2026 | NORTHWEST
FALL/WINTER
Return Undeliverable Canadian Items to: 3C-2020 Portage Ave, Winnipeg, MB R3J 0K4 PM #40065075
THE OFFICIAL PUBLICATION OF THE NORTHWEST CHAPTER OF THE NORTH AMERICAN SOCIETY FOR TRENCHLESS TECHNOLOGY
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION
Spray-In-Place-Pipe Rehabilitation
Before
Bring New Life To Old Pipes Affordably & Sustainably Restore service in as little as one day
Cleaned
Lined
Resiline 320 is projected to meet properties of ASTM F1216-16 after 50 years. Advantages of the SIPP In-Situ Lining Process • Significantly extends asset life and improves water quality • Prevents internal corrosion and tuberculation • Helps reduce water loss and repair certain cracks and pinholes • Helps restore internal pipe diameter and C factor • Allows for same-day return to service
w w w.induracoat.com
2026 | NORTHWEST
NASTT-NW BOARD OF DIRECTORS CHAIR RAVEN SHARMA City of Selkirk THE OFFICIAL PUBLICATION OF THE NORTHWEST CHAPTER OF THE NORTH AMERICAN SOCIETY FOR TRENCHLESS TECHNOLOGY
PAST CHAIR GEORGE BONTUS AECOM VICE-CHAIR CHAOSHI HU EPCOR
IN THIS ISSUE:
TREASURER CRAIG PASS Associated Engineering SECRETARY ZULFIQAR KHOWAJA City of Calgary
9
BOARD MEMBER ALI BAYAT University of Alberta BOARD MEMBER ALLISON HAHN City of Regina BOARD MEMBER CHAO KANG WSP Canada, Inc. BOARD MEMBER CHRIS LAMONT Associated Engineering
www.kelman.ca Managing Editor: Julia Waterer Design/Layout: Dani Goulet Marketing Manager: Chad Morrison Advertising Coordinator: Sabrina Simmonds
9
21 DEPARTMENTS:
ACCELERATING CALGARY’S BEARSPAW SOUTH FEEDERMAIN STAGE A EMERGENCY TRENCHLESS REPLACEMENT
MESSAGE FROM THE NASTT-NW CHAIR...................5
15
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION
ADVERTISER PRODUCT & SERVICE CENTRE........................30
21
PROJECT OF THE YEAR: CHAMPLAIN HUDSON POWER EXPRESS TERRESTRIAL PROJECT
MESSAGE FROM NASTT.................7
2026 | NORTHWEST
VIEW US ONLINE NASTT-NW.COM
FALL/WINTER
THE OFFICIAL PUBLICATION OF THE NORTHWEST CHAPTER OF THE NORTH AMERICAN SOCIETY FOR TRENCHLESS TECHNOLOGY
Return Undeliverable Canadian Items to: 3C-2020 Portage Ave, Winnipeg, MB R3J 0K4
Return Undeliverable Canadian Items to: 3C-2020 Portage Ave, Winnipeg, MB R3J 0K4 PM #40065075
Publication Mail Agreement #40065075 ©2026 Craig Kelman & Associates Ltd. All rights reserved. The contents of this publication, which does not necessarily reflect the opinion of the publisher or the association, may not be reproduced by any means, in whole or in part, without the prior written consent of the Northwest Chapter of the North American Society for Trenchless Technology.
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION
ON THE COVER: Calgary’s Bearspaw South Feedermain worksite. Photo courtesy of Zulfiqar Khowaja.
NASTT-NW.COM | 3
TEAR EARTH. TURN HEADS. Take on every bore path with confidence, from pilot drilling through reaming and pullback, backed by complete underground solutions and nationwide support from Brandt.
MORE POWER Drill faster and get more done with Ditch Witch® JT120 HDD performance.
MORE UPTIME
MORE SUPPORT
Stay on line and avoid rework with the Subsite® Marksman HDD Guidance System.
Keep crews working with 100+ Brandt service points and 24/7/365 support.
Scan to explore more or contact your Brandt dealer today. brandt.ca/DitchWitch
MESSAGE FROM THE NW CHAIR
Raven Sharma, NW Chair
GRATEFUL FOR BOARD SUPPORT
A
s Chair of the NASTT Northwest Chapter, I want to take this opportunity to sincerely thank our Board members for their ongoing work, dedication, and commitment to the continued growth of our organization. There is a great deal happening within our Calgary section, particularly in the areas of education, outreach, technical development, and industry engagement. None of this would be possible without the time and effort contributed by our Board members and volunteers. Their willingness to take on new initiatives, support our committees, develop educational opportunities, and continue moving ideas forward is greatly appreciated. We are continuing to build momentum through initiatives such as our Lunch and Learns. On September 24, we had a lunch in recognition of World Trenchless Day, the development of future technical sessions including CIPP lining education, and our ongoing work with SAIT toward establishing a Calgary Student Chapter. The Edmonton June Symposium was a great event and well attended. We are hopeful to have a Calgary June Symposium in 2027. These initiatives are important because they allow us to connect students, professionals, contractors, consultants, municipalities, and industry leaders while continuing to expand trenchless education and knowledge sharing.
Our concern for the environment is more than just talk
This publication is printed on Forest Stewardship Council® (FSC®) certified paper with vegetable oil-based inks. Please do your part for the environment by reusing and recycling.
BACK TO CONTENTS
I am especially grateful to each of our Board members for the work that happens behind the scenes. The meetings, planning, discussions, coordination, and follow-up all require a significant commitment of time. Your continued dedication is helping us strengthen the chapter and create more opportunities for our members and the broader trenchless community. Thank you for continuing to support one another, bring forward new ideas, and contribute your expertise. I am proud of the progress we are making together and excited about what we can accomplish as we continue building our education and outreach efforts in Calgary and across the chapter.
CARBON FIBRE TECHNOLOGIES
EXTEND Asset Life
REDUCE Risk of Failure Infrastructure Repair & Rehabilitation Carbon Fiber and Epoxy Internal & External Wrap System engineered for structural strengthening & rehabilitation.
NSF APPROVED & SWAT TESTED
www.tcicarbonfibre.com
NASTT-NW.COM | 5
Go Trenchless with TerraBrute™ CR
Available in
4”– 24” Engineered for Horizontal Directional Drilling (HDD) and other trenchless applications, TerraBrute® CR is a 100% non-metallic, AWWA C900 PVC pressure pipe system. Non-corroding and installation-friendly, TerraBrute® CR lets you standardize on PVC throughout your municipal water infrastructure. Designed for large diameter projects up to 24 inches, it offers unmatched strength and leak-free performance in high-pressure environments, ensuring efficient, cost-effective solutions with minimal disruption.
LEARN MORE
ipexna.com TerraBrute® CR is manufactured by IPEX Inc. TerraBrute® CR is a trademark of IPEX Branding Inc.
MESSAGE FROM NASTT
Greg Tippett, NASTT Chair
EXCITING EVENTS IN YOUR CHAPTER
A
s we move from another busy season of implementing trenchless technologies across the region, I’m pleased to share some of the exciting learning opportunities ahead for the NASTT Northwest Chapter and our members throughout the region. The Northwest Chapter holds Technical Luncheons most months in both Calgary and Edmonton. The trenchless industry never stands still. New technologies, evolving infrastructure needs, increasingly complex projects, and a continued focus on sustainable solutions mean there is always something new to learn. These in-person luncheons provide an opportunity to explore these developments at the regional level, with technical presentations and real-world perspectives that attendees can take back to their own organizations and projects. Just as important are the connections made outside of the technical program. Our Chapter events bring together engineers, contractors, manufacturers, suppliers, utility owners, municipalities, students, and other industry professionals who may approach underground infrastructure from different perspectives but share many of the same challenges and goals. I encourage you to take advantage of the opportunity to reconnect with colleagues, meet new people, exchange ideas, and strengthen relationships throughout the Northwest trenchless community. Beyond your Chapter, there is plenty happening across NASTT this fall. Coming up right in the heart of your Region is the NASTT 2026 No-Dig North conference, November 2–4 in Calgary, bringing the trenchless community together for Canada’s premier trenchless conference and exhibition. Attendees can look forward to technical education, an active exhibit hall, networking
BACK TO CONTENTS
opportunities, and the chance to learn from projects, technologies, and professionals from across Canada and beyond. And while 2026 is far from over, we’re already looking ahead to the NASTT 2027 No-Dig Show, taking place March 21–25, 2027, in Raleigh, NC. The No-Dig Show remains the cornerstone of NASTT’s educational and networking opportunities, bringing thousands of trenchless professionals together to share knowledge, discover new technologies, and advance our industry. These events are part of a much larger NASTT mission. Throughout the year, the Society and its Regional and Student Chapters provide education, technical resources, networking, volunteer opportunities, scholarships, industry recognition programs, and countless ways
to become more involved. Whether you are a longtime member or are just beginning to explore what NASTT has to offer, I encourage you to take advantage of these opportunities and find the ones that are most meaningful to you. Your Chapter is strongest when our members participate, share their expertise, and stay connected. Thank you to our volunteers, sponsors, speakers, members, and industry partners who continue to make our programs possible and support the growth of the trenchless community throughout the Northwest region. We look forward to seeing many of you in Calgary in November and Raleigh next March. There is a lot ahead for NASTT and our industry, and I’m excited for what we’ll accomplish together.
