CASE STUDY

HDD Pipeline Project

Denso Bore-Wrap System

Project Data

LocationItaly
Completion2024
Project TypePipeline HDD Full Encapsulation
Products UsedDenso Bore-Wrap®

Project Details

A pipeline installation beneath a rocky riverbed in Italy presented significant challenges due to a constrained right-of-way and steep entry/exit angles. The rocky terrain posed a high risk of coating damage during the horizontal directional drilling (HDD) process, prompting the operator to trial Bore-Wrap as a protective solution.

Methodology

Following consultation with the Denso distributor, a three-layer Bore-Wrap application was deemed optimal for abrasion resistance. To demonstrate its effectiveness, Bore-Wrap was applied starting several feet from the pipeline’s leading edge, leaving the standard three-layer polyethylene coating exposed to initial impacts. The application process involved:

  • Roughening a 6-foot section of the polyethylene coating using a grinding wheel.
  • Applying Bore-Wrap from front to back with minimal overlap to achieve three layers.
  • Spray water on the Bore-Wrap as it is applied to activate the resin curing mechanism and immediately wrap the product with Denso Poly-Wrap to compress the resin and hold the Bore-Wrap tightly to the surface.
  • Perforate the Poly-Wrap with a porcupine roller to allow off-gassing and excess resin and water to escape while the Bore-Wrap cures. 
  • Allow the Bore-Wrap to cure with the Poly-Wrap in place.  Leave the poly-wrap on until Bore-Wrap reaches a Shore-D of 65 or greater, then the product is ready to be pulled through the HDD.

Results

Post-installation evaluation revealed severe gouging on the unprotected polyethylene coating, exposing bare steel. In contrast, the Bore-Wrap-protected section absorbed the impact, preventing further gouging and sustaining only minor surface abrasion. The pipeline remained intact beyond this point, with no additional coating damage observed beyond this point, with no additional coating damage observed.

Conclusion

This project unequivocally demonstrated Bore-Wrap’s ability to protect pipelines in abrasive environments, even when applied over polyethylene coatings. As a result, the Italian operator has adopted Bore-Wrap into its specifications for HDD and direct pipe installations, affirming its value in enhancing pipeline durability and corrosion resistance.

Recommendation

We recommend specifying Bore-Wrap for HDD and direct pipe projects to minimize coating damage, reduce maintenance costs, and ensure long-term pipeline integrity. Contact us to explore how Bore-Wrap can enhance your pipeline protection strategy.

Project Key Performance Highlights

  • Challenging Installation Conditions: The HDD pipeline installation in Italy faced extreme conditions, including rocky terrain and steep entry/exit angles, increasing the risk of coating damage. Strategic Bore-Wrap Application: Bore-Wrap was applied in three layers starting just after the pipe’s leading edge, allowing for a side-by-side comparison with unprotected polyethylene coating.
  • Clear Performance Contrast: After installation, the standard coating suffered severe gouging and exposed steel, while the Bore-Wrap-protected section only showed minor surface abrasion.
  • Demonstrated Protective Strength: Bore-Wrap effectively absorbed mechanical impacts, preventing further coating damage and maintaining pipeline integrity.
  • Operator Endorsement and Adoption: Impressed by the results, the Italian pipeline operator integrated Bore-Wrap into its specifications for future HDD and direct pipe projects.
< BACK
DOWNLOAD