Pipeline Rehabilitation and Repair

Pipeline Rehabilitation and Repair
PEX enables installer to keep aesthetics in historic department store

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CIPP equipment keeps jail within budget, disruption-free

Problem: Rehabilitation of a sewer main running below four dormitories at Estrella Women’s Jail in Maricopa County, Arizona, came with some unusual job limitations. First, the work had to be performed at night but could not disturb the detainees, due to state law. The actual work window would be between 9 p.m. and 5 a.m. During that time, the crew had to complete any run it started. Plus, project funding restricted overtime pay for necessary extra security, so the crew was allowed to work only on the Thursday, Friday and Saturday nights of two consecutive weeks.

Solution: Digging up the pipe would have required relocation of half of Estrella’s inmates for the duration of the job, making CIPP rehabilitation the best choice for the county. Irontree Construction chose HammerHead Trenchless Equipment’s HydraLiner line of CIPP equipment and consumables. The first night began with jet cleaning and inspecting the main. Everything was made ready to begin inversion immediately once they returned. The next night, inversion began with wet-out. After wet-out, the crew wound the liner onto a spool inside the HydraLiner inversion drum. Pressurizing the drum forced the liner to spool out through the nozzle, turning itself inside out as it progressed, its epoxy resin side bonding and sealing with the existing pipe to create a continuous, jointless rehabilitated line.

Result: Work was completed on schedule and within budget. The job went so well that two more dormitories were slated for sewer rehabilitation. 800/331-6653; www.hammerheadtrenchless.com.

Liner installation avoids need for pits and ARCHAEOLOGISTS

Problem: Seamen’s Hospital, a two-story stone building constructed in 1833 in Hawaii, was experiencing daily backups and had resorted to renting portable toilets. The inversion process was not a viable option because it would have resulted in disturbing a historical site in a special management area, and a traditional repair would have cost more since an SMA permit and assessment would have been required with an archaeologist on site for the duration of the project.

Solution: Maui Plumbing was able to clean 120 feet of 4-inch cast iron through the existing clean-outs using the Pneumatic Micro-Cutter by Nu Flow. Once clean, technicians wet-out the Nu Drain liner using slow-cure epoxy because of the high humidity and temperatures that reached over 90 degrees Fahrenheit. The lining was performed in three separate sections, which had three reinstatements for the downstairs restroom, the upstairs plumbing stack and the clean-out.

Result: The system allowed Maui Plumbing to clean and line the historical property’s piping system without the need to dig pits, have an archaeologist or obtain SMA permits. 905/433-5510; www.nuflowtechnologies.com.

Lateral lining system used to repair collapsed drain

Problem: A warehouse facility housing three businesses in San Diego had a problem. The 4-inch common sewer drain buried under the floor of the warehouse was failing, and one section had already collapsed. Multiple contractors recommended cleaning 960 feet of pipe and replacing the remaining 140 feet of collapsed pipe.

Solution: The owner didn’t like that solution and asked Brink Services to look at the situation and see if it could solve the problem without disrupting day-to-day operations of the warehouse. The bottom was missing on the entire length of the 1,100-foot cast iron pipe, but it was still round except for the collapsed section. There was a lack of access points, with the shortest line segment being 70 feet, then 289, 141, 140, 220 and 240 feet. Brink Services determined it could employ the Quik Shot lateral lining inversion system from Quik-Lining Systems to make the long lengths between pits, with a 240-foot blind installation at the end. Epoxy resin was chosen to eliminate toxic fumes, and a 60-minute resin hardener was chosen to expedite the project.

Result: The project was completed with no issues, on budget and faster than anticipated. The warehouse was able to continue operations uninterrupted. 605/695-6778; www.quiklining.com.

Lining lowers ambient temperatures IN steam system

Problem: Pepco Energy Service of Atlantic City, New Jersey, maintains the steam distribution loop for the downtown district. Its utility vaults had extensive leaks and extremely high ambient temperatures, creating a hazardous environment where infiltrating water was being evaporated into steam.

Solution: A large ventilation system was installed in the vaults for employees to safely work. The vault walls were sandblasted and lined with a plural component waterproofing system from Triton Lining Systems. Existing insulated steam lines with metallic covers were sprayed with a thermal-insulating nano particulate material that substantially reduces heat loss.

