Marshall Pollock Monday, April 20, 2009

Marshall Pollock Monday, April 20, 2009
Effective and Environmentally Friendly Utility Cut Repairs UTILITY INDUSTRY WORKSHOP 2009 AASHTO Right-of-Way & Utilities Subcommittee Conference Oklahoma City, OK Marshall Pollock Utilicor Technologies Inc. Toronto, Canada April 20th, 2009 1

U.S. Underground Infrastructure
• 20 million miles of pipe, cable and wire - much of it buried in the Right-of-Way Electrical cables High and low voltage Signal cables Cathodic protection cabinets and cables Conduit systems, cable pits and chambers Gas lines Distribution lines (high, medium and low pressure, cast iron, steel, Polyethylene) Mains and Services (fittings, valves, service joints, casings, tracer wire, cathodic protection) Petroleum Lines Communication cables Phone lines -- copper and fibre optic Conduit systems Coaxial and data cables Sewer/water mains and services Pits Tunnels Connections Valves Steam Lines

Conventional Access to Buried Utilities
Repair & Replacement: Existing infrastructure has become very congested and is wearing out and needs to be repaired or replaced. New Installation: We continue to add and change utilities because of expansion, modernization and changing missions. Poor Pavement Repair: Once the work has been completed, if the repair is not properly done, the repaired pavement will settle or crack and allow groundwater to penetrate. Failure: Groundwater is the most common cause of pavement failure and potholes.

Conventional Excavation Methods Damage: Careless ROW excavation can result in destruction of underground facilities, damage or injury. Delay: Road work and utility cuts cause 400 million hours of traffic delay and disruption, cost drivers $6 Billion in wasted time and collectively waste 2.3 Billion gallons of fuel annually. Reduced Life Expectancy: Conventional utility cuts through pavement can significantly reduce the life expectancy of roads. 4

Conventional Utility Cut Repairs

Resulting in Potholes

Excavation Innovation
Marshall Pollock Monday, April 20, 2009 Excavation Innovation Prehistoric Sharp Sticks Hand Digging Trenching Machines 1950-Present Vacuum Excavating 1990-Present Coring and Reinstatement 8

Coring and Reinstatement

Keyhole Coring and Reinstatement A better, smarter and environmentally sensitive way of locating utilities and making and repairing utility cuts through pavement to: Reduce delays and disruption of traffic and public inconvenience during roadwork Minimize damage to roads Reduce impact of public works construction on the environment Facilitate repairs to underground utilities Improve worker safety and productivity through better excavation methods Avoid damage to underground utilities during excavation or HDD (“Potholing”) Locate and map underground utilities (S.U.E.) Save utilities and their contractors time and money A Core Strategy for Utility Cut Repairs 10

Coring and Reinstatement History
1988: Coring: Consumers Gas (Toronto) uses Rotary Coring equipment for cathodic protection, leak repair and main separation; 1992: Core Reinstatement program begun with Golder Associates -- tested 25 grouts; 1993: Utilibond developed, tested & approved by Ontario Ministry of Transportation (Feb. 1994); : Field Test: 892 keyhole jobs successfully performed; 1996: Pilot Project: Metro Toronto authorizes coring & reinstatement pilot project; 2002-4: Approval: City of Toronto approves coring & reinstatement process; 2007: Standard: City of Toronto prescribes coring & reinstatement Standard. THE FIRST DEMONSTRATION July 22, 1998: Consumers Gas demonstrates to GRI its field operational crew truck with a special circular, asphalt cutter for keyhole maintenance jobs.

Proof of Process Golder Associates Engineering Reports 1996 and 2003 Golder Associates: 10 year Engineering study ( ): “Based on trials carried out at our testing laboratory and our in-field performance observations, we are satisfied that the equipment, procedures and materials developed and used by Enbridge Gas Distribution over the last 10 years will ensure satisfactory long term performance of the pavement reinstatement. The pavement coupon has been bonded into the slab in such a manner that the loads of traffic are effectively transmitted to the remaining intact slab.” TEST: “degree of coupling between undisturbed road structure and newly restored cut.”