NASTT-NW.COM | 7
Congratulations, Jason Lueke Associated Engineering is very pleased to announce that Jason Lueke, Ph.D., P.Eng., was named Trenchless Technology Magazine’s Person of the Year! This recognition is awarded annually to an individual who has demonstrated significant achievement, and outstanding leadership in the advancement of trenchless technology. For nearly 25 years, Jason has been a driving force in the North American trenchless industry. At Associated, Jason plays a pivotal role on our most complex projects. He is a tireless advocate for the industry, mentoring young professionals and students, and volunteering his time locally and nationally. Congratulations, Jason! Jason Lueke, Ph.D., P.Eng. National Discipline Leader, Trenchless Technologies
www.ae.ca
8 | NASTT-NW JOURNAL | Fall/Winter 2026
BACK TO CONTENTS
ACCELERATING CALGARY’S BEARSPAW SOUTH FEEDERMAIN STAGE A
EMERGENCY TRENCHLESS REPLACEMENT
COLLABORATIVE DELIVERY, AND LESSONS FOR CRITICAL WATER INFRASTRUCTURE ZULFIQAR KHOWAJA, M.ENG., P.ENG., SENIOR PROJECT ENGINEER - CITY OF CALGARY
WHY THE PROJECT MATTERED
Calgary's Bearspaw South Feedermain (BSFM) is one of the City's highest consequence feedermain and carries approximately 60 percent of Calgary's drinking water supply. A major rupture in June 2024 exposed the operational consequences of losing the main. A second rupture on December 30, 2025, caused significant flooding, emergency rescues, and renewed water restrictions, confirming the
BACK TO CONTENTS
need to accelerate replacement of the aging prestressed concrete cylinder pipe (PCCP) system (Khowaja et al. 2026). Stage A includes approximately 3.8 km of new 1,950 mm welded steel feedermain installed inside a reinforced concrete microtunnelled casing between the West Sarcee area and Shaganappi Pump Station. FROM EMERGENCY RESPONSE TO RISK RETIREMENT The original phased program planned construction extending into 2028. After the December 2025 failure, the City established December 2026 as the operational target for the new main. The replacement was no longer treated as a conventional capital upgrade. Every month saved reduced the period in which Calgary depended on a deteriorated, single point of failure asset. This shift changed how the team evaluated procurement, design, work areas, equipment,
material commitments, and construction sequencing (Khowaja et al. 2026). BUILDING THE NEW FEEDERMAIN IN A CONSTRAINED CORRIDOR The City, designer, contractor, suppliers, construction manager, operators, and approval authorities had to organize the work around several concurrent production systems. Stage A uses a 1,950 mm welded steel carrier pipe installed within concrete jacking pipe. The tunnel remains generally in bedrock and below the operating feedermain, allowing major roads, rail, parks, utilities, and the Bow River corridor to be crossed while the existing main remains in service. The City selected shaft sites that limited surface disruption and protected the existing feedermain while providing sufficient work areas to accelerate the schedule (Khowaja et al. 2026; Kurre et al. 2026).
NASTT-NW.COM | 9
ACCELERATING CALGARY’S BEARSPAW SOUTH FEEDERMAIN STAGE A WHY MICROTUNNELLING SUPPORTED EMERGENCY DELIVERY Pressurized face microtunnelling gave the team a remotely operated method that could balance earth and groundwater pressures without broad construction dewatering. Keeping the alignment in Paskapoo Formation bedrock reduced settlement exposure near the existing feedermain and surface infrastructure while supporting long pipe jacking drives. Using shaft sites available to the City limited community disruption and avoided locations where shaft construction could compromise the existing feedermain, while providing work areas large enough to support an accelerated schedule. These characteristics made microtunnelling compatible with the central delivery requirement: build the replacement quickly without increasing risk to the live main (Khowaja et al. 2026; Kurre et al. 2026). The final method was also adaptable. The 2,500 mm internal diameter remained on the approximately 1.1 km drive, while most of the alignment was reduced to 2,286 mm internal diameter after the contractor confirmed that the smaller casing could accommodate the steel carrier and installation method. The smaller diameter reduced excavation, spoil haulage, and loading on slurry handling equipment. It also expanded the number of suitable microtunnel boring machine configurations available for simultaneous deployment (Khowaja et al. 2026).
TURNING SCHEDULE COMPRESSION INTO PARALLEL PRODUCTION Ward & Burke developed an execution plan that reduced the planned construction period from approximately 26 months to approximately 11 months. Within one week of award, four complete microtunnelling setups and crews were allocated to the project: three for active drives and one as standby capacity. The project could therefore advance several drives at once and redeploy equipment if site conditions or mechanical issues threatened a workfront. Table 1 summarizes three design changes that removed major sequential dependencies, while Table 2 shows how equipment, crews,
and material supply supported continuous production (Khowaja et al. 2026). SEPARATING TUNNELLING FROM PIPE INSTALLATION The two-pass system further separated specialized activities. Reinforced concrete jacking pipe is installed first to provide the tunnel and ground-support envelope. The 1,950 mm welded steel pressure pipe is then moved through the completed casing, positioned on spacers, welded, inspected, field coated, cleaned, tested, and grouted in place. Because carrier pipe installation does not occur at the tunnel face, pipe crews can follow completed drives while other MTBMs continue advancing.
MEASURE
ORIGINAL CONSTRAINT
PROJECT CHANGE
WORK UNLOCKED
SCHEDULE EFFECT
West Sarcee shaft
Approx. 38 m depth
Raised alignment; approx. 28 m shaft
Faster shaft preparation
Earlier MTBM launch
Approx. 1.4 km drive
Single sequential drive
Added intermediate shaft
Two parallel workfronts
Reduced elapsed tunnelling time
Valve chambers
Dependent on tunnelling
Separate temporary and permanent shafts
Chambers and tunnelling in parallel
Removed sequential dependency
Table 1. Design changes that enabled parallel delivery (Khowaja et al. 2026)
WORKSTREAM
PRIMARY RESOURCE
CAPACITY
OPERATING APPROACH
RISK CONTROL
SCHEDULE EFFECT
Tunnelling
AVN2500, AVN2200 and AVN2100
Three active; one standby
Parallel drives
Backup MTBM
Concurrent production
Longest drive
Two crews
Up to 24-hour operation
Continuous advance
Limit restart forces
Protect critical path
Pipe supply
Three Canadian precast plants
Concurrent production
Delivery by drive demand
Supplier redundancy
Avoid pipe shortages
Table 2. Acceleration resources and controls (Khowaja et al. 2026)
10 | NASTT-NW JOURNAL | Fall/Winter 2026
BACK TO CONTENTS
ACCELERATING CALGARY’S BEARSPAW SOUTH FEEDERMAIN STAGE A
Separating the temporary microtunnelling shafts from the permanent valve chambers removed another dependency and allowed chamber construction and tunnelling to proceed in parallel (Khowaja et al. 2026). COMPRESSING THE SCHEDULE The City had issued a competitive request for proposals before the second failure. Once the completion target changed, contractor selection, MTBM availability, jacking pipe, steel pipe, valves, temporary works, site access, permits, and commissioning all became schedule critical. Confidential Commercial Meetings were used to test construction methods and long-lead procurement strategies with industry. Ward & Burke was then selected through a single-source process based on the emergency schedule, relevant large-diameter bedrock microtunnelling experience, ability to self-perform critical work, and capacity to mobilize quickly (Khowaja et al. 2026). The contractor proposed several targeted changes. Raising the alignment at West Sarcee reduced the shaft depth from approximately
BACK TO CONTENTS
38 m to 28 m. An intermediate shaft divided an approximately 1.4 km drive into two workfronts. Separate temporary tunnelling and permanent valve-chamber shafts allowed both activities to start without waiting for the other. Three Herrenknecht AVN machines were mobilized, with another AVN2200 held on standby. When shutdown periods increased jacking forces on the longest 2,500 mm drive, a second crew was made available, providing the ability to operate for up to 24 hours per day. The combined strategy completed approximately 3.8 km of microtunnelling in less than five months, averaging about 186 m per week (Khowaja et al. 2026). KEEPING MATERIALS AND APPROVALS OFF THE CRITICAL PATH Multiple tunnelling spreads required a matching material and approval strategy. Three Canadian precast manufacturers produced concrete jacking pipe concurrently: Precon Manufacturing in Lethbridge, Amrize in British Columbia, and Decast in the Greater Toronto Area. Deliveries were prioritized against the advance of each drive so that pipe inventory
did not constrain the MTBMs. In parallel, the team advanced railway, utility, regulatory, mobility, power-servicing, operations, and public-interface requirements through direct and frequent coordination. Treating manufacturing, transportation, approvals, and construction as one schedule allowed the field work to benefit from the equipment capacity already mobilized (Khowaja et al. 2026). LESSONS FOR OTHER MUNICIPALITIES Stage A shows that emergency trenchless delivery depends on converting an operational deadline into specific decisions about procurement, design, resources, and materials. The accelerated schedule was achieved by removing dependencies: shallower shafts reduced preparatory work, an additional shaft enabled parallel drives, separate chamber shafts allowed permanent works to proceed independently, multiple MTBMs created production capacity, and three precast suppliers protected the flow of jacking pipe. Each measure addressed a defined constraint rather than relying on schedule pressure alone (Khowaja et al. 2026).
