11/13/2015

1

FY12 Special Project ST09-1884Replace 24-inch Underwater Waterline

Pearl City Peninsula to Ford Island

Presented by:Greg Hayashi, NAVFAC Hawaii UEM Water – Owner

Jon Muraoka, Fukunaga & Associates, Inc. – Designer Art Lambert, Healy Tibbitts Builders, Inc. – Contractor

Presentation Outline• Owner’s Perspective

NAVFAC Hawaii Water Utilities – Greg Hayashi

• Design ConsiderationsFukunaga & Associates, Inc. – Jon Muraoka

• Construction ChallengesHealy Tibbitts Builders, Inc. – Art Lambert

11/13/2015

2

Project Objective• Replace existing deteriorated 24-inch cast iron

submarine waterline under the Pearl Harbor North Channel

• The new waterline will provide reliable potable and fire protection water for Ford Island, Pearl Harbor Shipyard and Joint Base Pearl Harbor Hickam

11/13/2015

3

Existing Waterline• 24-inch cast iron, cement mortar-lined, ball joint (MOLOX)

waterline installed in 1952, approximately 2,500 LF across channel

• Waterline laid on channel bottom – susceptible to damage by dredging or anchors

• Major break caused shut down of water line in 2006

• Repair took about 7 months – required design, manufacture and installation of a custom repair sleeve.

PLUME OVER WATERLINE BREAK

11/13/2015

4

Original Project (from DD1391)• FY 2012 Special Projects Program

• Approximately 3,300 LF of deteriorated 24-inch cast iron pipe to be replaced with new 24-inch fusible polyvinyl chloride (FPVC) pipe

• Project Budget (original) = $11,294,000

11/13/2015

5

Pre-Design Coordination • Hydrographic survey (Underwater topography)

• Geotechnical investigations – landside (Ford Island & Pearl City Peninsula) and over-water

• Navy Installation Security requirements

• Hazardous material survey – esp. abandoned fuel lines

• Historic preservation coordination – Ford Island airfield pavement

• Work near family housing areas (Forest City managed developments – Ford Island & Pearl City Peninsula)

PRE-APPROVAL OF PIPE STAGING AND LAYDOWN AREA ON FORD ISLAND RUNWAY –SCHEDULED ROAD CLOSURES

PRE-APPROVAL OF WORK NEAR FAMILY HOUSING INCLUDING RESTORATION OF DAMAGED WORK AREAS AND MAINTAINING SECURED ZONES.

PRE-APPROVAL OF WORK NEAR FAMILY HOUSING AND NAVY BRIG INCLUDING RESTORATION OF DAMAGED WORK AREAS

Coordination with Base Activities

NOTIFICATION OF PORT OPS FOR WORK IN HARBOR

11/13/2015

6

Design Issues • Design for Horizontal Directional Drilling – avoid

disturbance of harbor bottom

• Varying subsurface conditions (soft sediment – hard rock)

• Underwater crossing – long pull distance (over 3,500 feet) – estimated pull load = 139,346 lbs

• Justification & Approval (J&A) for sole source pipe material – Fusible PVC Pipe – required due to high tensile strength

• High thrust forces for fittings on large diameter pipe

• Connection to existing major transmission main – service shutdown of potable water system

Fusible Polyvinyl Chloride (PVC) Pipe• Nominal Size: 24 inches

• Dimension Ratio: DR 18

• Series: Ductile Iron Pipe Size

• Outside Diameter: 25.8 inches

• Minimum Wall Thickness: 1.43 inches

• Weight: 71.08 pounds/foot

• Short Term Tensile Strength: 7,000 psi

• Allowable Pulling Force: 306,549 pounds

• Maximum Working Pressure: 235 psi

• Minimum Bending Radius: 538 feet

11/13/2015

7

Harbor Crossing Profile

CORALINE DEPOSITS

CORALINE DEPOSITS

MARINEDEPOSITS

ESTUARINEDEPOSITS

OLDER ALLUVIUM

OLDER ALLUVIUM

OLDER ALLUVIUM

CORALLINE/ MARINE DEPOSITSOLDER

ESTUARINEDEPOSITS

ALLUVIAL / MARINE DEPOSITS

Geologic Profile along HDD Alignment

CHANNEL DEPTH = 40’ +

FILLFILL

PEARL CITY PENINSULA

FORD ISLAND

Butt fusion welded pipe string allowed continuous HDD pulling installation; avoiding collapse of bore hole and binding of the pipeline. The continuous 3,500 foot long pipe string was pulled through the under-channel bore hole in one day

11/13/2015

8

Project Summary• Replaced 4,300 LF of deteriorated 24-inch cast iron pipe

• HDD installation of 3,500 LF with 24-inch Fusible PVC

• Conventional installation of 800 LF with 24-inch DIP

• Original Budget (DD1391) = $11.29 M

• Bids opened August 2013 – Low Bid = $10.04 M

• NAVFAC Pacific Waterfront MACC Contract – Watts-Healy Tibbitts JV (awarded September 2013)

Pre-construction/administrative/logistical Challenges:

• Stand alone NPDES Permit• Prequalification requirements for Subcontractors (HDD)

and special HDD QC Manager• Work schedule management to minimize impact on

operations and RIMPAC exercises• Work schedule management to minimize potable water

service “down time”

11/13/2015

9

Horizontal Directional Drilled (HDD) Section of Pipe:

• Coordination with HDD Subcontractor/Engineer/Fusible Pipe Supplier/Geo tech QC Specialist – partnering & collaboration

• Fusible pipe staging at Ford Island – use of Ford Island runway

• Noise abatement while driving casing/drilling at Pearl City Peninsula

• HDD Pilot Hole acceptance - trapped air issue• Pull forward/pull back the day of pullback to situate pipe

for pullback into directional drilled hole

Horizontal Directional Drilled (HDD) Section of Pipe:

• Exceeding bending radius’ – horizontal & vertical – of 24” diameter fusible pvc pipe during pull back

• Traffic control plan on Ford Island the day of pull back –September 23rd, 2014

• Water ballasting of fusible PVC pipe during pullback to achieve neutral buoyancy

• Disposal of drill spoils in “real time” in “Frac Tanks” and to PVT Landfill

• Cleaning/disinfecting HDD section of the new pipeline

11/13/2015

10

Epoxy Coated Ductile Iron Sections of Pipe:

• Ground water control – Ford Island• Ground water control – Pearl City Peninsula• Epoxy coating quality control/thickness• Thrust for restraints for large diameter pressure line –

“massive” thrust blocks and supports• Vaults – pros and cons to Pre casting vs Site casting• Sheet pile cofferdams – 8 each. Biggest Challenge:

working around overhead utilities at Pearl City Peninsula• Unforeseen obstructions

11/13/2015

11

11/13/2015

12

11/13/2015

13

11/13/2015

14

11/13/2015

15

11/13/2015

16

11/13/2015

17

11/13/2015

18

11/13/2015

19

11/13/2015

20

11/13/2015

21

11/13/2015

22

11/13/2015

23

11/13/2015

24

11/13/2015

25

11/13/2015

26

Questions ?