design and construction of the pearl city peninsula to ford island

Design and Construction of the

Pearl City Peninsula to Ford

Island Waterline Crossing Project

Devin Nakayama, PE

Yogi Kwong Engineers, LLC

Richard (Bo) Botteicher, PE

Underground Solutions, Inc.

Presentation Agenda

Presentation will cover the main portion of the project,

which was the Horizontal Directional Drill (HDD) design

and installation.

• Project Background

• Design Overview

• Construction Highlights

• Lessons Learned

Project InformationOwner: NAVFAC Pacific

Civil: Fukunaga & Associates, Inc.

Structural: Shigemura, Lau, Sakanashi, Higuchi and Associates, Inc.

Electrical: MK Engineers, Ltd.

Environmental: Element Environmental, LLC

Geotechnical: Yogi Kwong Engineers, LLC

General Contractor: Watts - Healy Tibbits A JV

HDD Subcontractor: Southeast Directional Drilling

Fusion Subcontractor: Underground Solutions, Inc.

Contract Award: $10,024,207

Notice To Proceed: September 2013

Onsite Start: April 2014

HDD Completion: September 2014

Project Background

Replacement of approximately 3,800 linear feet of deteriorated

24-inch cast iron waterline with new 24-inch fusible

polyvinylchloride pipe (FPVCP) from Pearl City Peninsula to Ford

Island

• Operating Pressure: 65-75 psi (typical)

• Test Pressure: 150 psi

The 24-inch waterline will serve as a primary potable water artery

connecting the existing Pearl Harbor Complex with its primary

source (Waiawa Shaft).

Project Location

PEARL CITY

PENINSULA

FORD

ISLAND

WATERLINE

ALIGNMENT

WATERLINE

ALIGNMENT

• 3,800 LF of waterline to be replaced.

• 3,500 LF to be installed by HDD.

• 2,500 LF will be below Pearl Harbor channel.

Horizontal Alignment Selection

PEARL CITY

PENINSULAFORD

ISLAND

WATERLINE

ALIGNMENT

• Straight alignments in plan view typically preferred.

• Horizontal curve was necessary to avoid piers, and

make the connections to existing lines.

Reference: Google Earth

Alignment at Pearl City Peninsula

SECURED

COMPOUNDPROPERTY

LINE

PROPERTY

LINE

• Initial design was to replace roughly 3,330 LF of

existing waterline.

• 500 LF added to move closer to Secured Compound

and Forest City property line.

FOREST CITY

RESIDENTIAL AREA


• Permission for work

area within Secured

Compound obtained

during design phase.

Work Area at Pearl City Peninsula

PROPERTY

LINE

PROPERTY

LINE

WORK AREA

EXTENTS

WORK AREA

EXTENTS

CONNECT TO

EXISTING

WATERLINE

CONNECT TO

EXISTING

WATERLINE

Alignment at Ford Island

UNDERGROUND

AMMO BUNKERS

UNDERGROUND

AMMO BUNKERS

PIPE STAGING AREAPIPE STAGING AREA

• 50’ clearance from underground ammo bunkers.

• Access to pipe staging area.


Work Area at Ford Island

• Abundant underground utilities.

• New vertical thrust blocks, vaults.

UNDERGROUND

AMMO BUNKERS

CORRIDOR TO

PIPE STAGING AREA

CORRIDOR TO

PIPE STAGING AREA

WORK AREA

EXTENTS

WORK AREA

EXTENTS

Ford Island Pipe Laydown Area

~3,500 FT OF

FUSIBLE PVC PIPE

~3,500 FT OF

FUSIBLE PVC PIPE

• 24-hour staging area for pipe laydown.

• Pullback in shorter segments while fusing in the

middle of pullback is feasible, but not preferred.

Geotechnical Exploration

• 5 on-land borings, 5 overwater borings.

• Deepest borings went to -140 feet MSL

• Additional borings on PCP side because of

potentially contaminated soils.

Generalized Geologic Profile

• Very soft compressible soils, 0 blow count

• Requires accurate and careful steering

• Minimum 40 foot ground cover

ESTUARINE

DEPOSITS


• Stiff to hard silts and clays

• Cobbles and boulders can typically be encountered

within alluvial deposits

ESTUARINE

DEPOSITSMARINE

DEPOSITSOLDER

ALLUVIUM

OLDER

ALLUVIUM


• Loose to dense sands and gravels

• Coral reef limestone

• Possible submarine landslide

ESTUARINE

DEPOSITSMARINE

DEPOSITS

CORALLINE

DEPOSITS

CORALLINE

DEPOSITS

POSSIBLE

SUBMARINE

LANDSLIDE

OLDER

ALLUVIUM

OLDER

ALLUVIUM


• Low to moderately hard

• Closely to intensely fractured

ESTUARINE

DEPOSITSMARINE

DEPOSITS

CORALLINE

DEPOSITS

CORALLINE

DEPOSITS

OLDER

ALLUVIUM

OLDER

ALLUVIUM

VOLCANIC

TUFF

POSSIBLE

SUBMARINE

LANDSLIDE


• Fill materials, Lagoonal Deposits, Older Estuarine

Deposits, Alluvial/Marine Deposits,

Coralline/Marine Deposits

ESTUARINE

DEPOSITSMARINE

DEPOSITS

CORALLINE

DEPOSITS

CORALLINE

DEPOSITS

OLDER

ALLUVIUM

OLDER

ALLUVIUM

VOLCANIC

TUFF

POSSIBLE

SUBMARINE

LANDSLIDE

FILL MATERIALS

LAGOONAL DEPOSITS

OLDER ESTUARINE

DEPOSITSALLUVIAL/MARINE

DEPOSITS

CORALLINE/MARINE

DEPOSITS

Environmental Issues

• Potentially contaminated soils were encountered during

geotechnical drilling at Pearl City Peninsula (PCP).

