November 2025 Vol. 80 No. 11
Features
UI Awards 2026 finalists announced, winners to be honored at UIC in San Antonio
(UI) — Awards season formerly arrives at the annual Underground Infrastructure Conference (UIC), where honorees will be recognized with the launch of The Awards: MVP + UI Honors program. This signifies the start of a powerful new tradition that unites the underground infrastructure community’s most-respected recognition programs: the Most Valuable Professional (MVP) Award and Underground Infrastructure (UI) Awards. The event is scheduled for noon, Jan. 27, at the Henry B. Gonzales Convention Center in San Antonio.
To register for any/all of these incredible events, go to ui-conference.com. or contact Karen Francis for more information: Karen@undergroundinfrastructure.com, (713) 487-5676.
To become an exclusive event sponsor or purchase a table, contact Josh Allen, josh@undergroundinfrastructure.com, (832) 922-9018, or Peter Royall, peter.royall@gulfenergyinfo.com.
Details of the impressive finalists for the Underground Infrastructure Awards are outlined below.
EMERGING TECHNOLOGY
The Revelation Technology
SonDance Solutions
www.sondancesolutions.com
SonDance Solutions creates advanced patented technologies which are used to solve tough challenges in risky and demanding situations.
Revelation is SonDance Solutions' flagship innovation in buried pipeline and utility line subsurface mapping. This patent-pending, passive electromagnetic field detection technology delivers precision 3D subsurface data. Revelation is a non-contact, non-destructive solution. Unlike conventional methods such as magnetometry, acoustics, or ground penetrating radar, Revelation does not emit energy relying on echoed energy reflections to obtain data. Revelation technology is a true passive system that delivers less subjective results compared with traditional technologies. This solution yields results with improved accuracy, typically shorter turnaround deliverables, including latitude, longitude, and elevation outputs ready for GIS integration.
Broadband IQ Geology Insights
VCTU
https://www.vcti.io/broadband-iq-how-to-build
VCTI Broadband IQ Geology Insights (formerly known as Geology IQ) leverages advanced mapping to analyze soil types and rock hardness to depths of one to 6 feet, delivering data that enables cost-to-build estimates 20–30 percent more accurate than traditional methods. By replacing manual field assessments with cloud-based intelligence, this SaaS solution accelerates time-to-market and safeguards budgets from costly underground surprises. Part of VCTI’s Broadband IQ SaaS suite, Geology Insights extends a platform already trusted to answer broadband’s two most critical questions: where to build and how to build. The suite identifies the most profitable markets, then builds more precise construction plans and budgets.
Broadband providers face relentless pressure to build networks faster, smarter, and more cost-effectively — yet what lies underground often stands in the way. Broadband IQ Geology Insights transforms this challenge by delivering instant, cloud-based underground intelligence directly to the desktop. The result: accelerated planning, more accurate cost estimates and fewer surprises in the field. By giving teams immediate access to geological data, Geology Insights empowers builders of networks to make faster, highly accurate data-driven decisions.
Vermeer BorePlan App
Vermeer
https://store.vermeer.com/navigation-items/products/vermeer-boreplan-app
Vermeer BorePlan is a mobile application for horizontal directional drilling contractors that streamlines planning, improves execution accuracy and simplifies project documentation. Available free on Apple iOS and Android devices, with a premium version for advanced capabilities. The app addresses utility avoidance and complex bore path management by putting digital planning tools directly at operators' fingertips. Key features include straight-line bore planning, basic utility mapping, rod-by-rod plans, high-accuracy GPS integration and aerial imagery provided by ESRI.
BorePlan Premium adds compound curve planning for complex bore paths, advanced calculators for setbacks and bore exit, comprehensive reporting packages, CAD and engineering plan exports and multi-project management capabilities. The interface caters to both experienced operators and newcomers, guiding users step-by-step through the planning process. The mobile-first design enables real-time jobsite modifications when conditions change, eliminating the traditional disconnect between office planning and field execution.
Vermeer BorePlan modernizes HDD planning by replacing manual calculations with digital tools that create accurate bore plans. The technology addresses the industry's movement toward more precise planning and comprehensive documentation requirements. Rod-by-rod planning enables operators to make quick drilling adjustments, helping crews adapt to unexpected challenges without costly project delays. This real-time decision-making capability supports data-driven responses to changing ground conditions. BorePlan Premium's advanced reporting tools address the growing number of states requiring detailed as-built documentation. Contractors can accurately document completed bores, generate comprehensive reports and export data in formats compatible with regulatory submission systems. BorePlan offers mobile professional planning tools for contractors, free for basic use and Premium for advanced needs. It removes the need for costly desktop software or engineering support, making advanced HDD planning accessible to all.
Utilizing LiDAR for Wet Well Condition Assessment
North Texas Municipal Water District (NTMWD) and Freese and Nichols Inc.
https://www.freese.com/lidar-offers-increased-accuracy-safety-to-structure-condition-assessments/
For the first time, utilities can see inside wet wells with unmatched clarity and without putting workers at risk. Utilizing LiDAR for Wet Well Condition Assessment applies advanced 3D laser scanning – long used in other industries – to one of the most hazardous and least understood parts of underground infrastructure. This novel application replaces subjective visual inspections and high-risk confined-space entry with precise, repeatable, data-rich digital models. By transforming inaccessible wet wells into accurate, navigable digital twins, this technology establishes a breakthrough in both safety and infrastructure intelligence, creating a new gold standard for condition assessment.
