Our client, New Jersey American Water, faced a critical problem — various exposed water mains were in need of restoration of their failing protective coatings to prevent corrosion and significant service disruption. To add further complications, the water mains needed to stay in service and the work had to be performed in extreme weather, including temperature and moisture elements that come with peak summer and winter conditions, without impacting the open waterways. Such weather conditions and the necessity to work in environmentally sensitive areas meant traditional rehabilitation methods wouldn’t meet the needs of the project. And while each of the six locations throughout southern New Jersey posed their own unique challenges, all crossings were over open tidal waterways where traditional blasting methods would require extensive containment, at significant cost, with some locations experiencing submersion due to the tides and weather impacts. Facing a myriad of hurdles, New Jersey American Water tapped into CP’s expertise to complete the project within budget and on time.
CP’s knowledgeable and enterprising experts reconsidered the traditional coating rehabilitation method of near-white blasting (SP-10), and applying a three-coat system, made up of zinc, epoxy, and urethane, for the existing water mains. The new system, which had never been utilized locally, uses Polyisobutene Sealants, providing an outstanding protective product while empowering our team to overcome weather and environmental challenges.
Specifically, the benefits include:
• Longevity: The Polyisobutene Sealant (PIB) product has a 30-year lifespan warranty, compared to 14-20 years using more traditional methods.
• Cost savings: With significantly reduced preparation needed before application, and reduced staff for application, PIB overall costs are 20-25% lower when compared to traditional methods.
• Simplicity: Because of the lack of SP-10, containment is not necessary, which also means the process is less complex and requires less equipment and storage space.
• Flexibility: PIB products can be installed in the heat of summer or dead of winter, reducing downtimes due to extreme temperatures and inclement weather. The product is designed to be resistant to salt and water which makes it perfect for tidal areas where the pipes can be submerged for periods of time.
• Environmentally responsible: The PIB is installed after a simple SP-2 and wipe down with Isopropyl alcohol which limits any environmental concerns and eliminates the need for costly personal protective equipment (PPE). PIB-coated pipes are also more aesthetically pleasing than traditional coating methods.
• Self-healing: The PIB wrapping system not only protects against corrosion, but is self-healing, if and/or when slices or scratches occur, providing significant advantage in the locations where debris was impacting the water mains during storm events. It is also useful in locations where the water mains were outboard of bridges, areas prone to coating damage from fishermen and crabbers walking on the pipes.
The quantifiable results of our efforts are undeniable. With reduced preparation time and effort, minimized environmental challenges, and the elimination of weather restrictions, New Jersey American Water saw a dramatic cost reduction for the overall project, despite increased material costs. All scoped water mains were completed on time, at the height of summer and winter, and under budget compared to the traditional methods used by other firms.