NASTT-NW.COM | 11
ACCELERATING CALGARY’S BEARSPAW SOUTH FEEDERMAIN STAGE A
Figure from the City of Calgary website.
The case also demonstrates the value of collaborative procurement under emergency conditions. Early dialogue allowed the City to test whether equipment fleets, work areas, construction methods, and supply chains could support the required date before committing to the execution plan. Once construction began, standby equipment, continuous operation on the critical drive, and active delivery control provided practical ways to respond to changing conditions. For other municipalities managing vulnerable PCCP systems, the lesson is direct: align commercial strategy, technical design, field resources, and material logistics around the time required to retire the operating risk. ACKNOWLEDGMENTS The author acknowledges the contributions of the City of Calgary project team, Jacobs,
12 | NASTT-NW JOURNAL | Fall/Winter 2026
Ward & Burke Microtunnelling Ltd., the construction management team, utility and regulatory groups, precast pipe suppliers, and other partners advancing the Bearspaw South Feedermain Improvements program. REFERENCES Associated Engineering. 2024. Bearspaw South Feedermain Repair Methods Identification and Considerations. Associated Engineering. 2025. Bearspaw South Feeder Main Investigation Report, IP20241237 (Public Version). City of Calgary. City of Calgary. 2021. Standard Specifications & Design Guidelines: Potable Water Feedermain Construction. City of Calgary. 2026. Non-Competitive Construction Services Procurement – Bearspaw South Feedermain Improvements Stage A and Stage B: Background and Rationale. Khowaja, Z., Ng, S., and Parata, M.
2026. Accelerating the Bearspaw South Feedermain: A Case Study in Emergency Trenchless Replacement and Collaborative Rapid Infrastructure Delivery. NASTT No-Dig North, Calgary, Alberta. Jacobs. 2025a. Bearspaw South Feedermain Twinning Project – Stage A Geotechnical Data Review. Jacobs. 2025b. Geotechnical Baseline Report: Bearspaw South Feedermain Improvements – Stage A and Stage B Phase 1. Kurre, R., Draper, M., Khowaja, Z., and Nummi, R. 2026. Emergency Twinning of a Critical Large Diameter PCCP Feedermain Using Microtunneling: Lessons from Calgary’s Bearspaw South Feedermain Improvements Stage A. NASTT No-Dig North, Calgary, Alberta. Thurber Engineering Ltd. 2025. Bearspaw South Feedermain Improvements Shaganappi Pump Station to 73 Street NW: Stage A and Stage B Phase 1 Geotechnical Data Report.
BACK TO CONTENTS
Our trenchless solutions and industry-leading products for water, wastewater, and conduit applications offer leak-free performance, minimize installation disruptions, and restore public services quickly and cost-effectively.
CIPP | Insitumain® | UV Lining | Geopolymer
insituform.com | 780.982.0257
Dr. Mark Knight, Consulting Engineer, PE, SIPP Americas LLC, Dallas, Texas
INTRODUCTION In 1982, the United Kingdom (UK) began testing the Spray in Place Polymer (SIPP) method to rehabilitate watermain pipes. This method used slow-curing epoxy coatings, 1 to 2 mm thick, as a replacement for AWWA Class I Cement Mortar linings, which had caused
higher pH levels and negatively affected water quality and taste. By the late 1980s, epoxy was approved for use in UK drinking water systems, leading to Section 19 water quality improvement projects throughout the 1990s. In the early 1990s, Dr. Ian Robinson at E. Woods Holdings PLC (E. Woods) in the
UK created a SIPP lining material with a 16-hour cure time, enabling pipes to be put back into service on the same day. Following this development, over 100 SIPP rigs were used throughout the United Kingdom to rehabilitate water mains by applying 1 to 2 mm of Generation 1 SIPP AWWA Class I polymers.
1980’s
2000’s
Gen 1 Class I Water Quality Coatings • Slow Cure Epoxy – 1 to 2mm
Gen 2 Class I to IV? • High Build (2 to 3mm per coat) Rapid Cure • Multi Application Fast Cure Linings
Gen 1 Class I Water Quality Coatings • Rapid Cure 1 to 2mm • Same Day Return to Service
Gen 3 Resiline 320 Class I to IV? • High Build (1 to 3mm per coat) • Rapid Cure • Multi Application Fast Cure Linings
1990’s
2020’s
Figure 1: Development of SIPP materials for Water Main Rehabilitation.
BACK TO CONTENTS
NASTT-NW.COM | 15
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION
Ring Fracture
Water Leakage
Water Tight Seals
External Mechanical Fitting
Cast Iron Pipe
Gap Pressurized Water 293 to 793 kPa
CIPP Liner Pressurized Watermain 293 to 793 kPa Figure 2: Water leaks through a liner-host pipe gap with no seals.
In 1999, Dr. Robinson obtained approval for the first high-build SIPP resin that could be applied in layers of 2 to 3 mm per coat and cured quickly. This second-generation SIPP resin made it possible to rapidly add multiple coats, creating liners that met AWWA Class I to III standards. Currently, it is estimated that around 10 percent of the UK's water network has been rehabilitated using the SIPP lining technique. In 2007, 3M acquired E. Woods for $78 million and subsequently launched SIPP water lining in the North American market utilizing E. Woods Generation 2 fast-cure, high-build SIPP polymer. From 2007 to 2017, prior to discontinuing its SIPP lining division, 3M successfully lined approximately 10 to 15 miles of water mains per year. In 2019, Dr. Ian Robinson of Resimac Ltd (UK) developed Resiline 320, a high-build, fast-curing SIPP polymer with superior wet mechanical properties compared to Generation 2. This third-generation material received NSF/ANSI/CAN 61 approval in 2020, leading to watermain lining trials in Canada and the U.S. Currently, in North America a variety of polymeric materials are available to rehabilitate pressure pipes i.e. sewerage force mains and potable water mains. WATER MAIN SPRAY-IN-PLACE POLYMER MATERIALS The term ‘polymer’ is widely utilized within the plastics and composites industry, frequently serving as a synonym for plastic or resin. Polymers are chemical compounds consisting of molecules that are bonded together in extended, repeating chains. Owing to their structural characteristics, polymers possess distinct properties that can be engineered for varied applications.
