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This is an excerpt from a technical paper presented at NASTT’s 2016 No-Dig Show in Dallas, Texas.
Paper TM2-T4-03 written by:
Simon Asinor Adamtey, Bowling Green State University, Bowling Green, Ohio
Lameck Mairura Onsarigo, Bowling Green State University, Bowling Green, Ohio
Alan Atalah, Bowling Green State University, Bowling Green, Ohio
ABSTRACT
Culverts are very critical to drainage and transportation of fluids under highways. State Departments of Transportation maintain thousands of these culverts under highways, road and freeways. The Ohio Department of Transportation alone maintains over 85,000 culverts under Ohio’s priority and general highways. Through regular inspections and condition assessment of these culverts, a course of action ranging from routine maintenance to replacement is recommended. Pipe bursting is a viable alternative to replace deteriorated culverts. However, a high percentage of these culverts are made of corrugated metal pipes which are challenging to burst because the ridges tend to fold under the compression stress making it difficult, and often times, impossible to burst. The research team at Bowling Green State University (BGSU) in collaboration with two pipe bursting manufacturers (TT Technologies and Hammerhead) conducted pipe bursting research tests aimed at finding solutions to bursting corrugated metal pipes. This paper provides an overview of the pipe bursting operations through which four corrugated metal pipe culverts (12”, 18”, and 24” in diameter) were successfully replaced through this collaborative effort.
INTRODUCTION
The State Departments of Transportation (DOTs) are responsible for a large number of highway assets including culverts, which are important drainage structures under roads. The main purpose of these culverts is to transport water or fluid from one side of the highway to the other. During the industrial growth in the 1950s, culvert construction became necessary as a result of the freeway construction projects initiated in United States through the Federal-Aid Highway Act of 1956 (Camp, Boyce, & Tenbusch, 2010). Corrugated pipe, and in particular, corrugated metal pipe (CMP), was generally the material of choice on these low bid projects because of the relative low cost for a given strength of the pipe. The corrugations add strength to the pipe while permitting a reduction in wall metal thickness resulting in lower pipe material cost per foot of pipe (Tenbusch, Dorwart, & Tenbusch, 2009). Many of these culverts were designed for a 50-year life cycle, which is now ending (Camp, Boyce, & Tenbusch, 2010). For these assets to continue to perform their intended function and meet future demands, they have to be replaced or rehabilitated.
As underground structures, culverts are less noticeable and are often ignored until a catastrophic failure occurs (Gee, 2007). These failures lead to temporarily roadway closure, disruption of traffic flow, and considerable re-installation costs. A complete collapse of the culvert may result in the collapse of the roadway posing a major safety risk or hazard to motorists. With factors such as aging and deteriorating national infrastructure, increasing congestion, highway safety challenges, and limited funds, state departments of transportation are looking for innovative ways to manage their transportation assets (Gee, 2007). Consequently, the selection of economic alternatives to replace deteriorated culverts has become an important aspect of managing these assets.
Open-cut, which is the traditional method for culvert rehabilitation, is an expensive alternative for deep installations due to the massive excavation and need for shoring. Apart from the direct cost, there are social costs such as traffic disruption, road closures, business interruptions, noise pollution, environmental impact, and reduced safety for both workers and road users associated with open-cut. Trenchless rehabilitation methods such as cured-in-place pipe, slip lining, fold and form and other relining techniques have the disadvantage of reducing the internal diameter of the existing pipe and hence not applicable where there is the need to increase the diameter and flow of the existing pipe.
Pipe bursting provides an innovative and practical alternative to open cut without the disturbance and the cost of excavating a trench (Atalah, 2008). Pipe bursting has several advantages over the traditional open-cut method; it is much faster, more efficient, and less expensive especially in gravity applications due to their deeper depths. Pipe bursting is the only trenchless rehabilitation method that can replace an existing pipe with an entirely new pipe resulting in total replacement of the existing deteriorated pipe (Lueke, 1999). Pipe bursting also has the advantage of maintaining or increasing the flow capacity of the existing deteriorated pipeline by increasing the diameter of the replacement pipe. Pipe bursting has been used to replace almost all types of pipes including lightly reinforced concrete pipes, ductile iron pipes, clay pipes, steel pipes, vitrified clay pipes (VCP), cast iron, plain concrete, asbestos and some plastics. However, corrugated metal pipe (CMP) is not considered a good candidate for pipe bursting because the ridges of CMP fold like an accordion under compression thickening the wall and making it almost impossible to burst or slit or split.