Result: The abatement of water infiltration comingled with heat reduction lowered the ambient temperature to 130 degrees Fahrenheit. The additional pipe insulation improved the overall steam system’s efficiency, which is directly affected by unrecoverable loss during transmission. 631/462-2952; www.tritonpipelining.com.

Pneumatic system meets pipe bursting challenge

Problem: Anticipated increased flows from the new 18,000-seat Avaya Soccer Stadium in San Jose, California, made an existing 12-inch vitrified clay sanitary sewer main inadequate. A new 20-inch HDPE line was proposed to replace the existing clay pipe. The privately funded project took place along a highly traveled thoroughfare in Silicon Valley.

Solution: Trenchless pneumatic pipe bursting was chosen for the project because of its ability to upsize the existing sanitary main while ultimately limiting disruption. The trenchless application required the closing of only a single lane of traffic in the heavily traveled area. A 14-inch-diameter Grundocrack Koloss pneumatic bursting system with rear expander from TT Technologies was used to burst the existing clay pipe and pull in the new 20-inch HDPE. It delivers 220 percussive impacts per minute at full power.  

Result: The 2,250-foot project layout was L-shaped. Crews divided it into a series of runs, varying in length dependent upon where manholes were replaced. Pipe depth was in the 20-foot range. Bursting runs averaged 700 feet in length and took approximately three to four hours each to successfully complete. 800/533-2078; www.tttechnologies.com.

Utility uses pipe bursting to replace ductile iron force main

Problem: The Cape Fear Public Utility Authority (CFPUA) Northeast Interceptor Rehabilitation Phase II Project in North Carolina, designed by Kimley-Horn & Associates, included replacing 5,039 linear feet of 20-inch DIP force main. The existing line was located in a tight easement with numerous utilities in the immediate vicinity. Standard open-cut replacement of the line was deemed unacceptable due to the intrusive nature of the open-cut installation method and the high cost of restoration for roadway and utilities.

Solution: Kimley-Horn & Associates evaluated a number of options before deciding to specify pipe bursting as the method of installation. Allowable pipeline materials were either 20-inch fusible PVC or 24-inch HDPE as a bid alternate. “With a narrow right-of-way and other utilities adjacent to the Northeast Interceptor, a trenchless solution was the most economical and least invasive project approach,” says Craig Wilson, senior project manager with CFPUA. During design, CFPUA’s consultant, Kimley-Horn, took care to specify pipe wall thickness to meet both the pressure and depth requirements. Consideration was given to the shallowness of the existing force main in some areas, raising concern over potential surface heave as well as potential disruption to nearby utilities, including fiber optic lines.

Result: State Utility Construction won the bid and hired KRG Utility to perform the pipe bursting. Underground Solutions supplied and fused the 20-inch DR18 Fusible PVC pipe. During construction, Project Manager Jeff Wing worked with the contractor to adjust some of the pit locations based on the conditions of the existing pipe and constructability issues. “The pipe met the project requirements, and the pipe bursting installation resulted in less impact to existing roads, utilities, landscaping and the public compared to the open-cut alternative,” says Wing. “In addition, the use of pipe bursting resulted in an expedited schedule that was beneficial to meeting deadlines.” 858/679-9551; www.undergroundsolutions.com.

PEX enables installer to keep aesthetics in historic department store

Problem: When a real estate development company in Tulsa, Oklahoma, sought to renovate the historic Vandever Department Store into a six-story apartment building, it was tasked with preserving the building’s historic charm while adding modern plumbing infrastructure in an efficient manner.

Solution: Installing PEX piping from Uponor reduced the required number of fittings and connections. Eliminating fittings meant less material, less installation labor and fewer potential leak points — all resulting in more efficient installs and lower costs. PEX’s ability to bend around corners and run through tight spots without fittings allowed installer Todd Ringgold to create a more cost-effective plumbing layout. This reduced the size of the required soffit, allowing the ceilings to be higher (around 13 feet) and preserving the building’s desired aesthetics.

Result: The design efficiencies saved 40 percent in labor and halved material costs. The building now has tenants, and there hasn’t been any callbacks on the plumbing job. The clean, efficient and flexible PEX design eliminated the copper-related chases, wiring, ductwork and hanging pipe that would have negatively affected the building’s historic charm. 800/321-4739; www.uponor-usa.com.


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