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.

Bumpers for Multi-Pipe Directional Drills

 Bumpers for Bundled Pipe Bores

     Another successful bumper project is underway.  As we often do, we were there to train crews at job kickoff.  It's certainly in EVERYONE'S best interest that our products are properly installed.  Though the product is quite simple to install, best to make sure everyone is on the same page from the jump.

     Utilizing our newest iteration of bumper material - we are now utilizing a trapezoid shaped bumper in order to give a slightly easier ride over the rollers.  Though an upset in the pipe will never bring a fully smooth transition, this bumper shape certainly brings a dramatically improved trip over the rollers.  If you have a job and would like a demonstration or sample of the product, reach out and we will make that happen!

     Utilizing that specially formulated trapezoidal bumper material along with our system for making sure that bumper does not move anywhere during the pull through, we have the best system in the market to protect your pipeline.  

  

     Preventing pipe on pipe collision damage is job #1 for the BBS bumper system.  Keeping space between the lines when they have reached their final resting place so that CP current can access the lines is job #2.  Both equally important. 

     If you have questions, please don't hesitate to reach out.  We love talking about this product!  

 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.

BBS Bumper for Bundled Bores - Included Components

 BBS Bumpers for Pipe Bundles - What is Included?

     Sometimes called Multi-Pipe Pullbacks; bundled road bores occur when more than one pipe is pulled through a bore hole.  It is a new tweak on a long time technology; the only difference is:  the bore hole is large enough to fit more than one pipeline.  In those cases, two things have to be considered:

1.   How do we make sure they pipelines don't damage one another during the pull through?  Pipes do jolt at times as they encounter rock, roots, etc.  You certainly don't want those lines that you are never going to see again experiencing damage to their corrosion coatings!
2.   How do we make sure we don't have pipelines resting upon one another?  We've supplied bumpers on bundles with as many as 11 pipelines involved.  Imagine 11 pipeline all resting on one another (picture a handful of uncooked spaghetti).  How is CP going to get to the line that is stuck in the middle of that bundle surrounded by a literal pipe wall keeping soil, water and current away from the line?  How about the "inside" sides of those pipes that are making up the "wall"?  You need to make sure there is space between those pipelines so that soil can ultimately fill those areas; creating a path for the CP. 

If you're curious - you can see a case study HERE.

     Now with nearly one hundred thousand bumpers installed and pulled through bore holes; we've yet to hear of a single bumper failure.  Yet to hear of a single bumper that disappeared during transit (the bumpers on the leading edge of the bundle always show up on the other end of the bore).   We've got a proven product, using our specially formulated bumper material --- and our proven system for making certain the bumper stays in place.  Many other folks have used this product successfully; so you can be confident you aren't taking any chances at all.

     So what comes in the system? See below:

Our specially formulated bumper material.  We are also working on new shapes to offer some advantages in the field.  Hopefully those evaluations will be completed in the months to come!

The epoxy bonding agent that gives fantastic shear and peel resistance to the bumper holding system.

The main component that holds the bumper in place with nowhere to go.  Tens of thousands installed with no reported failures.

Finally, the leading edge strip.  Probably not needed in all honesty, but this, installed on the leading edge of the system gives even more protection against some kind of peel back.

Bundled Pipe Bumpers: A Comprehensive Case Study

 Bundled Pipe Bumpers: A Comprehensive Case Study

Frequently, we receive calls from customers seeking assistance with challenging problems, and it is always gratifying to offer them simple and effective solutions. In this particular case study, a customer approached us with a bundled directional drilling project in Texas. Although the pipes had already been strung up, they were concerned about potential pipe collisions during the pull-through process. Complicating matters further, they were pulling four pipelines simultaneously, measuring 16", 16", 12", and 10" in diameter. The customer needed a swift and reliable solution. After multiple discussions, emails, and an in-person meeting, the customer was convinced that our BBS system was the answer. With the urgency of the situation in mind, we promptly coordinated with suppliers, mobilized additional labor, and commenced manufacturing to ensure the timely delivery of the required materials. Thus, the problem was successfully resolved.

Collaborative Efforts

Like any pipeline project, unexpected challenges emerged along the way. Fortunately, this project boasted an exceptional crew, consisting of a quality-focused contractor, a meticulous inspector scrutinizing every detail, an engaged end user, and a seasoned road bore team. Moreover, our company, Joint Specialists, contributed decades of experience in pipeline construction materials, further strengthening the collaborative approach.

