Guidelines for the application of pipe bursting
Nov 14, 2007
The number of pipelines to be repaired is ever increasing worldwide – e.g. in Germany, important pipeline rehabilitation projects are not carried out due to the devastating financial situation of the municipalities. Although this problem cannot be resolved completely, economical technologies can contribute toward repairing at least the worst damages. In general, it has to be decided whether repair, renovation or pipe renewal (replacement) is required. A pipe replacement is necessary:when repair or renovation is technically or economically inappropriatewhen the hydraulic capacity has to be improved by a greater pipe diameterwhen repair or renovation offers only a short term solution with a pipe replacement being inevitablewhen there is request for a long lasting pipe durability and or a higher product life spanwhen the static loading capacity of the defective pipe would be otherwise negatively affected
- Hydraulically operated static pipe bursting with ladder shaped Quicklock rods (Figure 1)
- Pneumatically operated dynamic pipe bursting with piercing tools or rammers.
The following phases are essential for the successful performance of pipe bursting:
- Planning phase
- Preparation phase
- Performance phase
- Completion phase.
- meticulous inspection of the existing host pipe and joints condition (including CCTV),
- survey of existing pipes and other underground structures in the proximity of the host pipe,
- ground survey in the periphery of the host pipe and
- determination of the new pipe and joint material and their dimensions (same diameter or larger).
A careful inspection of the host pipe proposed for replacement should include:
1.1.1 Pressure pipes
- Material and any changes of material
- Nominal diameter and any changes of diameter
- Replacement length
- Depth of ground cover (distance between the crown of the [new] pipe and the ground surface or river bed)
- Distance between the host pipe and adjacent underground structures, parallel or crossing pipes in close proximity
- Changes in pipe line direction, horizontally or vertically offset pipes
- Joints and connections
- Fittings, pipe clamps, valves, syphons, etc.
- Types of damages, i.e. of pressure pipes, particularly incrustations, deposits, etc.
- Obstacles in the pipe bedding (e.g. concrete surrounding host pipe)
- Space available for crew, material and equipment, etc.
- Material and any changes of the material
- Nominal diameter and any changes of the diameter
- Replacement length
- Depth of ground cover (distance between the crown of the [new] pipe and the ground surface or river bed)
- Distance between the host pipe and underground structures, parallel or crossing pipes in close proximity
- Changes in pipe line direction, horizontally or vertically offset pipes, bends
- Laterals and lateral joints (angles, location, depth, function, etc.)
- Types of damages, e.g. cracks, fractures, breakages, sags, slab-outs (missing pipe fragments), deformations, root infestations, pipe collapses, blockage debris, etc. (CCTV inspection necessary)
- Soil conditions, groundwater level
- Obstacles in the pipe bedding (e.g. concrete surrounding host pipe, old manholes, foundations, carriers, sheet pilings, sheeting material, etc.)
- Host pipe gradient
- Space available for crew, material and equipment, etc.
The following minimum criteria must be observed when selecting a new pipe to be installed by pipe bursting:
- Material, maximum admissible strength
- Nominal diameter, hydraulic capacity
- Type of pipe joints
- Surface cover
- Short pipe/long pipe/pipe in coils or on drums, etc.
The contractor should always be aware of existing pipes or other structures when working underground. This could include:
- Gas- or water mains and service pipes
- Electric cables
- Sewage mains and laterals
- Telecommunication lines
- District heating systems
- Traffic guidance systems
- Pipes for military purposes, e.g. fuel lines
- Other pipes, e.g. pipes for special chemicals, oil and gas pipelines, pneumatic post systems, etc.
When all information about the host pipe and soil conditions are available and it is feasible to actually install the selected new pipe applying dynamic pipe cracking or static pipe bursting, the principal (network owner) usually first invites bids to be submitted before awarding the pipe bursting contract.
- In the UK, there is specific requirement regarding a certification, however, manufacturers like TTUK Ltd. offer assessment and special operator training for pipe bursting. Successful participants are awarded City & Guilds certification. This qualification forms part of the City & Guilds 5831 Utilities Operations Scheme – Trenchless Technology. More and more network owners insist on contracting companies having trained and certified personnel.
