Post on 27-Aug-2018
24-Oct-17
1
www.ukstt.org.uk
Pipe Bursting & Keyhole
Technology for Water
Rehabilitation
Matthew Izzard
(Business Development Director – Tracto Technik UK)
(Vice Chairman UKSTT)
www.tracto-
technik.co.uk
Pipe Replacement Techniques:
Static Pipebursting Dynamic Pipe Bursting
Pipe Extraction /
Pulling
Insertion
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technik.co.uk
A Brief History of Pipe Bursting:
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technik.co.uk
• Developed in Late 1970’s by D J Ryan & British Gas
• Patents granted Worldwide for both Method & Equipment between 1980 & 1985
• Originally used for Gas Main replacement
• Since adopted for Water & Sewer Replacement
Courtesy Norman Howell Associates
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technik.co.uk
Only trenchless process where it is possible to replace size for size or upsize
an existing pipe.
Pipe material – old pipe or new pipe generally ‘irrelevant’ in terms of process.
Pipe Bursting Technique & Applications:
Applications:
Gas
Clean Water *Dynamic pipe bursting exhaust
Sewer, including gravity Drainage
Insertion (Tight Fit) Re-rounding
Cleaning
Both static & dynamic bursting can be ‘stop – start’ process.
Ground has to be physically displaceable.
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technik.co.uk
Pipe Bursting Technique & Applications:
Considerations that may Prevent the Successful Operation of the Technique:
• Proximity for Other Utility Services
• Repair Fittings & Clamps
• Reinforced Concrete Pipes
• Concrete Beds
• Concrete Bed & Surrounds
• Substantial Quantities of Concrete adjacent to the Pipeline at Connections & Chambers
Pipe Bursting Design & Risk
Mitigation:
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technik.co.uk
Site Access & Layout:
Static Equipment: Rig, Rod Packs, Power Pack, Hoses, Tooling
Dynamic: Hammer, Winch, Compressor, Hoses, Tooling
Pipe entry point & method – Coil, sticks or sections
100m lengths typical on smaller diameters generally based on pe coils.
1200mm Diameter possible based on upsize, ground conditions and power of
equipment.
Fast replacement speed – better for consumers as shorter streetworks and
disruption but longer disconnection time.
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Pipe Bursting Design & Risk
Mitigation:
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technik.co.uk
Ground Heave: Displacement factor critical when ‘expanding’ – Effects
around 10 x diameter of upsize in surrounding ground.
Pipe Wall Damage & Drag: Expander selection guideline 20% larger than final
pipe, bentonite fluid option to reduce friction & stablise fragments.
Pipe Bursting Design & Risk
Mitigation:
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technik.co.uk
(INS) (MM) 90 125 180 200 250 315 355 400 450 500 560 630 710 800
4 100 u u
6 150 u u u u
9 225 u u u u u
12 300 u u u u u u
15 375 u u u u u
18 450 u u u u
21 525 u u u
24 600 u u u
EXISTING PIPE
SIZENEW PIPE (OD) IN MM
Ground Conditions:
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technik.co.uk
Cohesive Soils • Firm to Soft Clays: Ideal • Hard Clays: Greater Bursting Power is needed to Achieve
Required Soil Compaction
Non-Cohesive Soils • Dry Sand: Most Difficult Conditions • Wet Sand: Provides Problems for Hydraulically Powered
Machines
Rock: Limits Upsizing Capabilities
Ground Water: High Water Tables can cause problems for both Pneumatically & Hydraulically Powered Machines
Pipe Replacement Options:
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technik.co.uk
Pipe Strings • Polyethylene Pipes
• Steel
Short Length Pipes
• Polyethylene
• Polypropylene
• UPVC
• Clayware Pipes
Static Pipe Bursting:
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technik.co.uk
Static Pipe Bursting:
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technik.co.uk
24-Oct-17
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Nominal Diameter OldPpipe Minimum Static Pipe
Bursting Rig
≤ ND 250 400 G/S
275 / 400 kN
> ND 250 - ≤ ND 400 800 G
256 / 769 kN
> ND 400 - ≤ ND 600 1250 G/CP
395 / 1272 kN
> ND 400 - ≤ ND 800 1900 G
716 / 1900 kN
> ND 600 - ≥ ND 1000 2500 G
1055 / 2550 kN
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technik.co.uk
Pipe Bursting Rig Size Selection:
Threaded Rods:
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technik.co.uk
QuickLock Rods:
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technik.co.uk
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technik.co.uk
Cable / Chain Systems:
• Typically used on laterals
• Service splitting
• Smaller Diameter pipes – 160mm
• Good for bends up to 45 degrees
• Pull distances typically 50m
• Versatile and portable
Old Pipe
Expander with blade
ledges
New Pipe
Rods
