Since 1998, power and energy projects have been at the core of our business. As a DTE and Consumers Energy strategic contractor of choice, our partnership has transformed our expertise into diversified energy construction solutions. From facility maintenance and repair services to new capital construction, CCI has executed hundreds of critical projects.
The expansion into the power & energy industry is a testament of both grit and perseverance, starting with our first project at the DTE Trenton Channel Power Plant. CCI earned the opportunity to provide self-perform millwright services on the Unit 1 Air Pre-Heater during a scheduled outage.
Upon successful completion of our first critical outage, our brand and reputation had expanded into other facilities including – River Rouge, Monroe, Belle River and St. Clair Power Plants. After establishing a trusted relationship, DTE entrusted CCI with additional projects throughout the five main fosgen power generation plants as well as various peaker stations throughout Michigan.
In 2000, CCI completed our first capital project, constructing the Refined Emissions Fuel (REF) Facility at the Monroe Power Plant. The first-of-its-kind facility provided a clean coal solution for the existing fuel handling operations. The project consisted of mechanical process equipment installation and structural steel erection. CCI’s self-perform divisions managed the installation of all conveyor galleries, hoppers, chutes, components and structural steel.
To this day, CCI continues to evolve as a trusted contractor for DTE and Consumers Energy, delivering critical maintenance and capital projects that support Michigan’s energy infrastructure. From ongoing facility upgrades to large-scale equipment installations, CCI’s expertise has been instrumental in helping DTE and Consumers achieve its operational and sustainability goals. See how we’ve earned our reputation for taking on complex projects in the case studies below:
In a proactive effort to upgrade multiple existing dry dust collection systems to wet dust collection systems, CCI partnered with DTE to provide general contracting and self-perform services at three power plants located in Monroe, St. Clair & Belle River. The Environmental Protection Agency identifies water dust collection as a Best Available Control Technology (BACT). The system also met National Fire Protection Association (NFPA) Standards for combustible dust.
The capital improvements were coordinated over a 4-year phasing plan where CCI was single-sourced for all but one unit. Serving as the general contractor, CCI self-performed all the demolition, rigging & machinery installation activities. In addition, CCI managed six subcontractors providing electrical, piping, abatement, scaffolding, ventilation and specialty cleaning services. To achieve the overall outage schedule, the majority of the work was performed on two shifts working around the clock.
CCI partnered with DTE to construct a stand-by power system for the four main Flue Gas Desulfurization (FGD) Units at the Monroe plant. The FGD consists of 4 Babcock Wilcox wet FGD absorbers which is designed to remove 97% of entering sulfur dioxide.
The scope of work included site excavation, underground mechanical piping & duct banks, new foundations and equipment setting of four (4) 1500KW diesel generators. Due to underground interferences & utilities, hydro-excavation was required in order to locate and preserve existing utilities. The foundation consisted of 48 deep foundation helical piles, 40 tons of rebar and 800 yards of concrete. Each generator set weighed in at approximately 60,000 lbs. Due to the location of underground utilities, site constraints and the weight of the units, an engineered rigging & lifting plan was required to execute the lifts. Our team safely & precisely coordinated & executed the lifts utilizing a 350-ton crane.
The Renaissance Power Plant required engineering, procurement and construction (EPC) services to replace the Units 1-4 turbine exhaust baffles. Over time, the internal fill materials degraded and the structural supports had cracked. Renaissance operates four simple-cycle natural gas Westinghouse W501D combustion turbines, generating 732 megawatts of electricity.
Serving as the prime EPC contractor, CCI was responsible for the conceptual design, final engineering, procurement and fabrication, removal and installation of a complete baffle system. Due to schedule demands, the majority of the outage was performed working two shifts to reduce downtime for plant operations. On Unit 2, a forced outage occurred requesting from our client that our team pull ahead and expedite the upgrades two months earlier than the planned outage. Our team was able to answer the call and adapt to the situation by expediting fabrication and mobilization.
The outage team completed the overhaul within the planned schedule with zero near misses or incidents. In addition, the overall far-field, A-weighted performance levels had improved by 4.0-5.0 dBA. This resulted in greater efficiency and lower noise levels for the nearby residential area.
In 2024, CCI was contracted to provide general contracting and self-perform construction services at the Blue Water Energy Center in East China, Michigan for two capital projects. The projects consisted of an administrative building and two independent structures designed to enclose the existing circulating water pumps and provide a wash down process station for the trash screens.