The Ohio Department of Transportation (ODOT), alone maintains over 85,000 culverts and about 20% (17,500) of these culverts are corrugated metal pipes (ODOT Culvert Database, 2014). Considering the large number of existing CMP culverts and the continual use of CMP for culverts, it is essential to expand the pipe bursting applications to these culverts, which will in turn provide an alternative rehabilitation method for municipalities and transportation agencies.
To determine the system and tools for successful bursting of corrugated metal pipes, field tests were conducted that involved the replacement of actual culverts under existing roads. The two pipe bursting manufacturers, TT Technologies and Hammerhead, contributed their bursting equipment and technicians. These tests provided the opportunity for the manufacturers to investigate different accessories, designs, and system configurations to successfully burst corrugated metal pipes.
Through the collaboration of ODOT, the manufacturers, and the research team from BGSU, four CMP culverts were successfully replaced using pipe bursting. The pipe bursting tests were done in ODOT’s Districts 2, 5, and 10. All the pipes were replaced with high density polyethylene (HDPE) DR 17 pipes which were delivered and fused on site. The District 10 test was done with a pneumatic bursting system, while the District 5 and 2 tests were done with a static bursting system.
To read the complete paper, download it here. Downloads are complementary for members so be sure to log in first.
Copyright 2016 by the North American Society for Trenchless Technology.
Original paper distributed at NASTT’s 2016 No-Dig Show.
All rights reserved.
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The UKSTT Awards and Gala Dinner in Association with Westrade
Venue: The Marriott Hotel, Peterborough Business Park, Lynch Wood, Peterborough, PE2 6GB
£2,000 bursary prize for the winner of the ‘Young Professional’ category!
Every year, the UKSTT presents the winner of the ‘Young Professional’ category with a £2,000.00 bursary to help fund their travel and accommodation to any part of the world, allowing them to undertake further research into their chosen area of Trenchless Technology.
The Society recognises the need to encourage the work that young professionals are bringing to the industry and are keen to recognise this at the awards ceremony.
Young Professionals (<30 years) are asked to submit a 1500 word entry that best demonstrates their contribution to the field of Trenchless Technology. UKSTT will be looking for evidence of an understanding of Trenchless Technology, the individual’s contribution made, the quality of the submission and the candidate’s vision for the future of Trenchless Technology.
Find out what other winners of this prestigious award experienced as a result of this bursary, visit our website http://ukstt.org.uk/about-ukstt/news/82-news/756-liammacfarlane
CALL FOR ENTRIES
This year submitting an award couldn’t be easier! A new online submission form has been created for each category that can be filled in and submitted on-line. For further information regarding the Awards or the Gala Dinner please visit the UKSTT website
Deadline date for all entries is the 1st July 2016
To sponsor the Awards & Gala Dinner– Please contact Paul Harwood at pharwood@westrade.co.uk
To book tickets or reserve a table, please contact Chantel Avis at cavis@westrade.co.uk
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New name reinforces editorial direction, executive-level audience
BRECKSVILLE, OHIO — UIM: Water Utility Infrastructure Management, the leading professional journal covering the municipal water and wastewater sector in North America, is changing its name to Water Finance & Management.
The partial rebranding will include the name change, a new logo, redesign of the print journal and a new website, waterfm.com, all launching in June 2016.
While the editorial direction of the publication is not changing, the new name will bring a more focused title to the content covered in the journal and redefine what the publication was initially built on – the finance and management of water systems. The journal’s distribution and audience of executive-level utility managers, decision-makers, elected officials and consultants will also remain the same.
Originally launched in 2004, UIM was initially branded by publisher Benjamin Media as Underground Infrastructure Management. Soon after, the emphasis became all about water and the name was tweaked to UIM: Water Utility Infrastructure Management.
