sustainable utility construction: methods and techniquessustainable utility construction: methods...

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Sustainable Utility Construction: Methods

and Techniques

September 19, 2011 APWA CongressDenver, Colorado

Murv MoreheadROW Coordinator

Overland Park, Kansas

Monty ZimmermanRow Manager

Lenexa, Kansas

Sustainability Is…Sustainability Is…In Public Works, best encapsulated in the phrase “everything we do with an eye to the future”. Essentially this means designing and constructing infrastructure that will not become a cost or maintenance burden to future generations and at the same time being mindful of the fact that the resources we need today must also be available for those to come after us. “Sustainable infrastructure is the development of water, sewer, roads and other infrastructure systems that meet the needs of current and future generations in a socially, economically and environmentally sustainable manner”.

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Why Should The Sustainability of Why Should The Sustainability of Our RightsOur Rights--of Way of Way

Be of Concern Be of Concern Today?Today?

This Is This Is NOTNOT Sustainable For The Sustainable For The Future…Future…

Nor Is This…Nor Is This…

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Or This…Or This…

The Concern Is…The Concern Is…

Sustainability/viability of the physical property that makes up our Rights of Way. Overcrowding from new buried facilities without removing abandoned plant or implementing organized utility corridors will eventually render our ROW “unmanageable” and unable to meet demands of future generations.

Removal Of Abandoned FacilitiesRemoval Of Abandoned Facilities

• Not a popular subject – “The elephant in the room”

• Generally not enforced although it is a requirement in some ROW mgmt. ordinances

• If our ROW is to remain viable for future generations, abandoned facility removal MUST be addressed

• Some lines may be “re-purposed” (i.e. fiber optic cable in abandoned gas line)

• Greatest challenge is “managing” abandoned lines (abandoned vs. live)

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• Utility corridors should be considered critical for any new development but are not feasible for existing infrastructure.

• Removal of abandoned facilities is also becoming a critical issue but is costly and not currently pursued by facility or ROW owners.

Removal Of Abandoned FacilitiesRemoval Of Abandoned Facilities

Why Remove Abandoned Why Remove Abandoned Facilities?Facilities?

• Abandoned facilities complicate repair of viable facilities

• Physical size of abandoned line renders that amount of ROW unavailable for future installations

• Abandoned lines/cables cause increasing confusion during locating activities

• Current practice is remove when encountered

Removal of Abandoned Removal of Abandoned FacilitiesFacilities

Until abandoned facility removal is adopted as a BMP, coupled with the inescapable fact that our ROW’s are becoming over

congested, we must embrace construction methods that will allow us to work within

the physical constraints we find ourselves in. One very important alternative at our

disposal is Trenchless Technologies

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Why Use Trenchless Technology?Why Use Trenchless Technology?

• To prevent this:

4 lane thoroughfarereduced to two lanesof traffic


• And this…

Even though street is repaired properly it is still a “patch”


• In favor of this…

Service Line connections

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Last But Not Least Last But Not Least Contractor SAFETY Contractor SAFETY and…and…

SAFETY of the PublicSAFETY of the Public

Some of The Most Common Trenchless Methods Are:

• Auger Boring – used for casing installations

• Pipe Bursting – used for pipe replacement• Slip Lining - used for pipe replacement• Horizontal Directional Drilling and

Pneumatic Piercing Tools – used for pipe and cable installations of all types and sizes

• CIPP (Cured in Place Pipe)

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Auger BoringAuger Boring

Used primarily for road crossings

Pipe BurstingPipe Bursting

• Pipe Bursting has been used primarily to replace water lines

• Methods vary but operation used in OP employed a winch assisted/pneumatic powered bursting head pulling in HDPE butt-fused pipe

• Open street cuts still necessary to install Tee’s and valves


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Slip LiningSlip Lining

• New method of water line replacement• Made possible due to opportunity to

downsize pipe (HDPE provides smoother flow characteristics)

• 1,350’ 8” diameter HDPE pipe pulled in place in just over 4 hours

• As with pipe bursting, open street cuts are still necessary

The Pipe StringThe Pipe String

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Slip Lining in Progress…Slip Lining in Progress…

HDPE being pulled intohost pipe

HDD and MissilesHDD and Missiles

• Horizontal Directional Drilling (HDD) and Pneumatic Piercing Tools (Missiles) are by far the most predominant methods of trenchless technology.

• Both processes lend themselves very well to installation of coax, copper and fiber optic cables.

• HDD is fast gaining acceptance for installation of gas and water lines as well.

The HDD OperationThe HDD Operation

• Bore out to termination point– Typical bore length is 500 ft.

