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STATIC PIPEBURSTING:
Rehabilitation Technology for Municipal
Water and Sewer Pipe Systems
www.Gajeske.com
.
Deteriorating Infrastructure
• Worldwide deteriorationof underground infrastructure– Water lines– Sewer lines– Gas lines
• Congested urban areas• Beneath buildings, roadways
and landscaping
Sanitary and Storm Sewer Systems
• Offset pipes• Deterioration• Root intrusion• Crowned or cracked• Leaking• Under capacity• Rain infiltration/inflow
Water Distribution Systems
• Encrusted• Corroded• Leaking (loss
up to 40%)• Under capacity• Drinking Water
Infrastructure over 700,000 Miles
Gas Distribution Systems
• Regulations require cast iron lines be replaced
• Cathodic protection failing, in turn steel lines are corroding and failing
• Leaking• Under capacity
Sewer and Water Main Bursting Market
• $1 Trillion– Next 20 years
• Water• Sewer
• More than 60 million feet to date
• 50% annual growth
Pipe Bursting
• The breaking of an existing pipe, expanding the broken pipe shards into the surrounding soil while simultaneously pulling in the “NEW” carrier line, usually polyethylene pipe (HDPE).
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
Pipe Bursting
• Sometimes classified as a repair versus new construction
• Often reduces engineering costs
• Permitting needs, requirements, costs and time required from planning, construction to final completion are impacted
Pipe Bursting
• 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.
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.
• Directional Drilling had difficulty due to the lack of knowing where the existing utilities were.
• In conjunction with a utility contractor, British Gas developed the patented the process of Pipe Bursting to replace fracturable pipes including water, sewer & gas. (Patents Expired April 2004)
• Utilizing the existing easement and path of existing utilities, pipe bursting proved a very effective method of replacement.
PROJECT CONSIDERATIONS
What materials can be burst?
Fracturable PipesCast iron, clay tile, concrete, reinforcedconcrete, asbestos cement, etc.
Non-fracturable PipesDuctile iron, steel, galvanized (require use ofspecialized tooling and static bursting machines.
IPBA Project Classification
Project classifications per IPBA (International Pipe Bursting Association) pipe burstingspecification.
ClassDepthof Pipe
Existing Pipe
Diameter
New PipeDiameterOptions
BurstLength
A <12 ft 4” – 12” Size for Size to 1 upsize 0 – 350 ft
B>12 ft < 18 ft 12” – 20” 2 upsizes 350 – 450 ft
C> 18 ft 20” – 36” 3 or more
upsizes > 450 ft
Upsizing – Expansion (where it goes)
Approximately 90% of compaction occurs upwards from the existing line.
Depth of Cover
8” DIPS Burst Head Expander OD – 11.50”
6” Clay PipeExisting Pipe ID – 5.94”
General rule is one (1)foot of cover for everyinch of expansion
Note: any compaction recedes over time. The deeper the line, the less chance of surface disruption
Upsizing: A Closer Look
Note: the above illustrations assume flow line remains the same.
Upsizing and Depth
• Has flow monitoring been completed?
• Is upsizing necessary if I/I is eliminated?
• A minimum of 4’(1.2m) of cover should be used when upsizing1 size
• Greater cover should be used if upsizing more than one size
Note: any compaction recedes over time. The deeper the line, the less chance of surface disruption
Flow Comparisons - HDPE
Cast Iron Pipe AC Pipe New DIPS HDPE SDR17 pipe
4" ID = 96 gpm 4" ID = 109 gpm 4" = 132 gpm; 6" = 299 gpm
6" ID = 217 gpm 6" ID = 247 gpm 6" = 300 gpm; 8" = 469 gpm
8" ID = 340 gpm 8" ID = 388 gpm 8" = 469 gpm; 10" = 706 gpm
10" ID = 511 gpm 10" ID = 583 gpm 10" = 706 gpm; 12" =997gpm
12" ID = 723 gpm 12" ID = 824 gpm 12" = 997 gpm
Soil Conditions
Going the Distance
• Static Energy• Increase Pulling Pressure
• Impact Energy– Use the largest Hammer for the job
• Soil Memory– Race againsttime
• Pipe Friction• Lubrication• Tractor Effect• Entry Pit Length
Depth of Existing Line
• Entrance and exit pit depths?• Can we dig an entry pit?
– Entry pit length is minimum 2 ½ times depth– With pipes larger than 12” diameter length of entry
pit will increase• Can we manhole exit?
– 8, 10 & 12” single upsize• Can we dig an exit (receiving) pit?
Length of Burst
• How Long is the Burst?– Bypass Needed?– Number of Services?– Has One Call been Contacted?– How Close are the are the other Utilities?
New Pipe Questions
• What kind of new pipe?• IPS or DIPS? (OD)
– Important for burst head adaptability– Existing clay to DIPS is a single upsize
• What is the SDR Rating– Recommend a minimum of SDR17 for pipe
bursting with HDPE
New Pipe Material
• HDPE is preferred pipe when pipe bursting
Use of Lubrication (Lube Manifold)
Small Dia.(6”-10”) Good Soil
Medium Dia.(12-16”)
Large Dia.(16” and larger)
Large Dia.Poor Soil
Large or long bursts: lubrication can increase production and the bursting distance capability
Current Video Available
• Current video is very important• Scenario: We have a video, but it is 2 years
old.• Problem: What has happened to the line in the
last 2 years.– Point repair on clay line with ductile repair section
and steel bands
Current Video
• Is there a dip in the line?• Is there a swell in the line?• Is a point repair needed prior to bursting?
