March 2010, Issue 64 PipeLine - HOBAS PIPE USA · MCUA was founded in 1950, in part to protect and...

March 2010, Issue 64

Contents1 I Long Life Key to Deep Tunnel Force Main5 I Lowest Installed Cost for Augusta8 I Product Profile: Wide Use and Acceptance10 I Culvert Repair in Michigan

Long Life Key to Deep Tunnel Force Main

PipeLine

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Two shafts over 70 feet deep were located on either side of the Raritan River.

It has been an ongoing priority of the State of New Jersey to improve its infrastructure for their 8.6 million residents. Overseeing the infrastructure improvements is the New Jersey Department of Environmental Protection (NJDEP), the government agency responsible for managing the state’s natural resources and pollution control issues.

A recent project undertaken by the Middlesex County Utilities Authority (MCUA), “Edison Force Mains/Edison Pump Station Upgrade,” consists of three phases of work which will be completed under the terms of three separate contracts: Phase One - Edison Pump Station Transformer Relocation; Phase Two - Construction of Tunnel and Edison Force Mains; Phase Three - Edison Pump Station Upgrade. This project is by the New Jersey Department of Environmental Protection and the New Jersey Environmental Infrastructure Trust.

MCUA was founded in 1950, in part to protect and enhance the vital marine habitat in the Raritan River and Bay by collecting and treating wastewater from nearly 800,000 people. Similar to many utilities, MCUA is charged with the upkeep of their aging infrastructure with dwindling dollars.

This project is part of an overall goal to provide a redundant means for sewage conveyance from MCUA’s Edison Pump Station (85 MGD) to their Central Wastewater Treatment Plant (400 MGD). The project consists of two parallel 3,940-foot long pipelines constructed in a tunnel beneath the 3,000-foot wide Raritan River and some shorter connections constructed in open trench excavations on the pump station and treatment plant grounds.

Under Phase Two, a 3,940 linear foot, 15-½ -foot diameter tunnel was constructed under the river. This tunnel has several uses with the most important being the connection of the Edison Pump Station, one of five contributing pump stations, to the Central Wastewater Treatment Plant. Within the primary tunnel are two parallel force mains. The new dual force main will replace MCUA’s existing 60-

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inch diameter Arsenal Force Main, which was installed in 1969. The existing line made of prestressed concrete cylinder pipe (PCCP) is supported on piles and is located several feet below the riverbed which is a navigable and dredged river maintained by the Army Corps of Engineers. The Arsenal Force Main accepts continuous flow of wastewater from the northern part of the county serving over 200,000 people. Since the pipeline has been in continuous service for 40 years with no ability to be inspected internally or externally, there was concern that the prestressing wire could fail, causing a catastrophic pipe failure and an uncontrolled discharge of raw sewage into the river.

To avoid the risk of a system failure, the NJDEP through an Administrative Consent Order required MCUA to construct a new redundant pipeline under the Raritan River. The first design concept was to build a tunnel in lieu of open-cutting the river and install a single 60-inch diameter pipe and after it was placed into service rehabilitate the existing PCCP

pipeline to develop a dual pipeline system. After researching

potential rehabilitation

techniques and the possible cost and risk to rehabilitate a 40-year-old pipeline, it was determined the most practical and economical solution was to enlarge the new primary tunnel diameter and install two new pipelines in lieu of rehabilitating the older PCCP pipeline. The new redundant line will allow for one line to be shut down and inspected or repaired without flow disruption providing for a safe, long-term solution.

Hatch Mott MacDonald of Freehold, NJ, was hired to design the new system. Angelo Bufaino, PE, Senior Project Engineer of the firm, explained their concerns, which included both installation and long term performance criteria. “MCUA wanted a pipe that was corrosion resistant both inside and out. Since the line was carrying raw sewage, the Authority wanted a pipeline that would be resistant to sulfuric acid, the byproduct of hydrogen sulfide gas. Additionally, the pipe was to be installed within a damp tunnel and partially encased in concrete and there would be no means to perform external repairs if external corrosion occurred. Centrifugally cast, fiberglass reinforced, polymer mortar (CCFRPM) and high-density polyethylene (HDPE) were the only two pipes considered to meet both internal and external corrosion resistance. HDPE presented a concern in installation because of potential thermal expansion and contraction with varying wastewater temperatures. CCFRPM had the better thermal properties,” explained Bufaino. Aside from the design aspects, because the pipeline was being constructed within a 3,900-foot-long tunnel, it had to be light enough to be transported through the tunnel and lifted to be set to grade. “The CCFRPM pipe provided benefits with regards to weight and jointing, making installation easier,” said Bufaino.