Static Bursting Principle:
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technik.co.uk
Old Pipe
Static Pipe Bursting
Rollerblade Hook knife Bursting head
Grey cast iron pipes X X
Ductile cast iron pipes X
Steel pipes X
PE / PP pipes X
PVC pipes X
Asbestos / fibre cement pipes
X
Vitrified clay pipes X
Concrete / reinforced concrete pipes
X X
GFRP pipes X
Brickwork X
Inliners X X
Bursting Techniques for Pipe Material:
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technik.co.uk
24-Oct-17
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Roller Blade - Ductile Cutter - PE
Delta Blade - Brittle Bursting Head / Expander - Brittle
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technik.co.uk
Receiving Pit & Pull Back:
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technik.co.uk
Static Pipe Bursting: “Stitching”
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technik.co.uk
Location: Kiruna (North of Sweden)
Existing pipe: Ductile Iron ID 500 with inner cement coating
New pipe: PE OD 500; SDR 17; PE 100
Length: 245 m (1 x 120 and 1 x 125 m)
Duration: 2 days
Depth: 3 – 5 meters
Contracting authority: Kiruna komun
Contractor: Oden
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technik.co.uk
GRUNDOBURST 1250: KIRUNA, SWEDEN
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technik.co.uk
GRUNDOBURST 1250: KIRUNA, SWEDEN
Machine Pit Reception Pit www.ukstt.org.uk www.tracto-
technik.co.uk
GRUNDOBURST 1250: KIRUNA, SWEDEN
24-Oct-17
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Roller blade
for ID 500
mm
Expander OD
550 with
blades
PE link
OD 500 mm
with
connection
PE pipe
OD 500 x
29,7
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technik.co.uk
GRUNDOBURST 1250: KIRUNA, SWEDEN
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technik.co.uk
GRUNDOBURST 1250: KIRUNA, SWEDEN
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technik.co.uk
GRUNDOBURST 1250: KIRUNA, SWEDEN
GRUNDOBURST 2500G: GLOGOW, POLAND
Location: Glogow in Poland
Existing pipe: Cast Iron ID 500 with inner cement coating
New pipe: PE OD 500 mm with outer PP protection coating
Length: 170 m
Depth: 2 – 2,5 meters
Contracting authority: PWIK w Glogowie Sp. z.o.o.
Contractor: ZISBD
Speciality: Usage of GRUNDOLOG 1250kN to measure the tensile forces on the new installed pipe
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technik.co.uk
Poland
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technik.co.uk
GRUNDOBURST 2500G: GLOGOW, POLAND
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technik.co.uk
GRUNDOBURST 2500G: GLOGOW, POLAND
24-Oct-17
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technik.co.uk
GRUNDOBURST 2500G: GLOGOW, POLAND
Tensile strength
measuring with
GRUNDOLOG
GRUNDOBURST 2500G: GLOGOW, POLAND
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technik.co.uk
GRUNDOBURST 2500G GLOGOW / POLAND
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technik.co.uk
Data Logging & Load Sensing:
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technik.co.uk
Data Logging & Load Sensing:
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technik.co.uk
Keyhole Hole Operation – Sewer Rehab:
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technik.co.uk
24-Oct-17
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Grundoburst 400S – Lisvane, Cardiff: May 2017
Client: Welsh Water
Contractors: Lakewell Utilities
Date: 3rd May 2017
Length: 23 meters
Existing pipe: 150mm Clayware
Access: Both Chambers 1200mm dia. Upstream 5 meters deep, Downstream 3.5 meters deep.
Pipe Condition: partially collapsed / blocked, causing occasional upstream overflow / flooding.
Replace with: 160mm dia, 750mm long Demco screw together short section pipe.
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technik.co.uk
Upstream Chamber:
Demco pipe drawn in from
this Chamber with Spanfix
Downstream Chamber:
Grundoburst launch pit
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technik.co.uk
Upstream
Chamber
Downstream
Chamber
(Launch Chamber)
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technik.co.uk
Equipment set up and Quicklock Rods pushed into receiving Chamber in 1.5 hours
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technik.co.uk
Equipment all on one trailer & vehicle
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technik.co.uk
Short section pipes, clamped together with Spanfix tensioning system
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technik.co.uk
24-Oct-17
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Bursting Head arrives in
the Chamber pulling the
new 160mm dia pipe
Due to the restricted working
area, it would have been quicker
to use snap together short
section pipes rather than screw
together. This was recommend
by Tracto Technik UK.