“Our journal has always been about finance and management, so in that respect, nothing has truly changed,” said Bernie Krzys, CEO of Benjamin Media. “We felt there was an opportunity to improve the identification of our brand with a more direct name that emphasizes what we’re all about. So circling around in a matter of speaking, this well-regarded journal’s name has evolved to become Water Finance & Management.”
The new name will better outline the editorial coverage of the journal. On the finance side, coverage includes traditional sources of utility funding, private financing and P3s, rate setting, affordability, regional cooperation and more. On the management side, coverage includes asset management, implementation of new technology, data management and application, smart water networks, water loss, leak detection and more.
The name change also streamlines other initiatives within the UIM brand, namely its two conferences – the Water Finance Conference and Water Asset Management Conference. The new Water Finance & Management logo has also been redesigned to convey the executive-level tone of the brand and reincorporates the goldfish from the UIM logo, representing the ecology of clean water and its importance to quality of life and environmental progress.
Be on the lookout for Water Finance & Management in the coming weeks as we look forward to continuing to serve the water market!
Editorial:
Andrew Farr
330.752.1919
Advertising:
Hannah Schiffman
330-315-2135
Conferences:
Jeni Leist
330.315.2209
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Intermediate Breakthrough is a Milestone in Difficult Ground
On March 29, 2016, North America’s first Crossover TBM broke new ground in Mexico City.
The 8.7 m (28.5 ft) diameter Robbins XRE—a cross between a rock TBM and an EPB—emerged into an intermediate shaft at Túnel Emisor Poniente (TEP) II.
The machine is undergoing some maintenance before continuing on to bore the final 3.2 km (2.0 mi) of tunnel. The customized TBM, for a consortium of Aldesem, Proacon, and Recsa, was chosen based on a number of parameters that included challenging ground conditions below an area to the west of downtown Mexico City.
The tunnel path travels through a mountain with cover as high as 170 m (560 ft), through fault zones and in a section with cover as low as 8.0 m (26.2 ft) above the tunnel crown. Much of the tunnel consists of andesite rock with bands of tuff, and softer material in fault zones as well as an 874 m (2,870 ft) long section in soft ground at the end of the tunnel.
“The geological profile of the project comprises six different lithologies, among them hard rock such as dacite. To get the best operation in both areas required use of dual mode technology such as the Crossover TBM,” said Enrique del Castillo of contractor Aldesem. The 8.7 m (28.5 ft) diameter Robbins XRE (Crossover between Rock/EPB) is a design that allows for the TBM to effectively bore in both hard rock and mixed ground.
The machine setup includes a canopy drill and positioner for enhanced ground consolidation, as well as gear reducers to adjust torque and RPM based on ground conditions. The TBM, initially launched in hard rock mode, can be operated in EPB mode later on by switching out the belt conveyor with a screw and converting the cutterhead.
The Robbins Crossover machine began its journey in August 2015, and advance rates picked up quickly. Project records were set in January 2016 after the machine achieved a best day of 42.8 m (140 ft) and a best week of 185.1 m (607 ft). By mid-March the machine had bored through the first of the contact zones, a 30 m wide section of fractured and blocky rock. While the excavation through the contact zone was slow going, progress picked up again in the more competent rock. Final breakthrough is expected in autumn 2016.
Once complete, the 5.8 km (3.6 mi) tunnel will supplement an existing and overtaxed wastewater line built in the 1970s. The deep drainage tunnel will serve to prevent recurrent flooding in Valle Dorado, and will benefit the cities of Cuautital Izcalli, Tlalnepantla, and Atizapan de Zaragoza, an area with a total population of 2.1 million inhabitants.
Image 1:Jobsite personnel celebrate the breakthrough of the 8.7 m (28.5) diameter Robbins Crossover (XRE) TBM for the Túnel Emisor Poniente (TEP) II project.
Image 2: The 5.8 km (3.6 mi) Túnel Emisor Poniente (TEP) II will prevent recurring flooding in three key areas surrounding Mexico City once complete.
Image 3: The crew for the Aldesem/Proacon/Recsa consortium had much to celebrate at the intermediate breakthrough of North America’s first Crossover TBM.