Portable LiDAR units capture millions of data points in minutes, providing a complete three-dimensional record of structural conditions unattainable through manual methods. These point clouds are processed into engineering-grade models, enabling measurable identification of surface wear, material loss, crack development, and structural integrity. The result is a digital twin that serves as a permanent baseline for future evaluations, supporting comparisons over time and revealing deterioration trends with unmatched accuracy.
This approach has been successfully implemented at the North Texas Municipal Water District’s Lift Stations. The deployments demonstrated scalability, speed and repeatability, confirming that utilities can adopt this technology across networks of assets. The process is entirely non-invasive and does not require draining, cleaning or taking facilities offline, reducing downtime while delivering richer data than conventional inspections. LiDAR data also enhances collaboration and decision-making. Stakeholders can virtually navigate assets using immersive visualization platforms, eliminating the need for physical entry and enabling shared understanding across teams. The datasets integrate seamlessly with asset management systems, digital twins, creating opportunities for long-term forecasting and strategic capital planning, and at the same time, the data is easily accessible for measurement.
Close Tolerance Pipe Slurrification - CTPS
Azuria Water Solutions
https://www.azuria.com/services/ctps
Close Tolerance Pipe Slurrification, or CTPS is the industry's only EPA approved trenchless method for the replacement of Asbestos Cement (AC) pipes. The CTPS method involves excavating pits to access AC pipelines, uses an HDD rig to pull in a rotating wet-cutting head which grinds down the asbestos pipe, mixes it into a slurry with bentonite drilling fluid, and pulls in a brand-new FPVC or HDPE pipe simultaneously in the process. The asbestos/bentonite slurry is pushed through to the pit, vacuumed out, and hauled away for disposal. The result is a new size-on-size or upsized pipe, installed trenchlessly, in full compliance with EPA’s guidelines on AC pipe remediation. CTPS's technical envelope is currently 4 -inches through 20-inches and can upsize 1-2 sizes in most instances.
As a trenchless technology, CTPS reduces excavations by about 90 percent, and severely limits the costs and disruption of restoration activities caused by open trenching and severely reduces social impacts/costs. CTPS projects are completed significantly faster than open cut projects, take less design time since the process uses the same alignment and eliminates the need for new route design, additional permitting, and easement acquisition. The process received an Alternative Work Practice from the EPA and has an ASTM standard.
CTPS projects are completed significantly faster than open cut projects, take less design time since the process uses the same alignment and eliminates the need for new route design, additional permitting, and easement acquisition. With over 600,000 miles of AC pipe in North America and a useful design life of 50-60 years, this aging infrastructure that was installed around the 1960's and 1970's is reaching a critical point and is in desperate need of replacement. CTPS allows owners/engineers the ability to replace this infrastructure with less digging and disruption, more efficiency, and a better price point.
Kormee Nanodrill 3004
Ravan Supply
ravansupply.com/nanodrill
The Kormee Nanodrill 3004 is a revolutionary piece of equipment for underground utility installations, providing an ultra-portable and powerful solution that redefines what’s possible in horizontal directional drilling.
The Nanodrill attaches directly to a mini excavator, making it incredibly versatile and accessible for a wide range of jobs. Its compact design means it can be transported in a standard pickup or trailer, making previously inaccessible or cost-prohibitive projects now viable. This system's greatest strength is its pinpoint precision. It offers nano-level pilot hole accuracy with full directional control, a leap forward from unguided methods that dramatically reduces the risk of hitting existing infrastructure. Built with a heavy-duty, sealed construction, this machine is made to handle tough underground conditions, ensuring maximum uptime.
Its seamless integration with the DCI Falcon guidance system provides advanced steering capabilities, allowing for tighter turns and intricate bore profiles. Completing the package is the integral MIPO1005 high-pressure mud-mixer, an expert accessory designed for efficient bentonite mixing and pumping to ensure optimal drilling fluid management. The Nanodrill's intuitive controls also help reduce operator fatigue. It's the ultimate tool for a variety of vital infrastructure projects, from natural gas and water to telecommunications and corrosion mitigation.
This innovation's impact is centered on three key areas: safety, efficiency and technological advancement, offering a critical advantage over traditional, unguided methods. This precision directly translates to enhanced public and worker safety by minimizing mistakes and safeguarding crucial infrastructure. The ability to receive critical real-time data on depth, pitch, and roll, combined with its precise guidance in congested urban environments, ensures crews can navigate complex underground landscapes with confidence.
ASSET MANAGEMENT PROJECT OF THE YEAR (2)
Buried Regulator Asset Program Development
Orbital Engineering, Inc.
www.orbitalengr.com
At Orbital Engineering Inc. we have a unified mission of working with our business partners to create, improve and sustain industry and infrastructure. With over 50 years of experience in electrical and natural gas utility transmission and distribution, midstream and downstream oil, gas and chemical, mining and metals, and infrastructure industries, Orbital Engineering has successfully supported our clients both nationally and abroad.
This innovation introduces a smarter, faster, and more cost-effective way to upgrade aging underground gas infrastructure. Rather than relying on a “one-size-fits-all” replacement strategy for buried regulators – typically serving only a single customer – this project established a practical decision-making tool built on real cost data and GIS mapping. Historically, buried regulators were replaced by extending medium-pressure mains. While effective, this process was slow, resource-heavy, and didn’t directly target the highest-risk assets. Originally scoped as a 25-year plan, it often took years and demanded substantial capital.
