This document discusses pipe bursting and pre-chlorination methods for replacing large-scale water distribution systems. It provides background on the state of aging water infrastructure in need of replacement. Pipe bursting is presented as a more cost-effective and socially acceptable alternative to open trench replacement methods. The document outlines the pipe bursting process, considerations for project design, and pre-chlorination procedures to ensure water quality. It provides a case study example of a large pipe bursting project in Brownstown, Michigan that utilized pre-chlorinated HDPE pipe.

1. PIPE BURSTING AND PRE CHLORINATION
COST EFFECTIVENESS ON LARGE SCALE PROJECTS

2. THE STATE OF WATER DISTRIBUTION SYSTEMS
• Encrusted
• Corroded
• Water loss up to 40%
• Under capacity
• Poor water quality
PIPE BURSTING AND PRE-CHLORINATION

3. BUSINESS OPPORTUNITY
• EPA estimates 750 billion dollars over
next 20 years
• AWWA estimates 1 trillion dollars over
next 20 years
PIPE BURSTING AND PRE-CHLORINATION

4. NOT ACCEPTABLE!
• The open trench method of replacement
is becoming more costly and socially
unacceptable.
PIPE BURSTING AND PRE-CHLORINATION

5. PIPE BURSTING PRESSURE PIPE
• Method was developed By British Gas and patented in 1980’s for gas distribution
rehabilitation.
• Success led to potable water crossover.
• Pipe bursting without protection sleeve accepted along with pre-chlorination
method in early 1990’s in the UK.
• Widely accepted in Europe with more than 60,000,000 feet installed in the past
17 years.
• Pre-Chlorinated method of pipe bursting is accepted by AWWA in November of
2000.
PIPE BURSTING AND PRE-CHLORINATION

6. PIPE BURSTING DEFINED
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 AND PRE-CHLORINATION

7. PIPE BURSTING
PROJECT CONSIDERATIONS

8. WHAT IS THE HOST MATERIAL?
• Cast Iron
• Clay tile
• Concrete
• Reinforced Concrete
• Asbestos Cement
• Non Fracturable Pipe
–Ductile Iron – Challenging
–Steel – Challenging
–Use Static Machines and Slitters
PIPE BURSTING AND PRE-CHLORINATION

9. WHAT MATERIALS CAN BE BURST?
Fracturable Pipes
Cast iron, clay tile, concrete, reinforced concrete, asbestos cement,
etc.
Non-fracturable Pipes
Ductile iron, steel, galvanized (require use of specialized tooling
and static bursting machines.
PIPE BURSTING AND PRE-CHLORINATION

10. IPBA PROJECT CLASSIFICATION
Project classifications per IPBA (International Pipe Bursting Association) pipe bursting specification.
PIPE BURSTING AND PRE-CHLORINATION

11. UPSIZING: A CLOSER LOOK
Note: Illustration assumes
flow line remains the same.
PIPE BURSTING AND PRE-CHLORINATION

12. UPSIZING: A CLOSER LOOK
Note: Illustration assumes
flow line remains the same.
PIPE BURSTING AND PRE-CHLORINATION

13. UPSIZING: A CLOSER LOOK
Note: Illustration assumes
flow line remains the same.
PIPE BURSTING AND PRE-CHLORINATION

14. UPSIZING: A CLOSER LOOK
Note: Illustration assumes
flow line remains the same.
PIPE BURSTING AND PRE-CHLORINATION

15. UPSIZING – EXPANSION (WHERE IT GOES)
Approximately 90% of compaction
occurs upwards from the existing line.
PIPE BURSTING AND PRE-CHLORINATION

16. PIPE BURSTING
PRE-CHLORINATION METHOD

17. Pipe Bursting / Pre-chlorination Method
• A preferred method of water line rehabilitation
–Follows path of the existing utility (reduces potential for 3rd party utility damage)
–Easement issues and line separation limitations are reduced - the existing utility path
is used
–Reduce excavation costs by up to 85%
–Able to increase the pipe diameter
–Production: Install up to 400’ of pipe in under 2 hours
–Pre-chlorination save cost and disruption of installing temporary services
–FL- No permitting required for bursting: Classed as a line repair
PIPE BURSTING AND PRE-CHLORINATION