16 | NASTT-NW JOURNAL | Fall/Winter 2026
SIPP materials are cross-linked polymers, categorized as thermoset resins. Thermoset polymers do not undergo melting and cannot be re-bonded once the cross-linked molecular bonds are broken. Consequently, cross-linked polymers typically demonstrate enhanced attributes such as increased strength, rigidity, thermal stability, and hardness. North America's plumbing codes and municipal water pipe rehabilitation standards specify that all water main lining products must be certified by an ANSI-accredited laboratory to comply with NSF/ANSI/CAN 61 Certified for Drinking Water System Components – Health Effects. NSF/ANSI/ CAN 61 is an American National Standard that sets minimum health-effects criteria for chemical contaminants and impurities that may be indirectly introduced to drinking water from products, components, and materials used in these systems. This standard does not address the material fit for purpose, taste and odor, or microbial growth support requirements for drinking water system products, components, or materials. NSF/ANSI/CAN 61 Certified products are also required to undergo routine testing by an independent, accredited laboratory, and must maintain a valid certification that is accessible to the public. Each NSF/ANSI/CAN 61 Certificate will list material characteristics such as: • Minimum pipe diameter • Maximum dry film thickness per coat; (mils) • Is additional coating required (e.g. topcoat, primer, intermediate coat)? (Y/N) • Total cure time and temperature • Shortest cure time between coats or layers • Final cure time • Water Flushing requirements • Ambient cure time • Mix ratio
Compliance with all requirements set forth in the valid NSF/ANSI/CAN 61 Certificate is essential to confirm that the rehabilitated pipe is suitable for potable water use. Because requirements may vary by product, system owners or their representatives should request and obtain a valid certificate issued by an accredited and certified testing laboratory. Polymers encompass a wide range of materials, each with distinct dry and wet mechanical properties, performance characteristics, and material costs. Common polymers utilized in SIPP rehabilitation of watermains include epoxy, polyurethane, and polyurea. The following sections will provide an overview of each polymer type. EPOXY Epoxy refers to a family of resins and cured products, known as polyepoxides, which are reactive prepolymers or polymers containing epoxide groups. Since the 1980s, NSFcertified epoxy coatings and CIPP liners have been used for water pipes. Water main epoxies are 100 percent solids, styrene-free, and demonstrate excellent dry and wet tensile and flexural mechanical properties once the liner is fully cured. For water main liners, dry mechanical properties are irrelevant to actual product performance, as the liners will remain fully saturated during service. Epoxy's main limitation is its long, temperature-sensitive curing time, preventing same-day service return. For CIPP epoxy liners hot water, steam or UV light is used to speed up and ensure consistent short and long-term liner mechanical properties. Water CIPP liner NSF certificates typically specify day one as curing, day two as water flushing and day three to four as ambient
BACK TO CONTENTS
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION curing. SIPP epoxies are normally ambient cure resins which will be impacted by the insitu pipe wall temperature. For example, a SIPP epoxy resin that has an NSF five-day cure at 70F (20C) will take a lot longer to cure when the pipe ground temperature is lower than this value. In Canada and the USA, the ground temperature at 8 feet (2.4m) deep generally stabilizes between 45°F to 60°F (7°C to 15°C), varying by region, but often around 50-55°F (10-13°C) in as deeper soil insulates against surface air temperature swings, providing a consistent, year-round mild temperature. Epoxies slow cure can result in liner defects at services and connection should drip back occur. High curing temperatures and exothermic reactions can cause liner shrinkage. Greater cure temperatures usually lead to more shrinkage, which may create gaps if adhesion bond strength is exceeded. If service connections and terminations are not properly sealed, water can travel between the liner and the host pipe under pressure and leak out through services, joints, or holes in the pipe as shown in Figure 2. The strength of the bond between the liner and host pipe is influenced by how well the pipe is cleaned and prepared. According to AWWA C620, the recommended minimum adhesion strength between the liner and pipe is 250 psi (1724 kPa). During the curing process of epoxy, an amine blush forms on the liner surface. This residue must be removed through washing or abrasion prior to applying a subsequent coat, as it can impede proper adhesion. Thorough preparation of the liner is essential to achieve optimal intercoat bonding. SIPP epoxy is generally restricted to a single coat up to 115 mils (2.9 mm) due to interbond issues. This limits SIPP epoxy liners to achieving AWWA Class I or II, and Class III only if no groundwater is present above the pipe. Because these liners lack ring stiffness to be self-supporting when not in service or under vacuum, thorough pipe cleaning and preparation are critical for long-term adhesion and liner performance. AWWA Class II liners are semi-structural, addressing pipe holes and gaps. AWWA Class I liners are non-structural and serve only as a barrier to enhance water quality. POLYURETHANE Polyurethane is a class of polymers composed of organic units joined by carbamate (urethane) links. Polyurethanes can be produced from a wide range of starting materials, resulting in various polymers
BACK TO CONTENTS
within the same group. This chemical variety produces polyurethanes with different chemical structures leading to many different applications. Aromatic Polyurethane is a rapid-curing (approximately one hour), high-build SIPP material that was designed for the rehabilitation of potable water mains, with a single coat thickness ranging from 40 to 275 mils (1 to 7 mm). While Aromatic Polyurethane exhibits high dry tensile and flexural modulus and strength, these properties are significantly reduced when samples are saturated and tested after 21 to 28 days. Given that the liner will be installed in continuously wet conditions within water pipes, it is imperative that all liner designs are based on the material's wet mechanical properties. Aromatic polyurethane without additives is extremely water sensitive and foams due the production of CO2. Additives are used during lining to absorb water and prevent foaming, but they often cause the liner to soften and delaminate. The softening and water absorption properties of aromatic polyurethane materials have limited their application in the renewal of potable water mains. POLYUREA Polyurea is a type of elastomer that is derived from the reaction product of an isocyanate component and a synthetic resin blend component through step-growth polymerization. The isocyanate can be aromatic or aliphatic in nature. Aromatic polyurea’s are based on an aromatic diisocyanate and have excellent performance except that they are water sensitive performance and have lower wet
properties than dry properties. Often these materials require the application of an external and internal coating to protect the liner from water absorption. Aliphatic Polyurea are polyurea’s based on an aliphatic diisocyanate are utilized when exposure to the environment or highperformance requirements are required. Aliphatic Polyurea has low water absorption, high dry and wet strengths, and exhibit less sensitivity to moisture during application. In 2019, Dr. Ian Robinson introduced Resiline 320, the first fast-cure (one hour), high-build (1 to 3 mm) aliphatic isocyanate polyurea formulated specifically for rehabilitation of potable water mains. Notable attributes include superior dry and wet strength, minimal water absorption, a rapid 15-minute cure permitting prompt CCTV inspection, and an eight-hour recoat window without the need to wash or abrade the surface prior to get excellent inter coat adhesion. The resin's high build, accelerated cure, and the ability to apply multiple coats and facilitate efficient construction of AWWA Class I to IV structural liners with same-day return to service. When applied at 86°F (30°C), the resin exhibits a minimal exothermic response, resulting in negligible shrinkage of the liner during curing and superior adhesion between the liner and the host pipe. Consequently, there is little to no risk of water migration between the liner and the host pipe. A drawback of this resin is that its raw material cost is higher than that of epoxy, polyurethane, or aromatic polyurea. RESILINE SIPP WATER MAIN LINING Resiline 320 NSF Certificate allows for lining pipes 6in (150mm) in diameter and
NASTT-NW.COM | 17
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION larger with multiple coats to build an AWWA Class I to IV liner that is 1 to 14mm thick. The certificate also has no requirement to water flush prior to returning to service. ASTM D1599 Hydrostatic bursting strength test for plastic pipe is a recognized test method for determining the short-
term hydrostatic burst strength of plastic pipe, tubing, and fittings. Five 6in (150mm) 3.5mm Resiline 320 test samples manufactured by Resimac and Schur-BPH in the United Kingdom were burst to determine the material burst pressure and liner maximum burst stress. The results
500 450
6in 3.5mm R320
P = 2 𝑡 𝜎 D [1]
Burst Pressure (psi)
400
where P= Liner Burst Pressure, 𝑡= Resiline 320 liner thickness, 𝜎 = 55.2 MPa (8000 psi), D = liner outer diameter.
350 300
Plot Area
250 200 150 100 50 0
0
10
20
30
from the burst tests are provided in Figure 3. The 3.5mm thick 6in (150mm) test samples were found to have a minimum and maximum short-term burst pressure of 360 to 474 psi (2482 to 3282 kPa) and a conservative tensile rupture stress value of 8000 psi (55.2 MPa). Using Equation 1 the Resiline 320 liner short-term burst stress for the liner can be determined for any liner thickness and diameter.
40
50
60
70
80
90
100
110
Time (seconds) Figure 3: ASTM D1599 Burst test results completed on 3.5mm thick 6in (150mm) Resiline 320 test samples.
120
Equation 1 can also be used to determine the liner thickness to achieve a specified short-term burst pressure. For example, if a 6in (150mm) liner is required to have a short-term burst pressure that is four times greater than the 100 psi (689 kPa) operating pressure, the liner will need to be 3.8mm thick. This thickness can be easily achieved in two 1.9 mm application coats. The preceding analysis indicates that Resiline 320 is suitable for constructing a SIPP liner capable of achieving, or surpassing, the short-term burst pressure
Municipal & Utility Scholarship APPLICATION DEADLINE: NOV 8
Municipal & Public Utility employees can attend the NASTT No-Dig Show with complimentary full registration passes and hotel accommodations! Learn more on the NASTT website.
No-Dig Show is owned by the North American Society for Trenchless Technology (NASTT), a not-for-profit educational and technical society established in 1990 to promote trenchless technology for the public benefit. For more information about NASTT, visit our website at nastt.org.
