A BBS Bumpers Success Story on Polypropylene Coated Pipe

We recently had the opportunity to work on a bundled road bore project using our BBS system—bumpers designed specifically to prevent pipe-on-pipe abrasion during the pull-through, with particular focus on protecting the girth welds.

There was just one catch: the pipeline was polypropylene coated.

Anyone who works in the coatings world knows that polypropylene can be a challenge. It’s a fantastic coating in many respects, but when the task at hand requires bonding something to it, the difficulty level increases quickly. And in this case, we weren’t just asking the system to stick.

We were asking it to:

• Bond reliably to polypropylene

• Survive being dragged thousands of feet through a bore hole

• Maintain position and integrity from entry to exit

That means the system had to deliver excellent shear strength, peel strength, penetration resistance, and abrasion resistance—all at the same time. That’s a big ask for any product.

Fortunately, the end user did something that almost never happens: they provided us with an actual sample of the polypropylene coating in advance. That allowed us to evaluate—firsthand—the bond our BBS system was making with their specific coating formulation.

To put that in perspective, roughly 95% of the orders we receive ship same day or next day. For a customer to give us a few weeks to slow down, test thoroughly, and validate performance in their environment? That’s a rare treat—and one we don’t take lightly.

After running the full gamut of testing, the results were clear. Our BBS system and this polypropylene coating were an excellent match. The bond performance met expectations across the board, giving everyone confidence heading into the installation.

And sure enough, the job went off without a hitch.

When the bundled pipe emerged from the exit hole, the bumpers were:

• Perfectly intact

• Undamaged

• In the exact same position they started in

No surprises. No failures. Just solid performance from start to finish.

This project was a great reminder that while coatings like polypropylene can present real challenges, the right testing—and the right solution—make all the difference.

BBS is an excellent product. And when paired correctly, it delivers exactly what bundled road bore applications demand: protection, durability, and peace of mind.

Pipe Bundle Bumpers: Use a Bumper System or You're Using Your Welds

 

A Critical Risk in Bundled Directional Drills (That’s Easy to Overlook)

I was reviewing a bundled directional drill specification this morning and ran across an interesting wrinkle — one that’s easy to overlook when talking about bundled road bores and spacer systems like our BBS Bumper System.

It comes down to this: girth welds are especially vulnerable to pipe-on-pipe damage.

Think about what’s happening inside a bundled bore. Each pipeline has raised girth welds, and those welds are typically protected by a field-applied coating. Unless a proper spacer or bumper system is used, those coated welds are rubbing directly against adjacent pipelines during installation — and potentially for the life of the line.

Field joints are already the most “at-risk” section of any pipeline. Coating thickness can vary, surface prep isn’t always perfect, and real-world field application rarely matches lab conditions. Add continuous contact and movement against another pipe, and you’ve just increased the likelihood of damage at the exact point you can least afford it.

Now layer in the reality of a bundled pipe bore.

If your pipelines aren’t riding on a bumper or spacer system, chances are they’re riding on something else — very likely a field joint. And beneath that field joint? A girth weld.

Let that sink in for a moment.

You may think your pipes are simply resting against each other, but in practice, you could be concentrating load, abrasion, and movement directly on a raised weld profile with a field-applied coating. Over time, that’s a recipe for coating damage and potential corrosion issues down the road.

This is exactly why spacer systems matter — and why they need to be designed with bundled installations in mind. A properly engineered bumper system like BBS keeps pipelines separated, transfers load away from girth welds, and protects the most vulnerable sections of the pipe during installation and service.

Because when you really visualize what’s happening inside that bore, it’s honestly a little scary to think about what’s riding on what.

And it’s far better to address that risk up front than to discover it later.

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!  

BBS System Improvements for your Bumpers on Bundled Drills

Joint Specialists Announces Improved BBS Bore Bumper System for Enhanced Performance

Trapezoidal Bumper as part of the BBS System for Bundled Pipe 

    Joint Specialists, a leading provider of innovative solutions for the oil and gas industry, is pleased to announce a significant improvement to their BBS bundled bore bumper systems. After an extensive research and development effort, the company has replaced the 1"x2" rectangular bumper with a new and improved trapezoid shaped rubber. This enhancement will transform the BBS system into a more 'roller friendly' product, providing enhanced performance and efficiency.

    The decision to upgrade the BBS system was made after careful consideration of customer feedback and market demands. The rectangular bumper, while effective, was not as efficient in handling the movement of rollers as desired. With the new trapezoid shaped rubber, the BBS system will now be able to smoothly and effectively handle the movement of rollers, making it a more reliable and user-friendly product.

