At nearly 50 years old and 20 years past its intended lifespan, the section of road between Michigan’s Interstate 94 and Island Highway had deteriorated significantly. With over 91,000 vehicles traveling its 200-mile length daily, the concrete was prone to buckling, especially during the scorching summer months.
Recognizing the urgent need for repair, the Michigan Department of Transportation (MDOT) embarked on the I-69 Reconstruction Design-Build Project, I-94 to Island Hwy project.
The project involved an overhaul of 22 miles of mainline roadway, two miles of additional pavement repairs, the renovation of multiple interchanges and significant bridge work, including the replacement of one bridge and rehabilitation of 26 others.
The project’s scale was ambitious, and its successful execution relied on meticulous planning and coordination among various teams, led by designer Michael Baker International and contractor Michigan Paving & Materials.
The project aimed to bring the highway up to current geometric design standards, ensuring a service life of 30 years for the reconstructed section. This massive undertaking was not just about upgrading pavement; it represented a $210 million investment in the state’s infrastructure and the local economy, supporting over 2,600 jobs during its execution.
To enhance efficiency and accuracy during the design and construction phases, the team employed advanced 3D modeling technology, a notable shift from traditional 2D planning.
This allowed for more precise visualizations and improved communication among team members, streamlining the entire process. The use of Open Roads Designer software also marked a pioneering step in Michigan’s construction practices.
As the project unfolded in 2020, the team tackled maintenance work, utilizing temporary pavements and conducting culvert videotaping to ensure progress before winter set in. They implemented several value-engineering solutions to cut costs and minimize delays, including a traffic study that enabled a full detour of a freeway-to-freeway ramp.
These strategic decisions resulted in significant time and cost savings, demonstrating the team’s ability to adapt and innovate under pressure.
The construction phase was uniquely challenging due to the project’s size. Originally divided into four smaller segments, the team was able to consolidate them into a single project, dramatically reducing the timeline from a decade to just three years. This allowed for more efficient resource allocation and quicker execution of construction activities.
Throughout the project, safety remained the highest priority. The team conducted annual contractor meetings to ensure that every worker understood safety protocols, marking hazards and implementing thorough signage to guide the motoring public. In the end, over 280,000 hours were worked without a single lost-time accident, a testament to the commitment to safety on site.
Ultimately, the successful completion of the I-69 reconstruction project was a triumph of teamwork, technology and tenacity. It revitalized a crucial corridor, serving the needs of the community and economy for decades to come. The effort was more than just a construction project; it was a commitment to a safer and more connected Michigan.
Project: I-69 Reconstruction Design-Build Project, I-94 to Island Hwy
Location: Calhoun and Eaton Counties, Michigan
Owners: Michigan Department of Transportation
Designer: Michael Baker International
Contractor: Michigan Paving & Materials
Cost: $210 million
Length: 22 miles