18. FORT PIERCE, FLORIDA
PIPE BURSTING AND PRE-CHLORINATION

19. Pipe Bursting with Pre-chlorination Method
using Fusible PVC
PIPE BURSTING AND PRE-CHLORINATION

20. PIPE BURSTING SETUP – PUSH OUT ROD
PIPE BURSTING AND PRE-CHLORINATION

21. PIPE BURSTING SETUP – ATTACH TOOLING & PIPE
PIPE BURSTING AND PRE-CHLORINATION

22. PIPE BURSTING SETUP – PULL BACK
PIPE BURSTING AND PRE-CHLORINATION

23. PROJECT CONSIDERATIONS – UK
• Preferred pipe material - Fusible PVC &
HDPE.
• Upsizing used only when required
–Bursting specifications limited to 1 upsize
• Avoid surface heave and 3rd party utility damage
• HDPE Pipe
–Electro-fusion couplers for mains and service
connections
PIPE BURSTING AND PRE-CHLORINATION

24. Pipe Bursting
PIPE BURSTING AND PRE-CHLORINATION

25. Pipe Bursting with Pre-chlorination Method
using HDPE
PIPE BURSTING AND PRE-CHLORINATION

26. FLOW COMPARISONS: HDPE
PIPE BURSTING AND PRE-CHLORINATION

27. FLOW COMPARISONS: HDPE
PIPE BURSTING AND PRE-CHLORINATION

28. EQUIPMENT SELECTION
• Static equipment is most common for water projects
• High tonnage static pull back force
–38 ton (2” – 6” pipe)
–58 ton (4” – 8” pipe)
–100 ton (4” – 16” pipe)
–125 ton (6” – 20” pipe)
–175 ton (6”- 24” pipe)
• No-contamination of the new Fusible PVC pipe or HDPE.
PIPE BURSTING AND PRE-CHLORINATION

29. WATER MAIN PROBLEMS
• Received complaints regarding potable water clarity and low pressure concerns
• Cast iron water main breaks
• New service line installations required
• Limited working space, easement issues, and heavy traffic
• Expense of open cut not a feasible option
• Congested utility infrastructure
PIPE BURSTING AND PRE-CHLORINATION

30. TYPICAL JOBSITE
Launch,
reception and
service pits.
PIPE BURSTING AND PRE-CHLORINATION

31. NETWORK MODELING/PROJECT DESIGN
• Flow requirements: HDPE / Fusible PVC Slip-line or Burst?
• Site investigation
–Pothole main and confirm main depth, location and material
–Review proximity to other utilities
• Sampling Investigations
–Downstream Series Sampling:-
• 1 Source
• 50 Address (>50μg/litre)
– (>20μg/litre more than source)
–Pre and Post Renovation Sampling:-
• 10 Source
• 10 Address (>50μg/litre)
– (>20μg/litre more than source)
PIPE BURSTING AND PRE-CHLORINATION

32. CUSTOMER NOTIFICATION
• Customers are notified of mains replacement project by door hanger outlining
the project scope
• Hanger is provided to home owner 48 hours prior to work being performed on
their line section
• Approximately 15 to 20 homes will be off water from 8:00 am to 3:00 pm on the
day of pipe bursting operations
• Construction crew will be moved onward the following day
PIPE BURSTING AND PRE-CHLORINATION

33. PRE-CHLORINATING PROCEDURES
• Liverpool Depot Coil Pre-chlorinating
Operations
–Chlorinated Water is filled into the HDPE
pipe coils and left for 24 hours then flushed
and a sample taken.
PIPE BURSTING AND PRE-CHLORINATION

34. FUSE ON ADAPTORS
PIPE BURSTING AND PRE-CHLORINATION

35. PRE-CHLORINATING PROCEDURES
–Passed Coils are Marked-up with Gang Name, Location and Sample Reference
Number.
–Coils are Stored in goods-out bay prior to collection
–Coils are Loaded on to Carousel by fork-lift truck
–2 No. Check Sample Points
• To check Dosage of Chloros is maintained at 25 to 30mg/l
• To check de-chlorination of water prior to disposal
PIPE BURSTING AND PRE-CHLORINATION