• Pre-ream if needed to increase bore diameter– Mixing (removes soil) vs. compaction

(displaces soil) reamer– Problems can arise if this step is neglected

• Pull back product

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The DrillThe Drill

The ReamerThe Reamer

Product PullbackProduct Pullback

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Product PullbackProduct Pullback

The Missile OperationThe Missile Operation

• Rectangular pits dug approximately 20’ apart

• Pneumatically powered non-steerable missile is lowered into pit and through percussive effect moves through the soil to exit into the next pit

• Conduit/cable is then manually pulled through newly created tunnel

The MissileThe Missile

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Missile OperationMissile Operation

“Not a pretty sight”

Vacuum ExcavationVacuum Excavation

• Is critical to trenchless technologies• Is ideally suited for locating existing buried

utilities prior to trenchless construction activities

• Is far less intrusive than open cut excavations

• Is the perfect complement to the Keyhole/Coring/Reinstatement process

• Damage to existing utilities is virtually eliminated

Vacuum ExcavationVacuum Excavation

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CIPP (Cured in Place Pipe)CIPP (Cured in Place Pipe)

• Method to rehabilitate existing pipe’s internal functionality without total pipe replacement

• Uncured material is introduced into host pipe; material is then inflated until contact is made with entire inside diameter of host pipe. New material is cured with steam or hot water.


Before

CIPP (Cured in Place Pipe) CIPP (Cured in Place Pipe)

Material ready for installation

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CIPP Curing ProcessCIPP Curing Process


After

Additional Trenchless MethodsAdditional Trenchless Methods

• Pipe Reaming - a system that was developed to utilize a directional drilling unit, specialized tooling and techniques to grind and remove the existing pipe as the replacement is pulled into place.

• Pipe reaming offers an alternative to abandoned facility removal.

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Pipe ReamingPipe Reaming

Pipe ReamingPipe Reaming

ArrowboreArrowbore

• Arrowbore – Patented Horizontal Directional Drilling Construction Method Technology that allows very precise line and grade control for installations of gravity flow lines

• Because Arrowbore uses HDD as the primary construction technique, surface disturbance is substantially reduced when compared to traditional open trench sewer installations

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Arrowbore Vertical Casing Arrowbore Vertical Casing InstallationInstallation

Arrowbore Arrowbore –– the Key to On Grade the Key to On Grade InstallationInstallation

Arrowbore ProcessArrowbore Process

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Cost ComparisonCost ComparisonOpen Excavation Fuel Consumption Verses The Patented ArrowBore Method

“Green Solutions for Today’s Environment”

Excavate and install 15 foot deep, with backfill only ArrowBore and install 15 foot deep"This doesn't include the cost of restoration". "90% less restoration"Gallons per day Gallons per day

125 Excavator #1 5 Vertical drilling rig100 Excavator #2 10 Horizontal drilling rig

50 Front end loader 3 Mini Excavator10 Uni Loader 4 Fluid mixing system40 Two dump trucks 5 Portable vacuum15 Misc. Pumps, generators, ect. 15 Truck vacuum 1/2 day20 Pickup trucks 15 Pickup trucks0 Dewatering System 00 Setting up the dewatering system 00 00 0

360 Total gallon per day 57 Total gallon per day

$3.00 Diesel fuel price per gallon $3.00 Diesel fuel price per gallon

$5,400.00 Fuel cost per week $855.00 Fuel cost per week

36 Weeks per year (9months) 36 Weeks per year (9months)

$194,400.00 Fuel cost per crew per year $30,780.00 Fuel cost per crew per year

FUEL SAVING PER YEAR PER CREW

$163,620.00 Open Cut Crew

$110,700.00 Restroation Crew

$243,540.00 Total Savings

All Trenchless Methods Are All Trenchless Methods Are Intended to Get Us from This..Intended to Get Us from This..


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To This..To This..

Arrow Bore installation

Locating UtilitiesLocating Utilities

Underground utilities can be located using this method…

Locating UtilitiesLocating Utilities

Unfortunately, there are many utility lines under pavement that need to be visually located prior to any trenchless activity andto avoid this…

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Keyhole, Coring and Reinstatement Keyhole, Coring and Reinstatement ProcessProcess

• This process involves core drilling through pavement cross section then using vacuum excavation to remove sub grade material until utility in question is found.

• Sub grade is then replaced and previously removed core is bonded back into place providing a waterproof virtually invisible repair.

Keyhole/Coring/ReinstatementKeyhole/Coring/Reinstatement

Core drills can be small or large

As can the vacuum unit…

The “Keyhole” processThe “Keyhole” process

• “Keyholing” can not only be used for utility exploration investigations but for utility repairs as well. Long – handled tooling has been developed that allows certain types of repair work to be accomplished while on the street surface…

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Repairs Being Made Through Repairs Being Made Through KeyholeKeyhole

Core ReinstatementCore ReinstatementBackfill & CompactBackfill & Compact Bonding CompoundBonding Compound

Core PlacementCore Placement Finished RepairFinished Repair

The Finished ProductThe Finished Product

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CoringCoring--Keyhole ProcessKeyhole Process

Which would you prefer on your streets?

