From Concrete Foundations to Renewable Energy with DTE
Projects
Since 1998, Barton Malow has embraced a sustainable future with key partner DTE Energy. From facility and sidewalk upgrades all the way to foundational power plant projects and renewable wind farms, the partnership has transformed Barton Malow’s experience in renewable energy.
Humble Beginnings
The collaboration between Barton Malow and DTE had humble beginnings, starting with renovations to the Lapeer Service Center in 1998. The service center underwent a one-story addition to the existing office building, where we provided self-perform services for concrete, interiors, repaving, and landscaping.
“Since our first project with DTE, the collaboration of our teams is a testament to what can be achieved when two organizations share a vision for sustainability and innovation,” said Chuck Binkowski, Chief Operating Officer at Barton Malow. “Our partnership is not just a reflection of our shared achievements but also of our dedication to transforming the energy landscape and driving progress for the future together.”
After establishing a relationship with DTE, the company entrusted Barton Malow with additional projects. In 1999, Barton Malow constructed the Greenwood Peaking Facility in Avoca, Michigan, the Del Ray Peaking Facility in Detroit, Michigan, and the Belle River Peaking Facility in St. Clair, Michigan, where we self-performed foundations and centerline erection. We have continued to provide updates and renovations to the facilities as recently as this year. The foundation built on the successful completion of these peaking facilities, or power plants that generally run only when there is a high demand, led to future collaborations in the 2000s.
Expansion and Key Projects
Barton Malow began working on larger projects with DTE in 2005, such as the Monroe Power Plant, where we have continuously had a team on site. Work was focused on Selective Catalytic Reduction (SCR) foundations and infrastructure improvements. In 2009, a major project included Flue Gas Desulfurization (FGD) foundations for Units 1, 2, 3, and 4. The completion of extensive environmental upgrades to these units and adjacent facilities continued to strengthen our partnership with DTE.
In 2011, the Environment Protection Agency updated its Mercury and Air Toxic Standards (MATS), limiting the emission of toxic air pollutants from coal and oil-fired power plants. This required DTE to address plant upgrades to meet the new standards by 2015, and if significant progress was shown, a one-year extension would be granted to achieve full compliance. Barton Malow competed to manage the significant undertaking, and the strong relationship with DTE played a pivotal role in securing the project.
Barton Malow provided Engineer-Procure-Construct (EPC) services on 11 coal-fired units in four power plants in Metro Detroit – St. Clair, Belle River, River Rouge, and Trenton Channel, totaling over 3,000 MW. We designed a Dry Sorbent Injection (DSI) and Activated Carbon Injection (ACI) Program to control and improve the outgoing air quality at the plants and self-performed civil and concrete to safely advance the schedule and earn DTE the one-year extension.
A project of that size and complexity would not have been successful without extensive collaboration among all team members, and the installation of these systems was completed under budget, on schedule, and with an exemplary safety record. The project later earned the Best Energy/Industrial Project by Engineering News-Record (ENR) Midwest in 2017.
“Undertaking the MATS compliance project proved our capabilities in delivering complex projects with DTE,” said Matt Lentini, Sr. Vice President, Industrial/Energy at Barton Malow. “By tackling the challenges of regulatory compliance and facility upgrades together, we solidified a partnership grounded in mutual success.”
In 2019, Barton Malow and LS Brinker partnered to construct a new Electrical Service Operations Center (ESOC) and Headquarters Energy Center (HQEC). The high-security ESOC included a three-story, 66,500 SF facility that can withstand up to 250 MPH winds with an equipment yard and full utility infrastructure. The new HQEC was needed to provide the entire DTE campus with Steam and Chilled water to supply heating and cooling. The HQEC construction scope included a new 14,400 SF two-story structure with full utility infrastructure, sitework, and pipe routing.
Despite challenges faced during the COVID-19 pandemic, the project was finished in 2021. Barton Malow utilized self-perform capabilities, including civil and concrete. Managing the tight site logistics in the heart of Downtown Detroit required continuous communication and coordination that successfully led to the safe completion of the project with limited interruptions to the surrounding community.
A Future in Renewable Energy
The continued collaboration on various maintenance and upgrade projects pushed the partnership forward. After completing the Stoney Corners Wind Farm in McBain, Michigan, for Heritage Sustainable Energy, now owned by DTE, Barton Malow set sights on additional renewable energy and wind projects.
“Our relationship with DTE was formed from the previous work we had done, but when they saw what we were able to accomplish on other wind projects, it helped to cultivate the relationship even more,” said Ryan Johnston, Project Director at Barton Malow Company. “From the start of our experience with DTE, we have consistently pushed the boundaries of what is possible in renewable energy.”
Completed in 2012, the Thumb Wind Park project, located on 15,000 acres spread over roughly 600 square miles, consisted of (69) 1.6-megawatt General Electric wind turbines, three electrical substations, and an associated electrical collection system. The 110 MW park is divided into three primary turbine sites in Minden, McKinley, and Sigel, Michigan, and generates renewable energy capable of powering 25,000 homes. The project went on to earn a Construction & Design Award from the Engineering Society of Detroit in 2013.