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April 25, 2016 – LAKE MILLS, Wisc.– HammerHead® Trenchless Equipment, a Charles Machine Works company, now offers the Picote Pipe Coating System and the Picote Smart Spider pipe cleaning tool. These new additions to the Picote product line allow HammerHead Trenchless Equipment to offer solutions for a larger range of pipe rehabilitation projects and conditions.
The Picote Pipe Coating System renovates pipes 1 ¼ to 6 inches in diameter up to 60 feet in 
length with a brush-cast, resin coating to form a new wear-resistant, non-corrosive pipe from the existing one. It is cost-effective alternative to pipe replacement because it leaves the existing pipe in place, eliminating the need for extensive demolition and restoration. It can be used to renovate an entire pipe system or finish off a point repair for a wide range of pipe materials including cast iron, PVC, concrete and clay.
Jake Saltzman, worldwide technical director for Picote Solutions Inc., said the slick inner surface of the cured coating increases flow rate and minimizes the risk of blockages similar to cured-in-place-pipe (CIPP) lining systems: “And the Pipe Coating System is actually comparable to CIPP in ease of application, durability and cost per linear foot. So it offers a cost-effective, noninvasive, trenchless alternative that can be used where CIPP and point repair can’t or in conjunction with them.”
Unlike inversion-process liner systems, a brush-cast application isn’t limited by abrupt angles. And unlike spray-on coatings that simply cover a substrate, brush-cast application works the coating into the substrate, pushing past residue and deeply into the surface material for the strongest bonding and adhesion.
Brush-cast pipe coating can be used to line pipes that are subject to high pressure, high temperature or frequent exposure to some chemical substances. Pipe coating also offers high production capability in larger, complex jobs, since the completed coatings do not require return trips to cut, trim and reinstate mid-run joints or fixtures.
HammerHead Trenchless sent its field technicians to Picote’s international headquarters in Finland for factory training to provide customers with top notch field support.
Ryan Boldan, product line manager for HammerHead Trenchless Equipment, said, “This means we not only can expand your range of solutions but can offer the same level of HammerHead product support and technical expertise we provide for all our lines. Picote is a quality brand offering proven solutions for the trenchless industry. You can use the Picote products with confidence knowing HammerHead will be right there with you, as always.”
A compact system that weighs only about 33 pounds, the Picote Pipe Coating System is easily used for projects in tight spaces. Applications are approximately 1/16 inch per pass, requiring just two to four coats to build the desired thickness.
The urethane coating dries to the touch within hours, reaching full hardness in seven days. Pipes can be reconnected in a day. Even after reaching full hardness after seven days, the coating remains flexible enough to withstand shock and bending, which greatly prolongs the service life of the pipe up to 50 years.
Use of the Picote Pipe Coating System requires a CCTV camera and Mini Miller to power the system. Brushes, hoses and shaft come in a variety of styles and sizes for a customized package.
Available in both 4- and 6-inch sizes, the Picote Smart Spider is a new tool designed to work in all pipes, including PVC and pipes with gaps that can catch a chain-style cleaner. The Spider operates at 1,000 rpm and is driven by a Picote Maxi Miller. The tool easily navigates 90-degree turns.
The Smart Spider is rebuild-able, offering users the economy of replacing individual components rather than the entire tool.
The Picote Pipe Coating System and Picote Spider are available directly from HammerHead Trenchless Equipment at www.hammerheadtrenchless.com or by calling 800.331.6653. (International: + [1] 920.648.4848).
Photo 1: Picote Pipe Coating System offered by HammerHead Trenchless Equipment
Photo 2: Picote Smart Spider offered by HammerHead Trenchless Equipment
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MASON COUNTY, TX– When Steve and Pam Bolt of Sonora, Texas purchased acreage on 
the Llano River in Mason County they knew they had some work in store for them. The land required a lot of time and energy to clear and clean-up the property after several years of growth and non-management. After putting in the time, their efforts paid off when they were able to add a custom built cabin as their vacation home on the river banks.