Bundled Pipe Bumper Installation Process

The four pipes were aligned side by side, and markings were made to indicate the precise locations for bumper installation. Preheating the pipes to 140°F, we carefully placed the bumpers in their designated spots. Next, a two-part epoxy was mixed and applied to the warmed pipe surface. Finally, the heat shrink, which serves as the primary anchor for the bumpers, was carefully shrunk in place. Overall, each bumper installation required a mere 3-5 minutes. Once all the BBS systems were installed, the pipes were bundled and ready for the subsequent pulling operation.

Unforeseen Obstacles

However, during the initial 400-foot segment of the pull-through, the pipe-grabbing mechanism unexpectedly snapped. Although such incidents were rare, it presented a significant challenge. Consequently, the pipe bundle that had reached 400 feet underground needed to be extracted in the opposite direction, necessitating a complex maneuver using side booms. This unexpected turn of events provided an exceptional opportunity to test the resilience of our BBS system. Notably, the subsequent operations involved pulling the pipe back 400 feet, then pushing it 1,700 feet back through the hole. Furthermore, this situation offered a unique chance to inspect our system after its 400-foot round trip into the depths of the Earth. The question lingered: would our system prove as effective as we believed? The ensuing inspection would yield the answer.

Thorough Inspection and Evaluation

The inspectors and representatives from the end user's team shared our excitement about this rare opportunity to closely examine several dozen BBS systems. The inspection aimed to determine if any bumpers were missing, whether any had been left behind in the mud, and whether any collisions had occurred among the pipes. Despite the layers of mud obscuring the bumpers, the inspectors meticulously examined each BBS system. Running their fingers along each side of the bumper, they ensured its presence, stability, and functionality. Remarkably, we achieved a 100% success rate in this evaluation.

Conclusion

In conclusion, the BBS system demonstrated its efficacy without a doubt. Its reliable performance and ability to prevent pipe collisions were reaffirmed through this case study. We confidently invite anyone claiming to possess alternative solutions to provide documented photographic evidence supporting their claims. Based on our extensive experience and the results of this study, we firmly believe that no other system can rival the effectiveness and reliability of our BBS system.

Pipe Bundle 6-inch and 12-inch

Pipe Bumpers Made Easy

     Another job in the books and another pipe successfully protected during a bundled road bore project.  Here are a few photos.

Pipe bundled, bumpered and resting on skids to move it toward the bore hole. 

All of this rain we've had is making for some wet, messy job sites.

Good photo showing the space the bumpers create.  Bumpers are located 10-20 feet 'off screen' but are still working to hold the lines separated at this point.

Neither rain, nor sleet, nor snow, nor mud can prevent our BBS system from doing what it is designed to do.

      Our bumper system (BBS or BBS/CCS) has now been used successfully on numerous projects with nary a sniff of a failure or even sub-par performance.  Simple to install.  Easy to install.  Fast to install, there is no other system on the market as easy to use that can perform this well.

     Using a high durometer, specially formulated and fully evaluated proven bumper material.  This system simply works.  Our system for holding that bumper in place through out the boring process is also unmatched.  This multi layer system can be installed in three to four minutes (depending on pipe size) and can see pipe stresses as soon as it has cooled.  You have enough to worry about on this project - let us worry about preventing pipe collisions during the boring process. 

     Contact us for pricing and lead times - steve@jsicoatings.com 936/321-3333

Pipe Bumper Doughnut

Bore Bumper System (BBS)

A JSI BBS installed on a 16" OD pipeline.

 

  Bundled Directional Bores

Directional drilling applications are one of the most difficult for a pipe coating to withstand.  With a bundled directional drill, the coating is challenged even more. 

Factory applied coatings are generally not designed to withstand the forces of a directional pull AND the tremendous impact caused by two heavy steel pipelines banging into one another.

Add in the fact that these sections of pipe will literally never be seen again and it quickly becomes clear that a reliable, proven bumper system is an absolute must if you want your pipeline properly coated and protected.

Here you see the BBS system installed on a 16" pipe fully supporting the weight of a 16" pipe and preventing pipe collisions

  Proven Bumper System

Incorporating a specially designed and formulated bumper/doughnut with a heat shrinkable holder proven to withstand the forces involved in a directional drill; the Joint Specialists system is superior to every other bumper out there.

No more rope bumpers.  No more steel banding next to your pipe.  No more polyurethane pours.  No more time consuming, unrepeatable installs. 

Your pipe is too important to risk letting it damage itself during a bundled road bore.  Install the best bumper system today so you can avoid major coating problems tomorrow.

 Prior to the bore hole, the pipe was suspended in this case to give it a good angle into the hole.

A rare sight indeeed.  Here is the BBS system AFTER the bore.  Bumper still in place. Sleeve unscathed.  Pipe protected.  The profile of the bumper is unchanged.  Another SUCCESS for the BBS bumper system.