Fully operational as of 2014, DTE Energy’s Echo Wind Park covers nearly 18,000 acres in Chandler and Oliver Townships in Michigan’s Thumb region. The site consists of 70 GE 1.6 MW turbines for a total generation capacity of 112 MW, enough to power 50,000 homes. Construction of the wind park required the use of 800 tons of concrete for the 70 turbine foundations ranging in size from 55 to 64-foot diameters. Echo Wind Park is the first of DTE’s wind energy projects to tie into a new 345,000-volt transmission system built to handle all the renewable energy flowing into the Thumb’s electric grid.
Barton Malow’s entrance into solar projects with DTE began with a partnership with Inovateus Solar. The Lapeer Solar Array installation is a 58MWDC (48MWAC) solar farm seated on more than 360 acres north of Detroit, Michigan. The farm features approximately 180,000 Canadian Solar panels on racking and generates 84,000 megawatt-hours annually, enough to power approximately 11,000 homes throughout the region. At the time of completion in 2016, the installation was the largest utility-owned array east of the Mississippi.
“Investing in Michigan’s clean energy transformation with DTE has been a key driver to our continued growth as we recognize our 100-year anniversary,” said Joe Blanchette, Vice President of Energy at Barton Malow Company.
Since entering the market in 2008, Barton Malow completed our largest renewable energy project in 2021, the DTE Energy Meridian Wind Park. Operational as of 2023, the park is the largest in Michigan, with 77 wind turbines over 51 square miles, generating enough clean energy to power over 78,000 homes. In the rural area, roads had to be altered to accommodate the delivery of the massive turbines and 27 miles of access roads were built.
The turbines aren’t the only impressive aspect of the project when it comes to size. Over 70 foundations, each with 65-foot diameters, were built to support the turbines, with about 450 yards of concrete for each foundation. The project required extraordinary planning, logistics coordination, and safety awareness.
“Barton Malow consistently managed any issues that arose with attention to detail by communicating, resolving, and correcting,” said Josh Holmes, Project Manager at DTE Energy. “We have received multiple compliments of Barton Malow, from supporting landowners, county, and township officials as them treating the community as their own. Barton Malow is a very experienced wind builder in the state of Michigan, and it shows with their commitment and adherence to safety, quality, and community.”
For those keeping count, these solar projects alone can power 164,000 Michigan homes. Barton Malow is also a member of the DTE MIGreenPower program, where 100% of the electricity that powers our Southfield headquarters building is derived from Michigan-made solar and wind energy. Barton Malow continues to assist DTE in achieving its goal of net zero carbon emissions by 2050 and adding 1,000 megawatts of new wind and solar annually to power five million homes with renewable energy by 2042.
Where We Stand Today
For two consecutive years, Barton Malow has performed the largest volume of revenue for periodic outages in our history of working at the Monroe Power Plant, with all projects being delivered on time and under budget.
The largest volume of outage work performed by Barton Malow Company to date was completed on the Unit 3 Spring Periodic Outage in 2024, with over 50,000 work hours. The Dry Fly Ash Conversion project was also recently completed, where we upgraded DTE’s fly ash handling system, and all units were successfully performance-tested.
On Monroe Power Plant Units 1 and 2, we are converting DTE’s existing Economizer Ash and Bottom Ash Systems to Dry Conveyance Systems to meet Effluent Limitations Guidelines (ELG) where we will self-perform civil, concrete, millwrights, ironworkers, boilermakers, and refractory work.
We continue to support DTE with its capital projects and operations and maintenance work. Over the past two decades, we have continually grown our teams and work volume to support these programs. We have maintained a presence on site through support of day-to-day operational support and small capital projects.
“Our significant involvement with DTE on power plant projects, such as our intensive work at the Monroe Power Plant, shows our dedication to delivering complex outage projects on schedule and under budget,” said David Evangelista, Director of Energy at Barton Malow Company.
Barton Malow is continuing our transition into the solar market by constructing DTE’s new portfolio of solar projects, including Sauk Solar Park, a 150MWAC project near Union City, Michigan, Pine River Solar Park, an 80MWAC project near Alma, Michigan, and Little Trout Solar Park, a 150MWAC project near Rogers City, Michigan. Once complete, 2,500 acres between these three projects will house more than 881,000 solar panels and provide 760,000 MWh of clean, renewable energy annually. We are in the planning stages with DTE on future solar projects over the next decade and beyond to continue efforts towards a cleaner Michigan.
The collaboration between DTE Energy and Barton Malow remains robust, with ongoing projects and a shared history of overcoming challenges and achieving milestones together. The partnership has exemplified our commitment to quality, innovation, and sustainability in construction over the past 100 years and continues to pave the way for future advancements in the industry.