- In Germany: Replacing gas and water pressure pipes a DVGW certification in the supplementary certification group GN 3 or AGN 3 according to DVGW GW 301 (A) „Qualifikationskriterien für Rohrleitungsbauunternehmen“ (Qualification criteria for pipe line installation contractors) or GW 302 (A) „Qualifikationskriterien an Unternehmen für grabenlose Neulegung und Rehabilitation von nicht in Betrieb befindlichen Rohrleitungen“ (Qualification criteria for contractors of trenchless new installations and renewal of pipes out of service). Replacing sewer pipes requires a certificate according to Gütesicherung (quality assurance) RAL-GZ 961 of the Gütegemeinschaft „Herstellung und Instandhaltung von Abwasserleitungen und -kanälen e.V.“ (Quality association “Installation and maintenance of sewer mains and laterals”)
- In the USA, requirements run the full spectrum from no qualifications to very detailed experience and qualification statements, references to past similar projects and acknowledgment of licensing by Advantica (not in effect any longer). The requirements are usually local and are not mandated by the federal or state governments.
Just as important as the existence of certificates are
- a well trained and experienced crew (evidence of continued education at regular intervals) and
- holding suitable machine technology.
Basis for the selection of a pipe bursting rig or hammer is the new pipe diameter in relation to the host pipe diameter. Will the replacement be size-for-size or has the host pipe to be upsized? The required performance of the machine (Table 1) is the result of these considerations. The selection of the dimensioning of the new pipe takes place according to the relevant regulations. It is important, that the loads affecting the new pipe during installation (pipe bursting process), are also taken into account.
Host pipe ND [mm/inch]th> | Recommended pulling capacity [kN/US to] | Recommended bursting hammer: Diameter [mm/inch] |
---|---|---|
250 12" | 400 kN 44 US ton | 130, 145, 180 mm 5", 5¾, 7" |
ND 250 - ND 400 ND 12" - ND 16" | 770 kN 85 US ton | 220, 260 mm 8½", 10" |
ND 400 - ND 600 ND 16" - ND 24" | 1250 kN 138 US ton | 350, 450 mm 14", 18" |
ND 600 - ND 1000 ND 24" - ND 39" | 2500 kN 275 US ton | 450, 600 mm 18", 24" |
After having determined the dimensions of the new pipes and the expander, the upsize coefficient (Figure 2) is determined. Upsize coefficient indicates the difference between the outer diameter of the expander minus the internal diameter of the existing host pipe.
The upsize coefficient helps to calculate the necessary minimum distance to adjacent existing pipes and structures and the required depth of cover.
Example: Internal diameter of the host pipe 150 mm (6"), outer diameter of the expander 225 mm (9") to install new pipe outer diameter 200 mm (8"): This results in the upsize coefficient: 225 – 150 = 75 mm (9" – 6" = 3").
Independent of the depth of cover, the installation depth of the host pipe influences the choice of pipe bursting equipment, because with increasing depth
- the surface friction of the new pipe increases,
- upsizing by several nominal diameters becomes more difficult,
- the achievable pipe bursting lengths become shorter.
If in sporadic lengths the distance to adjacent and crossing pipes is critical it is advisable to observe these converging areas by opening small pits by means of manual trial holes.
After having determined the required capacity of the pipe bursting rig or hammer and making sure that soil conditions and the distances to existing pipes and structures allow the installation of the desired new pipe, the next step is to determine the individual replacement lengths and the position of the required launch and exit pits.
The feasible pipe bursting section length depends on the upsizing degree, diameter and the type of new pipe (Table 2 and Table 3). The soil conditions also play a crucial role.
