Australian Pipeline Management, in collaboration with SAERTEX multiCom® and M. Tucker & Sons, has boldly embraced another complex renewal project and overcame formidable challenges.
Australian Pipeline Management (APM) was engaged by a Tier 1 contractor for a 80m mid-line install of a 160m reinforced concrete stormwater pipe running east-to-west under a nine-lane highway on the South Coast, NSW.
APM secured the contract with its innovative solution to reline only the damaged 80m section located near the halfway point of the 160m long pipe. This approach saved the client money but added complexities to the project.
The DN1500 pipe was carrying significant stormwater flows from the highway and surrounding area. To install the liner, APM completed months of planning to develop the flow management and address the difficult and high-risk site conditions.
“It was a natural choice to collaborate with M. Tucker & Sons on this project, knowing their high standards and professional attitude from previous joint projects,” APM director James Pickup said.
“This project required extensive preparation, above and beyond a normal relining job, particularly because of the distance between the two access pits.”
The two access points to the DN1500 pipe were on either side of a nine-lane highway, which meant good lines of communication were crucial for the project’s success.
“We needed a reliable method of communication between the upstream and downstream crews, who were a 15-minute drive from each other due to the lanes of traffic between them,” Pickup said.
To mitigate any risks, APM engaged a specialist company to install a system that would allow an open communication network between the crews at all times. This system enabled individuals to communicate with each other without the risk of phone signal loss.
“Mobile phone and standard two way radio reception was pretty patchy,” Pickup said.
“So, our communication protocol was paramount to the success of this project.”
As an additional aid to the crews, and a backup in case verbal communication failed, APM also set up a live video stream in the pipe. This allowed the crews to use hand signals to complete the job if required and also gave them the ability to monitor the light train.
Pickup was absolutely focused on delivering the project safely.
“During setup, we fixed lighting into the tunnel as a visual aid to the crews so they did not have to wear head torches that can be unreliable and do not provide adequate lighting of the work area,” he said.
Pickup also arranged for the operators in the pipeline to use breathing apparatuse to ensure a continuous volume of fresh air. This was achieved using a dedicated system to overcome the lack of air flow in the confined space.
APM established a designated command post to manage the project’s high-risk activities and daily project management. This included the signing in and out of operators and implementation of processes and procedures to meet the confined space permit regulations and the requirements of the project safety management plan.
Preparation ahead of the project required two weeks of civil works to enable entry to the upstream and downstream ends of the pipe and the erection of custom scaffolding for the crews to get in and out of the upstream head wall.
APM commissioned the construction of a platform for a 160-tonne crane supplied by WGC Cranes that would be used to lower the liner and equipment safely into the installation location.
APM selected SAERTEX-LINER® MULTI Type S+ FastPlus for the project from SAERTEX multiCom® GmbH, one of the largest and well trusted manufacturers of liners in the world.
This liner, available to Australian and New Zealand customers through Pipe Core, is known for its structural integrity, thinner wall thickness, and 100-year design life. The installation of a liner has the same technical service life as a new pipe and is approved for use by Transport for NSW.
“I’m very familiar with the product and find it extremely reliable and easy to work with,” Pickup said.
“The ‘FastPlus’ version we opted for has the great benefit of the inner foil not having to be removed, saving time on-site and reducing wastage.”
Ahead of the install, there was a series of workshops with APM and SAERTEX multiCom® to identify and mitigate project risks.
These workshops were invaluable to engineer solutions prior to commencing on-site by calling on the worldwide experience of SAERTEX multiCom® and the project delivery team.
An application engineer from SAERTEX multiCom® was on-site to support the crew installing the liner. Application Engineers are available from SAERTEX multiCom® for high-risk and high-value projects globally.
“It was one of the most organised, well-planned, and well-executed sites I have ever seen,” Alex Kaefer who was the SAERTEX multiCom® application engineer on-site said.
The project commenced with a toolbox talk and BBQ breakfast to run through final preparations and plans.
The weather hadn’t been on the crew’s side, with over 140ml of rain falling just prior to the job kicking off, which required extra measures to stop water infiltration during the relining process.
“We had to inject a water plug agent to stop water infiltrating into the pipeline to complete the liner installation,” Pickup said.
The approval for erecting a 160 tonne slew crane caused additional challenges due to the close proximity to the local airport.
Despite these challenges, all parties came together and delivered a successfully renewed pipeline.
APM, in collaboration with M. Tucker & Sons and SAERTEX multiCom® , has successfully navigated and triumphed over significant site challenges to deliver yet another complex renewal project.
This achievement not only underscores the effectiveness of collaboration among industry leaders but also showcases the transformative impact of UV technology in rehabilitating critical pipeline infrastructure.
For more information, visit Pipe Core or Australian Pipeline Management.
This article featured in the August edition of Trenchless Australasia.
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