Installing a Force Main Station in a Challenging Location

DVUC • July 21, 2022

Force mains are a vital part of our lives since these pipelines are a critical connection between the pump station and collection/treatment facility. We recently installed one for a large trucking repair shop in Burlington, New Jersey. As the architects and engineers planned out the new addition for the shop, it was decided that an increase in volume would be too much for the onsite septic system to handle. Thus, the engineers designed a small force main pump station to be installed. 


The pump station was placed at the side of the building and the 1.25 HDPE force main pipe was installed 300 feet across the property and 600 feet down the shoulder of the road to an existing manhole. Crossing the property was very challenging due to a large 24-inch high pressure gas main, a protected wetland, and a 1-to-1 vertical slope up 35 feet to the road. Below is step-by- step process of the installation. 

1. At the start of installation process, team member Roy inspected the drill head after a 480-foot bore. It looked good, so he attached the 1.25 inch HDPE pipe and trace wire for the pullback installation.

Connecting swivel HDPE pipe and trace wire.

2. We connected the swivel HDPE pipe and trace wire. A DVUC team member then tested the water jets before pullback. 

Drilling past the 24-inch high-pressure gas main.

3. After connecting the swivel HDPE pipe and trace wire, we drilled past the 24-inch high-pressure gas main. Next, we vacuumed out the drill pits so we could see the drill head go by.  

Crossing wetlands

4. At this point, we are halfway through the installation. We’ve crossed a 24-inch high-pressure gas main, went through some wetlands, and climbed the hill to cross the street. You can see the drill rig under the arrow in the picture. 

Looking at the pits

5. We are now vacuuming out the pits, giving us a better look at them.

drilling  through an 8-inch steel casing

6. We pushed the drill bit through an 8-inch steel casing that was placed perpendicular (open cut) over top of the 24-inch high-pressure gas main. 

Going through the 8-inch steel casing

7. We are in the home stretch in our force main installation! We’ve gone through the 8-inch steel casing that was placed 3 feet above the gas main, which was mandated by the gas company as extra protection for the 24-inch high pressure gas main.

Connection to the manhole.

8. The last step in the installation involves the connection to the manhole. We can see the drill bit coming into the final pit, where the pipe will then be tied into the manhole. We finished the project by cleaning up the work site. 

DVUC’s highly trained, experienced drill crew installed the force main in three days, keeping the general contractor and the owner on schedule and under budget. We appreciate the hard work of our team and for the opportunity. Contact us today to learn how we can make your next utility project run smoothly! 