Launch/exit situation | News pipe | New pipe nominal diameter | Method | Max. burst section length |
---|---|---|---|---|
a) Gas and water mains | ||||
Pit/pit | Long pipe | 800 mm 31" | Static | 200 m 660 ft |
600 mm 24" | Dynamic | 200 m 660 ft | ||
b) Gas and water service pipes | ||||
Pit/pit pit/cellar | Long pipe | 100 mm 4" | Static | 60 m 197 ft |
Pit/pit pit/cellar | Long pipe | 100 mm 4" | Static replacement | 25 m 82 ft |
Pit/pit pit/cellar | Long pipe | 100 mm 4" | Static replacement | 25 m 82 ft |
Pit/pit pit/cellar | Long pipe | 100 mm 4" | Dynamic | 60 m 197 ft |
Pit/pit pit/cellar | Long pipe | 100 mm 4" | Dynamic replacement | 15 m 19 ft |
Launch/exit situation | News pipe | New pipe nominal ∅ | Method | Max. burst section length |
---|---|---|---|---|
a) Sewerage | ||||
Manhole/ manhole | Short pipe | 300 12“ | Static | 70 m 230 ft |
200 8“ | Dynamic | 50 m 165 ft | ||
Manhole/pit | Short pipe | 300 12“ | Static | 70 m 230 ft |
Pit/manhole | Short pipe | 300 12“ | Static | 70 m 230 ft |
Long pipe | 300 12“ | 100 m 329 ft | ||
Short pipe | 300 12“ | Dynamic | 50 m 165 ft | |
Long pipe | 600 24“ | 70 m 230 ft | ||
Pit/pit | Short pipe | 1000 39“ | Static | 150 m 493 ft |
Long pipe | 1000 39“ | 200 m 657 ft | ||
Short pipe | 300 12“ | Dynamic | 70 m 230 ft | |
Long pipe | 1000 39“ | 200 m 657 ft | ||
b) Laterals | ||||
Manhole/ manhole | Short pipe | 150 6" | Static | 60 m 197 ft |
150 6" | Dynamic | 60 m 197 ft | ||
Pit/pit pit/cellar pit/manhole | Long pipe | 150 6" | Static | 60 m 197 ft |
150 6" | Dynamic | 60 m 197 ft |
a) Pressure mains and service pipes
- Method (static or dynamic pipe bursting)
- Description of renewable sections with consecutive numbering
- Section lengths
- Nominal diameter of the host and new pipe
- Material of the host and new pipe
- Soil type/soil properties
- Any method-specific information
- Any existing crossing or parallel pipes or structures
- Any changes in pipe line direction, horizontally or vertically offset pipes,
- Any existing service connections including connections out of use
- Access and excavation permits
- Coordination with any other construction projects, etc.
- Method (static or dynamic pipe bursting)
- Description of renewable sections with consecutive numbering
- Section lengths
- Nominal diameters of the host and new pipe
- Material of the host and new pipe
- Soil type/soil properties
- Any method-specific information
- Any existing crossing or parallel pipes or structures
- Any changes in pipe line direction, horizontally or vertically offset pipe
- Any existing laterals including laterals out of use
- Groundwater conditions, including groundwater control measures
- Mean sea level (MSL) of existing structures and connections
- Level and inclination of host pipe . Flow direction and gradient
- Hydraulic conditions
- Overpumping or bypass to ensure continued effluent disposal
- Access and excavation permits
- Coordination with any other construction projects, etc.
After all relevant details have been defined in the planning phase, it is the time to carry out the actual pipe bursting process. All preparations and set-up must be well planned in all details and in good time. Many questions should be clarified beforehand in order to avoid adverse effects, difficulties and delays. The arrangements on the jobsite should guarantee a safe operational performance without general disturbance. Examples:
- What kind of permits have to be obtained and for what duration? Which authorities are in charge? Who is responsible? Is it necessary to heed any special regional or environmental regulations (i.e. permitted working times, pit regulations or demands by residents)?
- Which information has to be given to the local residents?
- How are the traffic conditions on the jobsite? What measures must be taken to secure and regulate traffic? Is the jobsite easily accessible?
- What kind of machinery, equipment and material is needed? Are the machines and equipment ready and reserved for operation on the planned date? Will all required materials (i.e. backfill for the working pits) be delivered on time?
- Are there any space restrictions? Is the available storage space sufficient? Particularly within the pit area? Where can the Power Pack units be stored? Are the supply hoses long enough? Where can the bursting rod boxes be stored, if applicable?
- Where are convenient storage conditions? Where can the product pipes be stored? How are they laid out?
- What kind of bursting tools, expanders and pipe pullers are intended to be used? Are they suitable and in working order? Are alternative tools also available on site?
- Is there any support personnel and/or are lifting devices available for transporting heavy parts (e.g. like expanders)?
- How can water and electricity be provided if the need arises?
- Is it necessary to take groundwater control measures?
- Are all documents concerning ground investigations available, have all existing pipes and structures been recorded and marked? Are further obstacles to be expected? Are the complete jobsite drawings available (e.g. installation plans, etc.)?
- Which are the reference points for the subsequent mapping of the new pipe?, etc.