The new approach compares above-ground regulator costs to main extension costs, using a $220/foot and 165-foot threshold to guide decisions. This removes uncertainty and aligns investments with risk. The change was spurred by leadership’s call for better capital planning, risk management’s push to address regulatory hazards, and the need for consistent standards across the organization’s footprint. This tool now supports prioritization of 3,000+ buried regulators for quicker, lower-risk replacements. Though the technical elements are not new, the programmatic approach reflects the industry’s shift toward risk-based asset management, as outlined in API 1173. It enhances safety by reducing hidden risks of regulator failures and over-pressurization, shortens construction timelines, improves crew planning, and strengthens compliance with inspection standards. By replacing spreadsheets with GIS dashboards and automated reporting, it also improves collaboration and accountability. The result, a more agile program that conserves resources, reduces risk, and sets a new standard for buried asset management, turning data into action to help utilities modernize faster and smarter.
WINNER: North Texas Municipal Water District Wastewater Condition Assessment Program
North Texas Municipal Water District
https://www.ntmwd.com/
The North Texas Municipal Water District (NTMWD) launched a pioneering wastewater infrastructure asset management program that sets a new industry standard. Moving beyond traditional inspection, the program integrates advanced condition assessment technologies, risk modeling and GIS-enabled asset management platforms to deliver actionable insights. By combining innovation with measurable impact, the program proves how proactive asset management can protect public resources, reduce long-term costs and serve as a model for others. From 2017 to 2025, NTMWD inspected over 790,000 feet of gravity mains and 875 manholes, making it one of the most comprehensive efforts of its kind. Multi-sensor tools captured detailed data on wall loss and other structural defects, while 3D optical scanning provided precise manhole assessments. This large-scale data collection created a robust foundation for informed, defensible asset management decisions. To transform inspection results into actionable strategies, each asset was assigned a Remaining Useful Life score based on deterioration, material and defect severity. These scores guided targeted interventions ranging from point repairs to full replacements, helping prevent costly emergency failures, optimize spending and extend infrastructure life. By establishing baselines and tracking deterioration trends, the program also delivers long-term value through predictive planning and lifecycle cost reduction.
A cornerstone of the initiative is the risk-based assessment model, which calculates total risk by combining likelihood and consequence of failure, factoring in operational, environmental and social impacts. This forward-looking approach represents an evolution in utility risk management, aligning investments with the greatest value and protection for the public. The program is fully embedded across NTMWD, with inspection data, RUL scores and risk outputs integrated into GIS and asset management platforms (ITpipes and InfoAsset Planner). This supports collaboration across engineering, operations, planning and leadership, informing budgeting, project scoping and long-term capital planning. Ultimately, this initiative has redefined how NTMWD manages its critical wastewater assets. By combining advanced technologies, robust analytics, and organizational integration, it offers a scalable model that safeguards infrastructure, optimizes public funds, and positions NTMWD as a leader in proactive utility stewardship.
SEWER PROJECT of the YEAR (3)
Arkona Road 72” to 76” Transition UV CIPP Culvert Rehabilitation
Pipeline Management Company and Precision Trenchless (divisions of PowerVac of Group) & IMPREG LLC
impreg.com / powervacgroup.com
In the spring of 2025, UV CIPP installation in Washtenaw County, Mich., rehabilitated an aging, circular CMP culvert that transitioned from 72 to 76-inches in diameter mid-pipe and also included a 17-degree bend. The culvert conveys a creek underneath Arkona Road in a stretch of Washtenaw County frequently trafficked with heavy farm equipment, near Saline, Mich. The Washtenaw County Road Commission identified this culvert for replacement or repair primarily due to structural integrity concerns stemming from a deteriorating invert.
Also of concern was the transition. The culvert was constructed from different CMP sizes, with 72- and 76-inch diameter sections having been fitted together about 60 feet into the 100-foot host pipe. The inverts were set flush at the transition joint, but the inevitable void at the crown area from the mismatch had not been adequately sealed and was at this point a source of infiltration and debris. The liner was designed at 13.7 mm thickness with ASCE MOP 145 and manufactured by IMPREG in Richmond, Va., who also provided on-site support. The rehabilitation was carried out on May 15, 2025, by Pipeline Management Company and sister company Precision Trenchless, and the week’s work also included the UV-CIPP lining of additional 72- and 48-inch culverts. The creek, carving a hollow about 25 feet below road level, was fully bypassed via a six-inch pump and the culvert was cleared of debris and cleaned. The most challenging step was the staging of the crate, which could only be lowered into place from road level. This was accomplished with two rotator trucks rigged with a system of guy lines that allowed the crate – weighing in at close to 16,000 pounds – to be guided down to the landing area at the inlet. Once in place, the crew proceeded with the inflation stage with a number of ‘calibration steps’ to ensure the liner gradually stretched and adapted to the profile of the host pipe, especially at the transition section, where a close fit per design would only be accomplished by taking full advantage of the liner’s expansion capabilities and gradually coaxing the un-fixed overlapping layers to ‘unfurl’ into the irregular transition space. Curing was accomplished over the course of five hours with a UV light-train comprising two “supercores” each with four (4) x 1,500-Watt bulbs for a total of 12,000 Watts of curing power.