Convenient, Consistent, Replicable
Golder Report Comprehensive Laboratory Testing Poor bonding Good bonding Uncut Road Poorly Reinstated Properly Reinstated Effective Load Transfer Long Term Performance through freeze-thaw cycles Dec. 2002 Sep. 1995 Mechanical Bond No Voids Fast Setting, Rapid Strength Gain Convenient, Consistent, Replicable

Restoration of Utility Cut Study
Joint project of North American cities, utility companies and U.S. state departments of transportation ( ). Objective: to develop a guide for best restoration practice based on sound engineering principles. Toronto Field Experiment: Observations CONVENTIONAL TRENCH Noticeable failures in conventional cut. Conventionally repaired joint between road and the cut opened. Visible settlement in trench along wheel path. Material used to seal joint lost under action of traffic. Sand cover at base of trench exposed to higher than normal levels of moisture (compared with keyhole). ROTARY CUT KEYHOLE No defects in keyhole cut. Keyhole section established Oct continued to perform well throughout life of project. Surface of restored keyhole remained level with the road profile. The bonding material surrounding the AC/PCC core remained intact (no cracking or separation. Waterproof bond. “Keyhole construction is an effective restoration technique that should be encouraged whenever feasible to minimize need for opening large trenches in the future.” US Army Corps of Engineers National Research Council Canada

Conventional Repair Failures
The material used to seal the joint was lost under the action of traffic as a result of shear flow or pullout of the sealant, allowing groundwater penetration. South edge of Trench North edge of Trench Source: Joint Utility Cut Study: Toronto Field Experiment, US Army Corps of Engineers and NRCC. US Army Corps of Engineers National Research Council Canada

Keyhole Findings & Conclusions
No Distress: The keyhole restored October 2001 showed no distress during the inspections performed during the May 2002 and April 2003 visits. The grout remained intact and the surface is level with the road. Level -- No separation: The surface of the restored keyhole remained at level with the road profile. The grout [Utilibond] surrounding the AC/PCC plug remained intact (no cracking or separation). Lower Stress Levels: The keyhole opening is quite small (18 in., 457 mm, in diameter) compared with the area of a tire print of heavy trucks in contact with the road surface. As a result, low stresses are transmitted to the underlying sections of the restored keyhole. No Pressure Cracks: Based on basic rules of mechanics, a circular cut shape in the AC is ideal for preventing propagation of cracks into the surrounding road area. “The keyhole construction and restoration technique should be encouraged whenever feasible to minimize the need for opening large trenches in the future.” US Army Corps of Engineers National Research Council Canada Source: Joint Utility Cut Study: Toronto Field Experiment, US Army Corps of Engineers and NRCC.

Deteriorating Road Conditions
23% major metropolitan roads – interstates, freeways and other critical local routes – have pavements in poor condition, resulting in rough rides. $413 annually in additional vehicle operating costs due to accelerated vehicle deterioration, additional maintenance needs and increased fuel consumption. Los Angeles 65% San Francisco-Oakland 62% Honolulu 62% San Jose 60% San Diego 53% New Orleans 50% New York City 49% Sacramento 46% Baltimore 42% Oklahoma City 41% Tulsa 40% Albuquerque 39% Omaha 38% San Antonio, 37% Philadelphia 37% Riverside-San Bernardino 35% Oxnard-Ventura 35% Houston 33% Fresno 30% Washington, DC 30% Roads in Poor Condition 2008 TRIP Report