18 | NASTT-NW JOURNAL | Fall/Winter 2026
nastt.org/no-dig-show BACK TO CONTENTS
ADVANCES IN SPRAY IN PLACE POLYMER MATERIALS FOR WATER MAIN REHABILITATION
While other NSF Certified SIPP water main resins exist, their applications are restricted because they cure slowly at in-situ pipe temperatures or deteriorate in wet, saturated environments. When designing a watermain liner, it is crucial to use mechanical properties that accurately reflect field conditions – specifically wet, rather than dry, states.
performance of CIPP liners exhibiting wrinkles or folds, as well as AWWA Class I to IV liners. The SCHUR-BPH SR1000 and SR2000 SIPP rigs are equipped with umbilical’s that enable pipelining of water mains ranging from 6 to 48 inches (150 to 1220 mm) in diameter, with lengths up to 500 feet (152 m) in one workday. The SCHUR-BPH SR3000 is equipped with an umbilical designed to support pipelining applications for lengths of up to 1,410 feet (430 meters), suitable for water mains ranging from 8 to 98 inches (200 to 2,500 mm) in diameter. Resiline 320 with the SCHUR-BPH rig cleans and lines water mains from
6 to 24 inches (150 to 600 mm) in diameter for up to 2,500 feet (760 m) in a week. This method boosts productivity, eliminates temporary bypasses, and can cut costs by up to 50% compared to open cut or CIPP lining. CONCLUSIONS SIPP materials have evolved from the use of slow-cure epoxy resins in the early 1980s to advanced, high-build, fast-cure multi-coat Aliphatic Isocyanate Polyurea systems. The latest SIPP resins allow for the rehabilitation of up to 500 feet (152 m) of water mains ranging from 6 to 24 inches (150 to 600 mm) in diameter with AWWA Class I to IV liners within a single workday.
Additionally, these materials enable same-day return to service and can yield cost savings of up to 50 percent compared to CIPP lining and open-cut replacement methods. While other NSF Certified SIPP water main resins exist, their applications are restricted because they cure slowly at in-situ pipe temperatures or deteriorate in wet, saturated environments. When designing a watermain liner, it is crucial to use mechanical properties that accurately reflect field conditions – specifically wet, rather than dry, states. It is also essential that all requirements on publicly available NSF/ASNI/CAN 61 Certificates are followed prior to the SIPP rehabilitated pipe is returned to service.
HOW DOES NO DIG POINT REPAIR WORK? Instead of digging up the entire sewer line our non-destructive No Dig sewer line point repairs are done by accessing the damaged pipe through manhole locations. Our repair sleeve is inserted into the pipe directly from the manhole and delivered to the damaged section of pipe. The sleeve is then expanded by our inflatable packer and compressed against the inner pipe wall where it is permanently locked into position.
BEFORE
AFTER
We utilize the QuickLock point repair system which can be used on pipe diameters of 6” to 30” and repair the following defects: • • • •
Infiltrations Offset joints Abandoned laterals Root intrusions
BACK TO CONTENTS
• Holes • Longitudinal & circumferential cracks • Restore structural integrity of pipe
403-536-1415 | calgarysewerscope.ca info@calgarysewerscope.ca
NASTT-NW.COM | 19
Our concern for the environment is more than just talk
This publication is printed on Forest Stewardship Council® (FSC®) certified paper with vegetable oil-based inks. Please do your part for the environment by reusing and recycling.
SPECIALIZING IN LARGE DIAMETER PIPE CLEANING
UNIT 121: DOUBLE 1-1/4" FLUSHER • UNIT 117: 12" VACUUM TRUCK
12" VACUUM TRUCKS WITH 6800 CFM BLOWERS THAT CAN DECANT LIQUID ON THE FLY AT OVER 1600 GPM CAPABLE OF CLEANING ANY DIAMETER PIPE WITH OVER 850m BETWEEN ACCESS POINTS DEEP TUNNEL CLEANING ANY OF DIAMETER LINE AT DEPTHS OF OVER 150ft DOUBLE 1-1/4" FLUSHERS WHICH RUN 2900psi PUMPS AT 236 GPM
50 OMANDS CREEK BLVD • WINNIPEG, MANITOBA
20 | NASTT-NW JOURNAL | Fall/Winter 2026
(204) 633 - 4879
BACK TO CONTENTS
NASTT NO-DIG PROJECT OF THE YEAR 2026
CHAMPLAIN HUDSON POWER EXPRESS TERRESTRIAL PROJECT: TRENCHLESS CONSTRUCTION ON NORTH AMERICA'S LARGEST UNDERGROUND HVDC TRANSMISSION LINE
Phill Perron, MSc, PMP, RMC, Vice President Project Development & Delivery, The Crossing Group, New York Matt Smith, President, Michels Trenchless, Wisconsin Zach Dobrovolny, Operations Manager, Kiewit Infrastructure Co., Nebraska
PROJECT OVERVIEW AND ENERGY INFRASTRUCTURE CONTEXT
PROJECT PURPOSE AND ENERGY IMPACT The Champlain Hudson Power Express addresses a critical need in New York State’s energy infrastructure: delivering largescale renewable power to metropolitan demand centers while reducing reliance on fossil fuel generation. The project replaces fossil-fuel-based generation in New York City with clean hydroelectric power from Quebec, creating a direct high-capacity transmission pathway that bypasses known grid bottlenecks north of the metropolitan area. The 1,250-megawatt capacity represents substantial generation equivalent, enough to power approximately one million homes. From an environmental perspective, CHPE is projected to reduce carbon emissions by 37 million metric tons over its operational lifetime, equivalent to removing more than 500,000 passenger vehicles from roads annually. The project strengthens an aging, congested grid infrastructure while supporting New York State’s mandate to achieve 70 percent renewable energy generation by 2030. The transmission line enables utilization of existing Canadian hydroelectric capacity that otherwise lacks efficient pathways to reach downstate demand centers, effectively unlocking stranded renewable generation for deployment where it creates maximum grid reliability and emissions reduction value.
Map from chpexpress.com.
BACK TO CONTENTS
NASTT-NW.COM | 21
NASTT NO-DIG PROJECT OF THE YEAR 2026 REGULATORY FRAMEWORK AND STATE SUPPORT CHPE received comprehensive regulatory approval and state endorsement, with permits secured across multiple New York counties and construction segments. The project achieved recognition as a Tier 4 Clean Energy Standard initiative, formally designated as supporting the state’s renewable energy mandates and grid modernization objectives. Regulatory agencies approved route adjustments throughout the planning process to avoid sensitive environmental areas, enabling trenchless construction methods to further reduce surface disturbance beyond initial design assumptions. The project generated over 1,400 union construction jobs across the route corridor, reinforcing broad statewide political and economic support. State leadership consistently characterized CHPE as critical infrastructure for grid modernization, reliability enhancement, and long-term decarbonization strategy. This regulatory and political support proved essential for navigating the complex approval processes required for infrastructure spanning 339 miles (546 kms) through diverse jurisdictions, environmental zones, and community contexts. BROADER NATIONAL GRID CONTEXT Beyond New York State, CHPE advances national priorities for renewable energy transmission infrastructure. The project demonstrates a scalable model for longdistance clean power delivery, addressing the fundamental challenge that renewable generation resources often exist far from load centers requiring their output. By relieving major grid bottlenecks into New York City and reducing dependence on local natural gas generation, the project provides operational benefits extending throughout the regional transmission system. As the largest underground HVDC transmission project in North America, CHPE establishes technical and execution precedents for future clean energy corridors. The project proves that large-scale underground transmission is technically feasible, environmentally superior to overhead alternatives in many contexts, and executable within reasonable cost and schedule parameters when appropriate construction methods and project management frameworks are employed. These demonstrations carry significance for energy infrastructure
22 | NASTT-NW JOURNAL | Fall/Winter 2026
Spare terrestrial cable reels are offloaded for storage in November 2025.Photo from chpexpress.com
planning nationwide as grid operators and policymakers evaluate pathways for integrating increasing renewable generation into existing transmission networks. CONSTRUCTION PROGRESS AND IMPLEMENTATION STATUS Construction commenced November 30, 2022, with project completion targeted for mid-2026. At the end of 2025, the project had achieved substantial progress across all major construction elements. Terrestrial construction included 102 miles (164 kms) of open-cut trenching (completed November 2025) and 77 miles (124 kms)
of HDD installations (completed October 2025). Cable installation operations had completed all 556 cable pulls (November 2025) across terrestrial segments, with over 196 miles (315 kms) of cable successfully installed in underwater portions of the route. These progress metrics reflect successful execution of an extraordinarily complex construction program involving multiple simultaneous work fronts, diverse construction methods, challenging environmental and access constraints, and the coordination of numerous contractors, suppliers, and regulatory stakeholders. The sustained progress toward completion
BACK TO CONTENTS
NASTT NO-DIG PROJECT OF THE YEAR 2026 demonstrates the viability of the project’s execution strategy and the effectiveness of trenchless methods in enabling work to proceed through sensitive areas that would have presented insurmountable obstacles to conventional construction approaches.
