Trenchless Construction Technology and Issues

Trenchless Construction Technology and Issues

Dr. Mohammad Najafi, P.E., F. ASCE

Director, Center for Underground Infrastructure Research & Education (CUIRE)

Professor and Director of Construction Engineering & Management

Department of Civil Engineering

The University of Texas at Arlington

15th Annual Public Works RoundupWednesday, May 21, 2014

9:00 AM - 4:00 PMRuthe Jackson Center, Grand Prairie, Texas

Presentation Outline

• Pipeline Problems• Trenchless Technologies• Issues and Benefits• New Master of Construction Management• Center for Underground Infrastructure Research &

Education (CUIRE)• Resources• Summary and Conclusions

More than 3.5 million miles in U.S.Existing investment in the trillions of dollarsHaphazard, poorly documented, neglected

The Problem: Extensive and Deteriorating Networks

Pipeline Interactions Leading to Deterioration

Source: O’Day et al., 1986

5,200,000,000 feet of pipe21,000,000 manholes.

Approximately 800,000 miles of corroded and leaking wastewater are causing environmental problems.

Water transmission and distribution alone will require $80 billion over the next 20 years.

Approximately 200,000 miles of pipelines need immediate repair or replacement. Approximately 3

percent of the existing systems are added to this need annually.

State of the U.S. Infrastructure

Texas Drinking Water: D

• The population of Texas is expected to double in the next 30 to 40 years.

• If a drought occurs in Texas in 2050, 43% of municipal demand for water would not be satisfied by current water sources.

• In 2001, the EPA estimated that Texas had $13 billion in water infrastructure needs over the next 20 years.

• Other than low-interest loan programs, the State does not fund local water infrastructure construction or maintenance.

Source: ASCE

State Water Loss Standards 2001

15%

10%

10%

10%

20%15% 15%

15%

15%10%

10%15%

15%

15%

20%15%

7.5%

20%

20%

15%

15%

15%

Source: AWWA

How Did We Get Here?•Infrastructure deterioration is gradual.

•Utility customers have become accustomed to low sewer/water costs.

•Underground pipelines have difficulty competing for public funds with other “visible” infrastructure systems.

•We have forgotten the principles of “design life” and “replacement/lifecycle costs.”

How Does the Future Look?

Trenchless Technology Methods

Trenchless Technology:

All methods of pipeline and utility installation and renewal with minimum disruption of surface and subsurface

Comparison of cost-breakdown for open-cut and trenchless methods.

Benefits of Trenchless Technology

Comparison of Cost Factors Between Open-Cut & Trenchless Technology

Open-Cut Trenchless TechnologyDepth Major Minor

Diameter Moderate Moderate

Soil Conditions Major Moderate to Minor

Obstructions Major Minor

Water Table Major Minor

Existing Utilities Major Major to Moderate

Damage To Pavement Major Minor

Reinstatement Major Minor

Traffic Major Minor

Safety Issues Major Minor

Productivity Major Minor

Environmental Issues Major Minor



Trenching Design:Route at the Road ROW

Microtunneling Design: Shorter Route, Steeper Slopes, Smaller Pipe

Stream

HILL

Cost-effective route selection.

Growing public awareness to conserve and protect our environment and quality of life.


Asthama46%

Other respiratory ailments

12%

Allergies13%

Headache and

sickness2%

Cough and chest

problems8%

Irritation impacts

7% Sinus Problems

9%

Others3%

Major Health Issues due to Dust Generation

Source: Adopted from Bickerstaff & Walker, 1999


Business loss due to open cut construction.


Minimum damage to pavement and utilities.