Problems with Utility Cuts
Conventional Methods Coring & Reinstatement Excavation: Jack hammers and backhoes caused measurable damage to the unexcavated structure. Excavation: Surgical precision of coring saw causes no damage to pavement or to the unexcavated structure. Backfilling: Poor or irregular backfill compaction. Did not follow proper procedures requiring 8-10” lifts and 95% Proctor. Poor inspection. Backfilling: New backfill monitoring technology (Soil Compaction Supervisor) accurately monitors compacted soil density in real time can be audited by supervisors and municipality for accuracy. No on-site inspection needed. Failure to obtain waterproof joint: Tack coats and sealants lack adhesive and cohesive strength causing separation from the vertical edges of the asphalt cut. T-section cut backs exacerbate the problem by trebling the length of the perimeter cut. Waterproof Bond: Utilibond proven to create high-strength waterproof mechanical joint capable of supporting more than 50,000 lbs in 30 minutes. Geometry: Rectangular shape concentrates pressure in corners causing pressure cracks. Cut line parallel to traffic results in differential wheel pressures which can open cut. Geometry: Circular cut has no corners or straight edges.

Reduced Zone of Influence
Zone of influence is the area around the excavation that is susceptible to slippage or collapse resulting from external surface load, from vehicles, plant, or excavated material at or near the excavation. The precise coring process when combined with vacuum excavation reduces loading adjacent to the excavation and reduces or eliminates any zone of influence.

Keyhole coring and reinstatement is a better way
Marshall Pollock Monday, April 20, 2009 Keyhole coring and reinstatement is a better way Reduced Traffic Disruption: Faster, one-step permanent pavement repair means reduced traffic congestion with fewer and shorter road closings and no repeat visits. Reduced Pavement Damage: Less intrusive, more precise pavement coring and reinstatement process means less structural damage to road system, longer pavement life and reduced maintenance. Saves millions of tax dollars. Reduced Footprint: Neat, almost invisible 18 inch diameter circular cut (less than 1/4 the size of conventional road cut), means less scarring of the landscape and better pavement performance (no corner cracks). Environmentally Friendly: No road-cut spoil to be disposed of and no temporary patching compounds with volatile organic compounds (VOCs) to escape into the atmosphere. Cleaner, Safer, Less Intrusive Worksite: No jack-hammers or large excavation equipment means less mess during and after excavation and reduced disruption for neighbors. Huge Cost Savings for Utility: No repaving required, saves time and resources -- can reduce costs by more than 50% - 60%. 20

What is Keyhole Technology? Method of accessing or viewing underground utilities or plant through small holes or “keyholes” vacuum excavated through soft surfaces or through holes cut or cored through pavement. 21

Why Keyhole? Smaller is better and less intrusive. Laparoscopic Surgery Keyhole Operation Smaller Opening (keyhole) Faster Restoration Less Damage to Road System Smaller Repair Footprint Lower Cost Smaller Incision Short Recovery Period Faster Healing Smaller Scar Lower Cost and safer -- no men in the hole. 22

Keyhole Coring and Reinstatement
Size Matters ! Smaller, Less Intrusive NO jackhammers, backhoes NO spoil or waste NO “zone of influence” -- NO Cutbacks Size and Shape Rectangular cuts concentrate stress … Circular geometry with NO corner cracks Proven Strength -- NO Failures Reinstated core will support 50,000 lbs Greater Satisfaction -- Reduced Delay Reduced pavement deterioration -- NO potholes Reduced traffic delay -- no additional road closing for repaving -- In and Out the same day. Aesthetically pleasing -- almost invisible repair Reduces Pavement Restoration Cost by 87% Safer for Workers and Public No Corner Cracks

Keyhole Repairs Keyhole repairs are made from the surface using long-handled tools. Typical Gas Applications Cast iron joint repair Sacrificial anode installation Low pressure service cut off New service installation High pressure PE pipe repair Daylighting for directional drilling Pipeline integrity inspection Two out of every three feet of existing water pipe in service is made of either ductile or cast iron Typical Water Applications Cathodic Protection Service connection after pipe-splitting Daylighting for directional drilling 24

