Springville, PA Abandonment Grouting: Long-Run Natural Gas Pipelines
The Job
In Springville, Pennsylvania, a critical infrastructure project required the permanent abandonment grouting of three separate natural gas pipeline runs. The total scope involved 5,340 linear feet of pipe to be filled. Specifically, this included two runs of 2-inch pipe measuring 1,365 linear feet and 1,725 linear feet, respectively, and one run of 4-inch pipe spanning 2,250 linear feet.
Preparing to grout the pipes with CJFill-Ultra Lightweight cellular grout.
The Challenge
The primary difficulty stemmed from the site constraints imposed by the active natural gas infrastructure. All three pipelines crossed multiple other live natural gas lines, strictly prohibiting the excavation of any intermediate access points. The contractor required a reliable method to pump the grouting material the full distance, with the longest run extending 2,250 linear feet. Designing a zero-risk abandonment strategy was crucial to ensure the project’s success without impacting the surrounding active infrastructure.
The Solution
We deployed our truck-batch cellular grout generation system to address the extreme pumping distance requirement and eliminate project risk. Cellular grout provided the ideal combination of lightweight properties and high flowability necessary for reliable long-distance pumping. Our approach successfully pumped the cellular grout the full length of all three runs—1,365, 1,725, and 2,250 linear feet—without requiring any intermediate access points. This solution utilized careful design and the material’s extended workability time, ensuring complete, monolithic fill for all sections from only the initial injection point. We completed the project efficiently by engineering the risk out of the abandonment process, meeting the client’s safety and full-abandonment criteria.
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