Don’t Leave Your Bundled Bore Bumper System to Chance

 

Bundled directional drills are complex. They’re expensive. And they carry long-term consequences if something goes wrong.  So here’s a simple Public Service Announcement:

If your company does not have a thoughtfully written specification for bumpers on bundled bores, you are taking a serious risk with your pipeline.

When multiple 20" and 30" pipelines are bundled together and dragged thousands of feet through a bore, pipe-on-pipe contact isn’t a possibility — it’s a certainty. The real question is whether you’ve engineered protection into the project or left it up to chance.

Our BBS (Bundled Bumper System) was designed specifically to address these risks. It isn’t improvised. It isn’t pieced together on-site. It’s engineered for the application.

Here’s what that means:

• Two-part epoxy bonding agent applied directly to the factory-applied coating — with no abrasion required

• Bumper material backed by decades of bore experience

• Leader strip protection on the front end of the bundle

• A proven durometer rating engineered to handle the load

Most importantly:

The system is guaranteed to stay in place
The system is guaranteed to maintain the spacing you specify

Spacing isn’t cosmetic. It’s protection. Lose spacing, and you lose coating integrity. Lose coating integrity, and corrosion becomes part of your future maintenance plan.

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What Happens Without a Specification?

Let’s talk about what I’ve actually seen, including as recently as this morning.

If you don’t clearly write a bumper specification into the project, the decision doesn’t disappear. It simply shifts downstream.

And when cost pressure takes over, here’s what that “system” often becomes:

• A 1-inch rope

• Wrapped with a couple laps of cold-applied tape

• The kind with mesh backing and soft mastic

On a multi-million-dollar pipeline project.

Heavy 20" and 30" coated steel being dragged through the ground — relying on about $0.50 worth of rope and $2 worth of tape.

I’m confident even the tape manufacturer would tell you:
That is not a bundled bore solution.

Improvised bumper systems don’t usually fail immediately in a dramatic way.

They fail gradually.

• Tape shifts and/or rolls

• Rope slides or is pulled off

• Spacing disappears

• Coatings abrade

• Problems begin

And now you’re living with coating damage that will follow the asset for decades.

That’s not a small oversight. That’s a lifecycle decision.

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Write the Specification. Control the Outcome.

Bundled bores are the place to clearly define:

• Bumper material

• Durometer requirements

• Bonding method

• Spacing requirements

Because when you leave it unspecified, you’re not saving money.

You’re gambling with a buried asset that you can’t easily inspect or repair.

And that’s not going to help anyone sleep at night.

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.

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.

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.

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. 

Bumper for Bundle Bore Pipe Sizes

Bore Spacer Use History

     Our bumper spacers that are used to prevent lines from colliding with and damaging one another in bundled road bore applications have been successfully used on many projects now.  Simple to install and proven repeatedly to be reliable (with some before and after photos that can be found on this article).  In that light, I am finding that a couple of questions are asked often.  These two questions are:  what pipe sizes have used these bumpers....and how many have been installed?  I'll answer the second question first.

     So how many of our bumpers have been installed?  The simplest answer is:  thousands.  We've seen thousands of our bumpers installed successfully.  Those protected pipelines on many miles of bundled road bores.  Beyond all of that, we've heard repeatedly about the simplicity of the installation of the system and advantages over some of the other options out there.  I think I described in detail here recently how our bumpers will have no issue with hydrostatic testing (which I was told caused some of the other bumper systems to fail before the bundle ever saw the bore hole). 

     On what sizes lines have our bumpers been used?  At this moment, we've seen our bumpers installed on every pipe size between 3.5" and 20".  We've seen everything from two pipeline bundles to eleven pipeline bundles.  Beyond that though, our evaluation of both the specially formulated bumper material and our knowledge and experience of the system we use to hold the bumpers in place; tells us that this system will work on any sized line.  Our system has been used in slightly different application on lines up to forty eight inch with no issues (actually in those cases our system was used an actual pipeline coating in order to prevent corrosion for twenty plus years; so simply "surviving the bore process without losing track of the bumper" is a pretty small request when making a comparison. 

    

Pipe Bumpers and Hydrostatic Testing

Hydrostatic Testing and Pipeline Bumpers

     Heard from a contractor recently about an upcoming directional drill bundle he is running.  His customer (the end user) had tasked him with finding a product to use as the spacing bumpers on his bore bundle in order to insure that the pipe didn't damage itself bumping into other lines in the bundle during the pull through process.  On a previous project, this end user had used some kind of a mechanical bumper and things had not gone well at all.

     The contractor 'installed' all of the mechanical bumpers (screwed / bolted them together an in place) and they looked fantastic.  The problem became apparent when they ran their hydrostatic testing though.  If you're not familiar with hydrostatic testing; here is a very simple definition copied straight from wikipedia:

"A hydrostatic test is a way in which pressure vessels such as pipelines, plumbing, gas cylinders, boilers and fuel tanks can be tested for strength and leaks."

     So picture this:  you've got your pipelines all strung up.  You've got your bore hole drilled.  You've got all of your screwed on / bolted on mechanical bumpers in place.  You've got all of your pipe welded and you've got all of your field joints coated.  One last step before beginning the pull through - hydrostatic testing.

     Fire up the test and you hear something crack.  You also think you see something fly through the air a ways down the line but you can't be sure.  You kill the pressure and go to inspect the line.  Right off you see what flew through the air -- a small piece of plastic that came from one of those mechanical bumpers!  Upon further inspection  you go down the line and see that an alarmingly high number of your spacers were cracked during the hydrostatic testing!  What now??

     Good news.  Our product does not have any issue with hydrostatic testing and our product can be installed quickly and easily at just about any stage of construction....even in a hurry to get a job back on schedule.  Our system utilizes a specially designed heat shrink product to hold the bumper in place.  Heat shrink has been used on field joint coatings for decades and...these sleeves have withstood hydrostatic testing with no issues over those decades. 

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.