Cablecon, the annealed, heavy-wall, high-density polyethylene pipe manufactured by Integral Corp., Dallas, Texas, that ECI furnished for this job, was wound on special reels that belong to ECI. Each pipe was extruded in a continuous length that would extend from one river crossing manhole to the other. This pipe, because of a proprietary manufacturing process does not retain its coiled shape when taken off the reel. Its relative straightness makes it easy to pull through the borehole. ECI positioned its 12 reels of pipe in the parking lot of a bank near the north end of the job. Workers attached the 12 ducts to a proprietary pulling head 27 inches in diameter. They then connected this apparatus to a swivel on the end of the drill string. Workers stationed at the drill rig used the machine to pull all 12 ducts through the borehole and to the south manhole location in a single pass. During the pullback, a rig from Halliburton Services, Kalkaska, Michigan, pumped a special slurry of cement grout into the borehole in front of the pulling head to force out the bentonite drilling fluid that had been in the borehole. Then replaced it with a cement grout that filled the interstices and annular spaces between the pipes and the borehole. Once the grout was set, it provided the ducts with mechanical protection. The grout was a special blend that would remain workable for 24 hours, although it would gel much sooner than that. Within 2-1/2 hours after pulling began, the tired but triumphant crew saw the 12-duct formation arrive at the drilling rig, proving to skeptics that they were wrong. Ferguson Michiana Inc., a utility contractor from Eau Claire, Michigan, assisted ECI with various parts of the river crossing. When the river crossing was complete, they terminated the ducts into the existing manhole on the north end and set a new manhole at the drill entrance on the south side. They also drew a test mandrel through each duct as a verification of its roundness and freedom from obstructions. When traditional construction practices are followed, conduit projects of this magnitude tend to disrupt activities in the area and ordinarily taking months to complete. Except for a few unanticipated problems, this crossing was completed in less than three weeks. Allowed Indiana Bell to remove its cables from the old bridge once and for all and saved money by avoiding a second cutover. John C. Ellis is an Underground Structure and Conduit Design Engineer for Indiana Bell based in Indianapolis. Douglas P. Allman is Vice President of Engineering at Environmental Crossings Inc., Traverse City, Michigan. In October 1992 Environmental Crossings, Inc. (ECI) of Traverse City, MI, began a drilled crossing project for Connecticut Cable Construction & Maintenance, Inc. of Middlefield, CT. Project owner was Cox Greater Hartfort CATV. The project called for two directional crossings, one with a sharp lateral turn, but with both to terminate in a manhole location.
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