The Challenge: Navigating Tight Tolerances
Richway was recently commissioned to solve a unique decommissioning challenge: a retired 500-foot gas line with a 1/2″ internal diameter (I.D.). Most commonly pipe abandonment typically involves large-diameters, this project required a little more precision and thought. Filling a line this narrow over a football-field-and-a-half distance presents a higher risk of pockets forming and line blockage. To ensure a 100% void-fill guarantee, the Richway team stepped in to perform the work directly.
The Approach: Small-Batch, High-Control Cellular Concrete
Because the 1/2″ line size, we bypassed high-volume machinery in favor of a controlled, small-batch production strategy to manage cellular concrete mix design and density:
- Mixing: The cement slurry was hand-mixed to ensure consistent performance in such a small and unpredictable environment, in addition to the fact that such a small amount was required.
- Specialized Equipment: We utilized the Richway PF6-1C, our as our foam generation machine to create a highly flowable 35 PCF Lightweight Cellular Concrete (LCC).
- Pumping Strategy: Using a small progressive cavity pump, we maintained a steady injection rate of 8 GPM. This allowed the material to displace all air within the line without creating backpressure that could compromise the integrity of the aging pipe.
The Results: Exceeded Expectations
As is common in subsurface utility engineering, the scope evolved on-site. The initial 8-gallon estimate grew to 30 gallons as the material completely filled the retired line. Despite the increased volume and the natural compression of bubbles within such a narrow diameter, the flow remained consistent and the line was successfully decommissioned, meeting all safety and environmental standards.
Richway: The Industry Leaders in Problem Solving
At Richway, we don’t just manufacture cellular concrete equipment; we engineer solutions for the projects others won’t touch. From massive bridge abutment fills to record-breaking? 1/2″ gas lines, our expertise in foam concentrates and injection technology ensures that no job is too small, too long, or too complex.
Feel free to Contact us by email at info@richway.com or call us at (800) 553-2404 / (319) 987-2976