By DVUC June 13, 2025
Every year, the month of June is recognized as Trench Safety Month. Founded by the National Utility Contractors Association (NUCA), this campaign aims to raise awareness about the dangers of trenching and excavation work. For industries involved in construction, utilities, and civil engineering, this month serves as a powerful reminder that safe trenches save lives. So why does a month need to be dedicated to it? Keeping Trenches Safe Trenching and excavation are among the most hazardous activities in the construction and utility industries. A trench collapse (or cave-in) can bury workers in mere seconds. One square yard of soil equals over 3,000 pounds, which can easily crush or suffocate a worker. Alarming Trench Safety Statistics: 1 in 5 worker fatalities in construction is related to excavation or trenching. 80% of trench deaths occur in trenches less than 10 feet deep. Lack of protective systems is the leading cause of fatal trench collapses. We can reduce these statistics by increasing training on trenching and excavation safety practices. To help prevent a collapse, the Occupational Health and Safety Administration (OSHA) states the focus should be on the three S’s for trenches five feet deep or deeper: Slope or bench walls, shore the walls with supports, or shield trench walls with trench boxes. For trenches four feet deep, employers must provide ladders, steps, ramps, or other means of leaving the trench. Thus, employers must ensure there is a clear trench entrance and exit. What Is Trench Safety Month All About? Nine years ago, NUCA launched Trench Safety Month promoting trench safety awareness by providing critical training and driving accountability. It’s supported by OSHA’s Trench Safety Stand Down, where employers and workers take a break to focus solely on trench safety education. The theme of this year’s Trench Safety Stand Down is “Get People Home.” The goal is getting people home at the end of the day through the key objectives of Trench Safety Month: Promote trenching and excavation safety standards. Educate crews on soil types, protective systems, and hazards. Encourage participation in the Trench Safety Stand Down and toolbox talks on the topic. Reduce trench-related fatalities and injuries through awareness and prevention. At DVUC, we believe safety is not optional—it’s essential. Trench Safety Month is an opportunity to pause, reflect, and recommit to doing things the right way. Protecting workers is the top priority, which ensures a job well done.
By DVUC June 5, 2025
Summer is here and as the temperatures soar, so do the risks for utility workers who spend long hours under the blazing sun . Whether repairing underground lines or maintaining vital infrastructure, utility workers are on the front lines—often in full gear, with little relief from the elements. One of the most dangerous yet often underestimated risks? Heat stress. What Is Heat Stress? Heat stress occurs when the body cannot cool itself effectively, especially during prolonged exposure to high temperatures and humidity. It encompasses a range of conditions—from heat rash and heat cramps to the more severe heat exhaustion and heat stroke. In the utility industry, where physical labor, heavy PPE, and outdoor work are non-negotiable, the risks of heat stress are dramatically amplified. Why Utility Workers Are Especially Vulnerable 1. Prolonged Outdoor Exposure Utility crews often work 8 to 12-hour shifts outdoors. Unlike office jobs, there’s no air-conditioned break room a few steps away. 2. Physical Demands Climbing, digging, lifting, and troubleshooting electrical systems all increase internal body temperature—especially under a blazing sun. 3. Heavy PPE and Uniforms Essential for protection, personal protective equipment (PPE) often adds layers of insulation, making it harder for the body to dissipate heat. 4. Remote Work Locations Many job sites are isolated, meaning medical help may not be immediately available in case of a heat-related emergency. The Hidden Costs of Heat Stress Ignoring heat stress isn’t just a health hazard—it’s a business risk. Reduced productivity: Workers slow down or stop altogether to cope with rising temperatures. Increased errors: Fatigue and dehydration impair cognitive function, increasing the risk of accidents. Higher medical costs and liability: Heat stroke can be fatal and lead to costly compensation claims. Worker turnover: Unsafe working conditions can drive skilled workers away. Recognizing the Warning Signs Early symptoms of heat stress include: Excessive sweating Dizziness or confusion Muscle cramps Headache or nausea Rapid heartbeat If left untreated, these can progress to heat stroke, a life-threatening emergency that requires immediate medical attention. Tips for Protecting Yourself in Summer Heat Now that you understand the risks associated with heat stress, taking preventive measures becomes paramount: Stay Hydrated: Drink plenty of fluids like water and electrolyte-rich sports drinks. Avoid beverages with caffeine (e.g., soda), as they can contribute to dehydration. Use Sun Protection: Apply sunscreen with at least SPF 30 to exposed skin. Wearing hats and sunglasses provides additional protection where permissible. Take Regular Breaks: Despite deadlines, taking breaks helps prevent overheating and reduces the risk of heat-related illnesses. Don't Wait for a Heat Crisis As climate patterns shift, extreme heat events are becoming more frequent and intense. Protecting utility workers from heat stress isn’t just a seasonal concern—it’s a year-round responsibility. At DVUC, we prioritize safety above all else. We acknowledge the challenges of outdoor work in every season and provide comprehensive safety training to our team. Stay safe this summer!
By DVUC May 22, 2025
