12/8/2014. Brought To You By: This webcast is sponsored by NASSCO with the support of IPBA.

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1 Brought To You By: This webcast is sponsored by NASSCO with the support of IPBA. 1

2 Pipe Bursting A Mature and Diverse Trenchless Technology December 10, :00 3:00 pm Eastern How to Participate Today Audio Modes Listen using Mic & Speakers Or, select Use Telephone and dial the conference (please remember long distance phone charges apply). Submit your questions using the Questions pane. A recording will be available for replay shortly after this webcast. 2

3 Today s Sponsor Ted DeBoda, P.E., Executive Director, NASSCO, Inc. Pipe Bursting A Mature and Diverse Trenchless Technology Today s Presenters George Mallakis TT Technologies Matt Timberlake Ted Berry Company, Inc. Mike Woodcock Portland Utilities Construction Company, LLC 3

4 Pipe Bursting The Basics George Mallakis IPBA Division Chair TT Technologies, Inc. What is Pipe Bursting? Trenchless rehabilitation & replacement technology - staying in the existing pipe and utility corridor Fracture or split existing pipe while simultaneously installing a new factory manufactured pipe Replace aged, deteriorating, and capacity deficient mainline and lateral systems w/ same size or larger diameter pipes 4 inches to over 36 inches in diameter 4

5 Two Main Types of Pipe Bursting Systems Pneumatic Systems Static Systems Pneumatic Pipe Bursting System Constant Tension Winch 5

6 Pneumatic Pipe Bursting System Reversible Pneumatic Systems 6

7 Reversible Pneumatic Systems Constant Tension Winch Reversible Pneumatic Systems 7

8 Reversible Pneumatic Systems Reversible Pneumatic Systems 8

9 Reversible Pneumatic Systems CAPABILITIES: PNEUMATIC SYSTEMS Pipe Burst Existing Fracturable pipes only (VCP, Concrete, Cast Iron, PVC and Asbestos Cement Transite ) New Pipe - HDPE only 9

10 Static Pipe Bursting Systems Static Bursting Step 1 Static Bursting Equip. Static Bursting Step 2 Pipe Static Bursting Equip. 10

11 Static Bursting Step 3 Pipe Static Bursting Equip. Static Bursting 11

12 Capabilities: Static Systems Pipe Burst not only Existing Fracturable Pipe but, also Non-Fracturable Pipe (HDPE, Ductile Iron, Steel) Accessories used to help split mechanical repairs & fittings New Pipe - All types (FPVC, HDPE, Restrained Joint PVC, Ductile Iron, VCP) Attachments to Split Fittings Specialized Tooling 12

13 New Factory Manufactured Pipe Design Considerations 13

14 Classifications of Difficulty and Increase of New Pipe Diameter Expansion Where does it go? 14

15 Burst Depth of Cover 8 Pipe Expander Approx Existing Pipe - Rule of Thumb: 10 x upsize difference in diameters 6 to 8 requires an 11 O.D. expander The differential is 5 (11 expander 6 pipe) 5 x 10 = 50 or 4-2 min. depth to prevent heaving Soil Conditions 15

16 Lubrication Port - Pipe Bursting Construction 16

17 Bypass Systems Service Connections - Laterals 17

18 Crossing Utilities Fuse Pipe 18

19 Pipe Burst New Factory Manufactured Pipe 19

20 Service and Manhole Reconnect Resurface 20

21 Bursting vs. Open Cut Direct Costs Less material removed and replaced Less Dewatering Less equipment and labor Utilizes existing pipe, utility corridor and ROW Lower cost overall Bursting vs. Open Cut Indirect Costs Smaller work zone or footprint Less disturbance to traffic Less time Less Impact to businesses Less emissions lower carbon foot print Green Benefits 21