Due to these reasons, CCFRPM pipe was the only material specified for the force main.

Kenny Construction Company, headquartered in Northbrook, IL, was awarded the tunnel portion of the project and purchased the 7,785 linear feet of 60-inch, 100-psi pressure class, 46 stiffness pipe from Hobas Pipe USA. Kenny Construction had utilized the product on several past projects.

All pipes were installed from the Southeast shaft, located on the Sayreville side of the Raritan River.

Year of Construction 2009Total length of pipe 7,785 feetDiameter 60 inchStiffness class 46 psiPressure Class 100 psiInstallation method Two Pass Tunnel

Application Sewer force mainClient Middlesex County Utilities AuthorityContractor Kenny Construction CompanyAdvantages Corrosion resistant, lightweight and leak-free joints


Successful ConstructionTwo deep access shafts were required on each side of the Raritan River. Kenny Construction Company (KCC) subcontracted Bencor Corporation of America, a specialist in deep foundation work, to construct the shafts. Slurry wall construction methods were used to create the Southeast 36-foot diameter, 87-foot deep launch shaft and the 28-foot diameter, 70-foot deep Northwest receiving shaft. “In lieu of the specified jet grouted plug below the base slab to prevent soil heaving at the Southeast Shaft, Kenny Construction chose to excavate the final 15 feet of the shaft under water. Upon reaching an excavation depth of 70 feet, the shaft was flooded and the remaining 15 feet of soil was excavated underwater.

Commercial Diving was then brought on site and divers were used to verify the depth of the excavation as well as to set the final rebar mat and place the tremie concrete slab,” stated Bob Rautenberg, project manager for Kenny Construction Company. The two shafts are permanent and will remain after the project is completed.

The MCUA decided to leave the tunnel partially open to permit inspection of the pipelines and to permit future utilities to use the corridor to cross the 3,000-foot-wide Raritan River. In the final construction two additional 16-inch diameter HDPE pipelines were installed to convey landfill gas across the river.

Once shaft construction was complete, the 3,900 linear feet of 15-½-foot diameter tunnel was built using a Lovat Earth Pressure Balance (EPB) tunnel boring machine. The EPB machine mined through various ground types including clay, sand, silt and gravel layers. Crews followed behind the tunnel boring machine, placing the 13-foot-4-¾-inch inside diameter, nine-inch thick precast gasketed concrete segments. The annulus void of approximately 3-5/8 inches was grouted as the machine moved forward.

“The Contract Documents specified the use of a pressurized face tunnel boring machine due to the presence of soft ground deposits and potential flowing soils under atmospheric conditions,” stated Julian Prada, the Resident

Engineer for Hatch Mott MacDonald on the contract. KCC chose to use an EPB boring machine for the tunnel construction due to the soft ground conditions. Soil was mined with a rotating cutter head, and a screw conveyor allowed the contractor to control the volume of soil excavated. By this process, the boring machine supported the ground during excavation, therefore balancing the earth pressure. Preservation of the in situ soil was especially critical since the existing 60-inch diameter force main alignment was within 15 feet at one point. “The 3,940-foot long tunnel hit its target for both line and grade,“ exclaimed Prada.

Once the primary liner was in place, installation of the carrier pipe began. “The entire line (twin force mains) was installed from the Southeast shaft, located on the Sayreville side of the river. The pipe was installed on two shifts with our best day having installed 20 pipes,” stated Rautenberg. Kenny Construction utilized a Caterpillar Telehandler, with a custom fabricated handling device, to bring the pipe into the tunnel.

