NuFlow Midwest, in partnership with Althoff Industries, completed a large-scale pipe rehabilitation in a 60-story Chicago high-rise, resolving severe leaks and deterioration in residential lateral lines and kitchen sanitary mains. Using NuDrain CIPP lining technology, NuFlow restored the pipes in place, avoiding costly, disruptive removal and preserving vital building systems. This solution delivered major cost savings for the general contractor and HOA, showcasing expertise in minimally invasive solutions for high-rise environments.
Project Overview
NuFlow Midwest undertook a challenging pipe rehabilitation project in a 60-story mixed-use building in downtown Chicago. The structure comprises 24 floors of commercial office space beneath 35 floors of residential units, where significant issues with leaks and sludge buildup were affecting lateral lines and kitchen sanitary mains. The pipes were part of an intricate system running throughout the building, entwined with other mechanical systems such as electrical, HVAC, fire protection, and ductwork, with some sections encased in concrete slabs within shared gym and pool spaces.
Additionally, the commercial office spaces below, unaffected by the plumbing issues, needed to remain fully operational throughout the project.
Background and Challenges
Though only 30 years old, the building’s cast iron piping system was deteriorating, with degraded pipes and sludge accumulation along the exterior. An engineering firm identified the cause—gases from food waste in garbage disposals were corroding the pipes over time.
Access to the pipes was complicated by their integration with other building systems and encasement in concrete slabs. Traditional replacement would have required dismantling electrical, HVAC, and fire protection systems, resulting in extensive downtime and significant costs. Minimizing disruption to commercial tenants and residents was a priority, and the solution needed to align with the project’s tight timeline.
To address these issues, NuFlow Midwest proposed NuDrain Cured-In-Place Pipelining (CIPP), allowing for in-place pipe rehabilitation without removal. This approach preserved surrounding structures and minimized downtime, making it the ideal choice for the building’s unique requirements.
Project Solution and Execution
Collaborating with the general contractor and engineering firm, NuFlow Midwest designed a solution that combined CIPP lining for inaccessible pipes with traditional pipe replacement in accessible areas. This method ensured compliance with Chicago’s building codes while preserving mechanical systems and minimizing downtime.
Key Project Elements:
- NuDrain CIPP trenchless lining for hard-to-reach pipes
- Pre-lined cast iron pipe sections for accessible mechanical areas
- Precision installation techniques, including pull-in-place lining and mechanical reinstatements
- Installation of 30 pre-lined 4-inch cast iron cleanouts for long-term maintenance
NuFlow Midwest lined 510 feet of 4-inch, 265 feet of 5-inch, 105 feet of 6-inch, 75 feet of 8-inch, 85 feet of 10-inch, and 100 feet of 15-inch piping.
In accessible areas, such as mechanical rooms, the team pre-lined and installed 100 feet each of 6-inch and 8-inch cast iron pipe, enhancing durability to prevent future deterioration.
For fittings, the gap method and mechanical reinstatements were used to ensure branch connections remained intact for future rehabilitation.
When using a pull-in-place technique, the gap method is when, liners are precisely installed to start or stop at each fitting, overlapping the joints, leaving a “gap” to preserve the branch connection. This method is ideal when access to the branch is not possible for immediate reinstatement.
Additionally, approximately 30 pre-lined 4-inch cast iron cleanouts were installed to facilitate ongoing cleaning and maintenance. This approach minimized disruptions, enhanced system reliability, and ensured smooth transitions between lined and unlined sections.
Minimizing Disruptions with Strategic Scheduling
To limit tenant inconvenience:
- Shutdowns were scheduled during standard work hours
- Commercial office spaces remained fully operational
- Residents received a detailed daily schedule for transparency
These efforts ensured minimal disruption while keeping all systems functional.
Results and Benefits
The project was completed in 2-3 months, delivering significant cost savings and minimal tenant disruption. By rehabilitating pipes in place:
- Building systems were preserved
- Extensive mechanical dismantling was avoided
- Commercial offices continued operations uninterrupted
- Residents experienced minimal downtime
Since completion, there have been no reported issues, and both the HOA and general contractor praised the outcome, highlighting:
- Reduced costs
- Seamless execution
- Long-term system durability
Conclusion
This project underscores NuFlow Midwest’s expertise in complex high-rise pipe rehabilitation. By integrating NuDrain CIPP trenchless technology, they successfully extended the lifespan of aging pipes, reduced costs, and minimized disruption.
Contact NuFlow Technologies today to learn how trenchless solutions can restore aging infrastructure while avoiding costly downtime.
Today!