Innovating Infrastructure with Precision: How ECI Is Shaping the Future of Trenchless Construction in the Midwest

by Jason Holden, Akkerman Inc.

For over 25 years, Engineering & Construction Innovations, Inc. (ECI) has exemplified what it means to combine deep engineering knowledge with hands-on construction expertise. Based in Oakdale, Minnesota, founded and led by CEO Shane McFadden and President Robb Johnson, ECI has grown from a small operation into a respected firm serving the heavy civil construction industry. With over 80 professionals, including engineers, field specialists, and administrative staff, the company has earned a reputation for solving some of the most complex infrastructure challenges in the Midwest.

Their capabilities include dam and hydropower work, geotech- nical construction, pipeline rehabilitation, and underground infra- structure solutions. What truly distinguishes ECI is their commit- ment to engineering excellence and continuous innovation. This mindset is deeply rooted in the company’s name and culture. At Akkerman, we’ve had the privilege of working with ECI for more than 22 years, collaborating on numerous trenchless projects where their expertise and our equipment have seamlessly combined to de- liver outstanding results.

This article highlights three key projects where ECI applied ad- vanced trenchless techniques with notable success, using Akker- man equipment as a critical part of their solutions.

Beneath the River: 10th Avenue Bridge Microtunnel Project

In Minneapolis, the historic 10th Avenue Bridge once supported a 54-inch water main that crossed the Mississippi River. As part of a bridge renovation that began in 2019, the city needed a reliable, long-lasting way to replace the aging line. Rather than repeat past solutions that left the pipe exposed to the elements, the city opted for a more durable approach: installing a new waterline 30 feet beneath the riverbed using microtunneling technology.

Initially, ECI served as the general contractor. When a subcon- tractor was unable to successfully complete the trenchless por- tion of the project, ECI stepped in and took on the microtunneling themselves. Utilizing the Akkerman SL60P Microtunnel Boring Machine (MTBM) system, along with a full support package in- cluding a control container with remote monitoring, AZ-100 Total Guidance System, and accessories purpose-built for the project by Akkerman, ECI successfully completed the 900-ft drive under the river in just under two weeks.

The project marked a major milestone for ECI, solidifying their capability to self-perform complex microtunneling operations. It also ensured a more resilient and longer-lasting waterline for the 36 Utility Contractor | March/April 2026 Aurora Raw Water Intake Project in beautiful Northern Minnesota. City of Minneapolis, protected from weather, corrosion, and main- tenance challenges.

Regional Sewer Expansion: Lake Elmo West Project

As population and development surged in the eastern suburbs of the Twin Cities, local infrastructure had to keep pace. The Lake Elmo West Sewer Expansion Project, led by the Metropolitan Council Environmental Services (MCES), was designed to deliver regional sewer access to communities including Lake Elmo, Oakdale, and Woodbury, Minnesota.

The project involved installing nearly a mile of large-diameter sewer, including several critical trenchless crossings parallel to, and beneath Interstate 94. Ground conditions varied significantly, with glacial till, loose sands, and groundwater present at depths up to 39 feet. Long drive lengths up to 1350-lf were required, and environmental constraints with seasonal variability added further complexity.

To complete multiple drives using 74-inch diameter steel casing, ECI relied on their Akkerman SL74P MTBM system and an MT875K jacking frame. A notable part of their approach was the use of an Akkerman 240A Guided Boring Machine (GBM) for risk mitigation. This strategy helped ECI identify subsurface obstacles to eliminate risky underground compressed air interventions. The pilot tube probing method gave ECI confidence that the equipment was properly configured to handle the ground conditions beneath critical infrastructure where disturbance was not an option.

The final tunnel segment was completed in July 2025, following a successful 227-foot crossing beneath the Bielenberg Bridge earlier that spring. Through precise execution and collaboration with project stakeholders, ECI delivered results that will support regional development for decades to come.

Underwater Precision: Aurora Raw Water Intake Project

The city of Aurora, Minnesota, faced urgent water quality and supply issues. Drawing water from the aging St. James Mine Pit had become unsustainable due to rising water levels, sulfate content, and seasonal limitations. A solution was found in the Embarrass Pit, where a new intake system would feed a regional water treatment plant serving Aurora, Biwabik, Hoyt Lakes, and surrounding areas.

ECI was tasked with executing a specialized microtunneling operation beneath the lake. True to their name, the team innovated, engineered, and constructed a deep caisson launch shaft to safely support the work. The 120-foot drive presented significant challenges, including variable soils and groundwater pressures exceeding 20 feet of head. To address these conditions and ensure worker safety, ECI combined their design/build caisson shaft with a custom pit seal and pipe clamp capable of withstanding the water pressure.

The tunneling was performed using an Akkerman SL44C MTBM system, supported by a sealed pipe adapter and a retrieval bulkhead. ECI also added a secondary bulkhead in the first pipe segment to allow for safe underwater retrieval of the machine. Divers cut between the bulkheads to extract the MTBM without flooding the tunnel.

This innovative approach demonstrated ECI’s ability to solve complex problems with precision and care. The result was a critical piece of infrastructure that will provide reliable raw water supply for a growing population in northern Minnesota.

Collaboration That Drives Innovation

ECI’s success across these diverse projects stems from a unique combination of engineering depth, practical experience, and the right tools for the job. The partnership between ECI and Akkerman has allowed both companies to push the boundaries of what trenchless technology can accomplish.

With a growing demand for infrastructure rehabilitation across the Midwest, ECI is well positioned to continue delivering creative, reliable solutions for years to come. Their approach proves that when a contractor is willing to lead, adapt, and innovate, remarkable things are possible—even underground. At Akkerman, we are proud to play a supporting role in ECI’s journey and look forward to what we can achieve together next.