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technik.co.uk
Bursting Head and tooling
dismantled leaving the new
sewer pipe
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technik.co.uk
Dynamic Pipe Bursting:
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technik.co.uk
Dynamic Pipe Bursting:
Winch rope Front Expander Broken Shards
Of Old Pipe
New PE-HD GRUNDOCRACK Old Pipe
Brittle pipes only! *reinforced concrete
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technik.co.uk
Project example:
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technik.co.uk
Dynamic Pipe Bursting:
Old Pipe Dynamic
Bursting Process
Stoneware (Stz) X
Concrete (B) X
Cast Iron (GG) X
Polyvinylchlorid (PVC) X
Fibre Cement (FZ) X
Asbestos-Cement (AZ) X
Masonry Channels X
Stahl (St) X (conditioned)
Polyethylene (PE),
Polypropylene (PP) X (conditioned)
Fibre Glass Reinforced
Plastic(GRP) -
Ductile Cast Iron (GGG) -
Already Rehabilitated
Pipelines(Liner) -
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technik.co.uk
24-Oct-17
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Project example:
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technik.co.uk
Pipe replacement project(s)using Tracto Technik’s Hercules pipe cracking
equipment for the replacement of an existing 10” AC sewer pipe to a 280mm HDPE
pipe in the city of Riyadh, Saudi Arabia
Client: City of Riyadh Water and Sewerage Dept
Main Contractors: Bin Jarallah Est.
Depth of old/existing
10”AC sewer line (various): 2.8 – 3.0 metres
Existing ground conditions: Dry, loose sand with small stone
Project example:
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technik.co.uk
Project example:
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technik.co.uk
Project example:
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technik.co.uk
Dynamic Pipe Bursting: Keyhole
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technik.co.uk
Project example:
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technik.co.uk
24-Oct-17
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Project example:
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technik.co.uk
Project example:
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technik.co.uk
Dynamic Pipe Bursting: Keyhole
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technik.co.uk
HDD Pipe Bursting:
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technik.co.uk
Site Location
8-ft
Collaps
e
Courtesy Staheli Trenchless Consultants
HDD Pipe Bursting:
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technik.co.uk
Courtesy Staheli Trenchless Consultants
Existing Pipe: Combined Sewer 8-inch VCP
Collapse caused 6-ft diameter void.
Pipe 25-ft below pavement
Groundwater Table: •West End: 10-ft above existing 8-in VCP
•East End: 2-ft below
130’ Distance
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technik.co.uk
OPTION 1:OPEN TRENCH RE-ROUTE
Open Trench - Risk Probability Impact Risk Factor
Dewatering Requiring Deep Wells or Well
Points 5 3 15
Gradient Causing Non-Efficient Installation 6 1 6
Deep Excavation Affecting Ability to
Safely/Efficiently Shore 2 2 4
Complications due to Poor Existing
Infrastructure 2 1 2
Legal Implications (Shed/Fence Re-Location) 7 3 21
Cumulative Risk Score 48 Courtesy Staheli Trenchless Consultants
24-Oct-17
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technik.co.uk
OPTION 2B: PIPE BURSTING
Pipe Bursting - Risk Probability Impact Risk Factor
Dewatering Requiring Deep Wells or Well Points 2 2 4
Getting Stuck 1 5 5
Excessive Alignment Deviations 1 1 1
Complications due to Poor Existing Infrastructure 3 1 3
Settlement/Heave of WSB pavement 1 5 5
Legal Implications (Shed/Fence Re-Location) 1 3 3
Cumulative Risk Score 21 Courtesy Staheli Trenchless Consultants
HDD Pipe Bursting:
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technik.co.uk
HDD Rig set back : 40ft Courtesy Staheli Trenchless Consultants
HDD Pipe Bursting:
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technik.co.uk
Courtesy Staheli Trenchless Consultants
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technik.co.uk
Today & Tomorrow…
Water Pipelines
No joints: Provides long term leakage benefits.
Standard pipe materials are used which allows new Connections to be fitted easily.
No pre-cleansing required.
Minimal disruption to customers during installation works.
Can be operated from within existing manholes.
Can be used to replace pumping mains.
Substantial time saving possible on projects.
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technik.co.uk
Today & Tomorrow…
• Pipe capacity can be maintained or increased.
• A new pipe is provided with a 50 year asset life.
• Improved safety for operatives and the public due to
reduced open excavation.
• Direct cost savings due to reduced excavation, backfill and
reinstatement.
• Indirect cost savings as social & traffic disruption are
minimized.
• Reduced risk of damage to other utility plant.
Today & Tomorrow…
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technik.co.uk
Natural resources are Conserved & the impact on
the environment is less due reduced need for
quarried materials.
24-Oct-17
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Thank you for your time…
Matthew Izzard
T: 01234 342566 M: 07778 888844
E: matthew.izzard@tt-uk.com
www.pipe-bursting.co.uk www.ukstt.org.uk www.tracto-
technik.co.uk
Handbook of Pipe Bursting Practice
• Pipe bursting terms and
application range
Host pipe and new pipe materials
Planning and design guidelines
Pipe Bursting equipment and
accessories
Jobsite reports