Utilities Using Keyhole Technology
Alagasco Atlanta Gas & Light Atmos Energy Baltimore Gas & Electric Centerpoint Energy (Houston) Centerpoint Energy (Minnegasco) Colorado Springs Utilities Connecticut Natural Gas Consolidated Edison Enbridge Gas Distribution Energy East Corporation Equitable Gas Keyspan Energy Delivery Las Vegas Valley Water District Michcon (DTE) National Grid Nicor Gas Northwest Natural Pacific Gas & Electric PECO People’s Gas Philadelphia Gas Works PSNC Energy Questar Gas Sempra Energy Southwest Gas UGI Utilities Washington Gas Light WE Energies Xcel Energies Under Review Consumers Energy CINergy Dominion East Ohio Gas Knoxville Utilities National Fuel Gas NSTAR NYSEG Oklahoma Natural Gas South Jersey Gas

Keyhole Conflict Identification
Keyhole Coring and Vacuuming process allows you to identify and expose exact location of potential conflicts in advance of directional drilling; After drilling, conflict hole is back-filled and pavement core reinstated -- as a permanent repair.

Expose Multiple HDD Conflicts
HDD to connect services on east side with new 4” PPE main on west side Needed to identify: 48” trunk water main, 8” water main, and 6” gas main under road concrete telephone duct and high voltage electric conduit under sidewalk 5 inspection holes cored and reinstated along drill shot. 24” Trunk Water 8” Water 6” Gas R.B.Somerville for Enbridge Gas Distribution, Toronto ON, 2006 At least 2 lanes of traffic maintained at all times.

Keyhole Technology is a Process
Core Vacuum Repair or Locate Backfill Reinstate

Coring Process Series 500 Minicor Coring trucks or skid-steer mounted Minicor™ unit sets up at the repair site and cores an 18” hole through the roadway at previously located maintenance sites or potential HDD conflict sites (gas, water, sewer, fiber optic cable etc.). MD100 29

Rotary Coring Process (continued)
18” - 24” diameter hole up to 22” deep neat and accurate Time: minutes depending on depth and composition Center pilot hole is cut simultaneously Source: National Grid View: Inside coring drum showing center pilot bit

Cuts cores of different depths and materials
Rotary Coring Process (continued) Cuts cores of different depths and materials

… and get into tight spaces

Sometimes … two holes are better than one
When one 18 or 24 inch hole isn’t wide enough -- then two can be better … … and achieve the same economies in restoration costs and speed in reopening the road to traffic. Effective Opening Size: 30 inches x 12 inches (18 inch drum) 42 inches x 18 inches (24 inch drum)

Rotary Coring Process (continued)
Once the core has been cut through … a core puller is used to remove the core; The core is set aside (to be reinstated later).

Vacuum Excavation: the hole can then be vacuum excavated and the exact location of the potential conflict identified or the plant to be repaired exposed. 35

Backfilling The hole is then back-filled and compacted to the level of the base of the pavement so that the core or coupon of pavement can be reinstated. 36

Reinstatement of the Core A layer of pea gravel is used to level out the base and the Utilibond™ is mixed with water and poured into the hole … … the core is reinserted into the hole and fitted to the level of the surface. 37

Bond Strength Tests of 3 commercially available bonding compounds were conducted in July 2003 at the Department of Civil Engineering, University of Illinois at Urbana-Champaign. The Utilibond™ bonded core gained sufficient strength within 30 minutes to support the combined weight of five transit buses -- over 52,000 lbs. Safety Factor: 5 times the AASHTO H-25 standard.

Fast-Strength Gain Time is money … and Convenience !
Crew Cost $217 90 $217 Utilibond’s rapid hydration and ultra-fast strength-gain allows roadways to be re-opened in 30 minutes. Resulting in crew time savings of more than $70 per hole over other bonding products with slower strength-gain. Greater Public Convenience: road open to traffic again at least 1 hour sooner than conventional methods.

