LARGE DIAMETER DYNAMIC PIPE BURSTING FOR SEWER REPLACEMENT

Pubblicato il giugno 7, 2016 da Renzo Chirulli

Client: EUROSCAVI Srl – Italy

Year: 2016

What I did: I made the detailed design of the replacement by dynamic pipe bursting of a DN600 (24″) sewer concrete pipe with a DN800 (32″) HDPE pipe; I coordinated all the geological/geotechnical preliminary survey and I also made the detailed design of the bursting-expanding head, tailored shaped to work with a Tracto Technik TAURUS rammer (24″). The expander has an outside diameter of 1000 mm. The soil was sand with coarse to very coarse gravel.

LARGE DIAMETER DYNAMIC PIPE BURSTING FOR SEWER REPLACEMENT

Plan view of the pipe replaced by dynamic pipe bursting.

Longitudinal section of the pipe replaced by dynamic pipe bursting.

The soil was sand with coarse to very coarse gravel.

Longitudinal section and plan view of the insertion pit.

The tailored-shaped bursting-expanding head.

Close-up of the connection between the tail of the expander and the new HDPE pipe

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SEWER MAINS AND HOUSE CONNECTIONS BY HDD

Pubblicato il giugno 2, 2016 da Renzo Chirulli

Client: SE.T.A. Srl (today ETRA Spa) – Italy

Year: 2003-2004

What I did: I made the detailed design of the installation of pressure and gravity sewer pipes by directional drilling; I carried on the training of the technical personnel (engineers, supervisors and operators). I developed a dedicated and complete HDD pit launched installation system for the connection of houses to the sewer mains. I also wrote two technical standards: the first for preliminary underground mapping and the second for the construction of house connections by using pit launched HDD machines.

SEWER MAINS AND HOUSE CONNECTIONS BY HDD

longitudinal section of an HDD installation.

Detail of the connection between a concrete shaft and the newly installed culvert.

Pit launched HDD system for the connection of houses to the sewer main.

click on the image to see the index of the standard norm (language: Italian)

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DESIGN OF THE REHABILITATION OF LARGE DIAMETER SEWER MAINS BY CIPP

Pubblicato il maggio 31, 2016 da Renzo Chirulli

Client: ROTECH Srl – Italy

Year: 2010

What I did: I made the detailed design of the rehabilitation, by thermal and UV CIPP, of DN1200 and DN1000 (48 and 40 in) sewer mains for a total length of 220m, at the Petrochemical Plant of Porto Marghera, Italy; detailed design of the rehabilitation, by thermal CIPP, of DN1200 (48″) sewer mains for a total length of 1.250 m, in the cities of Scafati, Pompei e Sant’Antonio Abate, Italy.

DESIGN OF THE REHABILITATION OF LARGE DIAMETER SEWER MAINS BY CIPP

Comprensorio Medio Sarno (Italy) - longitudinal section of the sewer system to be rehabilitated.

Comprensorio Medio Sarno (Italy) - plan view of the sewer system to be rehabilitated.

Petrochemical Plant of Porto Marghera (Italy) - Plan view of the sewer line to be rehabilitated.

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UV-CIPP AT THE INTERNATIONAL AIRPORT OF ROME FIUMICINO

Pubblicato il maggio 31, 2016 da Renzo Chirulli

Client: Blueco Srl – Italy

Year: 2010

What I did: I made the detailed design and project management of the rehabilitation, by UV-CIPP, of air-conditioning pipes DN350, laid under runways, at the international airport of Fiumicino Leonardo da Vinci (Rome, Italy).

UV-CIPP AT THE INTERNATIONAL AIRPORT OF ROME FIUMICINO

Longitudinal section of the pipe to be rehabilitated - the host pipe present a 90deg curve and a vertical section.

Insertion of the liner into the host pipe.

The capstan winch while pulling the liner into the host pipe.

The UV light core used to polymerize the foto-polymerizing resin.

Inserting the UV light core into the liner.

Inflating the liner before starting the UV polymerization of the resin.

The diagram of the final air pressure test.

The final result: the liner perfectly fits the host pipe.

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DETAILED DESIGN OF A SEWER MAIN INSTALLATION BY HDD AND TRAINING OF THE ENGINEERING PERSONNEL

Pubblicato il maggio 30, 2016 da Renzo Chirulli

Client: TEA Spa – Italy

Year: 2011

What I did: I made the detailed design of o channel crossing, by HDD, for the installation of a pressure sewer main for a total length of 320 m (1.000 ft); this project was part of a specialized training program that I carried out with the engineering personnel of the company and that led to the completion of the project of installation of the whole sewer main, entirely made by HDD, for a total length of 5,9 km (3,7 miles), divided in 21 HDD crossings.

DETAILED DESIGN OF A SEWER MAIN INSTALLATION BY HDD AND TRAINING OF THE ENGINEERING PERSONNEL

Plan view and longitudinal section of an HDD crossing - DN900 steel pipe, 464,0 m long.

Job-site layout at the start point of the directional borehole.

CIPP TECHNOLOGY HANDBOOK

Pubblicato il maggio 30, 2016 da Renzo Chirulli

Client: S3 Soncini Spa – Italy

Year: 2004-2005

What I did: I wrote the whole know-how of the company in an internal handbook containing all the instructions concerning production procedures, calculation methods and in-situ procedures of the CIPP technology. I also organized and carried out the specialized training for engineers and operators of Soncini’s licensees.

CIPP TECHNOLOGY HANDBOOK

Studying the in-situ process for CIPP - a sewer by-pass.

Studying the in-situ process for CIPP - the inversion header.

Studying the in-situ process for CIPP - the liner during the inversion stage.