“As the pipe was installed, each joint was air pressure tested to 75 psi for two minutes per the project specifications using a full circle pipe joint tester to ensure leak-free performance. Upon completion of the shaft piping, each of the lines was subjected to a hydrostatic test of 75 psi. The pipeline passed all tests without a single leak,” explained Rautenberg.

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Mr. Peter E. Kocsik, P.E., Vice President - Hatch Mott MacDonald, Mr. Angelo Bufaino, P.E., Associate - Hatch Mott MacDonald and Mr. Donato J. Tanzi, P.E. Chief Engineer - Wastewater Division M anagerMiddlesex County Utilities Authority (from left to right).

One of the original problems with the existing line was the limited access. For this newly designed and redundant system, the Authority established man access points to permit internal inspection of the pipeline. Epoxy coated steel T-base manway entry fittings with alloy hardware were installed at three points along each pipeline.

Full inspection of the pipeline can be conducted within 500 feet of every tee location, which was a criteria established by local fire rescue teams. The 60-by-42-inch diameter tees were manufactured by Smith Blair. CCFRPM was continuous through the T-base, with a 42-inch diameter hole cut for the access manway.

The next phase of construction included grouting the dual lines in place. A blocking scheme was designed and installed to anchor the pipe and resist the uplift. “With the blocking in place, the backfill plan called for the first lift of material to be a lightweight cellular grout with a density of 35 pcf. The cellular grout encased the pipe to eight inches below the spring line. Once the cellular grout was in place, both of the pipes were filled with water for ballast, and then encased to a point approximately four inches below the outside crown of the pipe with 4,000 psi structural concrete,” explained Rautenberg. This design allowed for a six-foot high open walkway along the center of the tunnel for future access.

The CCFRPM pipe in the tunnel was connected to 60-inch diameter ductile iron pipe risers at the Northwest and Southeast shafts. These risers connect to the surface piping and are under a separate contract in Phase Three.

Once installed, access to the pipe for future repairs would prove quite difficult at depths of 70 to 90 feet. Centrifugally cast fiberglass pipe’s successful history of tunneling projects, ability to withstand the corrosive environment and leak-free joints made the pipe ideal for this force main project.


Federal dollars through the Georgia State Revolving Fund have been awarded to the City of Augusta, Ga., to complete reconstruction of a portion of their sewer system with Hobas pipe. The project’s old concrete pipe was installed in the early 1960s. In 2000, the city engaged Stevenson & Palmer Engineering, Inc.’s Augusta office to perform a condition assessment of the troubled line. Engineers found that hydrogen sulfide (H2S) and sulfuric acid (H2SO4) had attacked the crown of the pipe, weakening the structure.

“This is a typical occurrence in concrete pipe where you have considerable hydrogen sulfide formation,” explained James A. Willson II, P.E. with Stevenson & Palmer Engineering, Inc. “Numerous conditions lead to hydrogen sulfide formation. The time that sewage remains in the line from the source to the treatment plant and biological reactions that occur through oxygen

Lowest Installed Cost for Augustadepletion are primary contributors.” Thiobacillus bacteria metabolize the hydrogen sulfides, which produce sulfuric acid as a byproduct. The sulfuric acid reacts with moisture along the exposed pipe sidewalls and attacks the concrete pipe surfaces. Repeated sulfuric acid attack can deteriorate the concrete pipe leading to exposed rebar and structural concerns.

Stevenson & Palmer Engineering was subsequently engaged to design the new gravity sewer for the line with this chemistry in mind. The recommendation was made to replace almost six miles of the city’s sewer system and abandon in-place the existing concrete sewer. The city did not have the funds to replace this entire length at one time, so the project was divided into two phases.

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CCFRPM’s proven track record was key in making HOBAS the base bid.


