Installing a Force Main Station in a Challenging Location

DVUC • July 21, 2022

Force mains are a vital part of our lives since these pipelines are a critical connection between the pump station and collection/treatment facility. We recently installed one for a large trucking repair shop in Burlington, New Jersey. As the architects and engineers planned out the new addition for the shop, it was decided that an increase in volume would be too much for the onsite septic system to handle. Thus, the engineers designed a small force main pump station to be installed. 


The pump station was placed at the side of the building and the 1.25 HDPE force main pipe was installed 300 feet across the property and 600 feet down the shoulder of the road to an existing manhole. Crossing the property was very challenging due to a large 24-inch high pressure gas main, a protected wetland, and a 1-to-1 vertical slope up 35 feet to the road. Below is step-by- step process of the installation. 

1. At the start of installation process, team member Roy inspected the drill head after a 480-foot bore. It looked good, so he attached the 1.25 inch HDPE pipe and trace wire for the pullback installation.

Connecting swivel HDPE pipe and trace wire.

2. We connected the swivel HDPE pipe and trace wire. A DVUC team member then tested the water jets before pullback. 

Drilling past the 24-inch high-pressure gas main.

3. After connecting the swivel HDPE pipe and trace wire, we drilled past the 24-inch high-pressure gas main. Next, we vacuumed out the drill pits so we could see the drill head go by.  

Crossing wetlands

4. At this point, we are halfway through the installation. We’ve crossed a 24-inch high-pressure gas main, went through some wetlands, and climbed the hill to cross the street. You can see the drill rig under the arrow in the picture. 

Looking at the pits

5. We are now vacuuming out the pits, giving us a better look at them.

drilling  through an 8-inch steel casing

6. We pushed the drill bit through an 8-inch steel casing that was placed perpendicular (open cut) over top of the 24-inch high-pressure gas main. 

Going through the 8-inch steel casing

7. We are in the home stretch in our force main installation! We’ve gone through the 8-inch steel casing that was placed 3 feet above the gas main, which was mandated by the gas company as extra protection for the 24-inch high pressure gas main.

Connection to the manhole.

8. The last step in the installation involves the connection to the manhole. We can see the drill bit coming into the final pit, where the pipe will then be tied into the manhole. We finished the project by cleaning up the work site. 

DVUC’s highly trained, experienced drill crew installed the force main in three days, keeping the general contractor and the owner on schedule and under budget. We appreciate the hard work of our team and for the opportunity. Contact us today to learn how we can make your next utility project run smoothly! 


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