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During an expansion project at an industrial food processing facility, an existing 18-inch diameter concrete storm pipe had deteriorated and needed to be rehabilitated. Instead of removing and replacing the approximately 40-foot section of pipe, a new 13-inch diameter liner pipe was installed inside the existing concrete pipe to serve as the new storm drain. This created an annular void between the new liner and the deteriorated host pipe.
The annular space needed to be filled to support the existing pipe around the liner, help protect the new pipe from potential damage caused by further deterioration of the surrounding concrete pipe, and prevent the open space from creating an unintended pathway for water. The general contractor hired an HMI contractor to perform the annular grouting, with FillFoam® selected as the grout for the application.
Because the pipe run was approximately 40 feet long, a placement hose was extended through the annular space to the far end of the pipe. FillFoam was produced onsite and pumped through the hose. As material was placed, the hose was progressively withdrawn, allowing the annular space to be filled along the length of the pipe rather than attempting to push material through the full 40-foot run from a single injection point.
Once placement was complete, the accessible end of the annular space was sealed with a spray-applied bulkhead made with HMI dual-component polyurethane foam. FillFoam’s lightweight, pre-expanded formulation made it well suited for filling the irregular annular void while avoiding the additional weight associated with traditional cementitious fill materials.
Why FillFoam™?
This project demonstrates how FillFoam can be used for annular grouting applications where new infrastructure is installed within an existing pipe or conduit. By producing the material onsite and placing it progressively through a retractable hose, the project team was able to fill the annular space along the approximately 40-foot run without removing the deteriorated host pipe. For pipe rehabilitation, abandonment, backfill, and other large-void applications, FillFoam provides a lightweight solution that can be produced onsite and placed where conventional fill materials may be difficult or disruptive to install.
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