Burns & McDonnell: 9-Project, 764-MW Solar Portfolio

Shining a Light on the Future: Burns & McDonnell's Excellence in Wisconsin Solar Projects "

Burns & McDonnell has completed the design, procurement, construction (EPC), and self-perform construction services for nine solar projects in Wisconsin. These projects are part of Alliant Energy's clean energy blueprint and are expected to provide electricity to approximately 170,000 households in their first year of operation.

Scale and contribution of the nine solar projects

A solar contractor drives an all-terrain vehicle through a completed solar project site in Wisconsin. Burns & McDonnell initiated construction at these sites in 2021 and completed the projects in phases. Despite challenges posed by COVID-19, labor, and supply chain disruptions affecting the industry, all sites were delivered on time.

Chad Cotter, Vice President of Solar Construction at Burns & McDonnell, stated, "Looking back over the past three to four years in the solar industry, achieving on-time completion of these projects is a significant accomplishment." "Early integration of our EPC team, self-perform personnel, environmental and permitting experts, and substation and interconnection support teams with Alliant Energy and local union halls was crucial for ensuring certainty of outcomes and on-time delivery. But I believe the most important factor was Alliant Energy's bold vision driving these projects forward despite the turbulent times that led to many other projects across the nation being put on hold."

Project construction process and challenges

The solar projects employed over 1,300 craftsmen. As part of a commitment to support the local workforce, an apprenticeship program was developed by Burns & McDonnell's union construction subsidiary, AZCO. The program provided hands-on training and practical experience for 230 apprentices, helping them become carpenters, electricians, laborers, operators, and millwrights. Over 75% of the craft labor force in the program were residents of Wisconsin. Additionally, multiple visits were organized for students from local high schools and technical colleges, emphasizing career opportunities and pathways into the industry.

Community involvement and employment opportunities

Josh Ronk, Construction Project Manager at AZCO, said, "By closely collaborating with Alliant Energy, local union halls, and contractor partners, we were able to help Alliant Energy deliver exceptional value to customers across Wisconsin while keeping project funds within the community." "It's a great achievement when you can train craftsmen and provide them with the tools and resources to move on to the next job site."

Burns & McDonnell presented the Blue Heart Safety Award to seven employees of the Wood County solar project for their quick thinking and CPR skills that helped save the life of an operator who suffered a heart attack on the job site.

"'Everyone returns home more safely' is the mindset we apply every day at these sites," said Seth Hanebutt, Project Manager at Burns & McDonnell.

Sustainability and Partnerships

From the outset, Alliant Energy sought to develop and construct these projects in an environmentally favorable manner. To this end, Burns & McDonnell collaborated with Alliant Energy, following its Envision sustainable development framework. The Bear Creek, Wood County, and North Rock facilities received the highest level of Platinum Envision ISI certification, recognizing their contributions to sustainable development and clean and renewable energy. Certification applications for the other six sites are pending final decisions.

Allison Chapin, Environmental Project Manager at Burns & McDonnell, stated, "Planting native grasses and pollinator plant species can make these sites multi-functional lands, promoting biodiversity and supporting Alliant Energy's sustainable development plan."

During the project, nine new substations were constructed, with six power lines consisting of approximately 8 miles of 69 kV and 138 kV transmission lines used to deliver power to the grid. To mitigate supply chain issues, the team utilized temporary high-voltage gas circuit breakers retired from Alliant Energy's coal-fired plants to maintain project progress while awaiting the arrival of new high-voltage gas circuit breakers.

Successful experiences and future outlook

Josh Ahrens, Solar Engineering Manager at Burns & McDonnell, said, "Large-scale projects like this bring significant challenges, and our comprehensive project team rose to meet these challenges." "By integrating engineering into our self-perform team, we improved efficiency, helped identify critical paths, and worked together to meet timelines, while also enabling us to learn from the challenges encountered and build better mousetraps for future projects."

These nine solar facilities cover nearly 5,000 acres in total, adding 764 megawatts of solar capacity to Alliant Energy's diversified generation portfolio:

- Albany Solar Project, a 50-megawatt site.

- Bear Creek Solar Project, a 50-megawatt site.

- Beaver Dam Solar Project, a 50-megawatt site.

- Casville Solar Project, a 50-megawatt site.

- North Rock Solar Project, a 50-megawatt site.

- Paddock Solar Project, a 65-megawatt site.

- Springfield Solar Project, a 100-megawatt site.

- Wautoma Solar Project, a 99-megawatt site.

- Wood County Solar Project, a 150-megawatt site.