ECI Innovates Infrastructure with Precision

For more than 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, and founded and led by CEO Shane McFadden and President Robb Johnson, ECI has grown from a small operation into a respected firm. The company now serves the heavy civil construction industry.

With more than 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, geotechnical construction, pipeline rehabilitation, and underground infrastructure solutions. What truly distinguishes ECI is its commitment to engineering excellence and continuous innovation. This mindset is deeply rooted in the company’s name and culture.

At Akkerman, we have worked with ECI for more than 22 years. During this time, we have collaborated on numerous trenchless projects where its expertise and our equipment have seamlessly combined to deliver outstanding results.
This article highlights three key projects where ECI applied advanced trenchless techniques with notable success.

10th Avenue Bridge Microtunnel Project

In Minneapolis, the historic 10th Avenue Bridge once supported a 54-in. 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. The approach involved installing a new waterline 30 ft beneath the riverbed using microtunneling technology.

Initially, ECI served as the general contractor. When a subcontractor was unable to successfully complete the trenchless portion of the project, ECI stepped in and took on the microtunneling themselves.

Utilizing an Akkerman SL60P Microtunnel Boring Machine (MTBM) system, along with a full support package including a control container with remote monitoring, AZ-100 Total Guidance System, and accessory’s 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 its capability to self-perform complex microtunneling operations. It also ensured a more resilient and longer-lasting waterline for the City of Minneapolis, protected from weather, corrosion, and maintenance challenges.

Regional Sewer Expansion: Lake Elmo West Project

As population and development surged in the 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, 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. It included 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. Moreover, long drive lengths up to 1,350-lf were required, and environmental constraints with seasonal variability added further complexity.

To complete multiple drives using 74-in. diameter steel casing, ECI relied on its 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. In these locations, disturbance was not an option.

The final tunnel segment was completed in July 2025, following a successful 227-ft 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.

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. Here, 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. The team innovated, engineered, and constructed a deep caisson launch shaft to safely support the work. The 120-ft 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. This system was 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.

Jason Holden is vice president, CRO of Akkerman Inc.

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