Challenge: Old Guidelines

CIPP Problems

Bumping the Roads

Flooding The Basement

Flooding The Basement

Gas Explosion

Challenge: Making the Right Choice

Main Challenges for Trenchless Technology Projects• Difficulties in Locating Existing Underground

Utilities• Lack of Standard Guidelines & Specifications• Lack of Proper Geotechnical Investigations• Not Matching the Correct Method to the Project

Conditions • Lack of Proper Specification Interpretation

– Lack of Inspector & Operator Experience and Proper Training


Trenchless Methods

Construction Methods Renewal Methods

Utility Tunneling

Pipe Jacking

Horizontal Earth Boring

Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement

Horizontal Auger Boring

HDD

Microtunneling

Pipe Ramming

Utility Tunneling Method

• Utility Tunneling– Performed in two steps

• Excavation & Installation of Primary Support• Installation of pipe (Secondary Support/Liner

System)– Product pipe sizes 42” & larger– Limitations on length & size based on

logistical considerations & safety


Characteristic of Utility Tunneling

MethodDiameter

Range (inches)

Typical Installation

(feet)

Pipe Materials

Typical Applications

Accuracy( + or - )

Utility Tunneling 42” & larger 1,600 RCP, GRP,

Steel

Pressure & Gravity

Pipelines~1”

Typical Components of Utility Tunneling Method



Possible Liners for Utility Tunneling

Wood Lagging Tunnel Liner Plates




Trenchless Methods


Utility Tunneling

Pipe Jacking


Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement

Localized Repair

Lateral Renewal

Coatings & Linings

Manhole Renewal


HDD

Microtunneling

Pipe Ramming

Pipe Jacking Method

• Pipe Jacking– Similar to Utility Tunneling, except it

combines the excavation & pipe installation into one step

– Product pipe sizes 42” & larger– Limitations on length & size based on

logistical considerations & safety

Pipe Jacking

• Pipe jacking is a trenchless technique forinstalling new underground pipelines andculverts.– Conventional Pipe Jacking– Pilot Tube– Horizontal Auger Boring (Bore and Jack)– Microtunneling

Pipe Jacking Method

Characteristic of Pipe Jacking

MethodDiameter

Range (inches)

TypicalInstallation

(feet)

Pipe Materials


Accuracy( + or - )

Pipe Jacking 42” & larger 1,600 RCP, GRP, Steel

Pressure & Gravity

Pipelines~1”

Typical Components of a Pipe Jacking Operation

VentilationBlower

Generator Power Pack

Bentonite Pump

LaserTelescopic CylindersThrust Block

OperatorMCB Control Desk

Pit Floor

Skid BaseThrust Ring

Intermediate Jacking Station

Haul Unit

Jacking PipeDirt BucketConveyor

Boring Head

Pipe Jacking Components

1. Control and steering desk2. Crane 3. Jacking pipes4. Separation plant5. Mixing plant

6. Supply pump7. Shield machine8. Intermediate jacking station9. Main jacking station10. Abutment (Thrust block)

Pipe Jacking EquipmentLaser Guidance System for Pipe Jacking

Intermediate Jacking Stations

Source: Akkerman, Inc.

Trenchless Technology Methods(Road and Railroad Crossings)

Trenchless Methods


Utility Tunneling

Pipe Jacking


Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement

Localized Repair

Lateral Renewal

Coatings & Linings

Manhole Renewal


HDD

Microtunneling

Pipe Ramming

Horizontal Auger Boring Method

• Process of simultaneously jacking casing through the earth while removing the spoil inside the encasement by means of a rotating flight auger


• Horizontal Auger Boring– Performed in two steps:

• Excavation & installation of the casing pipe• Installation of carrier pipe & filling annular space

with grout– Crossing technique– Available with

• Dynamic grade control• Dynamic line & grade control


Characteristic of Horizontal Auger Boring

MethodDiameter

Range (inches)

Maximum Installation

(feet)

Pipe Materials


Accuracy( + or - )

Auger Boring 4”-60” 600’ Steel Road Crossings

1% of bore length

Auger Boring w/grade control

4”-60” 600’ Steel Road Crossings 12”

Auger Boring w/line &

grade control4”-60” 600’ Steel Road

Crossings 12”

Auger Boring Process

Horizontal Directional Drilling (HDD) (Pressure Pipelines and Conduits)

Trenchless Methods


Utility Tunneling

Pipe Jacking


Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement


HDD

Microtunneling

Pipe Ramming

Horizontal Directional Drilling (HDD) (Pressure Pipelines and Conduits)

• Usually performed in two (or more) steps:

• Drilling of pilot hole using a steerable drill head & locator system

• Backreaming to increase pilot hole diameter & pullback of product pipe

– Product pipe sizes up to about 60”

