, and mid-project design corrections.
  • Claims can run into millions of dollars, with 23% of insurers paying settlements of $5 million or more in 2023.
  • Engineers typically need E&O insurance to meet client contract requirements and protect business assets from professional liability exposure.

Engineers have a significant responsibility when working on infrastructure and building projects that affect public safety and client investments. When design errors occur, the financial consequences can destroy their business. With E&O insurance, engineers get the financial protection and legal support they need when professional mistakes result in expensive claims.

Why Engineers Are Subject to Growing Liability Pressure

Engineering firms constantly experience extensive liability pressure as professional expectations increase and projects become more complex. Infrastructure projects now involve larger budgets and incorporate far more sophisticated systems than previous decades. These factors combine to create substantial liability exposure for design professionals.

Client contracts frequently mandate specific insurance requirements before the project even starts. Government agencies and private companies typically require E&O insurance alongside general liability, commercial auto, and workers’ compensation coverage. The insurance requirement reflects the significant financial risks associated with engineering projects.

Industry data reveals important trends in the professional liability market. A 2024 survey of major insurers found that all but one carrier plans to increase rates for architects and engineers. Among those raising rates, 75% plan increases up to 5%, while 25% intend to raise rates by 6% or more. This marks the third consecutive year of rate increases.

Comprehending E&O Coverage for Engineering Firms

E&O Insurance Form with Pen and Hard Yellow HatE&O insurance addresses professional service failures that cause financial harm to clients or third parties. The coverage operates differently from general liability insurance, which handles physical accidents and property damage. Professional liability protection focuses specifically on mistakes in technical work and service delivery.
Engineering E&O policies typically cover several important areas.

  • Design mistakes represent the primary coverage category, protecting firms when calculation errors, specification problems, or planning failures cause client losses.
  • Inspection oversights receive coverage when site review failures lead to financial damages.
  • Pollution incidents arising from engineering miscalculations fall under many policies, though firms should verify this coverage inclusion
  • Legal defense costs often exceed settlement amounts in professional liability disputes. Engineering claims require specialized legal expertise, expert witness testimony, and extensive technical research. E&O policies cover these defense expenses, though the specific treatment varies by carrier.

Some policies include defense costs within the overall coverage limit, while others provide separate defense allocations. This distinction matters when selecting appropriate coverage amounts. Firms should know if their legal defense spending reduces available settlement funds.

A Real-World Scenario

Consider a civil engineering firm designing a municipal water system expansion. During construction, contractors found that the design specifications for pipe materials failed to account for soil acidity levels in certain zones. The oversight requires replacing already-installed materials and redesigning portions of the system.

The municipality files a claim for $2.3 million, for example, covering replacement costs, construction delays, and engineering fees for corrective work. The engineering firm’s E&O policy covers legal defense costs and the settlement amount, allowing the business to continue operations without depleting operating capital or liquidating assets.

Current Market Conditions and Claim Trends

Professional liability insurers report concerning trends in claim severity and frequency. Only 6% of surveyed carriers experienced decreased claim severity in 2023, while 18% saw their claim experience worsen compared to the previous year. These patterns drive the current rate increase environment.

The financial scope of claims continues expanding. Twenty-three percent of insurers paid claims exceeding $5 million in 2023, with 12% handling claims above $10 million. And construction inflation contributes significantly to rising costs, with 81% of insurance companies citing inflation as a primary factor driving increased claim expenses.

Specific engineering disciplines experience heightened scrutiny from insurers. Structural engineering tops the list for claim severity, with 82% of carriers identifying it as a high-risk discipline. Civil engineering follows at 59%, while architecture ranks third at 47%. These specialties often command higher premiums or additional underwriting requirements.

The availability of high coverage limits has contracted recently. Only 40% of insurers offer limits exceeding $5 million, down from approximately two-thirds in 2023. This reduction creates challenges for firms pursuing large infrastructure projects where clients mandate substantial coverage amounts.

Policy Structure Considerations

Worker Using Tablet Displaying Insurance Policy Structure at WorkplaceE&O insurance operates on a claims-made basis, establishing a specific timeframe for filing claims. Standard policies require that the alleged error and the claim submission occur during the policy period. This structure differs from occurrence-based policies used in general liability coverage.

Prior acts coverage extends protection backward to include historical work. Without this endorsement, firms can only claim protection for work performed after the policy inception date. Full prior acts coverage eliminates this gap, allowing claims from any point in the firm’s history.

Settlement authority varies among policies. Some carriers retain the right to settle claims without policyholder consent, while others require firm approval before accepting settlement offers. This provision is significant for professional reputation management.

CI Solutions Professionals Understand Engineering Liability Protection

Engineering firms need specialized insurance guidance to address professional liability exposures effectively. Proper E&O insurance requires expertise in engineering operations and insurance markets, from selecting appropriate coverage limits to comprehending claims-made policy structures.

CI Solutions combines insurance and industry knowledge to help engineering firms secure protection customized to their specific practice areas and project types. Contact us today at 703.988.3665 or visit us online to discuss your engineering firm’s professional liability insurance needs.

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