Multi Pipe Bundled Road Bores

 

The Rise of Multi-Pipe Bundled Road Bores — and How BBS Is Solving the Challenges

Another successful BBS project is in the books — and with it, another reminder of just how far bundled road bores have come. When we first started hearing about multi-pipe bundled bores over a decade ago, the concept was still relatively new and untested. Today, they’re becoming the norm rather than the exception.

BBS was created in 2014 with one clear mission: to make multi-line bundled bores safer, more reliable, and more efficient. Since then, our team has been directly involved in projects ranging from simple two-line bundles all the way to massive eleven-line bundles — an engineering feat that still amazes us every time we see it pulled through successfully.

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The Challenge of Bundled Bores

Bundled road bores present a fascinating engineering challenge. When multiple pipelines are pulled through a bore hole together, a few key questions immediately come up:

• How do you prevent the lines from abrading or damaging one another during the pull?

• Once installed, how do you ensure each line is properly separated to allow for effective cathodic protection?

• How can you verify that everything remains in its designed position throughout the bore and installation process?

Without a reliable spacer or separation system, bundled bores can result in significant risks — coating damage, interference with CP systems, and even long-term maintenance issues once the lines are in service.

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A Decade of Proven Performance

Our BBS system was designed to solve these exact challenges — and it’s been doing just that for more than ten years. With over 100,000 successful installations across more than a hundred projects, the performance history speaks for itself.

The BBS design ensures consistent separation, protection, and alignment through the entire bore process. The result? When that pipe bundle emerges from the other side of the borehole, the lead bumpers are right where they were installed — perfectly intact and doing their job (even if they’re covered in a little mud).

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From Concept to Completion — We’re With You All the Way

Our involvement doesn’t start when the bundle is pulled — it starts much earlier. We partner with engineers, contractors, and owners from the very beginning:

• Engineering and specification development

• Bid-stage support and design review

• Pre-project and on-site training

• Kick-off and installation guidance

• Field support and inspection at pull-through

We take pride in being there every step of the way, from design to execution, ensuring your bundled bore project performs exactly as planned.

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Looking Ahead

As multi-pipe bundled road bores continue to increase in frequency and complexity, the need for proven separation and support systems becomes even more critical. The lessons learned from a decade of BBS installations have positioned us to support the next generation of pipeline infrastructure — with smarter designs, faster installation methods, and even greater reliability.

If your next project involves a multi-line bundled bore, we’d love to share what we’ve learned and help you achieve a flawless installation.

 HDD Bundle Bumpers

     Another successful project in the books.  Here you see a photo of a training we've just completed.  Contractor was able to string quite a bit of pipe.  They then came through; coated field joints and then applied the bumpers before bundling up the lines and sending them through the hole.  Contractor, end users and inspectors were all very happy with the result.  The section of the bundle that came out of the hole on the other end still had bumpers in place exactly where they had been installed.  None were damaged.  None were lost.  None slid down the pipe.  

    We've now seen our BBS bumpers for pipe bundles installed on everything from 2" pipe to 36" pipe and have yet to hear of a problem or a failure.  It is a great product and we'd love to talk to you about your upcoming projects.  

     In addition, our bumpers have been used on everything from two line bundles; all the way up to an ELEVEN line bundle!  That one was wild to see.  If you're interested you can see one of our early CASE STUDIES by clicking on the link.

Bundled Bumper Spacing

 Spacing Options for Bundled Bore Bumpers

A BBS Bumper freshly installed

Nowhere to hide if these bumpers don't work.  In person, the space was clearly visible and the silence of the lines NOT rubbing on one another was deafening.

Here they go.  Bumpers still intact and in the same exact place when they came out of the ground 1500 feet away.

     When selecting your bumper spacing, I've seen a number of different philosophies.  First and foremost - it is important to share this disclaimer:  JSI never recommends bumper spacing.  In the first place, there are numerous factors including the flex in the pipe (which will be impacted by OD and wall thickness) then there is the depth and angles of the bore hole.  Because of those things; it is impossible for me to make a recommendation - that is a decision for the end user to make.

     But when we look at the multitude of jobs that have used our BBS system, I notice there are a few schools of thought out there.

1. Some folks are conservative.  They want a bumper every 8-10 feet.  They know how expensive directional drilling is - how expensive their pipe and coating are - and they don't want to take any chances with pipe on pipe damage -- or CP failures. 
2. Some folks seem to choose to put a bumper every 15-20 feet regardless of pipe OD.  
3. Some folks carefully calculate all the factors involved:  pipe flex, bore radius, number of lines in the bundle, etc and they come up with very specific spacing requirements:  as an example I've seen every 25 feet on a 20" line and every 20 feet on an 8" line.

    So there are many strategies that our clients have used.  What is your strategy going to be?  

Give me a call to discuss your next project!  steve@jsicoatings.com   936/321-3333

 

 Bumper System for Bundled Road Bores (BBS)

     Another successful bundled road bore using JSI's patent pending BBS bumper system.  This time our product was used on a project up in the Northeast USA.  We completed training on the morning of job kick off (though rain required we train in a warehouse instead of out on the right of way).  As you'll see in the photos below, we are installing on some scrap pipe for training purposes only.

We lightly preheat the surface of the pipe to be certain it is above the dew point and to be certain we are efficiently using the epoxy bonding agent in a very thin layer.  Other than preheating and wiping the pipe coating surface clean so that there is no dust, oil, dirt, grease, etc -- we do NOT damage the factory applied coating in any way. 

The epoxy bonding agent is applied to the preheated pipe surface.  The epoxy bonding agent is applied in a very thin layer.  Microns thick rather than mils.  We want a thickness at which we see the solid color of the epoxy we are applying.  The epoxy should be everywhere that the system will be -- and beyond so that inspectors can verify proper application, even at a later date.

Specially formulated bumper is wrapped around the pipe and secured temporarily using tape.  The bumpers will have been cut at an angle so that they fit together properly; forming a round circular shape.

The main sleeve is then wrapped around that bumper (centered) and the closure is secured.  It is critically important that the sleeve is one that has been proven successful in road bore applications; otherwise you are likely to end up with a pile of material that has torn off the pipeline in your bore hole.  

Main sleeve is then shrunk; starting over the bumper and moving to either end.  The sleeve should always be shrunk circumferentially (around the pipe) in a manner that prevents any air entrapment.  The sleeve will conform very nicely to the bumper profile.

For pipelines 12" and larger we recommend utilizing two installers; one on each side of the pipe - working in tandem.  

Here we see the profile of the bumper showing nicely and properly.  This is looking like a very good installation.  Good job to the crew!

We now see that the leading edge sleeve has been applied to the left side of the system.  This offers extra protection to the front end of the system.  

In this installation, the leading edge strip is on the right side of the system.  Another great install by this crew.  BBS Installation Certification cards are on their way to you!  In addition, we are available 24/7 for teleconference, video conference or any possible trouble shooting that may arise.