– Typically used for road and river crossings

Horizontal Directional Drilling Method (HDD)

Characteristic of Horizontal Directional Drilling

MethodDiameter

Range (inches)


(feet)

Pipe Materials


Accuracy( + or - )

Mini-HDD 4”-12” < 600’ PE, PVC, DIP

Pressure Pipe & Cables

Varies

Midi-HDD 12”-24” 600’ – 2,000’ PE, Steel Pressure Pipe Varies

Maxi-HDD 24” - 60” 2,000’ – 6,000’ Steel Pressure Pipe Varies


Source: Hair & Associates










Trenchless Methods


Utility Tunneling

Pipe Jacking


Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement

Localized Repair

Lateral Renewal

Coatings & Linings

Manhole Renewal


HDD

Microtunneling

Pipe Ramming

Microtunneling Method(Gravity Pipelines)

• Microtunneling– Also known as remote-controlled pipe jacking– Product pipe sizes 12” & larger– Uses automation for processes performed by

workers within the tunnel on pipe jacking• Remote controlled MTBM• Remote controlled excavation & spoil removal• Remote controlled guidance system

Microtunneling Method

Characteristic of Microtunneling

MethodDiameter

Range (inches)


(feet)

Pipe Materials


Accuracy( + or - )

Microtunneling > 12” 1,000’RCP, GRP, VCP, DIP,

Steel, PCP

GravityPipelines

~1”

Microtunnel Boring Machine (MTBM)

Microtunneling Method

• Guidance systems based on a laser set in jacking shaft

• Types of guidance systems– Passive– Active


Trenchless Methods


Utility Tunneling

Pipe Jacking


Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement


HDD

Pilot Tube Microtunneling

Microtunneling

Pipe Ramming

Trenchless Technology Methods(Road and Railroad Crossings)

• Pipe Ramming– Performed in two steps:

• Installation of the casing pipe by using an air hammer from a drive pit

• Use closed-end casing (<8” diameter)• Use open-end casing for >8”, clean spoil

from casing after drive completed• Installation of carrier pipe & filling annular

space with grout

– Best suited for road crossings

Pipe Ramming Method

Characteristic of Pipe Ramming

MethodDiameter

Range (inches)


(feet)

Pipe Materials


Accuracy( + or - )

Pipe Ramming < 150” 250 Steel Road Crossings

Depends on setup

Source: TT Technologies


Trenchless Methods


Utility Tunneling

Pipe Jacking


Cured-in-Place Pipe

Close-fit Pipe

Thermoformed Pipe

Sliplining

Modified Sliplining

In-line Replacement


HDD

Pilot Tube Microtunneling

Microtunneling

Pipe Ramming

Compaction Methods

Cured-in-Place Pipe (CIPP)(Gravity & Pressure Pipelines)

• Installs a resin-impregnated, thin-walled liner tube inside of host pipe

• Liner resin is cured with the liner in place inside of the host pipe

• Creates a new liner pipe within the host pipe

• Available in a variety of diameters & shapes

Cured-in-Place Pipe (CIPP)

Characteristic of CIPP MethodsMethod Diameter

Range (inches)


(feet)

Liner Materials Typical Applications

Inverted in

place

4” -108” 3,000’ Thermoset resin/fabric composite

Gravity & pressure pipelines

Winched in

Place

4” -100” 1,500’ Thermoset resin/fabric composite

Gravity & pressure pipelines

Cured-in-Place Pipe (CIPP)– Manufacturing (Wet-Out)

Felt is vacuum-impregnated with catalyzed resin, loaded onto a refrigerated truck and transported to the jobsite

Source: Insituform Technologies

Refrigerated Truck

Water Source

Cured-in-Place Pipe (CIPP)– Inversion method

Liner is brought to the site and inverted into place using a column of water or air pressure


Cured-in-Place Pipe (CIPP)– Water Inversion Method


Hot Water Cure

Boiler / platform truck

Recirculation piping

Cured-in-Place Pipe (CIPP)– Curing Cycle

Water is heated and continuously circulated through a boiler unit until the CIPP is fully cured


