Engineering design for HDD pipeline replacement under highway

About this project

Midwestern U.S.
completion date

After reviewing the in-line inspection data for features of concern, a client noticed a potential integrity issue with a pipeline under an interstate highway. Based on the location of the feature, the client decided to accelerate a replacement project.

Although an open-cut repair was explored, limited access and the possibility of impacting transportation infrastructure made horizontal directional drilling (HDD) the most viable option. 

The client selected Barr as its prime consultant to create a detailed engineering design. Our work entailed a geotechnical review of the subsurface conditions, mechanical analysis of tie-in connections, and a detailed civil plan to facilitate construction setup. 

We conducted a geotechnical investigation with borings to evaluate conditions at the new pipeline's proposed entry and exit points. Based on the results, we made geotechnical recommendations to J.D. Hair & Associates, our subconsultant and the HDD designer. Once the drilling profile was designed, Barr’s civil team developed the workspace layout, while our mechanical team supplied isometric drawings, hydrotest parameters, and a bill of materials. We remained on site during drilling to assist with construction concerns.

Key team members

Joe Lurkins

Senior Mechanical Engineer

Steve Marshik

Vice President
Senior Civil Engineer

Rob Olah

Senior Geotechnical Engineer

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