This project is innovative not only on account of the 76-inch section being the single largest host pipe by diameter rehabilitated with UV CIPP in North America, but also for the additional challenge of the mid-pipe diameter transition combined with a 17-degree bend.
Trinity River Authority CRWS Junction Box 1020J Replacement and Improvement
Lockwood, Andrews & Newnam, Inc.
lan-inc.com
The Trinity River Authority (TRA) Central Regional Water Supply (CRWS) Junction Box 1020J Replacement and Improvement project addresses the critical failure of the existing JB-1020J reinforced concrete structure, which suffered severe corrosion due to turbulent mixing of flows from four separate interceptors at the head of the Jefferson Avenue Relief Tunnel. This tunnel conveys 68 MGD flow to the TRA Central Regional Wastewater Treatment Plant in Grand Prairie, Texas. The project involves the realignment of 1,050 linear feet of influent interceptors ranging from 36- to72-inches and the consolidation of three interceptors into a single pipeline, significantly improving flow management and reducing turbulence. A new corrosion-resistant fiberglass (FRP) fitting replaces the failed junction box, and the project also includes the demolition of remaining structures at Lift Stations No. 2, 3, and 4J. LAN provided analysis, design, and comprehensive construction administrative services. LAN’s role also included providing emergency response, giving the TRA specific recommendations for temporary stabilization and conducting several drone lights to assess the extent of the damage and sol loss. The project features deep (over 50 feet) pipeline and fitting installation within a floodplain, requiring significant bypass pumping and live flow management. The design and construction approach ensures minimal disruption to ongoing plant operations and enhances the long-term reliability of the wastewater conveyance system.
The TRA CRWS Junction Box 1020J Replacement and Improvement project advances the underground infrastructure industry through its innovative use of corrosion-resistant materials and strategic flow management. By replacing the failed concrete structure with a fiberglass (FRP) fitting, the project significantly extends the service life of the junction box and reduces future maintenance costs associated with corrosion. The consolidation of multiple interceptors into a single pipeline streamlines flow, minimizes turbulence, and mitigates the risk of future structural failures. Deep installation techniques and construction within a floodplain required advanced bypass pumping and live flow management, demonstrating best practices for maintaining operations in critical infrastructure environments. The project’s approach to demolition, realignment, and installation in a congested site sets a precedent for similar large-diameter wastewater projects. These innovations collectively improve safety for workers, reduce long-term operational costs, and enhance the resilience and efficiency of wastewater systems, providing a replicable model for future infrastructure upgrades.
Frontera Force Main Emergency Replacement
HARDROCK Infrastructure Services
www.hardrockis.com
In January 2024, HDW initiated a tunneling project in El Paso, Texas, for El Paso Water. The project involved constructing a 1,740-foot tunnel with an 84-inch diameter. Tunneling began from the launch shaft in February 2024, with the receiving side starting in July. The tunnel was excavated using hand tunneling, a method where workers use pneumatic hammers (rivet busters) to break rock. Material was loaded into electric muck carts, transported back through the tunnel to the shaft, and lifted to the surface for disposal. The launch shaft was 13 feet deep and the receiving shaft 16 feet. The alignment passed beneath a small mountain, ranging from 15 feet to 110 feet in depth. As excavation progressed, liner plates were immediately installed to support the tunnel and protect workers from cave-ins. Assembled in segments, these plates formed a complete 84-inch ring. Continuous ventilation was maintained to manage dust and ensure airflow for worker safety.
The project operated 24/7 with four rotating crews. As tunneling advanced, the team encountered rock significantly harder than what was indicated in the geotechnical cores. In August 2024, HDW was acquired by HardRock Infrastructure. Both teams collaborated to find a solution that would allow the project to be completed safely and efficiently. After several strategy sessions, the decision was made to supplement the tunnel with a horizontal directional drilling (HDD) approach. A Vermeer 1000/900 rig was mobilized to drill upward from the low side toward the tunnel, enlarging the bore to 60 inches to accommodate the 54-inch force main. The casing was installed and grouted at the tunnel face to prevent fluid losses and control returns. At the time, tunneling had advanced 400 feet from the receiving side and 200 feet from the launch. Drilling began on Jan. 24, 2025, with grade and trajectory monitored closely to intersect precisely at the planned tunnel point. Once the punch-out was successful, the bore was reamed to final size, and a 54-inch casing was installed along the entire alignment. This project stands out as a major success, demonstrating true teamwork, adaptability, and field-level excellence in overcoming significant technical and geological challenges.
WATER PROJECT of the YEAR (5)
SHERMAN WEST 36" HDPE FORCE MAIN HDD
Dakota Utility Contractors LLC
https://dakotautility.com/
The 36-inch West Sherman Water Main Project was a critical water infrastructure initiative designed to support Texas Instruments’ expansion and future development in the western portion of Sherman, Texas. Once the design was finalized and the project awarded, DAKOTA was engaged to bond the job and mobilize our 330x500 rig to work alongside the city of Sherman, the railroad inspector, and the general contractor. Our team successfully executed a 2,000 LF bore of 36-inch HDPE, including fusing and installing the pipe beneath both Choctaw Creek and an active railroad line. Throughout the project, Dakota’s leadership team maintained constant communication with the customer, providing real-time updates through an active Gantt schedule. This transparency allowed the customer to track progress, anticipate adjustments, and plan effectively as each bore pass was completed. By keeping the customer fully informed and adapting projections as needed, Dakota delivered beyond expectations, finishing on schedule, maintaining quality, and ensuring the project’s success. The customer expressed strong appreciation for the proactive updates and the ability to deliver on project goals.