22 Bursting vs. other rehabilitation options (Slip-lining, CIPP, etc.) No reduction in inside diameter (improved hydraulic capacity) Same size or Increased pipe diameters Factory Manufactured Pipe (vs. field manufactured CIPP, epoxy, and CML, etc.) Hard service reconnects (not simply reinstated ) Better return on investment - engineering economic life (new pipe) Summary Pipe Bursting is Proven, has history, and widely used (not new, you will not be the first!) Effective (it works!) Costs less Lower impact to all New factory manufactured pipe Green Technology environmentally friendly 22

23 Questions? Myths and Misconceptions Matt Timberlake Ted Berry Company, Inc. Livermore, Maine 23

24 Top Pipe Bursting Myths and/or Misconceptions This list was developed through a working committee of the IPBA and outreach to industry professional from all aspects of the industry. 1. General Contractors 2. Specialty Contractors 3. Consulting Engineers 4. Equipment Manufacturers 5. Academia 6. Pipe Suppliers 7. Utility System Owners and Operators Top Pipe Bursting Myths and/or Misconceptions 1. What is trenchless? Is it all No-Dig? 2. Rehabilitation vs. Pipe Bursting What's the difference? 3. Pipe bursting is cost prohibitive. 4. Pipe Bursting should only be used when the existing pipe cannot be dug up and replaced. 5. Pipe Bursting is only practical when you need to upsize the existing pipe to a larger ID. 6. Too many laterals on a segment make pipe bursting not feasible. 7. Line and grade corrections can be controlled by pipe bursting 8. Pipe Bursting is only used in sanitary sewer applications 9. Only HDPE pipe can be used when pipe bursting 10.Ground heave and displacement is common with pipe bursting 24

25 Myth If there is digging, why is pipe bursting called trenchless? Truth The best definition of pipe bursting is that it is Trench-Less not Trench-Free. Pipe Bursting is a type of subsurface construction work that requires few trenches or no continuous trenches. In most cases pipe bursting will reduce the amount of excavation by approximately 80-90% % Excavated Open Cut Excavation Pipe Bursting Approximately 70% of the cost of open excavation construction is simply excavating and replacing the ground dug up during the process. (R. Mohammed et al. 2008) 25

26 Excavation Typical pits include Pipe Insertion Pits Pipe Receiving Pits Service Pits Pits are strategically placed to limit the amounts of excavation required. Myth Pipe bursting and other trenchless rehabilitation methods are comparable technologies 26

27 Truth Pipe bursting is a trenchless REPLACEMENT method REHABILITATION (Insitu-Methods) methods include Structural and Non- Structural CIPP FIPP CML Spray applied epoxies Grouting (test and seal) Truth CIPP is a trenchless REHABILITATION method CIPP New Pipe 27

28 Failed Sanitary Main 6-inch Cast Iron Water Main 28

29 Myth Pipe bursting is cost prohibitive Cost Studies / Regionalization Many existing pipe bursting cost studies and regional comparisons are based on small unit or high risk projects thus disproportionately inflating the unit cost for pipe bursting in an area. Typical 8 water main project Class D 20 sewer main project 29

30 Identify Costs for Pipe Bursting 1. Can it be done? Identify means and method? 2. Is a contractor in your area qualified to perform the work? 3. What are identifiable risks? Are they quantifiable? 4. What type of new pipe material needs to be used? 5. Design Bid Build Vs. Design Build 6. What is surface restoration costs? 7. Size of pipe and size of project? Pipe Bursting Typical Costs Mobilization Excavation Pipe insertion pits Pipe receiving pits Service lateral pits Materials Pipe Aggregates HDPE Fusion Installation Service Laterals reconnection Site restoration and pavement 30

31 Truth Pipe bursting IS a cost effective method of pipe replacement. What are ALL the costs? Contract value = X Social value = Y Environmental value = Z X + Y + Z = Total Project Impact Construction Costs The cost of trenchless technologies and primarily pipe bursting is coming down in North America. Contrary to that the costs of open cut construction are becoming more expensive due to the increased cost of fuel, disposal, environmental, and social impacts. Open Cut Costs Pipe Bursting Costs 31