System Selection
• Pneumatic systems• Static systems• Compact systems
PIPE BURSTING
Types of Systems
Pneumatic Pipe Bursting MethodA constant tension winch keeps a pneumatic hammer attached to a burst headonline to burst pipe and pull in new pipe.
Shown - 8, 10 & 12” single upsize bursts – PATENTED manhole exit method
Live Burst Video: www.youtube.com
Manhole Exiting
• Manhole exits save time and money
• Maneuverability to set up in difficult terrain
*Manhole exiting is a patented process of Earth ToolCompany LLC, US PATENT: US 6,299,382B1
Static Pipe Bursting MethodHigh tonnage pull back force pulls on rod attached to a bursting head or slitter and breaks existing pipe, expands surrounding soil and pulls in new pipe.
Small tonnage systems (up to 50 tons) available for 2 – 8” pipeLarge tonnage systems (up to 300 tons) available to burst 4 – 24” pipe and largerSpecialized equipment available to split steel and ductile pipes.
Live Static Burst Video: www.youtube.com
Static Pipe Bursting Systems
• Static systems provide the opportunity to replace non fracturable pipe with the use of slitters
• 2 – 16” host pipe– Ductile iron– Steel– Cast iron
Lateral Pipe Bursting MethodCompact static systems pull cable or chain attached to bursting head or puller that breaks existing pipe and pulls innew pipe.
Live Lateral Burst Video: www.youtube.com
Why Pipe Bursting for Lateral Replacement?
• Proven method• Reduces excavation
and surface disruption• Installs HDPE pipe
– New Pipe– No-joints– Superior flow
characteristics• Low initial equipment
investment
PIPE BURSTING CASE STUDIES
City
of C
alga
ry, A
lber
ta,C
anad
a Pneumatic PipeBursting
ProjectSewer mainreplacement
Product/Footage315 feet of 24” Clay Tile to 24” SDR17 HDPE
Equipment20” HammerHead bursting hammer, 26” bursting head, HydroGuide HG20 winch, 24” pipe pilot
Nor
thpo
rt,M
aine
Pneumatic PipeBursting
ProjectSewer mainreplacement
Product/Footage150’of 10” VCP to10” HDPE
Equipment8” HammerHead bursting hammer, HydroGuide HG12 winch, 10” burst head, manhole exit method
Plan
o,Te
xas Pneumatic PipeBursting
ProjectSanitary sewerreplacement
Product/Footage24” RCP to32”HDPE, 817 feet
Equipment20” and 24” HammerHead pipe bursting hammers, Hydroguide HG20 winch
Balti
mor
e,M
aryl
and Pneumatic PipeBursting
ProjectSanitary sewermain replacement
Product/Footage1,550 feet of 18” VCP to 24” IPD HDPE
Equipment20” HammerHead bursting hammer, HydroGuide HG20 winch, 20” bursthead, 24” tractorhead
Orl
ando
,Flo
rida
Static Pipe Bursting with Pre-Chlorination Method
ProjectWater mainreplacement
Product/Footage15,000 feet of 4 & 6” AC & Cast Iron replaced with 6” HDPE
EquipmentHydroBurstHB5058, PP20Power Pack, Ductile Slitter
Lync
hbur
g,Vi
rgin
ia Lateral Pipe Bursting
ProjectPrivate sewerlateral replacement
Product/Footage4” PVC to 4” HDPE
EquipmentPortaBurst PB30 Gen 2, 4” Quick Grip burst head, PP13 Power Pack, Connectra® fusion machine.
Wau
kesh
a, W
I: M
ay, 2
010 Hydroburst HB 125
ProjectSouth West St.,Waukesha, WIC.W. Purpero
Product/Footage1500’ of 10”Castreplaced w/ 10”DIPS HDPE DR 11
EquipmentHB 125 LongestPull: 980’
Open Cut VS: Bursting Cost Comparison
The City of Madison, AL. Purchased an 80-Ton Static Burst machineanddid a cost comparison on 4-different projects.
These prices are what it cost them to do all of the work in house.
Project #1 7,250’ existing 8” VCP replacing with 8” DIPS HDPE and replacing 40, 4’ pre-cast manholes.
Open cut=$281,262.00 Pipe Burst=$162,422.00Project #2 2,569’ existing 8” VCP replacing with 8” DIPS HDPE andreplacing 10, 4’ pre-cast manholes.Open cut=$123,056.00 Pipe Burst=$51,485.00Project #3 2,771’ existing 8” VCP replacing with 8” DIPS HDPE and replacing 13, 4’ pre-cast manholes.
Open cut=$130,764.00 Pipe Burst=$62,447.00Project #4 4,200’ existing 8” VCP replacing with 8” DIPS HDPE andreplacing 16, 4’ pre-cast manholes.
Open cut=$206,353 Pipe Burst=$111,823.00
Total Savings=$353,258.00
THANK YOU ! Gajeske, Inc.
6200 N. Houston Rosslyn Rd.Houston, Texas 77091
713-688-2728
www.Gajeske.com
Please Call For Pipe Inquiries, Fusion , Support and Service
PO Box 3 • Oconomowoc, WI 53066 USA • Phone: 800-331-6653 • Int: +1 262-567-8833 Fax: 262-567-5068 • Web: www.hammerheadtrenchless.com
Thank You
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