The Completed Repair Utilibond sets-up in 10-15 minutes
Bond gains sufficient strength in 30 minutes to support the single axel equivalent load equal to five transit buses 5 times the AASHTO standard or over 50,000 pounds. Coring & reinstatement cost: $375 The road can be safely reopened in 30 minutes! … with no subsequent repaving required

Excavation Alternatives
Jack hammer and Vacuum Jack hammer and Hand Digging Coring and Vacuum

Excavation and Repair Results
Conventional Rectangular Cut Temporary Patch Permanent Keyhole Core Reinstatement

Excavation and Repair Results
18” 4’ x 4’ Size Matters The Better Way

Advantages of Coring & Reinstatement
Operationally Superior; Aesthetically Pleasing; Functionally More Effective; Field Proven and Environmentally Friendly.

Operationally Superior
Reduced pavement restoration Improved Logistics: Single crew, one-stop, same-day coring and pavement reinstatement means simplified scheduling, no temporary patching or repaving and no repeat visits. Shorter and fewer road closings Fewer complaints about traffic disruption, weakened or failed roads. Faster, safer and physically less demanding on work force -- no jack hammers and reduced potential for workplace injury Less damage to the road system -- NO potholes A coring, vacuuming process.

Aesthetically Pleasing Creates favorable impression with the public Rotary cored and reinstated access hole almost invisible in the foreground. (Permanent) Conventionally repaired sidewalk cut in background. (Temporary) No unsightly utility cut “reminders” or potholes. No stress cracks or other failures. No “slip, trip and fall” litigation. 46

Functionally More Effective Works better -- less damage to pavement Reinstated core exactly matches the original pavement profile. The pavement system is restored to its original design specifications -- no deterioration in performance. No stress cracks, ground water penetration or premature failure. Road re-opened to traffic much sooner -- less inconvenience to public. KEY ISSUES for the DOT and municipalities. 47

Field-Proven Process Core Reinstated 1995 Same Core 2003
“Since the initial reinstatement, more than 145,000 transit buses and more than 13 million commercial and other vehicles have passed directly over the keyhole with no apparent weakening or other degradation of the reinstated core or the adjacent road system or paved surface.” Golder Associates April 21, 2003

Environmentally Friendly
Reuses the same material, in the same form, to repair pavement - no additional processing needed - no additional energy consumed Savings: 2 tons of asphalt concrete No pavement spoil to be trucked away to dump site Savings: 27 cubic feet of spoil No new pavement laid, no milling & overlay, no slurry etc. - no volatile organic compounds (VOCs) to evaporate - fewer GHG emissions - no additional energy or oil consumed in producing/heating HMA Savings: 2 tons of asphalt concrete + fuel + better air quality Shorter and Fewer Road Closings - road can be safely reopened to traffic in 30 minutes - permanent repair -- no additional site visits - reduced inspection & traffic control requirements Savings: hours reduced work zone delay

Environmental Benefits (cont’d)
Minimal Dust and Vibration - no dust -- water slurry easily vacuumed - no vibration and pounding or damage to “zone of influence” Savings: better air quality & reduced impact on neighbors Reduced Noise - coring saw: dB vs jackhammer: dB - no large equipment, trucking or paver noise Savings: work zone 8 times quieter Restored Road System with Waterproof Bond - no cracks, escaped sealant, or water infiltration - performs as load transfer system Savings: a better road system Reduced Cost - $75 vs $ conventional pavement repair with T-section - $75 vs $1,200 for mill and overlay Savings: $425 to $1,125 per utility cut

Reduced Carbon Footprint
Coring Conventional 1 1 Excavation Saw Cut Excavate Pavement Dump Spoil Core Vacuum Vacuum Temporary Asphalt Patch Compact Patch Same Day Months Later 2 Restoration Excavate Patch Dump Spoil Reinstate Finished Repair Concrete Base Asphalt Surface Compact Surface

