1 "Pipe Bursting A Revolution for Telecom, Electric, Gas, & Water" Presented by the Leadership of the IPBA International Pipe Bursting Association A Division of NASSCO National Association of Sewer Service
2 AGENDA IPBA Green Technology The Basics Types of Systems Case Studies Summary
3 I P B A INTERNATIONAL PIPE BURSTING ASSOCIATION
4 IPBA HISTORY & BACKGROUND Founded in 2000 Division of NASSCO NASSCO Technical Advisor Gerry Muenchmeyer Promote, Train, & Educate Pipe Bursting Independent and Non-Biased Publications Re-Organization in 2010 that includes a 5 year strategic plan and revitalized membership.
5 IPBA Current Objectives Vision Expand the use and acceptance of pipe bursting as the trenchless technology of choice, in pipe replacement throughout North America.
6 IPBA Current Objectives Mission Advance the acceptance of Pipe Bursting through education, training, standards, marketing & governmental support to replace existing piping infrastructure in the most cost effective method.
7 IPBA Current Objectives Objective Expand awareness of Pipe Bursting for the rehabilitation of North America s aging infrastructure, by providing leadership and fulfilling our mission, on behalf of all IPBA membership.
8 Industry Stakeholders Contractors Pipeline system owners Engineering firms Manufactures & suppliers Academia Municipal General public/home owners
9 Working Committees Marketing Membership Education & Training Specifications Governmental
10 IPBA Leadership & Presenters IPBA Leadership Committee Brian Metcalf, Chairman & President/CEO of HammerHead Trenchless Equipment George Mallakis, Vice Chairman & Regional Manager, TT Technologies Trenchless Equipment Matt Timberlake, Marketing Committee President Ted Berry Trenchless Technologies Team LLC. Mike Woodcock, Education Committee & President of Portland Utilities Construction Andy Mayer, Member & President of Murphy Pipelines
11 GREEN TECHNOLOGY
12 GREEN TECHNOLOGY Traditional Open Cut Construction 1) Excavate and remove all material. 2) Lay new pipe. 3) Truck in new backfill. 4) Placement of new pavement. 5) Traffic and Public disruption
13 Reduction in Carbon Emissions by as much as 95% with Trenchless Construction Open Cut Pipe Bursting The debate regarding climate change, the beliefs in your community, and an increased environmental awareness demands that we adopt new methods that will help reduce carbon emissions.
14 Green Technology Pipe Bursting Reduction in excavation by as much as 85% when compared to traditional open cut excavation.
15 THE BASICS
16 Not just for Sewer and Water Rehabilitation History and Technology advancement Applications & equipment Project considerations Case studies Gas main replacement Sewer Main decommissioning Telecom Water Electric
17 What is Pipe Bursting? The breaking of an existing pipe, expanding the broken pipe into the surrounding soil while simultaneously pulling in the NEW factory manufactured pipe.
18 Brief History of Pipe Bursting Developed by British Gas in the late 70 s when they were faced with deteriorating gas lines in severely congested and developed areas. Open cutting to replace these lines was cost prohibitive and sometimes not an option. In conjunction with a utility contractor, British Gas developed the process of Pipe Bursting to replace Fracturable pipes including water, sewer & gas. Patents and Licensing for pipe bursting no longer exists today.
19 Benefits of Pipe Bursting Eliminates up to 85% of excavation Damage prevention: Follows the path of the existing utility reducing risks of utility strikes Especially cost effective when compared to an open cut utility relocation design Reduced traffic disruption Minimal surface disruption
20 Install same size or larger diameter pipe Pipe bursting is often more cost effective than other methods when long term owner costs and capacity needs are considered. Reduced impact on local residents and business.
21 What materials can be burst? Fracturable Pipes Cast iron, clay tile, concrete, reinforced concrete, asbestos cement, etc. Non-Fracturable Pipes Ductile iron, steel, galvanized, HDPE, lined pipe, etc.
22 Current Technology Utilization
23 TYPES OF SYSTEMS: PNEUMATIC
24 Pneumatic Pneumatic Hammer Winch Air compressor Specialized tooling to match conditions New Pipe Typically used in waste water/sewer systems
25 Pneumatic Systems Pneumatic hammer Burst head/pulling head Winch or pulling device Most widely used system in sewer main replacement industry Utilized only with Fracturable host pipe and HDPE
26 Pneumatic Systems Consists primarily of pneumatic hammer, bursting/pulling head and pulling device. Pneumatic hammer Burst head/tooling Winch.