Sustainability Benefits from Sustainability Benefits from Trenchless TechnologyTrenchless Technology

• Significantly reduced surface disturbancetherefore significantly reduced restoration costs

• Significant reduction of inputs needed (i.e. fuel, asphalt, pieces of equipment, manpower, etc.)

• Significant reduction in traffic impact• Significant overall reduction in carbon footprint

of project

• Many methods require little or no additional ROW to be used

Sustainable Construction Sustainable Construction Techniques (Concepts) for Utility Techniques (Concepts) for Utility

InstallationsInstallations

• Shared Trench

• Common Trench

• BDN (Buried Duct Network)• Nojitech

• Duct Banks

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Why use these methods?Why use these methods?

To Avoid This…To Avoid This…


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Or ThisOr This

Shared TrenchShared Trench

• Two or more utilities agree to construct their facilities in the same excavated trench.

• This agreement saves all utilities who participate;

• Construction cost including restoration cost• Reduces carbon footprint• Reduces the area of right of way used


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Common TrenchCommon Trench

• Semi-Engineered trench in which two or more utilities agree to co-locate in the same trench. Locations within the trench are established based on clearances and depths that each utility requires.


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A Different type of Shared TrenchA Different type of Shared Trench

BDN (Buried Duct Networks)BDN (Buried Duct Networks)

• BDN’s overlay a minimum number of empty ducts on top of or next to direct buried cables for future expansion or replacement of damaged direct buried cables.

• Can be used by one utility operator or as extra space for future providers.

• The BDN can hold from 2 to 8 ducts ranging in size from 2” to 6”.

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BDN (Buried Duct Networks)BDN (Buried Duct Networks)

BDN (Buried Duct Network)BDN (Buried Duct Network)

BDN Installation Over Existing BDN Installation Over Existing UtilitiesUtilities

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BDN Installation Along Side BDN Installation Along Side Communications ProjectCommunications Project

Nojitech Raceway SystemNojitech Raceway System

• Multiple square sectioned PVC tubes placed in an outer casing that is either fire proof or has high weight tolerance.

• Connection design is simple, requiring four bolts to secure sections.

• Designed for quick and safe installation saving time and money.

Nojitech Raceway SystemNojitech Raceway SystemSpider SeriesSpider Series

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Nojitech Raceway SystemNojitech Raceway SystemSpider SeriesSpider Series

Nojitech Raceway SystemNojitech Raceway SystemGopher SeriesGopher Series

Nojitech Raceway SystemNojitech Raceway System

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Duct BanksDuct Banks

• Engineered with input from all existing utilities in the area where the duct bank will be constructed.

• Can be designed for any number or combination of compatible utilities.

• Installation cost can be shared in a number of ways to facilitate participation in the duct bank.

Duct BanksDuct Banks

• Each utilities' cost is proportional to the size and amount of ducts they require.

• How are cost savings attained:• One trench• One contractor doing construction• One location for all utilities

• One restoration effort

Japan’s Concrete Box TunnelJapan’s Concrete Box Tunnel

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European Duct TunnelEuropean Duct Tunnel

Open Trench Installed Open Trench Installed Communications and Electric Power Communications and Electric Power

Duct BankDuct Bank

Duct Bank for Ontario Highway Duct Bank for Ontario Highway ProjectProject

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Lenexa Duct BanksLenexa Duct Banks

• Lenexa has been incorporating duct banks with some road projects since 1998

• The construction of these duct banks has changed 4 times over the last 13 years

• The change of design was the result of more cooperation with the utility companies.

• New design characteristics will be added to future duct bank projects.

Duct Bank Duct Bank –– 33rdrd GenerationGeneration

Duct Bank Prairie Star ParkwayDuct Bank Prairie Star Parkway

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8787thth Street Duct BankStreet Duct Bank

• Road project the first phase of a 240 acre mixed use development project.

• Project took two years to design.

• City and design engineering firm meet with each utility 7 to 10 times during design to layout duct bank locations.

New Road AlignmentNew Road Alignment

8787thth Street Duct Bank Configuration Street Duct Bank Configuration

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8787thth Street Duct Bank Vault Street Duct Bank Vault Location #3Location #3

8787thth Street Duct Bank Vault location Street Duct Bank Vault location #1#1

Duct Bank 87Duct Bank 87thth StreetStreet

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Duct Bank 87Duct Bank 87thth Street Intersection Street Intersection ConnectionsConnections

8787thth Street Intersection SweepsStreet Intersection Sweeps

Manhole PlacementManhole Placement

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Hand Holes and Vaults Hand Holes and Vaults

8787thth Street Power ManholeStreet Power Manhole

Power ManholesPower Manholes

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Power Duct and ManholePower Duct and Manhole

Power Duct Bank Power Duct Bank

Questions ?

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Murv Morehead City of Overland Park

[email protected]

Monty ZimmermanCity of Lenexa

[email protected]

sustainable utility construction: methods and techniquessustainable utility construction: methods...

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