THE PROBLEM:                 

In 2022, Houston Water (Texas) began the rehabilitation of its potable water infrastructure. This included the rehabilitation of a critical 24-inch cast iron potable water main located in a congested metropolitan area. The pipe was highly corroded with several “kicked” joints, or areas where the pipe had shifted from its alignment.  The deteriorated pipe’s interior had heavy tuberculation, or mounds of corrosion forming rust.

OUR SOLUTION:

Spray in Place Solutions first performed closed circuit television video (CCTV) inspections of the pipe, which required extensive cleaning with specifically designed equipment including multiple pull-throughs of drag scraping and water jetting. After cleaning, it was confirmed the pipe was in a highly deteriorated condition which required the kicks to be grouted via a robotic system before coating.  Once the pipe’s surface was prepped, Spray in Place Solutions applied approximately 3 mm (120 mils) of Warren Environmental’s 301-01 NSF certified high build epoxy in a single coat using its SIPP technology.

Due to the project’s location, a small construction footprint was critical to minimizing traffic disruptions. The crew operated out of only two six-by-six-foot pits, located within the shoulder of the busy road.  These access points were spaced up to 650 linear feet apart and the road remained open to traffic during the project.

Spray in Place Solutions completed the project in just four days in comparison to what normally would have taken four to six weeks for open cut replacement of the pipe. The SIPP rehabilitation method translated into major cost and schedule savings for the client and its community, while avoiding the inconvenience of construction related traffic during the process.

This project was nominated for Underground Infrastructure‘s (UIC) 2023 Water Project of the Year Award.