27 TYPES OF SYSTEMS: STATIC
28 Static Hydraulic power pack Pulling/Lower unit Steel rod to provide static pulling Specialized tooling to match conditions New Pipe Machine tonnage capacities range from 20 tons to 300 tons available from several manufacturers.
29 Static Pipe Bursting Systems
31 TYPES OF SYSTEMS: COMPACT LATERAL
32 Compact/Lateral Hydraulic power pack Pulling/Lower unit Pulling cable/chain Specialized tooling to match conditions New Pipe Machine tonnage capacities range from 15 tons to 30 tons Typically utilized in replacement of fracturable sewer and nonfracturable water and gas services
33 Compact / Lateral Systems
35 IPBA PROJECT CONSIDERATIONS
36 IPBA Project Classification Class Depth of Pipe Existing Pipe Diameter New Pipe Diameter Options A <12 ft 4 12 Size for Size to 1 upsize Burst Length ft B >12 ft < 18 ft upsizes ft C > 18 ft or more upsizes > 450 ft Project classifications per IPBA (International Pipe Bursting Association) pipe bursting specification.
37 Upsizing: A Closer Look Note: the above illustrations assume flow line remains the same.
38 Upsizing Expansion (where it goes) Approximately 90% of compaction occurs upwards from the existing line.
39 Depth of Cover General rule is one (1) foot of cover for every inch of expansion 8 DIPS Burst Head Expander OD Clay Pipe Existing Pipe ID 5.94 Note: any compaction recedes over time. The deeper the line, the less chance of surface disruption
40 Soil Conditions
41 Going the Distance Increase static energy (pneumatic and static applications) Increase impact energy (pneumatic applications) Soil memory Race against time Reduce pipe friction Lubrication Tractor Effect Entry pit length
42 Depth of Existing Line Is there adequate depth of cover? Utility depth determines new pipe entry pit length. Entry pit length is minimum 2 ½ times depth With pipes larger than 12 diameter length of entry pit will increase
43 New Pipe Questions What kind of new pipe? HDPE is preferred pipe when pipe bursting Fusible PVC, restrained joint PVC, ductile (DI) and clay have been used successfully but require additional project and site considerations. IPS or DIPS? (OD vs. ID) Important for burst/pulling head adaptability Existing clay to DIPS is a single upsize What is the SDR Rating Recommend a min. of SDR17 for pipe bursting with HDPE
44 CASE STUDIES
45 SMALL DIAMETER THE 80/20 RULE
46 Small Diameter Sewer Main Houston Replaced 100,000 LF of 8, 10, & 12 Mostly 8 Product/Footage Pull Lengths Equipment 7 Diameter pneumatic tool with winch system
47 Small Diameter Pipe Bursting Most Pipe Bursting In The U.S. consists of Small Diameter Pipe Bursting 6, 8, 10, & 12 Size on Size or One Upsize Pipe bursting is the only trenchless technology that can increase the inside diameter (ID) of an existing pipe line.
48 Small Diameter Pipe Bursting Many municipalities look to pipe bursting as the first choice. City of Houston Jacksonville Electric Authority Knoxville Utility Board Others Pipe Bursting Actually Replaces the Existing Pipe.