After the jobsite is finally set up, the working pits (Exit pit = machine pit, intermediate pits if required, starting pit = pipe launch pit) are prepared and shored in accordance to the existing regulations. Examples:
- UK: Health and safety in excavations ´Be safe and sure´ HSG185 (which comes under the construction regulations ´Managing Construction for Health and Safety ´)
- Germany: DIN 4124 and the relevant accident prevention regulations
- USA: OSHA, State and local regulations, shoring over a certain depth, 6 m (20’) or more is required to be Certified by a structural engineer.
Intermediate pits may become necessary as soon as bends, laterals, service pipes and other known obstacles are expected to obstruct the pipe bursting process, but also when new connections need to be integrated. When working in areas with groundwater, the working pits must be secured to prevent any water ingress.
Static burst rig | Minimum machine pit length |
---|---|
400 G | 3.00 m (10 ft) |
800 G | 4.00 m (13 ft) |
1250 G | 6.00 m (19.5 ft) |
2500 G | 9.00 m (29.5 ft) |
After the working pits have been prepared, the pipe replacement section must be separated from the network and the service pipes or laterals and any possibly existing pipe tees in a working pit. They have to be cut back sufficiently to avoid damage during the pipe bursting process.
For gas and water pipes, disconnection and taking out of service has to be carried out according to the relevant regulations for gas and water pipe installation/maintenance. Should the need arise, a substitute supply must be arranged. If the host pipe is asbestos-cement specific personnel safety measures have to be considered when taking the pipe out of service.
Quite often for the renewal section and the laterals a substitute effluent disposal measure must be installed. The effluent disposal can be maintained by over pumping or bypassing or even blocking the upstream pipe during the downstream pipe bursting process.
2.7.1 Pipe bursting equipment
Every day before starting to operate, the bursting equipment must be checked regarding its completeness and maintenance condition. This is valid for all jobsite safety facilities and lubricants as well as consumables. Even before the equipment is transported to the jobsite, all important parameters should be checked by using a check list and the instructions and recommendations given by the manufacturer.
In some countries (e.g. Spain, Germany) the pulling forces directly affecting the new pipe must be monitored from the front end of the new pipe during the entire static pipe bursting process. In the US Gas industry, it is normal to pull new pipe with some sort of a “weak link”. Water and Sewer projects have not required this, yet. Chart recorders, data loggers are going to become more noticeable. In several other countries this quality control procedure is expected to be standardised in the near future. However, tensile force measurement is not possible with the dynamic pipe cracking method. Therefore, the use of an alternative overload in-line pipeline protection (“weak link”) can be used for that purpose (also for static pipe bursting), whereby the pipe breaks before the permissible tensile stress of the pipe rises above manufacturer specified load. The cross-sectional area of the overload pipe protection for PE-pipes, for instance, must not exceed a maximum of 40% of the cross-sectional area of the new pipe.
- New pipe PE 100, OD = 200 mm (8"), ID = 163.2 mm (6.4"), wall thickness s = 18.2 mm (0.72") = SDR 11
- Cross-sectional area A of the new pipe = 10.366 mm2 (16.04"2)
- Cross-sectional area Amax of the overload protection = 0.40 · 10.366 = 4.146 mm2 (6.43"2)
- by slots spread evenly over the circumference of the pipe (Attention: to prevent dirt from entering!) or
- by using a pipe section (Attention: must be same material!) with a smaller wall thickness. In our example, one would take a PE pipe OD 200 mm (8") SDR 33 with a wall thickness of 6.2 mm / 0.24" (A = 3.773 mm2 / 5.85"2 < 4.146 mm2 / 6.43"2). A PE pipe section, turned-out internally, can also be used as another alternative.
The specifications of the new pipe material to be installed must be available on site even before the material is delivered. Upon delivery, the specifications must be immediately compared with the information printed on the new pipes. A visual inspection of the delivered material is absolutely necessary in order to make sure the pipes are not damaged. Faulty pipe and/or damaged surface coating material should never be installed. However, some surface spot repairs may be permissible.
If the result of the inspection of the host pipe shows obstacles that might affect or aggravate the pipe bursting process, these must be removed before the process starts. Reduction of the host pipe profile due to incrustation, etc. needs no correction, as long as there is enough space to pull in a winch cable or push in the bursting rods.
It may become necessary, however, to clean the host pipe, if there is a risk of freeing substances which are hazardous from an environmental point of view (e.g. in some places the contents of gas pipes, tar, creosotes, stabilising agent residues, phenolic dusts). In such cases, cleaning must be performed as carefully as possible to avoid the release of these substances. Keep an eye on condensate collectors and extenders.