32 Myth Pipe Bursting should only be used when the existing pipe cannot be dug up and replaced. Truth Pipe Bursting can and should be considered when any/all of the following are taken into consideration Is pipe located in a environmentally sensitive area? Is pipe located in a high traffic area? Is disruption to the public not desirable? Are surface restoration costs high? Is a reduced construction schedule desirable? Is replacing the pipe in the same trench without securing additional utility easements desirable? Is a reduction in greenhouse emissions from the project desirable? Is an alternative method desirable? Pipe is at or near capacity and the ID must be increased. 32

33 Myth Pipe Bursting is only practical when you need to upsize the existing pipe to a larger ID Truth Approximately 80% of pipe bursting completed in the United States is size on size pipe bursting where the newly installed pipe has the same ID as the existing pipe. % of market Class A- B Class C Class D % of market Class A-B 80 Class C 19 Class D 1 Typical breakdown of 100 pipe bursting projects 33

34 Myth Pipe Bursting is only practical where there are not many service connections. Typical insertion pit for HDPE pipe bursting. Typical insertion pit and service pits after final restoration. Truth In all cases the number of service connections will increase the unit cost of pipe bursting as each will need to be excavated and individually connected, however it will NOT always result in a project cost higher or more disruptive than traditional open cut or CIPP A typical service lateral pit is +/- 4 feet x 4 feet Do the math on quantities and total project duration. Much like with typical CIPP reinstatement laterals are on a per each unit cost Additional benefits include a new hard connection of the newly installed pipe to the service lateral 34

35 Case Study SEWER Nantucket, Massachusetts Replaced +-7,000 LF of 6-12-inch VCP Myth Pipe Bursting will remove sags in an existing gravity sewer line. (line and grade corrections?) 35

36 Truth Pipe bursting can remove sags and deflections in a line; however the process has no consistent method for grade control or realignment and should not be considered where correcting the existing line and grade of the pipe is essential. It is essential to identify areas of deficiencies in pre-bid CCTV inspection, and bid documents clearly define areas where corrections in grade are required that may require localized excavation to correct and reset line and grade. Myth Pipe Bursting is only used in sanitary sewer applications 36

37 Truth Pipe Bursting of municipal potable water and gas mains is wildly popular in Europe and gaining acceptance throughout North America. Typical water mains constructed of Cast Iron Pipe, PVC, or Asbestos Cement are in most cases bursted with ease and the ability to increase the ID of the pipe allows for correction of hydraulic and structural deficiencies where insitu methods like Cement Mortar Lining (CML) can only restore design flows at best. Water Main Pipe Bursting Typical cast iron water main condition. 37

38 Water Main Pipe Bursting Replacing 6 CI with new 8 HDPE Myth You can only install HDPE pipe with Pipe Bursting 38

39 Truth Advancement in pipe materials and compatibility with pipe bursting systems makes a number of types and makes of pipes applicable for pipe bursting in water, sewer, and gas mains. PVC (static installation only) Continuous Fusible (FPVC ) Segmental DI VCP Others coming to market Successes Fusing 12-inch HDPE water main Landing 12-inch FPVC 39

40 Myths The ground will heave up during the pipe bursting process Insufficient ground cover for expansion Typical Expansion 40

41 Depth of Cover and Potential Impact Zone Expander Head OD Existing Pipe ID x (10 to 12 )* = Calculated minimum depth of cover and potential impact zone *actual will vary based on actual geotechnical conditions Examples Theoretical Versus Actual 41

42 Truth Pipe Bursting design and execution requires a thorough understanding of the process and how certain types of soils will react to the pipe bursting process. Ground heave is possible if the volumetric displacement of the soil above the bursting head is greater than the required depth of cover. An expansion head of 20-25% larger than the OD of the new pipe being installed will determine the potential for ground heave coupled with the type of soil in the existing trench. In conclusion The highest ability to influence the cost of a project takes place in the design stage. Dr. Alan Atalah, P.E. The highest ability to influence the cost of a pipe bursting project takes place in the design stage. Matt Timberlake, Contractor 42