TRENCHLESS CONSTRUCTION SCOPE AND TECHNICAL DETAILS
OVERALL TRENCHLESS SCOPE The CHPE terrestrial route encompasses 137 miles (220 kms) of land-based installation within the 339-mile (128,019-metre) total corridor. While 60 percent of the overall route utilizes underwater installation to minimize surface and community impacts, the terrestrial 40 percent required trenchless methods to protect the remaining environmentally sensitive areas, residential communities, transportation corridors, and utility infrastructure. The trenchless program installed approximately 420,000 linear feet of HDPE and FPVC conduit through more than
300 individual HDD crossings distributed across 15 distinct construction segments. This scale of trenchless deployment, 300+ crossings across a multi-year program, required systematic approaches to design, execution, quality assurance, and logistics that extended beyond typical HDD project frameworks. The geographic distribution across New York State, from the Canadian border to New York City, created challenges in crew mobilization, equipment positioning, regulatory coordination, and environmental compliance that demanded sophisticated project management and supply chain architecture. Trenchless construction represented not a specialty component of the project but a core execution method essential to project feasibility and environmental commitments. CONDUIT SYSTEMS AND INSTALLATION SPECIFICATIONS HDD-installed conduit systems consisted of 10-inch (25.4-cm) diameter HDPE
conduits or 8-inch (20-cm) diameter Fusible PVC (FPVC) for HVDC cable protection, with 3-inch (7.6-cm) telecommunication conduits bundled within the cable duct packages. Conduit spacing maintained approximately 15-foot (4.6-metre) separation to manage thermal dissipation and electrical performance characteristics of the high-voltage transmission system. Material selection between HDPE and FPVC depended on site-specific factors including geology, crossing length, pullback strategy, and fusion logistics. FPVC offered advantages for certain applications through its ‘stab-and-grab’ installation method, while HDPE provided proven performance for long crossings and challenging ground conditions. Installation depths varied based on crossing type and existing infrastructure. Congested infrastructure zones require installations approximately 25 feet (7.6 metres) below grade to clear existing utilities, building foundations, and subsurface structures. Wetland crossings maintained
CHPE cable laying vessel prepares to pass under the Lake Champlain Bridge near Crown Point, NY in August 2025. Photo from chpexpress.com.
BACK TO CONTENTS
NASTT-NW.COM | 23
NASTT NO-DIG PROJECT OF THE YEAR 2026
Vessels are arranged in the Hudson River to successfully prepare to pull the cable from the river to land in Congers, NY. Photo from chpexpress.com.
15 to 25 feet (4.6 to 7.6 metres) of cover to protect sensitive surface features while providing adequate depth for hydraulic and environmental stability. Open water crossings achieved 35 to 45 feet (10.7 to 13.7 metres) of depth, up to 120 feet (36.6 metres), to ensure navigational clearance, scour protection, and long-term pipeline stability under hydrodynamic loading conditions. STEEL CASING AND SPECIALIZED APPLICATIONS The 5,100-foot (1554.5-metre) East River crossing required specialized steel casing to enable HDD installation through Manhattan bedrock and past a fault zone under one of the nation’s most congested waterways. The installation utilized over 10,000 linear feet (3048 metres) of 20-inch diameter Permalok steel casing system featuring press-fit, weldfree joints that dramatically accelerated installation in the extremely constrained urban work environment. Traditional welded casing
24 | NASTT-NW JOURNAL | Fall/Winter 2026
Beyond the East River installation, the project executed numerous long-distance HDDs that required advanced techniques to overcome challenging geology and extended crossing lengths. would have required prohibitive setup time, hot work permits, quality control inspections, and schedule duration incompatible with the limited work windows and staging space available at urban river crossing sites. The Permalok system’s mechanical joint technology enabled rapid pipe string assembly with quality assurance through dimensional tolerances rather than weld inspection procedures. This innovation proved essential for executing what became the challenging HDD crossing of the East River, establishing new technical precedents for long urban rock drilling in one of the most challenging construction environments
in North America. The successful completion demonstrated that HDD technology could tackle crossings previously assumed to require more invasive construction methods or costly alternatives such as deep tunnel boring. MAJOR CROSSINGS AND TECHNICAL CHALLENGES Beyond the East River installation, the project executed numerous long-distance HDDs that required advanced techniques to overcome challenging geology and extended crossing lengths. Intersect HDDs, wherein drilling rigs operate simultaneously from both ends of a crossing to meet in the
BACK TO CONTENTS
NASTT NO-DIG PROJECT OF THE YEAR 2026 middle, enabled installations that would have exceeded practical limits for single-direction drilling. This technique proved particularly valuable for rock crossings where drill string length, hydraulic power requirements, and steering accuracy constraints would have prevented completion from a single setup. The project deployed surface casing techniques to navigate soft-over-hard ground transitions where conventional drilling methods risk losing borehole stability or steering control. Light and medium-class HDD rigs (100-ton to 220-ton, or 90,700‑kg to 199,500-kg, capacity) executed high volumes of crossings through tight urban corridors and active rail rights-of-way where larger equipment could not access or operate. The diversity of rig classes, drilling methods, and technical approaches reflected the project’s geographic and geologic variability, requiring flexibility in execution strategy while maintaining consistent quality and safety standards across all installation types.
PROJECT ORGANIZATION AND INDUSTRY PARTNERSHIPS
PRIME CONTRACTOR AND ENGINEERING TEAM Kiewit Power Constructors served as the Engineering, procurement, and construction prime contractor for the terrestrial scope. Kiewit’s integrated project delivery model combined design, engineering, procurement, and construction management under unified leadership, enabling close coordination between design intent and field execution. The engineering team included Kiewit Infrastructure Engineering alongside specialized consultants Brierley Associates, CHA Consulting, Kilduff Underground Engineering, and Tetra Tech, bringing deep expertise in underground transmission design, geotechnical engineering, HDD design, and environmental compliance. This collaborative engineering approach proved essential for a project spanning such diverse terrain and regulatory jurisdictions. Design decisions require balancing technical feasibility, environmental constraints, community impacts, constructability, cost, and schedule across hundreds of individual crossings. The engineering team’s ability to adapt designs based on field conditions, incorporate lessons learned across segments, and respond to unforeseen site conditions while maintaining overall project integrity demonstrated the value of integrated project delivery models for complex linear infrastructure.
BACK TO CONTENTS
HDD CONTRACTORS AND TRENCHLESS SPECIALISTS The HDD program’s successful execution reflected contributions from multiple specialized contractors deploying diverse capabilities across the 15-segment project. The Crossing Group completed 134,637 linear feet (41,037 metres) of HDD installations, representing the largest individual contractor scope and demonstrating high-volume multi-rig deployment capabilities across urban and rural segments. Kiewit self-performed 92,690 linear feet (28,252 metres) while serving as prime contractor and construction manager, maintaining direct execution capacity alongside management responsibilities. Haugland Group installed 84,163 linear feet (25,650 metres), bringing regional expertise and established relationships with New York regulatory agencies and communities. Aaron Enterprises contributed 81,870 linear feet (24,950 metres) of installations across varied terrain types and crossing complexities. Michels Trenchless executed 27,214 linear feet (8,294 metres) including the technically demanding 5,100-foot (1,554-metre) East River crossing, demonstrating that specialized high-difficulty installations often carry greater technical significance than linear footage alone suggests. This multi-contractor approach enabled parallel execution across geographically distributed segments while leveraging each organization’s particular strengths and proven capabilities. The multi-contractor model created both challenges and opportunities. Challenges included maintaining consistent quality standards, coordinating equipment and material logistics, and managing interfaces between different organizations’ work zones. Opportunities emerged through competitive performance dynamics, diverse technical approaches brought by different contractors’ experience bases, and flexibility to reallocate work to high-performing teams when schedule pressures or technical challenges required adaptive management. The prime contractor’s ability to orchestrate this complex contractor ecosystem while preserving quality, safety, and schedule commitments proved critical to project success. SUPPLY CHAIN AND TECHNICAL SUPPORT PARTNERS The trenchless program required extensive partnerships with specialized suppliers and service providers. Northwest Pipe Company
supplied the Permalok steel casing system that enabled the East River crossing. Underground Solutions provided Fusible PVC technology for installations where its unique characteristics offered advantages over conventional HDPE. Ferguson Industrial, ISCO, and others supplied HDPE materials and fusion equipment across multiple segments. Radian delivered wireless steering systems and technical guidance services that proved instrumental in executing long, deep installations in congested areas. Drilling fluid suppliers provided bentonite products and technical support for fluid management across varying geologic conditions. Specialized internal and third-party fusion subcontractors performed fusion services ensuring quality pipe joints throughout the extensive conduit system. Drilling tooling providers such as Inrock and others provided HDD tooling, drill bits, and steering technical services. Engineering support from Bennett Trenchless Engineering, Jacobs, and Campos EPC contributed specialized HDD design calculations and technical analysis. These partnerships extended beyond traditional vendor relationships to become integrated components of project execution. Technical representatives from key suppliersmaintained presence at critical work fronts, contributing expertise during challenging installations and accelerating problem resolution when technical issues emerged. The project demonstrated that mega-scale trenchless construction requires not just capable contractors, but a full ecosystem of specialized suppliers, service providers, and technical experts coordinated through deliberate partnership management.