Dallas Water Utilities Cedar Crest Water Line
Lockwood, Andrews & Newnam, Inc.
The Dallas Water Utilities Cedar Crest Water Line project involved the design and installation of 1,000 linear feet of 84-inch steel water line, including a 385-foot, 108-inch diameter tunnel crossing beneath the Trinity River through hard rock. This critical infrastructure replaced a 72-inch pre-stressed concrete steel cylinder water line that had previously experienced catastrophic failure after becoming exposed due to erosion, threatening the reliability of Dallas’s water transmission system. The project’s innovative tunnel design featured vertical drop pipes within 100-foot-deep secant pile construction shafts, which not only improved constructability and safety but also resulted in cost savings estimated at approximately $11 million. To further enhance the project’s value, steel fittings were engineered to accommodate either ASME pipe wrappers or AWWA crotch plates, providing flexibility and additional cost reductions. A galvanic cathodic protection system was incorporated to prevent corrosion and extend the pipeline’s service life. The project required close coordination with multiple stakeholders and careful planning to minimize construction risks within the 100-year floodplain of the Trinity River. The result is a robust, resilient, and long-lasting water transmission solution that secures a vital water supply corridor for the City of Dallas.
The Dallas Water Utilities Cedar Crest Water Line project sets a new benchmark for innovation in underground infrastructure. By utilizing a 108-inch tunnel through hard rock beneath the Trinity River, the project eliminated the need for open-cut construction in a sensitive and challenging environment, significantly reducing environmental impacts. The use of deep secant pile shafts for vertical drop pipes not only improved worker safety by providing stable access but also streamlined construction logistics, resulting in an estimated $11 million in construction savings. Technological advancements included provisions in the vertical drop shafts for maintenance and operation activity, including maximizing worker safety by including safety barriers and fall protection at the drop shaft within the pipe and installing large manways that typical of a transmission system to allow for insertion of maintenance equipment and/or a mechanized lift. The design also accounted for the owner’s frequent use of internal pipe inspection/assessment technology, ensuring equipment could be retrieved, even through the 100-feet deep vertical shaft.
City of Tempe Rehabilitation of 30" Water Main
CPM Pipelines
A 30-inch water line running under a highway was a mile away from the one that had recently burst. It was decided that the consequence of failure was high and that this pipe should be inspected. The pipe was inspected and found to have defects that could cause negative outcomes. Based on the inspection results the city directed the as-needed engineering consultant to perform an analysis and develop options for rehabilitation or replacement.
The options considered were jack and bore for full replacement, CIPP liner, loose fit liner or close fit FFRPP liner. The CPM Pipelines FFRPP BulletLiner System solution was deemed the best option for this application. This Flexible Fabric Reinforced Plastic Pipe (FFRPP) close fit solution is a three layer system comprised of an inner woven layer of polyester or aramid fibers with an outer jacket and inner liner layer embedded through the woven fabric layer, creating a seamless, high-strength, semi-structural liner inside the pipe. This when installed in combination with the structural capacity of the host pipe creates a structural class IV system. This process restores pipelines while preserving their flexibility and preventing leaks. The pipe repair began with dewatering using soft foam pigs deployed through the valve vaults. A CCTV visual inspection was performed to ensure pipe was properly cleaned and that there were no major structural defects that might cause installation issues or compromise the installation. All debris was removed from the pipe prior to liner installation. The BulletLiner was pulled into place from vault to vault, under the highway, navigating four 45-degree bends with minimal extraneous force applied. A total of 700 feet of liner was installed to complete the rehabilitation. After the liner was inflated, it was air pressure tested at 2 psi to confirm integrity. Termination fittings were installed over the following days using a hydraulic jacking device. A final hydrostatic pressure test was conducted to ensure the liner expanded tightly within the existing pipe. The pipe was disinfected and put back into service. The project was successfully completed quickly, on budget and with no impact on the highway or surrounding businesses. It is the largest and most complicated installation of FFRPP to date.
The project showcased the capabilities of FFRPP, close fit pressure pipe liners to successfully rehabilitate pipelines in difficult locations. In this case a pipeline was under a highway and the cost, complexity and disturbance a replacement project would have caused was unacceptable. The project was completed quickly without having to shut down the highway. The cost was many times lower than a jack and bore replacement. The liner chosen for this project is able to create a Class IV system in conjunction with the structural integrity of the host pipe. The system can be used on pipe from 2 to 60 inches in diameter.
West Harris County Regional Water Authority - Segment B3
West Harris County Regional Water Authority (WHCRWA)
https://surfacewatersupplyproject.com/construction/segment-b/
Segment B3, nicknamed “The Long Tunnel’, represents a remarkable advancement in regional water infrastructure executed by the West Harris County Regional Water Authority. Spanning 4.4 miles with a 96-inch diameter finished waterline, this critical tunneling and waterline project was accomplished by Jay Dee Contractors Inc. and HB Trenchless as a joint venture, using a 128-inch tunnel boring machine named “Suzzann” to tunnel through complex soils with precision and minimal surface disruption. Through collaborative planning and seamless execution, the Project mobilized in May 2022, and the team achieved the final breakthrough in February 2024 with the tunnel and continues to steadily advance toward a final completion in fall 2025. This segment bolsters WHCRWA’s broader mission: delivering sustainable, surface-water supply to counter annual land subsidence, all while exceeding engineering benchmarks for efficiency, community impact mitigation, and technical innovation.
