Many construction projects are proposed but never move forward or are delayed. There are a host of reasons why projects may suffer this fate though money – or lack thereof – is often the issue. Even so, the U.S. 31 reconstruction in Berrien County, Michigan, has been a long time coming – over 50 years. While the Michigan Department of Transportation (MDOT) has been making progress on the project, the last step had its own unique reason for being delayed.The idea to build a freeway connecting the Indiana Toll Road and I-94 was conceived in the late 1960s. It’s a 30-mile stretch. A direct route between the two roads will reduce traffic and therefore crashes along the existing Napier Avenue connection, especially at intersections, and will facilitate more efficient freight movement through the travel time savings.

So, why the latest delay? At one point, money was the issue. The state of Michigan paused new road construction in order to focus on ensuring all existing roadways were up to date.

And then there was the Mitchell’s Satyr butterfly, and their habitat, the Blue Creek Fen.

While performing the standard environmental study, the habitat of the Mitchell’s Satyr butterfly – which is a protected and endangered species – was identified within the project limits. Project design was halted while the study went on and ultimately was modified and relocated, so the butterfly’s habitat could be avoided. This delayed the project by 18 years.

“The current project includes multiple elements,” said Sarah Fedders, a Project Manager for MDOT. The project originally focused solely on adding 2.3 miles to complete the connection the U.S. 31 freeway and I-94.

“Other elements were added on make it a smooth corridor, and the interchange impacted the Business Loop (BL),” said Fedders.

Those other parts include includes reconstruction of approximately 3 miles of I-94, a new interchange to connect U.S. 31 and the I-94 BL, reconstructing the I-94 BL – including adding a roundabout, and work on six bridges. Bridge work includes one replacement, one rehabilitation, two removals, and two new bridges.

The BL is currently a four-lane divided highway. Upon reconstruction, it will be reduced to a two- and three-lane highway. The BL’s currently construction – a wide open straight road – has led to speeding and accidents.

“Reducing the size of the I-94 BL should create a safer roadway for the motoring public as it will encourage vehicles to slow down and travel the posted speed, provide fewer lanes for pedestrians to have to cross from north to south, and provide the continuity of design commuters are used to,” said Fedders.

The revision to the design due to the need to avoid the butterfly habitat led MDOT to design a plan that included a shorter stretch of road and reduced the amount of bridges impacted.

The sheer size or scope of the project has been a challenge according to Fedders. “With work taking place on three different roadways, each with its own concerns, so this project keeps us all on our toes,” said Fedders. Multiple crews are working on various aspects of the job simultaneously.

Fedders credits team coordination and communication in enabling the project to run smoothly. “We have regular meetings to check in with everyone to keep the project moving forward,” said Fedders.

Another essential in keeping the project moving forward is making sure construction elements are on site in a timely manner. The team needs to order materials, so they are there on time for when the crew needs them. So far, so good according to Fedders.

The budget for the entire project, including Right of Way, is $148.6 million. The project has multiple funding sources. The state, via its Rebuilding Michigan bond, is funding $82 million. A BUILD Grant was secured for an additional $20 million. The rest of the funding is a standard mix of federal and state funds to round out the remaining construction budget $46.6 million.

The support of various public entities and private businesses as well as past and present government officials helped the project secure the grant. “Because the project was on the books for so long, many people and entities were anxious to get it completed,” said Fedders.

While the project is in its early stages, it is on budget so far. Fedders credits communication between design, construction, and the project management team for keeping the project on budget.

Because this is a design-build project, MDOT has two project managers on the project. The other project manager is Dharmesh Valsadia. The two project managers communicate multiple times each week and strive to be clear on the division of roles to make sure everything is moving along smoothly.

The project began this past summer and is expected to open to traffic in December 2022. Landscaping and other elements will wrap up in spring 2023.

Fedders, who notes the heavy lifting will begin in the spring of 2021, views the schedule as very tight. However, she is confident it can be met. “MDOT is in close communication with the contractor team to see where they are in the schedule, and they left time at the end to allow some extra time for completing work,” said Fedders.

When the U.S. 31 reconstruction in Berrien County is complete, it will be the culmination of a long journey. Drivers will have a direct connection to I-94. There will be safety improvements and reduced traffic. Finally, the project will facilitate more efficient freight movement. The long wait will have been worth it.