NOTABLE ACHIEVEMENTS AND TECHNICAL INNOVATIONS
EAST RIVER CROSSING: CHALLENGING URBAN BEDROCK HDD The 5,100-foot East River HDD represents a landmark achievement in urban underground construction and the first East River crossing via HDD in many years. The installation drilled through Manhattan schist bedrock under one of the world’s most active waterways, navigating a complex subsurface environment of existing tunnels, utility corridors, building foundations, and geologic discontinuities. The crossing’s technical difficulty stemmed not only from its length and geology but from the severely constrained urban work environment
NASTT-NW.COM | 25
NASTT NO-DIG PROJECT OF THE YEAR 2026 offering minimal staging space and limited access windows in one of North America’s most congested infrastructure corridors. Success required multiple technical innovations working in concert. The Permalok weld-free casing system, the first deployment of press-fit steel casing technology on an East River crossing, accelerated installation in severely spaceconstrained urban staging areas where traditional welded casing would have required prohibitive setup time, hot work permits, and quality control procedures incompatible with available work windows. Advanced geotechnical modeling predicted rock characteristics and structural geology controlling drilling performance and tool selection. Gyroscopic steering technology provided the accuracy and reliability required for threading the bore path between existing underground structures with minimal clearance margins. Specialized rock drilling tools and fluid management strategies-maintained borehole stability through fractured zones and varying rock competency. The East River crossing demonstrated that modern HDD technology, when combined with innovative casing systems and advanced planning, can tackle urban crossings of exceptional technical difficulty. The successful installation proved that trenchless methods remain viable for complex urban installations that might otherwise default to more invasive construction approaches, providing a technical reference point for future projects evaluating HDD feasibility in similarly challenging environments. MASS DEPLOYMENT OF HDD RESOURCES CHPE’s geographic scale required unprecedented deployment of HDD equipment and crews. At peak operations, over 20 active drilling rigs operated simultaneously across New York State, representing one of the largest concentrations of HDD equipment ever assembled on a single project. This mass deployment enabled parallel production across multiple segments, creating schedule certainty through geographic distribution of work and reducing vulnerability to localized delays affecting overall completion. Managing this scale of operations requires sophisticated logistics, supply chain coordination, and crew management. Equipment, consumables, and technical support had to reach dozens of active sites
26 | NASTT-NW JOURNAL | Fall/Winter 2026
simultaneously across hundreds of miles. Quality assurance and safety management needed consistent implementation despite distributed work locations and multiple contractor organizations. Lessons learned from one segment had to propagate rapidly to other ongoing installations to prevent repeated problems. The project’s success in maintaining production, quality, and safety across this distributed operational model demonstrated that systematic management frameworks can effectively coordinate megascale trenchless construction when properly designed and disciplined in execution. WIRELESS STEERING TECHNOLOGY AT SCALE The project deployed wireless steering systems across a substantial portion of its HDD program, representing one of the largest implementations of this emerging technology in trenchless construction. Wireless steering eliminates traditional wireline connections between downhole steering tools and surface operators, using electromagnetic signal transmission instead. This technology offers multiple advantages: elimination of wireline as a failure mode, faster rod-to-rod connections without wireline handling, improved mobility in congested work corridors, and enhanced accuracy for long or deep installations where wireline signal degradation becomes problematic. CHPE’s scale-deployment of wireless steering contributed valuable operational data regarding the technology’s performance, reliability, and economic value proposition. The project confirmed that wireless systems deliver genuine benefits for highvolume programs where wireline incidents historically constrain productivity, while also identifying operational considerations including battery management requirements, operator training needs, and site conditions where wireless steering provides
maximum advantage. This large-scale field validation accelerates broader industry adoption by providing performance data and best practices that smaller projects cannot generate. ADAPTIVE METHODS AND TAILORED SOLUTIONS The project’s geological and environmental diversity required multiple HDD techniques and product strategies tailored to specific conditions. Surface casing installations managed soft-over-hard ground transitions that challenge conventional drilling. Intersect HDDs from dual rigs enabled long rock crossings beyond single-direction capabilities as well as reduced inadvertent fluid release risk. Light and medium rigs accessed tight urban and rail corridors. Different buoyancy control strategies addressed pullback strategies and elevation differences. Material selection between HDPE and FPVC optimized performance for each crossing’s specific requirements. This technical diversity reflected deliberate strategy rather than ad hoc problem-solving. The project team recognized early that no single approach would succeed across all 300+ crossings. By developing a toolkit of proven methods and maintaining flexibility to select appropriate techniques for each installation, the team avoided forcing unsuitable approaches into incompatible conditions, a common failure mode on large projects where standardization becomes counterproductive rigidity. The successful demonstration of this adaptive approach provides a model for future mega-projects facing similar geographic and geologic variability. DRILLING FLUID RECLAMATION SYSTEM The project implemented a microtunnelinggrade fluid separation system for drilling fluid reclamation, processing used returns to remove cuttings and ultra-fine solids,
By developing a toolkit of proven methods and maintaining flexibility to select appropriate techniques for each installation, the team avoided forcing unsuitable approaches into incompatible conditions, a common failure mode on large projects where standardization becomes counterproductive rigidity. BACK TO CONTENTS
NASTT NO-DIG PROJECT OF THE YEAR 2026 Environmental protection becomes an execution problem rather than a productivity constraint when planning incorporates environmental requirements as design parameters rather than retrofit constraints. reconstituting cleaned fluid with fresh additives, and returning reclaimed fluid to active drilling operations. This closed-loop approach generated substantial cost savings by reducing virgin fluid consumption and disposal volumes while delivering environmental benefits through minimized waste generation. Additionally, the reclamation process lowered fluid mud weight by removing ultra-fine particles, reducing inadvertent return risk in sensitive formations. The fluid reclamation system demonstrated that technologies from other trenchless methods can transfer effectively to HDD applications when project scale justifies the investment. The system’s success required disciplined contamination control to prevent cross-contamination between bore sites, consistent operational tempo to maintain economic efficiency, and rigorous quality assurance ensuring reclaimed fluid met performance standards. The project’s positive experience with fluid reclamation at scale provides a proven model for future large HDD programs evaluating similar sustainability and cost-reduction strategies.
