Contexte du projet
While traditional cured-in-place pipe (CIPP) for gravity pipeline systems has been established for more than 45 years, the use of reinforced CIPP for pressurised force mains and potable water systems is still relatively new. As part of its continued development of pressure pipe technologies, Insituform took on a complex rehabilitation project for the City of Daytona Beach, involving a disused raw water transmission pipeline being converted to a sanitary sewer force main.
The project involved rehabilitating a 30-inch prestressed concrete cylinder pipeline (PCCP) originally built decades earlier. McKim & Creed served as the project design and inspection engineer, and following a public bid process, a fibre-reinforced CIPP system was selected. The approved product, known commercially as Insituform® RPP (Reinforced Pressure Pipe), uses a vinyl ester resin and specially needled fibreglass material to provide the tensile strength and internal pressure resistance required for pressurised pipeline performance.
As prime contractor, Insituform delivered the CIPP installation while also managing project coordination, subcontractors, site activities, and supporting works including CCTV, cleaning, jack and bore operations, ductile iron pipe (DIP) installation, and excavation.
Working in a High-Profile Location
The project route passed directly through some of Daytona Beach’s most recognisable locations. Large portions of the work took place along the front parking area of the Daytona International Speedway, home of the Daytona 500, located on Speedway Boulevard (Florida Highway 92).
Because of this, the project team navigated several logistical and operational challenges:
- Work occurred during major events including Daytona Bike Week and Daytona 500 activities
- Crew lodging and meals became difficult during peak tourism periods
- The pipeline alignment ran from a golf course access point, through commercial zones, across Speedway property, and toward the airport boundary
The overall project duration spanned from late 2014 through to the second quarter of 2015.
Project Overview and Scope
The work was divided into three bid components:
Project A
Renovation and improvements to the lift station responsible for pumping sewage into the 30-inch force main.
Project B
Rehabilitation of approximately 8,400 feet of 30-inch PCCP using the Insituform® RPP fibre-reinforced CIPP system.
Project C
Direct burial of new ductile iron pipe (DIP) west of the CIPP termination point.
Access, Installation and Bypass Requirements
Crews accessed the site via a utility easement between golf course holes, then worked through a light commercial district before reaching Speedway Boulevard. From that point, sections of DIP were installed and jack and bore operations were performed beneath the roadway to access Speedway property and, later, the airport entrance.
A similar jack and bore approach was also required beneath the Daytona Beach Airport roadway. The CIPP installation extended across airport-adjacent land to the property line.
Because the pipeline had a 30-inch diameter, installation used:
- A steel inversion frame
- A 30-foot roller bed to transport the pre-wet-out tube from the refrigerated lorry to the inversion point
- A water inversion and water cure method
Trench boxes, dewatering, and shoring were required throughout due to the presence of deep, wet sand soils. The total 8,400 LF of PCCP was rehabilitated in two phases, requiring 14 separate CIPP installations.
Subcontractor Contributions
Several subcontractors supported the project:
- Cleaning: Performed using standard jet cleaning equipment, supported by multiple subcontractors
- Pipe installation: Provided by Hazen Construction
- Jack and bore works: Delivered by Downtown Underground, Inc.
- Additional access pits and support: Provided by JD Weber Construction, particularly where unexpected conditions required deviations from original plans
During cleaning and CCTV inspection, crews identified unforeseen bends not shown on the as-built drawings. The City instructed excavation and replacement of these sections with new DIP, removing old fittings and enabling consistent CIPP installation.
Environmental and Weather Challenges
Weather created significant obstacles, with several heavy storm events producing up to 8 inches of rainfall per day. This caused flooding, access issues, pit instability, and required re-cleaning of previously prepared pipe.
Once lining was completed, Hymax fittings from Krausz USA were installed at termination points to connect the CIPP to the DIP closure pipes. These fittings helped the system achieve its 50 psi design requirement. The completed pipeline was then pressure tested to 100 psi, meeting trenchless industry standards.
Project Insight
“Several rain events, topping out at 8 inches a day, created problems with pipe access, pit access and stability and required re-cleaning previously prepared pipelines. Although not typical rainfall events, these storms are not unheard of in Florida. It is common that storms like the ones encountered on this project can create numerous construction challenges such as delays and rework.”
– Rick Baxter, U.S. Operations Manager for Pressure Pipe, Insituform
Détails du gazoduc et résumé du projet
Projet : Réhabilitation de la conduite de refoulement de 30 pouces (CIPP) à Daytona Beach
Localisation : Daytona Beach, Floride
Length and Size: 8,400 LF of 30-inch diameter pipe
Pression : 100 psi selon la norme ASTM F1216
Méthode d'installation : L'inversion de l'eau
Propriétaire : Ville de Daytona Beach
Ingénieur : McKim & Creed
Entrepreneur principal : Insituform
