Cable Replacement Program

INTREN has been managing a Cable Replacement Program (CRP) in Northern Illinois and Suburban Chicago for over a decade, ensuring the safe and efficient replacement of underground residential distribution (URD) systems. This project involved full-scale planning, permitting, and a comprehensive communications program with municipalities and customers. To date, INTREN has successfully replaced over 6,000 miles of cable, often operating with over 44 drill rigs per day and at peak levels managing up to 52 drill rigs, including subcontractors.

Damage Prevention & Safety Measures

INTREN is committed to implementing measures that maximize safety across all facets of our work. Damage prevention was a critical component of this project, and our team successfully executed several strategies:

• Pre-Task Hazard Analysis & Job Briefing Process: The CRP team excelled in utilizing job briefings to emphasize pre-task hazard analysis. Each project phase began with a thorough assessment of potential risks, ensuring that all team members were aware of safety protocols and site-specific challenges.
• Utilization of HP Toolbook: The team effectively used tools from the HP Toolbook, particularly the 4 Key Questions and STAR principles (Stop, Think, Act, Review), to enhance safety awareness and proactive decision-making on-site.
• INTREN’s Rules to Dig By: Every day, crews incorporated INTREN’s Rules to Dig By as an additional damage prevention measure, reducing the risk of striking existing underground utilities and ensuring compliance with best practices.
• Culture of Collaboration & Accountability: INTREN fostered a strong culture of collaboration among field crews, leadership, and subcontractors. This culture was integral to maintaining error-free performance and a heightened sense of responsibility across all levels of the organization.

Challenges & Solutions

Like any large-scale infrastructure project, the Cable Replacement Program faced challenges, particularly with underground utility conflicts, permitting delays, and workforce training. INTREN successfully navigated these roadblocks using strategic solutions:

• Underground Utility Conflicts: With extensive underground infrastructure already in place, identifying and avoiding existing utilities was a major challenge. By leveraging advanced utility locating technology and adhering to our Rules to Dig By, we minimized damages and kept operations on schedule.
• Permitting & Municipal Coordination: Working with multiple municipalities required an efficient permitting process. INTREN implemented a dedicated communications team to streamline approvals and keep all management involved, reducing delays and enhancing community relations.
• Workforce Development & Safety Compliance: Managing up to 52 drill rigs required a skilled and safety-conscious workforce. INTREN’s Green Hard Hat Mentoring Program was introduced to provide hands-on training for inexperienced employees. Additionally, continuous compliance and technical training ensured that all employees adhered to the highest safety standards.
• Leadership-Driven Safety Program: INTREN’s executive leadership drove a measured approach to safety, focusing on leading indicators and root cause analysis. Field audits were conducted at all levels, and targeted safety metrics were established to track progress and reinforce accountability.

Results & Impact

Through meticulous planning, a safety-first approach, and a commitment to innovation, INTREN successfully executed the Cable Replacement Program with outstanding results:

• 6,000+ miles of URD cable replaced safely and efficiently
• Over 44 drill rigs operating daily, with peaks of 52 rigs
• Significant reduction in utility damages through proactive damage prevention
• Enhanced workforce development through mentoring, compliance training, and leadership engagement

INTREN’s Cable Replacement Program stands as a testament to the company’s unwavering commitment to safety, accountability, and efficiency. By integrating pre-task hazard analysis, safety tools, and a culture of collaboration, INTREN continues to set the standard for excellence in utility infrastructure projects. The program’s success highlights INTREN’s ability to manage complex electric projects while maintaining a steadfast focus on damage prevention, workforce safety, and operational excellence.