Coke Gas Pipe Fill
The Job
This coke gas pipe fill project is located in Middletown, Ohio, at Cleveland Cliff’s Middletown Works facility. Middletown Works determined that the coke plant would be more costly to repair than to replace, so elected to demolish the plant.
The Challenge
A demolition contractor working to dismantle parts of the onsite coking plant had to remove approximately 350LF of coke gas pipe. The work area is located in the basement of the coking plant.
Coke gas residuals will spontaneously combust when exposed to the air, but the pipe had to be cut into roughly 3′ pieces to remove it. The pipe fill grout had to:
- completely fill the pipe
- coat the residuals to minimize air exposure
- cut easily
- add as little weight as possible to the pipe sections
The Solution
CJGeo proposed using CJGrout-20SDB to fill the pipes. 20SDB is a 2lb/cuft rigid polyurethane foam, specifically formulated to flow long distances before setting.
CJGrout 20SDB is generated onsite by special polyurethane grouting rigs. The rigs have hoses up to 400 feet long, which convey the material from the grouting rigs to the placement area. For this coke gas pipe fill project, the crew had to run hoses approximately 250 feet into the building, down multiple stair cases. The hoses are lightweight and about 2 inches in diameter, so this isn’t a problem.
One of CJGeo’s polyurethane grouting crews was onsite for two days to complete the project. Once the coke gas pipes were filled, the demolition contractor cut them into 3 foot long pieces with traditional band saws bagged the sections, and removed them from site.
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Facing a similar challenge? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.
NY Thruway HDD Annular Space Grouting
The Job
This HDD annular space grouting project is east of Buffalo, New York, under the New York Thruway. As part of distribution improvements, National Grid’s contractor bored 830LF through rock using HDD. The bore was 30″, with a 16″ HDPE casing, carrying three, 4″ HDPE conduits.
As part of the installation, the NY Thruway Authority call for casing back grouting, and the casing pipe’s annular space grout filling.
The Challenge
The proposed back-grout had to be:
- pumpable 830LF at very low pressure,
- dense enough to displace the 10 pound per gallon drilling mud, and
- provide sufficient strength to meet Thruway requirements.
The proposed annular space grout had to be:
- pumpable 830LF at very low pressure,
- light enough to not apply excessive pressure on the conduit pipes, and
- also provide sufficient strength to meet Thruway requirements.
The Solution
CJGeo proposed two different grout mixes to meet the project requirements. 85lb/cuft CJFill-Under Water casing backgrout for the displacement of the 10PPG (75lb/cuft) drilling mud. And 25lb/cuft CJFill-Ultra Lightweight annular space grout within the casing.
CJGeo’s crew mobilized to the site, and successfully performed the back-grouting and annular space grouting in a single day. A tremie pipe strapped to the HDD casing was used for the back grouting. By pumping the 85lb/cuft (11 pound per gallon) CJFill-Under Water to the low point, the drilling mud was floated out of the reamed hole annulus.
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Facing a similar challenge to this HDD annular space grouting project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.