The innovations implemented on this project have advanced the underground infrastructure industry by demonstrating how integrated monitoring, adaptive liner design, and proactive ground control can improve safety, efficiency, and reliability. A robust geotechnical instrumentation program with real-time online systems allowed continuous monitoring of settlement and tunnel performance, ensuring excavation remained within strict tolerances under critical highway infrastructure. This not only improved safety but also reduced risk for owners and contractors by providing immediate data-driven decision-making. The use of galvanized channel lagging in lieu of grouted liner plates streamlined operations by eliminating annular grouting, providing a seamless liner transition, and maintaining production rates. This change reduced costs, minimized construction risks, and improved overall efficiency. Ground stabilization using chemical grouting at shaft breakout locations minimized settlement and distortion, reducing surface impact and increasing safety in sensitive areas. Flood mitigation strategies, including concrete collars and elevated platforms for critical electrical systems, proved resilient during Hurricane Beryl, setting a precedent for climate-adaptive tunnel design. Finally, advancements in face pressure control through custom instrumentation, TBM flood doors, and in-house data logging allowed precise control of ground conditions, reducing settlement to less than 0.1 inches after initial calibration.
Navajo-Gallup Water Supply Project
S.J. Louis Construction, Inc.
https://www.ksut.org/news/2025-07-11/navajo-gallup-water-supply-project-is-on-track-for-completion-at-end-of-2029
Navajo Code Talkers Pipeline 17-mile ROW between Tohlakai Pumping Plant in Yatahey, New Mexico and end of Reach 12.2 in Tse Bonito, N.Mex., roughly paralleling the north side of New Mexico Highway 264. The principal components of work for NGWSP Navajo Code Talker Sublateral include, but are not limited to, the following: 1. Approximately 5-miles of 30-inch diameter water transmission pipeline 2. Approximately 12-miles of 24-inch diameter water transmission pipeline 3. One and a half million-gallon ground level storage tank and yard. 4. Eight-foot diameter by 37-foot-high surge tank5. Supervisory Control and Data Acquisition (SCADA) equipment and fiber optic cabling. 6. Pipeline construction also included several horizontal directional drill (HDD) and auger jack and bore installations
Some communities on the Navajo Nation do get drinking water from groundwater currently, but it's poor quality. It's quickly being depleted because hydrology has not kept up with the use over the last several decades. The Navajo-Gallup Water Supply Project will provide a much cleaner and reliable water source for those communities. The project was delivered and awarded as best value, where SJ Louis submitted value-engineering opportunities which included HDD design revisions intended to save overall costs as well as constructability.
HDD PROJECT of the YEAR (6)
Freezer Underground Heating
Dakota Utility Contractors LLC
https://dakotautility.com/
Under Floor Heating Retrofit Underfloor Heating used horizontal drilling for freezer facilities to prevent heaving and thaw ground for freezer slab(s) to settle back in place. Prior Options were to break up concrete and use glycol that interrupts operations, facility use, concrete repair (needed 21 days to cure), inventory and racking to be removed and reinstalled while facility loses revenue. Using HDD: Facility stays open throughout construction. With a man inside to tack drill head. Drilling takes place in exterior of facility going directly into frost. Heat trace wire is installed in Pipes and wired by an electrician, then tested with HDD Crew on site. Proven successful and have one drill traveling the country completing each of these facilities completing 153 Bores approx. 27,000 LF in eight cities in North America in the past 12 months. DAKOTA team has been entrusted to accomplish each of these assignments with many more in the horizon. Our crews have been able to rise to each new challenge as they occur negative -20 degrees typically but as low as -35 Degrees, interference with locator, personal fatigue with such temperatures. Duration of day as we are on time limit to complete as electricians are behind us as well as customers targets to complete.
James River Crossing Sewage Force Main Horizontal Directional Drill
Garney Construction, Dewberry, Huxted Trenchless, Brierley Associates
https://www.garney.com/projects/james-river-crossing-jrx/
The James River Crossing (JRX) project is part of Hampton Roads Sanitation District's (HRSD) SWIFT (Sustainable Water Initiative for Tomorrow) program. SWIFT is an innovative water treatment and conveyance program in eastern Virginia designed to further protect the region’s environment, enhance the sustainability of the region’s long-term groundwater supply and help address environmental pressures such as Chesapeake Bay restoration, sea level rise and saltwater intrusion. JRX was executed using a design-build (DB) delivery method that was awarded in April 2022 to the Garney/Dewberry design-build team. This project included designing, permitting, and installing a raw wastewater force main across the James River from Newport News to Suffolk. The total crossing is over 4.5 miles comprised of new HDPE pipe ranging in size from 42-inch to 54-inch diameter.