However, one aspect of vacation living still remained. The home needed a water source to serve the Bolt’s personal and landscaping needs. They hauled water for a few years but a long term solution of drilling a water well on the property was required. The Bolt’s called in a water well company to drill but unfortunately the company was not successful. The difficult unconsolidated Texas ground conditions resulted in the hole caving-in after drilling only 10 feet and the operator had no other solution. The Bolt’s were in a bind.
Disappointed but not beaten, the Bolt’s contacted President Clark Abel of Abel Water Systems in San Angelo, TX based upon his expertise in difficult drilling conditions. Clark discussed the complications of drilling a well in the unconsolidated formation of gravel, sand, and fractured limestone. He further detailed that a well location situated close to the river added additional issues to the well planning and drilling process. Clark explained how this well would take special equipment and careful drilling in order to be successful. 
Abel Water Systems contacted Kathy Wagoner from ToolHand, LLC of Menard, TX to discuss the complications of drilling the well. ToolHand suggested running the Numa Super Jaws® Overburden Drilling System. ToolHand informed Clark that the Numa Super Jaws System sets the well casing simultaneously while drilling the hole. With its unique wing design, the Super Jaws bit goes inside of casing and its wings extend out further than the casing OD. This allows Super Jaws to drill and advance the casing at the same time to prevent hole collapse in unconsolidated formations. Another benefit is the wings retract back into the guide body for extraction of all tooling while leaving the casing in place. Saving time and money for drillers.
ToolHand and Abel Water Systems agreed the Numa Super Jaws Drilling System was the perfect solution for the Bolt’s water well. They designed a well plan that incorporated a T140 Super Jaws System for setting the 6 5/8” casing and taking into account the close proximity to the river. Clark presented Steve and Pam with the well plan, pointing out the dependable performance of Super Jaws drilling through unconsolidated ground conditions. The Bolt’s agreed to proceed so they could get running water in their vacation home.
It was now time to get to work. Abel Water Systems, ToolHand, LLC and Numa field technical support were all welcomed on the drill site by the Bolt’s. The IR T3 rig was set up and the Super Jaws System was prepared for installing the 6 5/8” casing. The unconsolidated river formation was as tough and unpredictable as expected but it was no match for Super Jaws. Numa’s bit was able to drill and case the complete hole in one easy application. The 81’ (27.4 m) water well was simultaneously drilled and cased in about four (4) hours.
“Super Jaws opens new markets in which we haven’t been able to drill before. It allows for 
drilling in any kind of unconsolidated formation, such as riverbed rock,” commented Kathy Wagoner of ToolHand.“Also, Numa provided great field support on this project but, as Abel Water Systems will attest, Super Jaws was real easy to deploy and use.”
The Bolt’s were delighted with the results and amazed with the successful drilling. The Super Jaws well now provides plenty of water to supply their Mason County vacation home and property. There was only one way to give the Bolt’s the water well they required. So when ToolHand and Abel Water Systems had to be right, they choose the Numa Super Jaws overburden bit to get the job done for their customer.
For more information on Numa products and services, please email us at info@numahammers.com, call us on 860.923.9551, or visit our website at www.numahammers.com
ABOUT NUMA
Numa is the world’s leading designer of rock drilling equipment with over 110 DTH Hammer and Bit products serving 11 different industries. Our products are capable of drilling vertical, horizontal, and reverse circulation holes from 3½ to 48 inches (89 – 1,219 mm) in diameter and are used in 105+ countries. We have built our customer-centric reputation on providing the highest value in products, performance and personal service available in the rock drilling marketplace.
ABOUT TOOLHAND LLC
ToolHand based in Menard, TX carries a diverse selection of products designed to keep your operation running. From hammer bits to air drill foam, ToolHand has what you need at prices you can afford. ToolHand experts ensure your air hammer drilling equipment is always in the best shape for maximum efficiency. In addition to general maintenance, we also inspect and repair your drilling equipment. We also sharpen carbide bits in the shop and on location. Backed by more than 30 years of industry experience, 20 of which our service manager spent in the shop and field, ToolHand is trusted by many air hammer drilling contractors to handle their equipment with integrity and respect. For more information on ToolHand, please contact:
ToolHand, LLC
Kathy Wagoner
Menard, TX. 76859
325-396-4563
325-456-0407
kwagoner@toolhandserviceandsupply.com