FHWA Recycled Material Policy: Reduce • Re-use • Recycle
“The same materials used to build the original highway system can be re-used to repair, reconstruct, and maintain them.” Where appropriate, recycling of aggregates and other highway construction materials makes sound economic, environmental, and engineering sense. The economic benefits from the re-use of nonrenewable highway materials can provide a great boost to the highway industry. Recycling highway construction materials can be a cost-saving measure, freeing funds for additional highway construction, rehabilitation, preservation or maintenance. Recycling presents environmental opportunities and challenges, which, when appropriately addressed, can maximize the benefits of re-use. The use of most recycled materials poses no threat or danger to the air, soil, or water. Furthermore, careful design, engineering and application of recycled materials can reduce or eliminate the need to search for and extract new, virgin materials from the land. The engineering feasibility of using recycled materials has been demonstrated in research, field studies, experimental projects and long-term performance testing and analysis. Significant advances in technology over the past decade have increased the types of recycled materials in use and the range of their applications. When appropriately used, recycled materials can effectively and safely reduce cost, save time, offer equal or, in some cases, significant improvement to performance qualities, and provide long-term environmental benefits.”

3.6 million Utility Cut Permits (issued by municipalities every year )

20-25% Utility Cut Permits for Small Holes
Estimated that 700, ,000 utility cut permits in US issued each year for work that can be performed through a 2 ft x 2 ft or 2 ft x 3 ft or smaller opening -- perfect for keyhole work Conventional small utility cuts 18 in diameter keyhole cut

Potential Nationwide Impact of Coring
If 800,000 utility cuts were performed with keyhole coring and reinstatement, ANNUAL savings would be: Reduction in asphalt used: 2 million tons -- equal to 20,000 mi 4-lane highway Reduction in spoil disposal: 27 million cu. ft. -- enough to fill 200,000 dump trucks Reduction in work zone delay: 2.8 million hours 1.9 million gal fuel $520 million cost Restoration Cost Savings: $340 to $900 million Reduction in GHG, VOCs and other emissions, energy consumption, noise, inconvenience, complaints: …. Priceless !

Equivalent of 10 football fields stacked 50 feet high
27 million cubic feet Road Spoil Equivalent of 10 football fields stacked 50 feet high

Summary of Advantages FOR THE UTILITY/CONTRACTOR
Saves Money: Dramatically reduced paving budgets. Positive Community Relations: Faster, less intrusive process. Fewer complaints from municipalities about traffic disruption, unsightly road cuts, sunken patches or weakened or failed roads. Improved Logistics: Single crew, one-stop, same-day coring and pavement reinstatement means simplified scheduling, no temporary patching or repaving and no repeat visits. Field-Proven Process: Zero reported failures in more than 15 years and over 60,000 successful corings in tough urban climates. FOR THE CREW Easy to Operate: No extensive training required. Easy on the Back: Physically less demanding, no jack-hammers, shovels and backhoes. Reduces potential for workplace injury. Easy to Use: Utilibond packaged in easy-open, pre-measured polyethylene pails. Just add water, mix and pour. No awkward measuring from fragile paper bags.

Summary of Advantages (continued)
FOR THE COMMUNITY Reduced Traffic Disruption: faster, one-step permanent pavement repair means reduced traffic congestion with fewer and shorter road closings and no repeat visits. Saves Tax Dollars: Less intrusive, more precise pavement coring and reinstatement process means less structural damage to road system, longer pavement life and reduced maintenance. Saves millions of tax dollars. Reduced Footprint: neat, almost invisible 18 inch diameter circular core (less than 1/4 the size of conventional road cut), means less scarring of the landscape and better pavement performance (no corner cracks). Environmentally Friendly: No road-cut spoil to be disposed of and no temporary patching compounds with volatile organic compounds (VOCs) to escape into the atmosphere, and no wasteful T-section cutbacks needed. Cleaner, Safer, Less Intrusive Worksite: No jack-hammers or large excavation equipment means less noise and mess during and after excavation and reduced disruption for neighbors.

Questions and Discussion Marshall Pollock Utilicor Technologies Inc. Toll Free: Website: 59

Marshall Pollock Monday, April 20, 2009

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