The project includes installation of the new force main under the Newport News Shipping Channel and through a heavily used marine terminal. The basis for the DB request for proposal (RFP) was to perform a water-to-water HDD of approximately 3,200 LF using HDPE pipe under the channel. Early on, the team identified this HDD installation as one of the biggest project challenges. Due to the criticality of the HDD component, the team worked diligently to identify industry leaders with technical expertise, specialized equipment and project experience to perform this one-of-a-kind HDD. Accordingly, Huxted Trenchless and Brierley Associates were brought onto the team as nationally recognized leaders in the trenchless industry.
The JRX project showcases the longest single HDD installation of HDPE pipe of this diameter and dimension ration (DR) that has ever been accomplished and set a world record. The HDD installation crossed nearly 100 feet below the channel, at elevation -160 ft. The deep HDD geometry was necessitated by regional geology, with very soft clays overlying older loose to medium dense silty sands and fine sands. Advancing the HDD through these materials required careful steering and mud control. The JRX project exemplifies how collaboration amongst engineers and contractors can leverage innovation to successfully address project challenges and provide best value solutions. The planning of the JRX HDD installation started prior to the RFP over four years ago, culminating in a successful pullback in May 2024, with final overall project completion in summer 2025.
During procurement, the DB team further analyzed the feasibility of extending the HDD to the shoreline, and the decision was made to proceed with this approach. As a result, more than 2,300 LF of pipeline length was added to the project scope, for a new total (and record breaking) HDD length of over 5,700 LF resulting in savings of over $10 million for the project owner.
Port Arthur Pipeline Louisiana Connector Trenchless Project
Sempra Infrastructure
https://semprainfrastructure.com/what-we-do/energy-networks/port-arthur-pipeline-louisiana-connector/
Sempra Infrastructure worked with HDR as trenchless detailed design, geotechnical engineering, and construction consultant for its Port Arthur Pipeline Louisiana Connector Project that included approximately 72 miles of 42-inch-diameter pipeline and 18 trenchless crossings (over 57,000 feet), making it a significant trenchless project worthy of recognition. Other important project contributors included general contractor Troy Construction, and HDD subcontractors MAXX HDD, Michels, Hardrock, and North Country Directional Drilling. The crossings included 17 HDDs and one direct steerable pipe thrust, which subcontractor The Trenchless Company installed. The trenchless crossing designs included 13 water, one foreign pipeline, and five road or highway crossings, including Interstate 10. The longest HDD crossing design, which was water-to-water, was 6,874 and shortest was 1,909 feet horizontal length. HDR performed an extensive subsurface investigation campaign on land and overwater, including 72 bores totaling 10,075 feet of drilling, to support detailed designs and constructability evaluations for the proposed HDD and DSPT crossings. The detailed investigations were critical to evaluating feasibility as well as meeting the requirements for permitting agencies to approve the planned trenchless construction methods. In parallel, HDR’s FERC permitting specialists assisted Sempra Infrastructure in preparing Resource Reports and an APEA. Construction of the trenchless crossings started in late March and ended earlier than forecasted in September 2025. HDR monitored construction on site, providing real-time recommendations in the field to address construction and site challenges that arose, which helped avoid construction delays. The Port Arthur LNG project, including this trenchless pipeline project in Texas and Louisiana, is expected to generate thousands of jobs, has a positive impact on the US economy, and provides access to reliable US natural gas to markets worldwide.
Sempra Infrastructure's PAPLC Project included over 57,000 feet of 42-inch-diameter trenchless (HDD and DSPT) crossings successfully installed between the end of March and Sept. 11, 2025.
Gibsonton Septic to Sewer Conversion Force main
Westlake Pipe & Fittings
https://hcfl.gov/government/septic-to-sewer-and-lpss-conversion-projects/gibsonton-septic-to-sewer-conversion-project
The Hillsborough County, Fla., Water Resources Department launched a comprehensive wastewater service improvement project in the Gibsonton area to connect businesses and property owners to safe, reliable and environmentally responsible wastewater services. This initiative will transition utility customers from septic systems to the county’s centralized wastewater collection and treatment system. Known as the Gibsonton Septic-to-Sewer (S2S) Conversion Project, the effort is part of a countywide strategy to protect groundwater and enhance the quality of natural water systems by eliminating septic tanks and low-pressure sewer systems near Tampa Bay.
The overall project includes the construction of new vacuum sewer pipelines, a new vacuum sewer pump station and effluent force main, a booster pump station, and replacement of water pipelines in the area. Phase 1B is a force main connecting the new vacuum sewer pump station to a new inline booster pump station. The project will improve water quality, protect local waterways – including the Alafia River, Bullfrog Creek and Tampa Bay – and enhance fire protection.
The Phase 1B project involved installation of approximately 18,000 LF of primarily 12- and 16-inch PVC force main, including seven HDDs totally approximately 6,300 LF. The project corridor consisted of three, two-lane county roadways: Nundy Avenue, East Bay Road and Symmes Road. Major obstacles included two Bullfrog Creek crossings adjacent bridges, an overpass crossing of FDOT’s I-75, and adjacency to dozens of high mast electrical transmission poles.