LESSONS LEARNED AND INDUSTRY INSIGHTS
EARLY GEOTECHNICAL INVESTIGATION AND MODELING Comprehensive geotechnical investigation proved essential for successful execution across CHPE’s diverse terrain. Early subsurface investigations reduced unknowns, prevented mid-construction redesigns, and enabled informed HDD method selection. Accurate geotechnical data drove correct decisions regarding rock versus mixed ground drilling approaches, surface casing requirements, intersect strategy deployment, and steering technology selection. Modeling allowed advance planning for fluid management strategies, borehole stability measures, and equipment specifications tailored to encountered conditions. The investment in front-end geotechnical work paid dividends throughout construction by reducing inadvertent return incidents, maintaining consistent production rates, and minimizing technical surprises requiring costly field redesigns or
BACK TO CONTENTS
method changes. The lesson for the industry: comprehensive geotechnical investigation represents project insurance, not optional expense. The cost of thorough subsurface characterization is invariably less than the consequences of insufficient data when drilling encounters unexpected conditions requiring reactive problem-solving under schedule and cost pressure. INTEGRATING ENVIRONMENTAL PROTECTIONS WITHOUT PRODUCTIVITY LOSS CHPE demonstrated that environmental stewardship and construction productivity are compatible when environmental requirements integrate into planning from project inception rather than imposed as constraints on predetermined approaches. Early coordination with environmental teams aligned construction windows with sensitive habitat periods, preventing conflicts between biological constraints and construction schedules. Trenchless methods eliminated open-cut work in many protected areas, maintaining workflow while meeting regulatory requirements. Fluid containment systems, access matting, and low-impact staging strategies avoided delays from environmental non-compliance incidents. The critical insight: environmental protection becomes an execution problem rather than a productivity constraint when planning incorporates environmental requirements as design parameters rather than retrofit constraints. By frontloading environmental expectations, planning requirements, and compliance strategies during preconstruction, the project minimized delays and conflicts that plague projects where environmental considerations emerge as surprises during construction. This integrated approach provides a model for future large infrastructure projects navigating complex environmental regulatory frameworks. ADAPTIVE SCOPE MANAGEMENT AND PERFORMANCE-BASED ALLOCATION One of CHPE’s most significant management innovations involved maintaining a reserve pool of HDD scope
that enabled dynamic work redistribution as production rates varied across contractors and segments. When certain contractors or crews demonstrate superior performance, additional crossings could be allocated to capitalize on their productivity and established momentum. Conversely, underperforming operations could shed scope to focus on fundamental execution improvements without schedule pressure driving unsafe or low-quality work. This performance-based allocation encouraged steady, safe productivity rather than encouraging risk-taking or corner-cutting to retain assigned scope. The adaptive approach kept the overall trenchless program on schedule despite varying geology, access constraints, environmental windows, and contractor performance differences. It demonstrated that flexibility in work allocation, enabled by appropriate contractual frameworks established during procurement, creates more schedule certainty than rigid scope assignments that cannot adapt to actual field conditions and performance realities. The lesson for prime contractors and owners: building allocation flexibility into project structure from the outset provides a powerful management tool for maintaining programlevel success even when individual operations encounter difficulties. FLEXIBILITY IN MEANS AND METHODS CHPE’s execution philosophy balanced clear requirements with contractor flexibility in means and methods. The prime contractor defined constraints, required outcomes, and environmental protections while allowing contractors to propose their own trenchless approaches. This created what might be termed an ‘innovation sandbox’; contractors could lean into their expertise, deploy familiar techniques, and optimize their execution strategies within defined boundaries. The prime contractor evaluated and approved proposed methods to ensure safety, technical feasibility, and regulatory compliance, but did not prescribe tactical execution details. This approach generated multiple benefits. Contractors brought their best
NASTT-NW.COM | 27
NASTT NO-DIG PROJECT OF THE YEAR 2026
Spare terrestrial cable reels are offloaded for storage in November 2025.Photo from chpexpress.com
methods and most effective crews rather than struggling with unfamiliar mandated approaches. Innovation emerged as contractors deployed new techniques, adaptive strategies, and creative solutions to overcome site-specific challenges. Safety improved because crews worked with methods they understood thoroughly rather than executing prescribed approaches, they lacked experience with. Performance increased because contractors optimized their own operations rather than complying with potentially suboptimal mandated methods. The critical balance: the prime contractor maintained responsible governance ensuring all work met safety, quality, and environmental standards while granting sufficient flexibility for contractors to execute effectively. This balance, neither prescriptive micromanagement nor uncontrolled autonomy, enabled better outcomes than either extreme would have produced. The lesson applies broadly: defining what must
28 | NASTT-NW JOURNAL | Fall/Winter 2026
be achieved while allowing flexibility in how to achieve it produces superior results when contractors possess genuine expertise. CONCLUSIONS The Champlain Hudson Power Express represents a landmark achievement in trenchless construction and underground transmission infrastructure. The project’s successful execution demonstrates that trenchless technology can meet the demands of mega-scale infrastructure projects when supported by comprehensive planning, sophisticated project management, innovative technical solutions, and effective industry partnerships. The installation of over 420,000 linear feet (128,016 metres) of conduit through 300+ HDD crossings across diverse terrain, sensitive environmental areas, and complex regulatory authorities establishes new benchmarks for what the trenchless construction industry can accomplish.
CHPE’s achievements extend beyond construction metrics to demonstrate broader principles applicable to future large infrastructure projects. Early geotechnical investigation prevents costly mid-construction surprises and enables informed technical decisions. Environmental requirements integrated into planning from inception become enablers rather than constraints. Performance-based work allocation and adaptive scope management create schedule certainty despite inevitable variations in field conditions and contractor performance. Flexibility in means and methods, balanced with responsible governance, produces superior outcomes by leveraging contractor expertise while maintaining quality and safety standards. The project proves that trenchless methods are not merely alternatives to conventional construction but often the superior or only viable approach for sensitive areas, congested corridors, and
BACK TO CONTENTS
NASTT NO-DIG PROJECT OF THE YEAR 2026
environmentally protected zones. The East River crossing demonstrated that HDD technology continues advancing its technical envelope, enabling installations previously considered impractical or impossible. The mass deployment of equipment and crews showed that the industry possesses the capacity to execute mega-scale programs when projects provide appropriate lead time, resources, and management frameworks. As energy infrastructure modernization accelerates to support renewable energy integration and grid resilience, projects of CHPE’s scale and complexity will become increasingly common. The lessons learned, technical innovations, and execution strategies proven on CHPE provide valuable precedents for these future undertakings. The project demonstrates
BACK TO CONTENTS
that when trenchless technology combines with comprehensive planning, innovative problem-solving, effective partnerships, and adaptive management, the industry can successfully deliver critical infrastructure projects that balance technical performance, environmental stewardship, community impact minimization, and economic viability. CHPE stands as testament to what collaborative excellence in trenchless construction can achieve. The project’s success reflects the dedication and expertise of hundreds of engineers, contractors, crew members, suppliers, and support personnel who brought their best efforts to one of North America’s most challenging infrastructure undertakings. Their collective achievement advances not only New York State’s clean energy future but the trenchless
construction industry’s capabilities and confidence for the next generation of mega‑infrastructure challenges. ACKNOWLEDGMENTS The authors gratefully acknowledge the contributions of the entire CHPE project team, including Transmission Developers, Inc. (project developer), Kiewit Power and its engineering partners, all HDD contractors and their crews, equipment and material suppliers, regulatory agencies, and the communities along the route who supported this critical infrastructure project. Special recognition to the field crews whose skill, dedication, and problem-solving abilities transformed engineering designs into constructed reality across hundreds of challenging installations.
NASTT-NW.COM | 29
ADVERTISER PRODUCT & SERVICE CENTRE The NW Trenchless Journal is made possible by the companies below who convey their important messages on our pages. We thank them for their support of NASTT-NW and its publication and encourage you to contact them when making your purchasing decisions. To make it easier to contact these companies, we have included the page number of their advertisement, their phone number, and, where applicable, their website. COMPANY NAME
PAGE
PHONE
WEBSITE/EMAIL
Associated Engineering
8
780-451-7666
www.ae.ca
Brandt Tractor Ltd.
4
888-2BRANDT
www.brandttractor.com
Calgary Sewer Scope, Inc.
19
403-536-1415
www.calgarysewerscope.ca
Canadian Induracoat Corporation
2
855-652-0812
www.induracoat.com
Herrenknecht Tunnelling Systems Canada, Inc.
8
253-447-2300
www.herrenknecht.com
Insituform Technologies
13
800-234-2992
www.insituform.com
IPEX Management, Inc.
6
866-473-9462
www.ipexna.com
Michels Canada
32
780-955-2120
www.michelscanada.com
SFE Global
31
780-461-0171
www.sfeglobal.com
TCI Carbon Fibre Technologies
5
416-409-2211
www.tcicarbonfibre.com
Uni-Jet Industrial Pipe Services
20
204-633-4879
www.uni-jetindustrialpipe.ca
VIEW US ONLINE NASTT-NW.COM
Use Paper Responsibly Today’s forest industry is working hard to become one of the greenest industries on earth. Paper is an essential part of human civilization. While we all use and depend upon electronic communications, it is easy to ignore that it comes at an environmental cost. Worldwide spam email traffic creates greenhouse gases equivalent to burning two billion gallons of gasoline yearly, with numbers rising. More than $55 billion in toxic e-waste material is thrown away every year in the US alone, with a recycling rate of only 20% compared to 64.7% for paper. No industry is perfect. But the paper industry has made, and continues to make, huge investments in environmental responsibility. Specifying and buying paper from certified sources ensures the continuation and growth of carbon absorbing forests. Using paper with appropriate amounts of recycled fibre helps preserve forests, conserve energy, and maximize fibre usage through paper lifecycles.
30 | NASTT-NW JOURNAL | Fall/Winter 2026
BACK TO CONTENTS
Above. Beyond. Below. Civil Construction Energy & Renewables Engineering & Design Water & Wastewater Mission Critical
www.MichelsCanada.com