    According to the company's blog, the new trapezoid shaped rubber has undergone rigorous testing and has shown promising results. It has been designed to withstand extreme temperatures and harsh environments, making it suitable for a wide range of applications. The improved BBS system is now available for purchase and more information can be found on the company's website at http://blog.heatshrinksleeves.com/search?q=BBS.

   JSI is committed to providing innovative and high-quality solutions to their customers. The improved BBS system is a testament to their dedication to constantly improving and evolving their products to meet the ever-changing needs of the industry. The company is confident that this enhancement will greatly benefit their customers and contribute to the overall success of their operations.

    Joint Specialists is excited to introduce the new and improved BBS system to the market and looks forward to the positive impact it will have on their customers. With this upgrade, the company continues to solidify its position as a leader in the industry, providing cutting-edge solutions that drive efficiency and productivity.

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.

Zip Ties to Hold Bumpers on a Bundled Directional Drill?

 Zip Ties to Hold Pipe Bumpers on a Road Bore?

     I've had an interesting week.  There is a pipeline project going on out there that is using zip ties as the primary method of keeping pipe bumpers on the pipeline.  In this particular case, two 12" pipelines are being dragged through the same bore hole at the same time.  A bumper is needed there for a variety of reasons, but most importantly:

1. To prevent pipe on pipe damage during the pull through
2. To keep space between the pipelines to allow room for the cathodic protection system to do its job (pipe cannot be resting on pipe)

     In this case, I've had phone calls from an inspector on the line and from a QA employee who works for the end user.  In both cases the question was the same:  Do you think it is going to work if we have our bumpers secured with zip ties?  (not coincidentally; both people asked that their identities remain confidential of course). 

     My first response:  "WHAT???"

     My second response:  "Are you serious?"

     My third response:  "No, I don't think that is going to work."

     Now, everyone who has experience with a directional drilling application understands that tremendous forces are going to be put on the pipe.  That is the reason that Powercrete DD is such a sought after product!  It has excellent abrasion resistance, penetration resistance, gouge resistance, etc.  When that pipe that is travelling under ground collides with rocks and roots; the Powercrete DD is tough enough to survive without a scratch.  

     When you're pulling muliple pipelines through the same hole; at the same time -- those forces are all magnified.  Those lines are bouncing around in that hole; and bouncing off of each other if a proper bumper system isn't used (see JSI's bumper system here).  Consider more than one very heavy section of pipe; consider the forces when that pipe 'bounces' off of a rock -- and anything used in that situation had better be tough.  

     Say you're pulling 24" OD pipe through a bundled bore (along with a 12" line).  That 24" OD pipe might way 100 plus pounds per foot.  If you have a bumper of some kind on that line every 20 feet - that means each bumper is responsible for 2000 pounds of weight!  Now add in the massive spikes in force when that line collides with a rock!  Consider that there might also be a 12" line in that hole!  There could me more than 1 extra line (the most we have seen is 11 lines in 1 hole!).

     Those are incredible weights.  

     How much weight can a zip tie hold?  Keep in mind; even industrial zip ties are at most 1/2" wide (often 1/3" or less).  In my research, I do find a few zip ties that claim to hold 250 pounds and many more that claim to be able to hold 175 pounds or less.  If that 2000 pound figure that I cite up above (the weight of 20 feet of larger diameter pipe) for a stationary pipe; how much weight do those zip ties need to contain when that line bounces off of a rock; bounces off of another pipe; bottoms out in the bore hole as the pipe turns to head to the surface, etc.  Could you trust that to say 4 zip ties?  Absolutely not!!

     Meanwhile JSI's Bore Bumper System is proven over the course of hundreds of bores representing many, many miles of bundled bores.  Our system utilizes a material with a tensile strength of greater than 2500 newtons.  A simple conversion indicates that can be in the neighborhood of more than 500 psi.  Our system on a 20" line would have ~90 square inches of material permanently bonded to that pipe surface.  

     These aren't even two system that can be compared.  More than likely the zip ties begin popping shortly after the bundle enters the earth.  Soon after the bumpers likely begin falling off.  Shortly after that, the pipe likely begins to collide with each resulting in damage to your factory applied coating.  And then finally, the pipe very likely reaches its permanent resting place; with two steel pipeline resting on one another.  As time goes by and wet/dry and hot/cold cycles reign for weeks, months and years; the very expensive factory applied coating you paid for is worn away and massive corrosion problems occur.  All because someone chose to trust a zip tie. 

Another Successful Bundled Road Bore Project

 Bumpers for Bundled Directional Drills

     Joint Specialists is the leader in the bundled directional drilling bumper market.  Having been supplying the market for seven years now; we can say that our system is proven superior to everything else out there in the marketplace. With dozens of projects and more than 70 miles of pipeline, the BBS system has been used to protect pipelines from pipe on pipe collision damage during the pull through - and leave space between the pipelines when they reach their final resting place.  The system is designed to last just as long as the pipeline itself (likely longer).  