Serving as the general contractor, our team provided front-end design assist to take the project design from 60% to final design. With several project constraints presented, our team worked diligently to offer value engineering and cost competitive solutions. CCI’s civil/concrete and structural divisions lead the projects on the front-end by self-performing all sitework, foundations and structural steel erection. In addition to our self-perform activities, six specialty subcontractors were managed under CCI’s supervision.
Our ability to coordinate with internal resources allowed our project teams to better control safety, quality, and schedule, delivering our client the confidence and certainty critical milestones were achieved as planned.
During a routine scheduled outage, CCI’s millwright division was tasked with the Unit 1-1 Silencer Replacement and Unit 1-2 Compressor Overhaul at the St. Clair Compressor Station. The work was performed on the two main Solar turbine units that generate the power fueled by natural gas.
When removing the compressor, the main large bore piping shifted back approximately 3-4 inches resulting in an emergency repair scenario. CCI and our partners quickly developed a repair plan including a new spool piece custom fabricated to fit up to the existing gas line and compressor.
Although additional days were required to make the repairs, the overall outage schedule was not compromised. The compressor was re-installed and aligned, achieving operational run-off according to the OEM specifications.
Since 2014, CCI’s millwright division has maintained an onsite presence at the D.E. Karn Generating Complex. With a trailer, tools and manpower onsite, our teams have supported several critical maintenance and repair projects throughout the facility.
As one of the contractors of choice for plantwide maintenance, our teams provide responsive field services for various types of rotating and fixed machinery in the plant as well as fuel supply.
In 2016, our team responded to an emergency turbine outage on Unit 1B. In less than 24-hours, a crew was mobilized with the proper tools and equipment to start assessing the failure. For proper inspection, the shell was removed to gain access to the bearings. It was then revealed that multiple bearings had failed requiring replacement. The final inspection and overhaul of the bearings were completed in under three weeks.
“Our long-standing relationship with DTE and Consumers Energy showcases our ability to deliver results that exceed industry standards in safety, efficiency, and quality.”
Principal
In 2022, CCI provided civil/concrete and structural construction services for a state-of-the-art Renewable Natural Gas (RNG) Facility located in Riverview, Michigan. CCI’s civil & concrete division lead the project in the early stages completing all equipment and building foundations during phase 1. Additional civil infrastructure work packages were released for underground utilities, site drainage and H2S pipeline tie-in.
Upon completion of all civil and concrete packages, CCI’s structural division erected two (2) pre-engineered metal buildings. The main 8,500 sqft. metal building was erected over the four compressor skids to protect the assets from the weather elements and reduce overall noise decibels. The building system also included a 7.5-ton bridge crane to service the units for maintenance and repair operations. The second metal building was erected to support maintenance and operations activities.
The project teams executed all work packages ahead of schedule without disruption to existing plant operations or other trade contractors. With a strong work history in energy infrastructure projects, our client received the confidence and reliability in executing according to the project specifications and timeline.
“The Riverview RNG plant was a very exciting project to be a part of as we continue to scale our civil and concrete divisions,” said Brad Musolf, Civil/Concrete Division Manager. Converting waste to RNG is a win-win, both for local landfills and the local environment. We’re proud of our direct contribution towards delivering solutions for clean energy infrastructure.”
In 2024, CCI performed the largest volume of revenue for DTE’s FosGen Capital Construction group. All projects were delivered safely without any injuries or incidents and within budget.
As we continue to support DTE and Consumers with its capital and maintenance projects, we have continually grown our teams, systems, processes, and company-owned equipment to enhance our position as a strategic partner.
“We’re extremely grateful for the opportunities that DTE and Consumers have presented to CCI. Our long-term partnerships is a representation of our brand promise, which demonstrates our commitment to delivering a higher standard of service for our clients,” said Phillip Garcia, Principal.
CCI is continuing to support and build new relationships within DTE and Consumer Energy’s diversified business units. With new opportunities developing with facilities, distribution operations and the non-regulated divisions, our teams are continuing to collaborate and offer high-performing teams.
The partnership between DTE, Consumers and CCI remains one built on trust, honesty, and reliability. With ongoing projects and a rich history of overcoming challenges and constructing rewarding projects together. Our partnership has exemplified our relentless commitment to leading our projects with safety, providing quality services and offering dependable solutions for complex challenges. As we evolve as a contractor, we continue to set a standard in the construction industry leading by example and demonstrating how to safely manage critical projects.