49 10 VCP Sanitary Sewer Replace an existing 10 VCP gravity sewer with a new 10 HDPE in a sensitive area Product/Footage Installed in a single 300 burst Equipment 7 pneumatic tool and a 12 ton downhole winch No Flamingo's were harmed during the replacement of this utility!! 49
50 8 CI Sanitary Sewer Force Main Ogunquit, Maine Replaced 800 of 8 CI force main with new 10 HDPE Product/Footage installations Equipment 80 ton static burst unit 50
51 LARGE DIAMETER
52 Large Diameter Gravity Sewer Atlanta Upsized 25,000 LF 15 & 18 Concrete & Clay to 24 & 28 Product/Footage 250 to 350 Pull Lengths Equipment 18 Diameter Tool
53 Large Diameter Forcemain - Tallahassee Replaced 5,000 LF of 36 Hobas with 36 DIPS HDPE Product/Footage 600 Pull Lengths Equipment 24 Diameter Tool
54 MAIN REPLACEMENT - STEEL
55 Gas Main Replacement Steel Static Pipe Bursting Product/Footage 700 feet of 4 Steel to 4 HDPE Equipment 50 ton rod pulling machine, 20HP hydraulic power pack, 4 slitter
56 SERVICE REPLACEMENT - HDPE
57 Gas Service Replacement HDPE Static Pipe Bursting Product/Footage Gas service replacement Equipment Cable, specialized tooling, pulling medium
58 PRESSURE REPLACEMENT - STEEL
59 Pressure Sewer Replacement - Steel Static Pipe Bursting Product/Footage 150 mm steel to 160 mm HDPE Equipment 50 ton rod pulling machine, 20HP hydraulic power pack, 150 mm slitter
60 MAIN REPLACEMENT DUCTILE IRON
61 Water Main Replacement Ductile Iron Static Pipe Bursting Product/Footage Replacement of 1,800 feet of 4 ductile iron to 5 HDPE. Equipment 50 ton rod pulling machine, 20HP hydraulic power pack, 4 slitter
62 MAIN REPLACEMENT PVC
63 Sewer Main Replacement PVC Static Pipe Bursting Product/Footage 430 feet of 8" PVC to 12" HDPE, SDR 17 Equipment 125 ton rod pulling machine, 73HP hydraulic power pack, 8 slitter
64 MAIN PRE CHLORINATED PROCESSES
65 Preparation of Pipe All work involving the renewal of water lines using pipe bursting techniques shall be carried out as hygienically as practical in accordance with applicable specifications, procedures, codes, regulations, and laws of the governing regulatory authorities, and the American Water Association with all reasonable steps being taken to avoid contamination of water supplies. Murphy Pipeline Contractors, Inc. Telephone:
66 Preparation of the Pipe Murphy Pipeline Contractors, Inc. Telephone: A free chlorine residual of 25mg/L should be maintained for a minimum contact time of 24 hours. After thorough flushing the new pipe shall be sample at each end at intervals no greater than 1200 feet, only by fully qualified rehabilitation staff, who will then fill in a log book/passport form detailing the date, coil number and time sample was taken. A copy of this form will also be taped to the coil to ensure the correct pipe is referred to.
67 MAIN REPLACEMENT: CIPP/HDPE LINED CONCRETE
68 Sewer Main Replacement CIPP/HDPE Lined Concrete Static Pipe Bursting Sewer main replacement Product/Footage 2,500 feet of 8 Concrete lined with CIPP and Sliplined replaced with 8 HDPE Equipment HydroBurst HB100, PP70 Power Pack, Specialized Tooling
69 MAIN DECOMMISSIONING HDPE
70 Gas Main Decommissioning HDPE Static Pipe Bursting Product/Footage Decommissioning of 3,000 feet of HDPE gas main Equipment 12 ton cable winch, specialized tooling
71 There are growing concerns related to abandoned gas lines. Current decommissioning methods are expensive or do not provide visual proof of pipe taken out of service. Open cut pipe removal Void fill grouting
72 Cost Effective, Eliminates Doubt Permanently makes the old line unusable and obvious to all that is now a dead line. Production varies according to conditions and pipe type. In all cases cost is often just a fraction of the cost to dig up and discard.
73 SUMMARY & ACTION STEPS
74 Conclusion Nearly any kind of pipe can be burst or split and replaced with new pipe. The same benefits afforded to the sewer and water markets can be achieved in gas, telecom and electric industries. Advancements in technology and experience have been applied to and continue to expand into other markets outside of sewer and water. Pipe bursting is not just for sewer and water rehab anymore!
75 Action Steps Drive innovation use the technology Get involved - IPBA Tremendous opportunity to drive positive change across the industry
76 IPBA Leadership & Presenters IPBA Leadership Committee Brian Metcalf, Chairman & President/CEO of HammerHead Trenchless Equipment George Mallakis, Vice Chairman & Regional Manager, TT Technologies Trenchless Equipment Matt Timberlake, Marketing Committee President Ted Berry Trenchless Technologies Team LLC Mike Woodcock, Education Committee & President of Portland Utilities Construction Andy Mayer, Member & President of Murphy Pipelines
77 THANK YOU "Pipe Bursting: A Revolution for Telecom, Electric, Gas, & Water"
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