43 Questions? Matt Timberlake Vice President and Senior Project Manager Ted Berry Company Inc. Livermore, Maine USA The Bread & Butter Benefits of Pipe Bursting Mike Woodcock Portland Utilities Construction Company, LLC Matt Timberlake Ted Berry Company, Inc. 43

44 PIPES are Everywhere! What are the practical options for replacement, rehabilitation, or renewal? Where, When, & Why are the benefits of Pipe Bursting realized in the real world. The Bread and Butter Benefits Of Pipe Bursting Why/When Is Pipe Bursting the Method of Choice 1. Utilizes the Original Trench/Easement 2. Smaller Footprint 3. Less Expensive 4. Better Return On Investment Over Other Rehab Methods 5. Upsizing 44

45 1. Utilizes the Original Trench Easements Pipe Bursting is Easier to Design, Plan, & Execute 2. Smaller Footprint Pipe Bursting allows for flexibility of access points and areas where excavation can take place 45

46 2. Smaller Footprint Less Disruptive to Residents 2. Smaller Footprint Less Disruptive to Businesses 46

47 2. Smaller Footprint Less Disruptive to Traffic 3. Less Expensive Smaller Foot Print = Less Restoration = Less Expensive 47

48 3. Less Expensive Smaller Foot Print = Less Restoration = Less Expensive Savings are realized for the following; 1. Stone Backfill 2. Asphalt Pavement 3. Concrete Restoration 4. Easements Clearing/Landscaping/Fencing 5. Utility Relocation 6. Traffic Control 7. Bypass During Construction Envision How Open Cut Replacement Would Look 48

49 After Much Less Stone & Asphalt Used 4. Better Return On Investment Over Other Rehab Methods Pipe Bursting Replaces the Existing Pipe for Almost the Same Costs As Other Rehab Methods New Pipe The Cost of Point Repairs on a CIPP Project Often Off-set the Potential Savings of CIPP ($3,000 Point Repair = $10 Per LF on a 300 LF section of Pipe) 49

50 4. Better Return On Investment Over Other Rehab Methods Programs That Take This Approach City of Houston, Texas Almost 1,000,000 LF of Size On Size Pipe Bursting per Year Knoxville Utilities Board Bid Pipe Bursting VS CIPP Less Than 10% Difference Jacksonville Electric Authority (JEA) Design Criteria Pipe Burst CIPP Open Cut 5. Upsizing Size On Size, One Upsize, Two Upsize, Three Upsize 50

51 5. Upsizing 36-inch to 42-inch Upsize Dallas, TX Case Study SEWER 51

52 Case Study SEWER Service Excavation Receiving Manhole Case Study SEWER Receiving manhole Lateral Connections 52

53 Case Study SEWER Foot Pull Lengths 7-inch Diameter Tool Replaced 100,000 LF of 8-, 10-, & 12-inch, mostly 8- inch Case Study SEWER FORCE MAIN 9000 LF 36-inch Hobas to 42-inch HDPE DR Foot Pulls Capital Circle BLVD Flowable Fill Required 53

54 Case Study WATER 1,200+ LF of 8-inch CI Installed new 8-inch FPVC Case Study SEWER Nantucket, Massachusetts Replaced +-7,000 LF of 6-12-inch VCP 54

55 Case Study SEWER Replace existing 15-inch VCP Pneumatic Case Study SEWER 10-inch VCP Sanitary Sewer No Flamingo's were harmed during the replacement of this utility!! 55

56 Case Study SEWER 8-inch CI to 10-inch HDPE Force Main Case Study SEWER Insertion pit VERY tight easement 56

57 Case Study SEWER Start Finish PLAN FOR SUCCESS Questions? 57

58 58

59 Upcoming Trade Shows 59

60 Brought To You By: This webcast is sponsored by NASSCO with the support of IPBA. 60

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