Any known concrete beddings and partial or complete concrete casings surrounding the host pipe which prevent the use of pipe bursting are to be removed by using excavations.
Having prepared the working pits and disconnecting the host pipe from the network, the pipe bursting equipment can be installed:
- Static pipe bursting: First, the bursting rig is safely installed in the machine pit (Figure 3) and fixed against the reacting forces. If the rig has a telescopic pipe recovery frame, this remains completely jacked-in during the bursting process. Assisted by a guide rod, the quick-lock rods are then pushed into the host pipe (Figure 4).
- Dynamic pipe cracking: Before dynamic pipe cracking can commence, the constant tension hydraulic twin capstan cable winch has to be safely installed in the exit pit or manhole and fixed against the reacting forces. Then the winch cable is pulled in to the host pipe using a flexible fibre rod.
- by utilising QuickLock rods with hydraulic tensioner “Burstfix” (Figure 8), for static pipe bursting;
- by utilising a chain with hydraulic tensioner “Spannfix”, for dynamic pipe cracking,
- by utilizing restrained joint pipe such as Ductile Iron, example; TR Flex Joint (US Pipe & Foundry). This allows for pulling instead of pushing the column of new pipe. Other restrained joints for PVC is Certainteed’s CertaLok as an example.
After the winch cable and bursting hammer respectively bursting head and QuickLock rods have been connected to the new pipe string, the bursting procedure and the simultaneous pipe pulling can begin. Whenever long pipe strings are installed, great care must be taken to avoid disruption of traffic on the roads. The pipe string should slide on rollers laid on the road surface in order to protect the outer coating from damage. When entering the working pit and the underground, or whenever sliding over sharp edges, the new pipe must be protected by means of deflection rollers or lead-in funnels.
On recovery of the bursting equipment, the required inspections can now take place. The exact kind of visual and technical tests and inspections to be carried out and recorded depends on the type of pipe line installed. The bare pipe sections lying exposed in the pits, at least every 100 m (329 ft), should always be visually examined for possible deformation or damage, no matter what kind of pipe has been installed. A CCTV inspection is also an option, if required.
- Pressure pipes: Before the pipe can be put into service (again) a pressure test according to the local regulations is usually obligatory.
- Sewage pipes: Visual inspection (CCTV) and a leak test according to the local regulations must be performed.
If the testing and inspecting of the renewed pipe ends with satisfactory results, the pipe must now be re-integrated into the existing pipe network, the service connections and laterals which had been disconnected for pipe bursting can be re-connected. This has to be done in accordance with the relevant technical standards valid in the different countries.
- Pressure pipes: Integration and putting the renewed pipe section back into service is executed according to the local gas and water regulations.
- Sewage Pipes: The integration of the renewed sewer pipe into the manhole must be absolutely water tight. Laterals are reconnected in working pits. If the replacement method was close fit pipe bursting, laterals can be re-connected by means of robotic technology, provided the new sewer main is minimum DN 200.
The final steps of a pipe bursting job are refilling the working pits and restoring the original state of the ground surface. (Note: The new pipe that is exposed in launching, receiving or other pits must be carefully backfilled and compacted to prevent deflection of the pipe. This usually is revealed by CCTV inspection.) These final tasks must also be performed strictly by professionals and to the local regulations if not, damage like ground settlement may occur. This could unfairly be blamed on the pipe bursting method. It goes without saying that the jobsite has to be left in a perfectly clean and orderly condition.
[2] Emmerich, P., Schmidt, R.: Erneuerung einer Ortsnetzleitung im Berstlining-Verfahren [Renewal of a local net line with the pipe bursting method], FGR Gussrohrtechnik issue 39, 2005
[3] Schill, J.: Bursting around the bend, Underground Construction, October 2004
[4] Gardener, N., Rameil, M.: Guidelines for the Use of Pipe Bursting: Pipe bursting method for trenchless replacement of cast iron and ductile steel pipes, No Dig International Conference, Hamburg 2004
[5] www.nodig-construction.com
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Contact
Dipl.-Ing. Meinolf Rameil [Technical Director, Tracto-Technik GmbH, Lennestadt (Germany)]
57368 Lennestadt (Germany)
Phone:
+49 (0)2723 808-187