36. PRE-CHLORINATING PROCEDURES
• Lengths of Main Above and Below Ground Pre-chlorinating Operations
–Very similar to coil pre-chlorinating procedure
–Source of water from on-site hydrant
–All hoses used in operation are pre-chlorinated
–Mobile dosage unit is used
• Inputs the required chloros in to the main
• De-chlorinates the water prior to discharge to sanitary sewer
–Each length requires a 12 hour dosage period prior to laboratory sample being taken
–Results are received next day via fax prior to being put into commission
PIPE BURSTING AND PRE-CHLORINATION

37. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Excavate launch, reception
and service pits.
PIPE BURSTING AND PRE-CHLORINATION

38. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Cut existing cast-iron main, install
cap end and secure. Re-establish
supply to existing main.
PIPE BURSTING AND PRE-CHLORINATION

39. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Position rig into launch and reception pit
and pay out rod. (avg. 45 minutes to
payout 350’ of rod)
PIPE BURSTING AND PRE-CHLORINATION

40. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Guide rod enters reception pit.
PIPE BURSTING AND PRE-CHLORINATION

41. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Connect pulling head to fusible PVC or HDPE
pipe. Bursting blade and expander to pulling
rods.
PIPE BURSTING AND PRE-CHLORINATION

42. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Pull back until bursting blade arrives at
reception pit. (This takes an average of
45 – 60 minutes for 350’)
PIPE BURSTING AND PRE-CHLORINATION

43. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Undertake swabbing exercise
• Purge air out of new HDPE main through Installed ferrule at pipe end
• Connect cap-end control and pressure test pipe.
• Take bacteriological sample
• Turn water back on
PIPE BURSTING AND PRE-CHLORINATION

44. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Install necessary branches, valves
and hydrants.
PIPE BURSTING AND PRE-CHLORINATION

45. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Pneumatic piercing tools used for
installing new services.
PIPE BURSTING AND PRE-CHLORINATION

46. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Install electro-fusion saddles for service
connections.
PIPE BURSTING AND PRE-CHLORINATION

47. CONSTRUCTION ACTIVITY: DAY OF OPERATIONS
• Backfill excavation and permanently re-
instate.
PIPE BURSTING AND PRE-CHLORINATION

48. CONCLUSIONS
• UK has 13 major water companies serving 66 million people.
• Pre-chlorinated Pipe Bursting has nearly obsoleted open trench replacement of
water mains in the UK
• USA has approved pre-chlorination in the majority of the US. Pipe Bursting
water mains in the USA will continue to see solid growth, but is currently limited
by:
–Engineers specifying and water companies embracing HDPE for water rehab jobs
–Lack of projects specifying the Pipe Bursting and pre-chlorinated methods
PIPE BURSTING AND PRE-CHLORINATION

49. CASE STUDY
BROWNSTOWN WATER IMPROVEMENT PROJECT
A joint venture of Bidigare Contractors, Inc., Northville, Michigan
and D & D Water & Sewer, Inc., Canton, Michigan.

50. TOWNSHIP OF BROWNSTOWN, MICHIGAN
• Ambitious water-system improvement program that includes replacing nearly
eight miles of water mains.
• Most of it with pre-chlorinated HDPE pipe installed by pipe bursting.
• It is the first time the Township has installed pre-chlorinated pipe or used pipe
bursting.
• Their contract calls for installation of 43,000 feet of new water mains, most of it
8- and 12-inch pre-chlorinated HDPE pipe and installation of fire hydrants and
gatewells.
PIPE BURSTING AND PRE-CHLORINATION

51. Existing water main pipes in Brownstown, Michigan.

52. Setting the down hole machine for the first burst.

53. Fusion of the new pipe to be installed.

54. Staging of HDPE pipe sticks for fusion.

55. The bursting process.

56. A section of new pipe shown with the tooling required to
replace the existing pipe. The tooling will be attached to
the rod string that is pushed out by the down hole unit.

57. Inside of a connection pit, the bursting process is shown.

58. Inside of another connection pit, the expander and
tooling is shown bursting through old segments of pipe.

59. CONCLUSION
• Township is so satisfied with how the project progressed; another 30,000 feet of
improvements have been added that will extend completion to 2013.

60. THANK YOU
FIRST NAME LAST NAME
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