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There were THREE
installation methods and TWO contractors on the McKinley Avenue
Supplemental Sewer Interceptor project, but only ONE pipe, HOBAS
centrifugally cast fiberglass reinforced polymer mortar (CCFRPM)
pipe, was needed for this new sewer system which consisted of over
10,000 feet of 36" and 48" gravity pipe. These lines
were designed and constructed to expand the existing Stevens Creek
Supplemental Sewer Interceptor, which also used HOBAS pipe, to
accommodate the industrial growth seen from ADM and A.E. Staley
Foods, two industrial giants in Decatur, Illinois.
Direction changes at manholes easily
accomplished with HOBAS mitered tee bases. |
Bainbridge, Gee,
Milanski & Associates, the design engineers, were faced with a
challenging project due to varying conditions and requirements.
First, corrosion resistance was essential due to the wastewater
flows generated by the industrial plants. Secondly, sections of
the run required aerial installations with spans of 19.5 feet,
center to center, on concrete piers. Furthermore, boring and
jacking of a 60" steel casing with a 48" HOBAS pipe
grouted inside was required on portions of the line passing under
the Illinois Central Railroad right-of-way. Additionally, high
strength pipe was necessary to handle deep covers up to 34 feet.
Only HOBAS
CCFRPM was specified for all installations, with alternates
including Class 160 (23 psi pipe stiffness) profile wall HDPE for
the direct-bury and in the casing, and polythane lined ductile
iron for the aerial. Ease of installation, high strength, and a
lower installed cost are just a few reasons HOBAS pipe was
preferred on approximately 8,500 feet of direct-bury (36"
& 48" SN 36), over 830 feet of aerial (36" &
48"), and 960 feet of direct jacking, originally direct-bury,
(48" 400 Ton). The direct jacking method, approved by the
District, was preferred due to the depth and adjacent location to
the railroad.
Tough & UV resistant HOBAS pipes
ideal for aerials |
Bodine Services,
Inc., the general contractor, installed the open-cut portion,
which also included twenty-seven mitered and straight 48"
manhole tee-bases, and the aerial portion. Fast and easy assembly
was customary due to the push-together, gasket-sealed FWC
coupling. Bodine reported an average productivity rate, on the
direct-bury portion, of 300 feet/day with covers between 7 ft to
20 ft and approximately 100 ft/day at deeper covers. Additionally,
the 36" and 48" aerial pipes were specially fabricated
to have mid-span deflections of 1/16" or less, even when
flowing full.
Midwest Mole, subcontracted by Bodine for the jacking segment,
installed the remaining 960 feet in 2 drives of approximately 480
feet each, in a clay/sand environment, using a conventional
jacking machine and without intermediate jacking stations. HOBAS
pipe’s smooth and constant O.D. contributed to the low loads
reported, with a maximum of 200 tons occurring at start-up after a
routine weekend shutdown.
Installation success with crushed
rock embedment. |
The SN 36
direct-bury pipes, embedded in angular limestone rock, easily
passed the 5% deflection mandrel test. Furthermore, the individual
joint air tests of 4 psi passed with zero leakage! This project is
another testament to the success that can be achieved by using
HOBAS pipe! Pleased with the performance of HOBAS pipes, the
Sanitary District of Decatur has once again specified HOBAS on
another project, the Hickory Point West Interceptor Sewer, which
includes approximately 6,000 feet of direct-bury and boring &
jacking of 24" diameter pipe.
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08
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116 |
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