In the ever-evolving landscape of the utility industry, safety, precision, and environmental responsibility are more important than ever. One technology making a significant impact is vacuum excavation—a non-destructive digging method that's reshaping how utility companies approach excavation work. Whether you're a project manager, utility contractor, or municipal decision-maker, understanding vacuum excavation’s benefits can help you improve operational efficiency, reduce risk, and stay compliant with modern regulations. What Is Vacuum Excavation? Vacuum excavation, also known as soft digging or hydro excavation, is a trenching method that uses high-pressure air or water to loosen soil, which is then removed via a powerful vacuum system. This exposes underground utilities without causing damage to pipes, cables, or surrounding infrastructure. The process typically involves two main techniques: Hydro excavation : Uses pressurized water to break up soil. Air excavation : Uses compressed air, ideal for dry or sensitive environments. Why Vacuum Excavation Is Gaining Ground in the Utility Sector The utility industry is no stranger to underground risks. From gas lines to fiber optics, a single misstep can lead to costly damage, service outages, or even injury. Here's why vacuum excavation is becoming the go-to solution: 1. Enhanced Safety Traditional digging methods like backhoes and manual trenching increase the risk of damaging underground utilities. Vacuum excavation is minimally invasive, drastically reducing the chance of utility strikes. This translates to fewer accidents, lower liability, and improved public safety. 2. Regulatory Compliance With stricter regulations around safe digging and utility locating, vacuum excavation supports compliance with standards such as OSHA and 811 Call Before You Dig . Many municipalities now mandate soft digging near critical infrastructure. 3. Precision and Efficiency Vacuum excavation allows for surgical precision, making it ideal for tight urban environments or areas with congested underground networks. Crews can quickly expose only the necessary sections, speeding up the job without compromising accuracy. 4. Environmental Responsibility Because it disturbs less soil and reduces the need for large-scale site restoration, vacuum excavation is considered more environmentally friendly than traditional methods. It also reduces sediment runoff and minimizes landscape damage. 5. Cost Savings Over Time While the upfront cost of vacuum excavation equipment may seem high, the reduction in utility strikes, insurance claims, and project delays more than offsets the investment. In fact, studies show that non-destructive digging methods can reduce overall project costs by up to 30%. Applications Across the Utility Industry Vacuum excavation is versatile and widely used in sectors such as: Telecom : Safe exposure of fiber optic lines during installation or repairs. Gas and Energy : Non-invasive digging near volatile gas lines. Water and Sewer : Accessing buried pipelines without flooding or trench collapse. Municipal Projects : Potholing and daylighting in urban infrastructure upgrades.  Smart Digging with Smart Data As utility networks become smarter and more complex, the need for digital mapping, subsurface utility engineering (SUE), and precision excavation continues to grow. Vacuum excavation plays a vital role in this trend, often working together with GIS data, ground-penetrating radar (GPR), and lidar technologies to support intelligent asset management. Vacuum excavation is more than just a safer alternative to traditional digging—it's a smarter, faster, and more sustainable way to support the utility industry's modern demands. At DVUC, our experienced team utilizes vacuum excavation to access hard-to-reach areas quickly and safely for a successful project. Contact us today to learn how your project will benefit from our vacuum excavation services.
By DVUC May 1, 2025
In the ever-evolving utility industry, choosing the right method for installing or repairing underground infrastructure is critical. Among the various techniques available, open cut trenching remains one of the most reliable and cost-effective solutions. Whether you're laying new pipelines, installing cables, or repairing existing utility lines, open cut trenching continues to offer unparalleled advantages. In this blog, we’ll explore the some of the key benefits of open cut trenching and why it remains a top choice for utility contractors and municipalities around the world.
By DVUC April 11, 2025
April is National Safe Digging Month: Why You Should Care A s the days get longer and the temperature begins to rise, spring signals the start of the construction season. Whether you're planning a home renovation, landscaping project, or commercial construction, one thing remains constant: safety. And when it comes to digging, safety isn't just about following the right protocols above ground – it's about what lies beneath our feet. This April, National Safe Digging Month serves as a crucial reminder to dig with care and be mindful of the unseen dangers lurking below the surface. What is National Safe Digging Month? Established in 2007 by the Common Ground Alliance (CGA), National Safe Digging Month is an annual initiative aimed at raising awareness about the importance of underground safety. With millions of miles of utilities running beneath our feet, digging without knowledge can lead to accidents that disrupt not only your project but also the surrounding community. Why You Should Care: The Hidden Dangers Below D id you know that there are over 20 million miles of underground utilities across the United States? From power lines and pipelines to telecommunications cables and sewer systems, these critical networks keep our daily lives running smoothly. However, because they’re hidden below ground, they often go unnoticed until something goes wrong. 
By DVUC January 10, 2025