HDD was utilized primarily along Symmes Road, a major east-west connector roadway between US41 and US301. This heavily trafficked roadway included a narrow, varying-width right-of-way and significant utility congestion. HDD allowed the contractor to install the pipelines while minimizing impacts to the travelling public, maintaining two-way traffic throughout construction. In lieu of the “rolling” lane closures typically required by open-cut construction, HDD allowed for stationary staging areas and lane shifts at the drill entry and exits, leading to reduced public impact and increased traffic safety. Symmes Road also features a significant number of intersections including many single-access neighborhoods. This meant that most HDDs would not have the ability to stage long segments for pullback without costly provisions. In the Gibsonton S2S Phase 1B project, the strategic use of horizontal directional drilling with segmental PVC, along congested and high-traffic corridors, minimized disruptions to the community while ensuring the safe and efficient installation of critical force mains. The project successfully executed a 1,540 LF, 16-inch diameter Certa-Lok PVC HDD segment – the longest of its kind in Florida – through proper planning and design along with coordination of ballasting and joint assembly logistics.
Port of Corpus Line Replacement
HARDROCK Infrastructure Services
www.hardrockis.com
The Port of Corpus Christi is the fifth-largest port in the United States and the leading hub for oil exports. As part of a major expansion to accommodate larger vessels, the ship channel is being widened and deepened, requiring the relocation of multiple existing utilities. One such utility relocation involved the installation of a 24-inch waterline beneath the ship channel, extending through a sensitive wetland area known as Tule Lake. This HDD crossing spanned 6,189 feet using 24-inch steel pipe and included a 17-degree horizontal curve at the exit.
The project presented a range of complex challenges, including difficult ground conditions typical of the Corpus Christi region, as well as the intricate layout of the bore path. The pipe was installed approximately 140 feet below the proposed final depth of the ship channel. Geotechnical conditions were especially demanding, with frequent transitions between sand and fat clay, two soil types that are incompatible in drilling fluid management. These transitions required close monitoring and adjustments to maintain effective mud properties throughout the bore. Given the total length and the significant horizontal curve at the exit, it was determined early in the planning phase that an intersect would be the most viable solution. An exit rig was used to initiate the intersect, which allowed for better control and precision when navigating the vertical and horizontal curves, especially compared to managing the curve from the entry point over 4,500 feet away.
From the beginning, the team faced complex and ever-changing ground conditions constantly transitioning between sand and fat clay. These unpredictable transitions required constant monitoring and adjustment of drilling fluid properties to maintain borehole stability and prevent costly failures. Effective mud management became a critical factor, and the crew’s ability to adapt in real-time was nothing short of remarkable. In addition to ground conditions, the bore path presented significant technical challenges with both vertical and horizontal curves particularly near the exit, where the intersecting rig was required to navigate a tight, 17-degree horizontal curve. Precision was essential, and the team executed flawlessly. Logistics added yet another layer of complexity.
To lay out the 6,189 feet of 24-inch product pipe, the crew had to coordinate a temporary shutdown of Up River Road a major public roadway. This required collaboration with local authorities and meticulous planning to ensure both public safety and project efficiency. Successfully managing this closure, and executing the pullback under such constraints, was a major feat in itself.
Navajo-Gallup Water Supply Project
Atlas Trenchless, LLC
https://www.ksut.org/news/2025-07-11/navajo-gallup-water-supply-project-is-on-track-for-completion-at-end-of-2029
Navajo Code Talkers Pipeline 17-mile pipeline was installed between Tohlakai Pumping Plant in Yatahey, N. Mex., and end of Reach 12.2 in Tse Bonito, N. Mex., roughly paralleling the north side of New Mexico Highway 264. The principal components of work for NGWSP Navajo Code Talker Sublateral include, but were not limited to, the following:
- Approximately 5-miles of 30-inch diameter water transmission pipeline
- Approximately 12-miles of 24-inch diameter water transmission pipeline
- One and a half million-gallon ground level storage tank and yard
- Eight-foot diameter by 37-foot-high surge tank
- Supervisory Control and Data Acquisition (SCADA) equipment and fiber optic cabling
- Pipeline construction also included six horizontal directional drills up to 36-inches, as well as auger jack and bore installations
Some communities on the Navajo Nation do get drinking water from groundwater currently, but it's poor quality. It's quickly being depleted because hydrology is not keeping up with the use over the last several decades. The Navajo-Gallup Water Supply Project will provide a much cleaner and reliable water source for those communities. Atlas Trenchless took a collaborative approach with the General Contractor (SJ Louis Construction) at bid time to submit value-engineering opportunities to pass on to the Bureau of Reclamation. After award, and during construction, Atlas and SJ Louis worked with the Bureau and their TSC to fine-tune the submittal expectations - as they lacked sufficient knowledge on large HDD projects. Atlas was able to complete all of the HDDs successfully and keep the project on-track.
FIBER PROJECT of the YEAR (1)
160 Miles Fiber Snyder-Post-Gail Texas
Dakota Utility Contractors LLC
https://dakotautility.com/
Dakota with a challenge when a customer was facing a fiber project that was a span of approximately 160 total miles from Snyder to Post, Texas then to Gail, Texas, that consisted of many open cuts and 560 total bores for 129,051 LF in a rural area with its challenges of three river crossings, changing soil conditions that utilized our fleet of drills soaking up at least six rigs at any given time but successfully completed in 66 days beginning Feb. 11, 2025. February weather typically can shut down work for up to a week. The Dakota team hustled and reminded both themselves and their dedicated partner that they were the right choice to tackle such a large project. The Dakota project management team, back office and supervisors stayed dialed in to each other while we reported production daily, weekly & monthly to all involved in this project which was successfully completed ahead of schedule.
Comments