• Specifications require a larger diameter protective steel casing

(conductor barrel) to be installed at the PCP end of the HDD

alignment.

• Isolate possible contaminated soils and groundwater from the

HDD slurry returns.

• Conductor barrel to extend at least 15 feet below Mean Sea

Level.

Inadvertent Mud Returns

• Potential for inadvertent returns is highest where ground

cover is less than 15 feet, such as near on-land entry / exit pits.

• Measures to minimize the potential for inadvertent returns

include lowering the drill path depth to approximately 40 feet

below the mudline of the deepest part of the channel.

• Contractor required to submit detailed work plan to minimize

potential inadvertent mud return and contingency plans in the

event of inadvertent returns.

Contractor Qualifications and Submittals

• Project specifications required experienced and qualified HDD

contractor and personnel, who have performed similar work

under waterways in similar ground conditions and ground

cover.

• Required preconstruction submittals include HDD Work Plan

and contingency measures.

• Contractor required to retain QC specialist full-time onsite

during HDD operations.

48-inch Isolation Casing

• 170 ft installed from the PCP side.

• Tip of casing extended below groundwater.

• Isolate potential contaminated soils.

ISOLATION CASINGISOLATION CASING

DRILL RODSDRILL RODS

Pilot Hole Drilling

• HDD rig on PCP side.

• 10-5/8 inch pilot hole drill bit.

• Gyroscope tracking system.

Pilot Hole Breakthrough

TARGETED

EXIT POINT

TARGETED

EXIT POINT

PILOT HOLE

DRILL BIT

PILOT HOLE

DRILL BIT

• Actual exit point was inside excavated exit pit, 3

feet below target.

Reaming

• Initial plan by Contractor was to ream with 24-inch,

then 38-inch reamer.

• Contractor elected to ream entire length in one

pass with 38-inch reamer.

Reaming

DRILL RODSDRILL RODS

• Track excavator was used to pull the reamer

through the hole, from the PCP side to Ford Island.

• Rotation was provided by HDD rig on PCP side.

Mud / Swab Pass

• Performed prior to pullback with 36-inch ball

reamer.

• Ball reamer pulled from Ford Island to PCP side.

Pipe Fusion and Staging

• 24-inch AWWA C905 PVC Pressure Pipe DR 18, PC

235 psi

• Thermally Butt-Fused = Fusible PVC® pipe

• McElroy T-900 fusion equipment – Underground

Soltuions, Inc. Fusion Technician.

Ford Island Pipe Laydown Area

3,500 FT OF

FUSIBLE PVC PIPE

3,500 FT OF

FUSIBLE PVC PIPE

• Pipe assembly done concurrently with HDD reaming.

• Low-pressure, “vandalism check” air test on full

length of 3,510 LF performed prior to pullback.

Pipe Assembly Schematic

Pipe Fusion

Assembly

Area

Pipe Fusion

Assembly

Area

Assembled Pipe String

Staged, 3,510 LF

Assembled Pipe String

Staged, 3,510 LF


Pipe Movement Schematic

Assembled pipe string

Pulled back

Assembled pipe string

Pulled back

Location of horizontal

bend for insertion

Location of horizontal

bend for insertion

Road Closures coordinated

With pipe movement


With pipe movement



Final position for

insertion

Final position for

insertion

Location of

insertion

Location of

insertion


With pipe movement


With pipe movement



Horizontal Curve

Into insertion alignment

Horizontal Curve

Into insertion alignment

Insertion locationInsertion location

Drill locationDrill location

Pipe Alignment Specifics

• At-grade alignment surveyed in from

plan.

• Alignment used to meet bend radius

requirements and avoid obstacles.

TreesTrees

Baseball field

backstop

Baseball field

backstop

Pipe Roller Set Ups

• Fully supported

on rollers

entire time

• Lateral support

on horizontal

curve

• Fabricated

‘skids’ during

staging

• Less desirable

rollers used for

initial

movement

Pipe Insertion Planning vs. Actual

Pipe Insertion Planning vs. Actual

• Slight horizontal deflection

accommodated

• Three pick-points used to elevate

the pipe and curve to the correct

insertion angle

Internal Ballasting

Clean water pumped into pipe as it is

inserted to reduce buoyant drag,

reduce pull forces required

Pipe Pullback Forces

Estimated maximum

pullback force:

Actual maximum

pullback force observed:

Force required to pull

drill rig carriage:

Safe pulling force

for 24” DN :

140,000 to 150,000 lbs

164,000 lbs

~17,000 lbs

307,100 lbs

Challenges and Lessons Learned:

• Never underestimate the value of good

teamwork

– Ideas and problem solving

– Experts in their respective fields

• Field test processes as much as practical!

– Ballast water flow check

• When the going gets tough, the tough get

creative

– Use of ‘fashioned’ roller cradle

– Use of fabricated pipe supports

– Roller supports for curves

– Adjustment of roller supports during staging

movement

Future Interconnection…

PEARL CITY

PENINSULA

FORD

ISLAND

FUTURE PROPOSED

WATERLINE ALIGNMENT

FUTURE PROPOSED

WATERLINE ALIGNMENT

Design and Construction of the

Pearl City Peninsula to Ford

Island Waterline Crossing Project

Devin Nakayama, PE

Yogi Kwong Engineers, LLC

Richard (Bo) Botteicher, PE

Underground Solutions, Inc.

design and construction of the pearl city peninsula to ford island

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