Refrigerated Truck

Winch

Cured-in-Place Pipe (CIPP)– Pull-In-Place Method

Liner is brought to the site, carefully pulled into place and expanded using a water or air-inverted calibration tube


CameraCutter

• Service Reinstatements


Cured-in-Place Pipe (CIPP)• On-site (Over-the-Hole) Wet-outs


THE UNIVERSITY OF TEXAS AT ARLINGTONCOLLEGE OF ENGINEERING

NEW MASTER OF CONSTRUCTION MANAGEMENT (MCM)

Center for Underground Infrastructure Research & Education

Grouping of university, municipal, industrial, business and governmental representatives committed to the advancement of knowledge in materials, methods and equipment used in underground infrastructure.

RESEARCH CONSORTIUM

Source: TRWD

Research Projects

Validation of Culvert Standards SCP-MD and Jack and Bore Issues

WERF INFR1R12STRUCTURAL CAPABILITIES OF NO-DIG MANHOLE REHABILITATION

Current Research at The University of Texas at Arlington

Design Guide Scope:- An overview of planning and design requirements

for structural renewal of water pipes utilizing Spray-in-PlacePipe (SIPP) lining, a Hybrid Polyurea Structuralenhancement spray method.

Topics Addressed Method Selection Design Principles Lining Thickness Calculations Material Consumption Quality Control Cost Analysis

Design Guide3MTM TM

Spray In Place Pipe (SIPP) 269 Lining

(Hybrid Polyurea Structural Linings) for Water Pipes

Prepared By:The Center For Underground

Infrastructure Research and Education(CUIRE)

The University of Texas at ArlingtonDr. Mohammad Najafi

Current Research at The University of Texas at Arlington

Installation Guide

Scope:- An overview of each phase of installationfrom pipe preparation, cleaning, disinfecting toproject closeout and delivery.

Topics Addressed

Condition Assessment Inspection Methods Cleaning Methods Disinfection Curing Project Safety Project Delivery

Installation Guide3MTM TM

Spray-In-Place Pipe (SIPP) 269 Coating(Hybrid Polyurea Structural) for Water Pipes

Prepared By:The Center For Underground Infrastructure Research and

Education(CUIRE)

The University of Texas at ArlingtonDr. Mohammad Najafi

ASTM & ASCE Working Committees Working Group WK23937 Collaboration Standard Practice for Renewal of Existing Pressure Pipes by

Spray in Place Pipe with Polyurea Resin. Scope: This practice describes the procedures for renewal of water

pipes by using 100% polyurea lining. It covers proposed designmethod, installation techniques and inspection required for liningwater pipes using polyurea resin.

Topics Addressed: Standards Methods Preparation Work Designing Testing

Long-Term Testing

Durability and Reliability of Large Diameter

(16 in. and Larger) HDPE Pipe for Water Main Applications (Project #4485)

Test Setup

CUIRE Board Members

Publications

Classroom Training

Journal of Pipeline Systems (JPS) Engineering and Practice

• New pipeline technologies, • Planning, engineering, design,

construction (conventional and trenchless),

• Renewal, safety, operation and maintenance,

• Asset management, • Environmental aspects, and• Sustainability of pipeline

systems.http://www.editorialmanager.com/jrnpseng/

• Need more hybrid methods with enhanced capabilities.

• Need more standards and guidelines.• Need more training and education.• Due to nature of trenchless technology

projects, the Contractor and the Engineer must work together to understand the project’s expectations and work through potential problems.

Summary

• Selection of the best method is a function of many issues including:– Size (diameter)– Shape– Alignment– Environment (soil, fluid & temperature)– Structural needs– Loads (overburden, hydrostatic, surface)– Flow capacity (hydraulics) – Others????

Summary

Conclusions• CUIRE can be a resource for you!

– Pipe/soil interactions– Physical testing & computer modeling– Review of design alternatives– Life-cycle cost analysis– Constructability– Trenchless technology– Education, training and certification courses

Questions?Dr. Mohammad Najafi, P.E., F. ASCE

Director of Center for Underground Infrastructure Research & Education (CUIRE)

Phone: 817-272-0507

Email: [email protected]

www.cuire.org

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Trenchless Construction Technology and Issues

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