Studying the industrial process for CIPP products production - the felt assembling line.

Studying the industrial process for CIPP products production - calendering of the impregnated liner.

Studying the industrial process for CIPP products production - loading of the impregnated liner in a refrigerated truck.

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DESIGN OF THE CROSSING BY HDD OF A ROCKY HILL

Pubblicato il maggio 30, 2016 da Renzo Chirulli

Client: Appennino Energia Srl – Italy

Year: 2009-2010

What I did: I made the design of the installation by HDD, in medium to hard and high abrasive sandstone, of a pressure water HDPE pipe, DN630 mm (25 in), for a total length of 530 m (1,740 ft) along an uphill drill path, for a mini hydro-power plant.

DESIGN OF THE CROSSING BY HDD OF A ROCKY HILL

Piastroso (Italy) - longitudinal section of the hill crossing.

A sample of the seismic survey made before the detailed design.

Core sampling - part of the pre-design survey campaign.

Cross section of the borehole with the pipe to be installed inside.

Job-site layout at the exit point of the directional borehole.

CEMENT MORTAR LINING TECHNOLOGY AT MILANO

Pubblicato il maggio 30, 2016 da Renzo Chirulli

Client: Risanamento Condotte Srl – Italy

Year: 2008-2010

What I did: the R&D for the improvement of the Cement Mortar Lining (CML) technology and the detailed design and manufacturing supervision of motorized lining machines.On the application side I made the detailed design of the rehabilitation, by CML, of existing DN1000 (40″) and DN 1200 (48″) steel water mains, for a total length of 3.000 m (9.800 ft), in the City of Milano, Italy. Thanks to CML technology the Client, Metropolitana Milanese Spa, saved more than 80% of construction costs and up to 98% of earth-moving compared to a traditional open-trench replacement.

CEMENT MORTAR LINING TECHNOLOGY AT MILANO

The pressure test equipment of the cement mortar liner

The testing hole has a diameter of 25,4 mm (1

Experimental relationship between liner thickness and filtration pressure (in blue) and explosion pressure (in red).

Location of the first part of the project - DN1200 steel water main.

Plan view and longitudinal section of the first part of the project - DN1200 steel water main.

Location of the second part of the project - DN1000 steel water main.

Plan view of the second part of the project - DN1000 steel water main.

The job-site - preparation of the cement mortar.

The lining machine while working inside a DN1200 steel water main.

The lining machine while going backwards to the exit pit.

The inner wall of the water main before (right) and after (left) the rehabilitation treatment by CML.

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HDD RIVER CROSSING WITH SHARP BENDING RADIUS IN VERY DIFFICULT SOIL CONDITIONS

Pubblicato il maggio 30, 2016 da Renzo Chirulli

Client: EDIL IDRAULICA Sas – Italy

Year: 2011

What I did: I made the project management and the supervision of the installation, by HDD, of three HDPE DN 560 (22 in) pressure sewer pipes under the Foglia river, Pesaro, Italy. Three directional pilot bore, with an interaxis of just 1,5 m, along a drill path with a very sharp bending radius (70 m), were successfully drilled under the river bed, facing challenging soil conditions, with big boulders and blocks of stone in a matrix of silt and clay. Although the three pilot bores were perfectly completed, on the first alignment, after completed the first final reaming at 700 mm, the first pull-back failed due to the collapse of underground unstable big blocks of rock. Despite the prohibitive soil conditions we successfully completed the pullback of the two remaining product pipes, achieving a remarkable result in a very difficult HDD work.

HDD RIVER CROSSING WITH SHARP BENDING RADIUS IN VERY DIFFICULT SOIL CONDITIONS

Longitudinal section of the river crossing.

The pipes to be installed - DN560 PE100 pipe. Nominal diameter of the reamed borehole: 700 mm.

A complete set of preliminary survey were done before the detailed project - in the picture a 3D geoelectrical tomography.

Rock boulders in a matrix of silt and clay, represent a challenging soil condition for HDD.

Creating a laser level for depth measuring while drilling.

Continuous mud control and prime drilling fluids were crucial to face so difficult soil conditions.

The HDD rig used to complete the job (Vermeer D50 - 50.000 lbs - 23t pullback force)

The three drill strings laying underground.

Pre-reaming stage - reamer diameter 500 mm.

Final reaming stage - reamer diameter 700 mm.

The pullback stages were carried out during the night shifts to not interfere with traffic.

Pullback of the second product pipe during a night shift

The unexpected presence of big blocks of rocks, along the drilling path, made the work extremely difficult causing the block of the first pullback - in the picture the attempt to clear the drill path of the rocky blocks.

Although more than 20 blocks of rock (dimension ranging in the interval 0,6 - 1,2 m) were removed, the first pipe remained definitively stuck underground.

Although more than 20 blocks of rock (dimension ranging in the interval 0,6 - 1,2 m) were removed, the pipe remained definitively stuck underground.

LANDFILLS INSULATION BY HDD

Pubblicato il maggio 29, 2016 da Renzo Chirulli

Client: MC Scarl – Cooperativa MUCAFER Scpa – Italy

Year: 2010

What I did: I worked for the main contractor MC Scarl – Cooperativa MUCAFER Scpa, as the specialized advisor for the HDD operations in the insulation of two urban landfills, for the environmental securing of the area. In less than one year approximately 60 km (37 miles) – corresponding to more than 500 horizontal directional boreholes – were drilled through soft to hard limestone rock in order to carry out underground injections to create a bottom screen below the garbage level (total value of the HDD installations: €14M). This was the biggest project of ever for a landfill insulation made by HDD. The specialized subcontractor for HDD and soil treatments was TREVI Spa.

LANDFILLS INSULATION BY HDD