Year of Construction 2007 to 2010Total length of pipe 27,400 feetDiameter 24 to 84 inchStiffness cl ass 46, 72, 700 and 900 tonInstallation m ethod Direct bury and jackingApplication Sanitary Sewer

Client City of Augusta, Ga.Contractor Oscar Renda Contracting, Southland Contracting, John D. StephensAdvantages Quick installa-tion, proven track record

Choosing Hobas A number of factors led to Stevenson & Palmer specifying Hobas centrifugally cast fiberglass reinforced polymer mortar (CCFRPM) pipe for the replacement line. CCFRPM Pipe is highly resistant to the H2S and H2SO4 combination that caused the corrosive damage to the concrete pipe. CCFRPM pipe’s lighter weight compared to concrete and ductile iron makes transportation and installation easier and more economical than fully lined concrete. While high density polyethylene (HDPE) pipe and filament-wound fiberglass reinforced pipe (FRP) are also corrosion resistant relative to concrete and are comparatively lightweight, Hobas’ other benefits weighed into the selection.

It was CCFRPM pipe’s proven track record of successful North American service in corrosive and large diameter gravity sewer applications dating from the 1980s, their southern U.S. manufacturing location, and their easy-to-install push-together joints that triumphed over the more labor intensive installations, according to Mr. Willson.

“Although the CCFRPM pipe was expected to be bid at a higher material cost per lineal foot, the additional installation costs associated with HDPE pipe: the additional man-hours of field welding, backfilling operations, and lack of contractor experience installing HDPE pipe, make the installed cost of HDPE actually more expensive,”

said Mr. Willson. Stevenson & Palmer engineers were comfortable using Hobas’ product as the base bid and recommending CCFRPM pipe to the City of Augusta.

Phase IThe City of Augusta bid Phase I in late 2006, with Oscar Renda Contracting (ORC) of Roanoke, Texas, winning this $16 million contract to replace over 13,000 lineal feet, or about 2.5 miles of the line. Work began in February 2007 in the mid-city at the intersection of Laney-Walker Blvd. and New Savannah Rd. and proceeded southward through a light commercial zone. The line crossed Gordon Hwy./US 1 toward Doug Barnard Pkwy./GA SR Spur 56, following that route to its intersection with Dan Bowles. The contractor installed over 6,000 lineal feet of 63-inch diameter and 7,200 lineal feet of 72-inch diameter new CCFRPM pipe prior to decommissioning the existing 54-inch concrete pipe.

The Oscar Renda crew laid the new line parallel to the old line, adjacent at a distance of approximately 10 to 15 feet. The old line was replaced only at connection points: two main line junction boxes and three 36-inch tributaries, according to ORC project manager Dennis Bailey. About 6,300 feet (almost 1.2 miles) of the 63-inch diameter pipe were installed directly under New Savannah Rd.

AboveThe line was tested using a full circle pipe joint tester.

RightA short section of pipe with closure couplings is lowered into the trench


“We went right down the center of the street with it,” stated Bailey. “We had to keep access to all the businesses and residences, so we closed portions of the street and then backfilled with a temporary surface.” The faster installation of CCFRPM pipe as compared to other materials shortened the duration of inconvenience for local traffic by several weeks.

Southland Contracting was subcontracted to perform the directional bores: a 280-foot bore took the 72-inch diameter line under Gordon

Hwy./US 1; a 72-inch casing was bored 160 feet for 63-inch diameter CCFRPM pipe under the

Norfolk Southern railroad tracks, and a 116-foot bore for 48-inch diameter pipe under Doug Barnard Pkwy./GA SR Spur 56. Phase 2The City of Augusta’s plans for Phase 2, the completion of the replacement project, is currently under contract approval and will be constructed by John D. Stephens of Lawrenceville Ga. The city’s resources of funds were focused

on upgrading the Messerly Wastewater Pollution Control Facility, where the main

interceptor sanitary sewer discharges for final treatment. Stevenson & Palmer Engineering

assisted the City of Augusta in completing an application to receive funding under the American Recovery and Reinvestment Act (ARRA) economic stimulus for Phase 2 as a State Revolving Fund (SRF) project. Due to the competitive nature of the ARRA program, the city did not get selected for ARRA stimulus funds, but did qualify for a long-term, low-interest loan from GEFA backed by federal funds.