Here are some photos from our most recent project:

Your typical bundled directional drill right of way!  Three pipelines ready to go.  We've seen this many times with our Road Bore Bumper System (BBS)

A well installed (after training of course) BBS Bumper Sleeve!  The pipe will be heading toward the right when it enters the hole.  

Another view one of the installed BBS bumpers.

Another Successful Bundled Road Bore Completed

Pipe Bore Bumpers (Doughnuts) - Another Success!

     Another bundled road bore where the pipelines have been successfully prevented from pipe against pipe damage during the boring process by our bumpers!  This line was in the Houston area and the bundle pulled was a 16 inch line, a 12 inch line and a 6 inch line.  With bumpers appropriately spaced and the bumper system properly installed (we always like to have an expert on site wherever possible to make sure everything is installed properly), another successful bore was completed. 

Fully installed BBS Bumper Bundle System on 12" Pipe

     This proven system is sold as a single line item part which includes:

- 2" wide by 1" tall specially formulated bumper material

- 17" wide sleeve proven to hold that bumper in place throughout the bore process

- 3" wide leader strip / wear cone for extra protection on the front end of the sleeve

- suitable mount of the two part S1301M bonding agent

     Each bumper is generally installed in 5 minutes or less.  It does not require any special training or tools (propane torch and silicone roller are about it).  This proven, field friendly solution has been used by major pipeline contractors and end users around the country.  Contact us for a quote or simply for a copy of the brochure affiliated with this BBS (or BBS/CCS) product line. 

Pipeline Bumpers

Pipeline Spacer Bumpers

     As you've likely seen elsewhere within this website, our BBS Bumper System (used on bundled road bore projects) has seen great success.  As always seems to be the case, with success comes customization.  Since we pride ourselves on our ingenuity and our ability to engineer solutions to customer needs, we always welcome customizing our products to specific projects.  In this particular case, we've been asked to modify our current BBS system to incorporate a 2" tall bumper rather than the traditionally used 1" tall bumper.  The answer (due to the specific pipe sizes associated with this pipe bundle) is YES.

     We utilize two different systems for our bumper system.  These two systems are:

- BBS - a very thick, tough and rugged bumper containment system with a standard shrink ratio (~25%).  This is our most commonly sold bumper system installed on pipelines 8" OD and larger. 

- BBS/CCS - a slightly less thick, tough and rugged bumper containment system with a high expansion backing (~66%).  This is our most commonly sold bumper system on pipe sizes: 6", 4", 3" and 2". 

    Both of these systems have been utilized and to this point, all has been installed with a 1" tall bumper (by 2" wide).  Those time may be changing, however.

Our specially formulated bumper in a 1" thickness.

     For those customers who are interest in using a 2" tall bumper instead of a 1" tall bumper, we have good news.  It can be done.

     With our BBS system, the limiting factor is the shrink ratio built into the sleeves.  Since the BBS material shrinks only ~25%, the BBS system can be used with a two inch bumper only for pipe diameters 14" and up.  For smaller diameter lines, the BBS/CCS is fully capable of utilizing the two inch tall bumpers in the system.  So, what do you prefer?  1" or 2"?  Now you've got a choice. 

2" thick bumper system utilizing specially formulated and custom cut bumpers.

     

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.

Pipe Bundle Directional Drill

Suspended Pipe Bundle

     If you saw yesterdays blog post showing the video of the four pipe bundle burrowing its way into the deep, dark earth; you might have been wondering "ok, so where was the pipe just before it entered the bore?"  Good question and thankfully - one I can answer pretty easily. 

 

     The situation I described yesterday was one in which as the pipe is on its journey to the center of the earth, at least one of those pipe sections absolutely MUST be surfing on the other pipelines.  Yes, surfing.  52" of pipe will absolutely not fit straight across in a 48" OD hole.  It simply can't happen. 

 

     Well, will it surprise you to learn that just before burrowing and surfing, these pipelines were flying through the air!  It was like the X-Games of natural gas out on that pipeline spread!  In order to get the right angles and in order to prevent any unnecessary stress on those pipelines, they were bundled together and suspended by side booms so that they'd have a good angle down into the hole.  These are not your Father's directional drilling applications, people!

     First: The side booms

 

 

     Then:  Pipe pulled into the mud...never to be seen again.

 

     Fortunately, all involved were able to rest easy knowing that the Joint Specialists BBS bumper system was properly installed assuring that the pipe would get to its final resting place undamaged and secure.