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