Phase 2, which begins where Phase 1 ended, at the intersection of Doug Barnard Pkwy./GA SR Spur 56 and Dan Bowles, will continue southeastward, terminating at the headworks of the Messerly Wastewater Pollution Control Plant near Augusta Regional at Bush Field Airport. It will involve the installation of approximately 9,000 lineal feet of 84-inch diameter and about 5,200 lineal feet of 72-inch diameter Hobas pipe. Two bores will be required. One will be a 210-foot direct jack and tunnel of 72-inch diameter CCFRPM pipe under Rocky Creek. The other will be a 335-foot direct bore will take

84-inch diameter CCFRPM pipe under Federal Highway I-520, the Bobby Jones Expressway.

By specifying CCFRPM as the base bid, the ARRA/SRF Stimulus “Buy American” requirement is met, since Hobas manufactures CCFRPM pipe at their manufacturing facility in Houston, Texas. The HDPE pipe specified as an alternate bid to ensure competitive pipe material pricing is manufactured in Canada. The city would have had to apply for an exception to the “Buy American” clause if the HDPE material bid at a relatively lower installed cost and was ultimately chosen.

The Phase 2 project, which bid July 14, 2009, is expected to break ground in February 2010. John D. Stephens’ bid came in well below the engineer’s opinion. Mr. Willson expects the changes in the economy since Phase 1 was built led to the bids being considerably lower than was initially budgeted. Bid tab results showed all bidders included a significantly higher cost to use the alternate pipe material (HDPE), confirming Hobas as the selected main interceptor pipe system.


IntroductionSince their introduction into the USA from Europe in the mid 1980’s HOBAS pipes have achieved wide use and acceptance here. HOBAS pipes have proven to be a premier performance product capable of solving problems and excelling in applications where other pipes cannot.

Environments• Sanitary Sewers• Sea Water• Industrial Effluents• Raw Water• Storm Drainage

Service Range• Gravity flow to 250 psi operating pressure• Burial depths over 80 feet• Full vacuum• Rated for highway, railway and aircraft loading

Installations• Open cut• Sliplining• Jacking• Microtunneling• Tunnel lining• Above ground

Product Profile: Wide Use and Acceptance

Bentonville, AR

Baltimore, MD

Kailua, HI

Wichita, KS

Albuquerque, NM

Dallas, TX

Tucson, AZ


SummaryThe use of HOBAS pipes is expanding rapidly, not only in the USA, but also around the world. Over 36,000 miles are in service worldwide, with production in 14 different countries.

ConclusionSpecify and use HOBAS centrifugally cast fiberglass pipes now, so you won’t be the last community to enjoy their many benefits.

AcceptanceUSA manufactured HOBAS pipes have been installed in nearly every U.S. state, Canada, Mexico and beyond. Total footage delivered by the end of 2009 exceeded 7 million feet. Most major USA municipalities now have HOBAS pipes in their systems.

Milwaukee, WI

Montgomery, AL

Los Angeles, CA

Wichita, KS

Shoreline, WA

Albuquerque, NM

Dallas, TX

Culvert Repair in Michigan

Year of Construction 2009Total length of pipe 500 feetDiameter 54 inchStiffness class 65 psiInstallation method Sliplining and direct buryApplication Storm drain

Client Macomb County, MIContractor Tyger Excavating, Inc.Advantages High strength, long-term solution

The existing drain lines failed, leaving a massive sinkhole.

“This is a case where corrugated metal storm drains that were installed in the mid-1940s

rotted away, blocking the flow of storm water and caused severe underground

soil erosion,” said Macomb County Public Works Commissioner, Anthony Marrocco.

The underground erosion caused by deteriorated pipe and wet sandy soils eventually created a 20-foot by 10-foot sinkhole and collapsing the

Cottrell Creek Drain. The 65-year old Cottrell Creek Drain accepts over 300

acres of drainage from Clinton Township and surrounding areas.

Clinton Township, located within Macomb County, has lots of older infrastructure to maintain. Tom Stockel, Construction Engineer with Macomb County Drain Commission, said, “A lot of our work is infrastructure; we are trying to do what we can do with the resources we have. We have been able to get some federal money for some projects.”