When it comes to installing underground utilities, there’s a more advanced and efficient method that has been gaining traction: boring. Also known as horizontal directional drilling (HDD) or directional boring, this technique is a more advanced method of installing underground utilities. It used for a number of applications, including installing drainage and sewer systems and drilling under sensitive ecosystems, It’s faster, less disruptive, and, in many cases, more cost-effective than traditional methods like trenching. But what exactly is boring, and why has become such a popular choice for utility contractors? What Is Boring? Boring is a specialized method used to install utilities beneath the earth’s surface. Instead of digging up large sections of ground or concrete, like traditional trenching methods, boring uses specialized drilling equipment to create underground pathways. The beauty of boring lies in its precision and efficiency. It’s particularly useful in areas where traditional trenching would be difficult or environmentally damaging. The contractor drills a series of boreholes along a planned route, allowing utility lines to be installed without the need for extensive excavation or surface disruption. However, the first step in the process is to locate existing utilities before the pilot hole is drilled. Next, the reamer is pulled through the hole to widen it out to the correct size. Once completed, the pipe (HDPE pipe) can be pulled through the hole to the end point. After the installation is done, site cleanup and restoration are performed. Advantages of Boring Boring offers distinct benefits that make it an ideal solution for specific projects. Here’s why more utility contractors are choosing boring over conventional methods: 1. Potential for Lower Costs One of the most significant advantages of boring is the potential for cost savings. Traditional trenching often requires demolition of existing structures, such as sidewalks, buildings, and roads. In contrast, boring requires minimal surface disruption, reducing the need for expensive restoration work. By avoiding the need to dig large trenches or destroy existing infrastructure, contractors can keep project costs down, making boring a more budget-friendly option in many cases. 2. Ideal for Complex Properties Properties with complex landscapes, such as steep hills, rocky terrain, or dense vegetation, are perfect candidates for boring. Trenching in these types of environments can be challenging, expensive, and time-consuming. With boring, contractors can drill through obstacles like boulders, hills, and difficult slopes without the need for extensive excavation or time-consuming trenching work. 3. Better for the Environment Another major advantage of boring is its minimal environmental impact. Unlike trenching, which can disturb large sections of land, boring enables utility installation beneath trees, streams, ponds, and wetlands without environmental damage. The technique can also avoid disruption to lawns and gardens, reducing the need for costly surface restoration after the project is completed. 4. Lower Risks Safety is always a top priority in construction, and boring has several inherent safety advantages over traditional trenching. Trenching can pose significant risks, such as cave-ins, flooding, and groundwater contamination. These risks are drastically reduced with boring, which is a safer and more reliable method, especially in specific circumstances. Boring or Horizontal directional drilling is transforming how utilities are installed. With its ability to reduce costs, minimize environmental impact, and offer safer and more efficient solutions in complex environments, it’s no wonder that this method is becoming more popular among utility contractors. So, if you’re planning a utility installation project and need a solution that’s cost-effective, environmentally friendly, and reliable, boring is the perfect choice. At DVUC, we have the experience and equipment to provide quick and efficient boring for a variety of projects. Contact us today learn how we can help make your project run smoothly!
By DVUC December 13, 2024
It’s hard to believe it’s the end of 2024! We are grateful for another great year. There have been many projects was involved
By DVUC October 15, 2024
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By DVUC July 12, 2024
When we think of utility repair, we think of a bursting water main at a busy intersection. While utility companies do repair them, they also do a lot more. You can find a utility crew installing an electric service, repairing a gas line, fusing a pipe or replacing a sewer pipe. DVUC tackles these jobs at a variety of job sites, especially residential developments. At these job sites, minimal disruption to properties and traffic flow is crucial to a successful project. Let's take a look at few of them. Giving a Boost to a Senior Residential Development Discover how DVUC transforms utility installation for developments! Recently, our skilled New Jersey crew installed 343 feet of 35kv 1/0 primary wire in a senior residential development in Manchester, New Jersey. Check out the photos below showcasing our team in action. At left, a team member uses a locator to ensure the drill underground is at the correct depth avoiding any underground utilities. At right, a team member watches the rod go through the catch hole as it drills through the ground towards the final destination.
By DVUC June 19, 2024
In the modern world, it's easy to take the utilities industry for granted. Yet, behind the scenes, there lies a complex network fraught with dangers that often go unnoticed by the average consumer. From electrical hazards to environmental risks, the utilities sector presents a myriad of challenges that demand attention and action. Let’s take a look at the top four jobsite risks and hazards in the utilities industry.
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