A trenchless pipeline replacement project in Kenya was successfully completed using the Drillto S80 Pipe Bursting Machine. The project involved replacing an existing 100 mm cast iron pipeline with a new 160 mm polyethylene (PE) pipe over a total length of 93 meters.
The existing cast iron pipe needed to be replaced while minimizing the excavation required along the pipeline route. Pipe bursting technology provided a practical solution by breaking apart the old pipe and creating space for the new PE pipe to be installed along the existing alignment.
The construction team completed the guide rod pushing stage in approximately 40 minutes and the pipe pulling stage in approximately 1 hour and 40 minutes. The entire project was completed within one day.
This case demonstrates the practical application of trenchless pipe replacement technology for upgrading existing underground utility pipelines.
| Parameter | Project Details |
| Project Location | Kenya |
| Equipment | S80 Pipe Bursting Machine |
| Construction Method | Trenchless Pipe Bursting |
| Existing Pipe Material | Cast Iron |
| Existing Pipe Diameter | 100 mm |
| Replacement Pipe Material | Polyethylene (PE) |
| Replacement Pipe Diameter | 160 mm |
| Pipeline Replacement Length | 93 m |
| Guide Rod Pushing Time | Approximately 40 minutes |
| Pipe Pulling Time | Approximately 1 hour 40 minutes |
| Total Project Duration | Completed in one day |
Replacing aging underground pipelines can be challenging, particularly when the existing pipe runs beneath roads, paved surfaces or developed areas.
Traditional open-cut replacement typically requires excavation along much of the pipeline route. Depending on site conditions, this can increase surface disruption, excavation work, reinstatement requirements and construction time.
For this project in Kenya, the objective was to replace the existing 100 mm cast iron pipe with a larger 160 mm PE pipe over a 93-meter route.
The construction method needed to accommodate the existing pipeline while providing a suitable underground path for the replacement pipe.
The Drillto S80 Pipe Bursting Machine was used to carry out the pipeline replacement.
Pipe bursting is a trenchless rehabilitation method in which a bursting tool fractures or breaks apart the existing pipe while advancing through the pipeline route. The replacement pipe is pulled into position behind the bursting assembly.
For suitable existing pipelines, this method can allow replacement along the original alignment while reducing the need for continuous excavation.
In this Kenyan project, the existing 100 mm cast iron pipe was replaced with a 160 mm PE pipe. Because the replacement pipe had a larger diameter than the original pipe, the bursting and installation process needed to create sufficient space for the new pipeline.
Actual suitability depends on the existing pipe condition, surrounding soil, adjacent utilities, required expansion diameter and the configuration of the pipe bursting system.
The guide rod pushing stage took approximately 40 minutes.
The guide rod establishes the path for the subsequent bursting and replacement operation. Accurate alignment is important because the rod guides the tooling through the existing pipeline route.
The construction team completed this stage before proceeding with the pipe replacement operation.
After the guide rod was in place, the team proceeded with the pipe pulling stage, which took approximately 1 hour and 40 minutes.
During a typical pipe bursting operation, the bursting tool travels along the existing pipeline, fractures the old pipe and creates space for the replacement pipe. The new PE pipe is pulled into the prepared path as the tool advances.
The process requires coordination between the bursting equipment, pulling system, replacement pipe and site personnel.
For this project, the replacement involved upgrading from a 100 mm cast iron pipe to a 160 mm PE pipe over a distance of 93 meters.
The guide rod pushing and pipe pulling stages took approximately 2 hours and 20 minutes combined.
The entire pipeline replacement project was completed within one day, including the overall construction work.
This result illustrates how trenchless pipe bursting can support efficient pipeline renewal when the existing infrastructure, ground conditions, access arrangements and equipment configuration are suitable.
The recorded stage times refer to guide rod pushing and pipe pulling. They should not be interpreted as the complete project duration, which also includes other preparation and finishing activities.
The Kenya project achieved several important outcomes:
93 m pipeline replacement using a trenchless construction method.
100 mm cast iron pipe replaced with 160 mm PE pipe.
40 minutes for the guide rod pushing stage.
1 hour 40 minutes for the pipe pulling stage.
One-day completion for the overall project.
The replacement increased the nominal pipe diameter from 100 mm to 160 mm. However, the actual improvement in pipeline flow capacity depends on the internal diameter, pipe wall thickness, hydraulic design and operating conditions.
The S80 Pipe Bursting Machine was used for this 93-meter pipeline replacement in Kenya.
For contractors planning similar projects, equipment selection should consider:
Existing pipe material and diameter
Required replacement pipe diameter
Pipeline length and alignment
Soil conditions and underground obstructions
Adjacent utility locations
Access pit dimensions and working space
Required bursting force and tooling configuration
Replacement pipe material and jointing method
A project-specific assessment helps determine whether the S80 or another pipe bursting configuration is appropriate for the intended replacement work.
The successful pipeline replacement project in Kenya demonstrates the application of the Drillto S80 Pipe Bursting Machine in trenchless infrastructure renewal.
Over a 93-meter route, the team replaced an existing 100 mm cast iron pipe with a 160 mm PE pipe. Guide rod pushing took approximately 40 minutes, while the pipe pulling stage took approximately 1 hour and 40 minutes. The overall project was completed within one day.
For contractors upgrading aging underground utility networks, pipe bursting offers a potential alternative to conventional open-cut replacement when site and engineering conditions are suitable.