With so many lines to maintain, and funding as thin as ever, the ongoing maintenance of the many drains is enormous. “We have 800 or so drains in the county to maintain,

some open and some closed,” Stockel added. “This was one of those cases classified as an

emergency repair.” The commission chose to slipline the collapsed line with HOBAS pipe to prevent further damage.

Emergency RepairsGeneral contractor, Tyger Excavating, Inc. of New Haven, MI, which provides services including sewer, drainage, water, utilities, excavation and commercial subdivisions, was contacted and hired to perform the remediation work and repairs to the aging infrastructure. They started work on the line in September 2009, repairing the deteriorated pipe by sliplining with HOBAS CCFRPM (centrifugal cast fiberglass reinforced polymer mortar) pipes. The 20-foot-long sections of 54-inch diameter, 65 psi stiffness class HOBAS pipe were inserted into an existing 60-inch CMP. The pipes were manufactured with a flush bell spigot to ease installation into the deteriorated CMP.

Tyger installed the liner pipe in two runs of 250 linear feet each and utilized open cut installation methods for the 10-foot deep area where the 20-foot by 10-foot sinkhole originally appeared.

“The storm pipe was running between two houses and drains into Lake Sinclair,” Stockel elaborated. “The old CMP pipe installed years ago had rotted over time, we didn’t know there was a problem until we had a sinkhole in the ground. We looked at the best economical way to make the repair, and we didn’t want an open cut option due to the location.

“We had used the pipe previously on a job and I like the product,” Stockel added. “I have seen the product in use on a few applications. It is very smooth, it is a good product. I’d like to see the product used more often. In this instance, the contractor suggested the use of the HOBAS product at no additional cost to the County and we accepted his proposal.”

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Jeff Peyerk of Tyger Excavating stated, “We had never used HOBAS before this project. After we learned about it, we thought it was a more durable option for this installation than the proposed profile wall PVC product. The installation is now complete, and we are pleased with the performance.”

On this project, there were segments that were too damaged to reline, and in these areas the pipe was direct buried. The project had its challenges in areas where the pipe had to be jacked into place – being pushed through the existing pipe that was filled with soil. Once the HOBAS was in place, the material was excavated from within the pipe.

“HOBAS pipes are extremely strong,” said Dave Furnari, foreman for Tyger Excavating, who was onsite during the installation. He said the big advantage of HOBAS pipe is the ability to push it directly into the existing pipe. After insertion, the annular space between the liner pipe and the deteriorated CMP was grouted.

“The grout used to fill the annular space gives off heat as it cures, and can cause problems for some pipes that are not as heat resistant. HOBAS, being a thermosetting material, is not as affected by elevated temperatures as many thermoplastics which more rapidly lose properties with elevated temperature. HOBAS

can maintain adequate strength and, therefore, resistance to collapse during grouting,” stated Randy Whiddon, Field Service Manager with HOBAS.

Not only are the pipes user-friendly to install but, they are a long term solution. “These pipes will be here long after we’re gone,” commented Stockel. “They’re estimated to last more than 100 years.”

Neighbors were also pleased by the use of trenchless technology to solve the drainage problem. With the sliplining installation, the area was subjected to less disruption than if the entire line had been removed and replaced.

Completion“We expected to have more challenges than we actually had,” observed Tyger’s Peyerk. “The

combination of the strength of the HOBAS Pipe and the ability to push with our bore

machine made for an easier job than we anticipated. We would definitely

recommend HOBAS Pipe for future projects. The delivery was quick and on time as promised.”

With the end of September 2009, the line is once again in operation and “everything is fine,” stated Stockel. “As they say, the line is out of sight and out of mind for many years to come.”



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Hobas Pipe USA1413 E. Richey RoadHouston, Texas 77073Tel: (281) 821-2200

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The HOBAS PIPE USA sales team is located regionally throughout the USA. To find the contact for your area, visit our website at www.hobaspipe.com.

March 2010, Issue 64 PipeLine - HOBAS PIPE USA · MCUA was founded in 1950, in part to protect and...

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Transcript of March 2010, Issue 64 PipeLine - HOBAS PIPE USA · MCUA was founded in 1950, in part to protect and...