From Residential Roots to Mainline Capability
Since becoming a NuFlow Certified Contractor in 2016, NuFlow Indy has grown from a residential sewer lining provider into a trusted partner for commercial and industrial trenchless rehabilitation. What began as small-diameter work inside homes steadily expanded into more complex projects within manufacturing environments, where precision and performance are critical.
Rather than staying within a defined comfort zone, the team consistently pursued opportunities to grow. Each project added new experience, new capabilities, and greater confidence. As they took on more demanding industrial work, it became clear that the next step was entering the large-diameter mainline market.
That transition didn’t happen overnight. NuFlow Indy explored mainline UV curing technology, initially evaluating smaller systems and even renting equipment to complete an 8-inch mainline project. That hands-on experience proved valuable – not only in building technical confidence, but also in understanding what it would take to scale. The takeaway was clear: if they were going to pursue larger opportunities, they needed to invest in a system built for it.
When the right project came along, they were ready.
The Project
After completing previous work for a large industrial processing facility, NuFlow Indy was brought in to address critical issues within the plant’s underground piping system. The project involved restoring a combination storm and sewer line comprised of aging vitrified clay and reinforced concrete pipes that were suffering from heavy infiltration, structural deterioration, and chemical corrosion caused by ongoing pH-balancing treatments. The effluent moving through the system was not only chemically aggressive but also elevated in temperature, creating an environment that could accelerate the breakdown of traditional materials. With the need to maintain full operations, the facility required a durable, non-disruptive rehabilitation solution specifically suited to these demanding conditions.
Following a detailed evaluation of the system, NuFlow Indy identified UV-cured CIPP with pre-impregnated GRP liners as the best fit. The selected liner system was engineered to handle both the chemical exposure and higher temperatures, ensuring long-term performance without compromising the host pipe. At the same time, the scale and complexity of the project reinforced a pivotal business decision – fully committing to large-diameter mainline work.
To meet the demands of the job and support long-term growth, NuFlow Indy invested in the Trelleborg Mainline UV PowerLight Pro system. With capabilities up to 72 inches, the system allowed them to confidently take on the project and scale into larger-diameter work. A key advantage of the Trelleborg system is its integrated KAESER blower, which enables rapid liner inflation and precise control of process pressure through automated controls – giving installers greater consistency and control in the field. Once the customer understood this expanded capacity, the scope increased, ultimately totaling 1,826 linear feet of pipe ranging from 12 to 48 inches in diameter.
Installation began in November 2025 and continued through March 2026, all while the facility remained fully operational during an active steam plant rebuild. The work was executed in 16 controlled sections, requiring constant coordination with plant engineers and careful management of flow, temperature, and chemical conditions.
Traditional bypass methods were used for portions of the project; however, some sections required a more customized approach due to the nature of the process water and ongoing plant operations. Flow management was handled by R.H. Marlin, who worked closely with plant engineers to implement and manage a system utilizing approximately 20 frac tanks and up to 420,000 gallons of process water per line while continuously monitoring flow and maintaining proper pH balance. NuFlow Indy coordinated closely with both the bypass team and plant personnel to ensure conditions supported safe and effective liner installation. This collaboration allowed their crew to stay focused on execution, with nine technicians working extended hours and following a strategic approach that progressed from smaller to larger diameters to reduce risk and maintain efficiency.
Even with detailed planning, the team faced extreme conditions, including a historic rainfall event that caused system surges and backflow into active work zones. Despite these challenges, they adapted in real time – adjusting bypass strategies and maintaining control of the environment to keep the project on track.
The result was the successful rehabilitation of all 1,826 linear feet with zero unplanned downtime, reinforcing both the effectiveness of the solution and NuFlow Indy’s ability to execute at a higher level.
A Turning Point
This project represents a defining moment for NuFlow Indy. It validated their ability to successfully execute large-diameter UV CIPP installations in complex industrial environments and marked their transition into mainline work at scale.
Where the company once focused primarily on residential and small commercial projects, they now operate with the capability and confidence to pursue industrial and municipal opportunities. Their crews are cross trained across applications, allowing them to move seamlessly from a single-family home to a large-scale infrastructure project.
With the addition of the PowerLight Pro system and the experience gained in the field, NuFlow Indy is now positioned to take on projects up to 72 inches in diameter – significantly expanding both their market reach and service offering.
Conclusion
This project highlights the power of CIPP as a reliable, efficient solution for large-scale pipe rehabilitation – even in the most complex industrial environments. From managing extreme flows and corrosive conditions to maintaining full operational uptime, trenchless technology continues to prove its value on critical infrastructure projects.
It also underscores what’s required to successfully scale in this space. Companies that invest in the right equipment, build skilled teams, and leverage strong training and support systems are best positioned to take on larger, more demanding work. With that foundation in place, projects like this are not just a milestone – they become a launching point for what comes next.
Ready to scale your pipe rehabilitation capabilities or tackle complex infrastructure projects? Call us now at 855-371-0053 or fill out our online form to schedule your free consultation!
FAQ: Large-Diameter UV CIPP and Industrial Pipe Rehabilitation
Q: What is UV-cured CIPP?
A: UV-cured CIPP, or ultraviolet-cured cured-in-place pipe, is a trenchless rehabilitation method that uses a resin-impregnated liner inserted into an existing pipe and cured with UV light to create a new structural pipe within the old one.
Q: Why was UV-cured CIPP the right solution for this project?
A: The system needed to withstand chemical exposure, elevated temperatures, and ongoing plant operations. UV-cured CIPP with pre-impregnated GRP liners offered a durable, non-disruptive solution suited to those demanding conditions.
Q: What pipe sizes were involved in this rehabilitation project?
A: The total project covered 1,826 linear feet of pipe ranging from 12 inches to 48 inches in diameter.
Q: What types of pipe were being restored?
A: The project involved a combination storm and sewer line made up of aging vitrified clay and reinforced concrete pipes.
Q: What made this industrial pipe lining project especially challenging?
A: The project required managing heavy infiltration, structural deterioration, chemical corrosion, elevated temperatures, active plant operations, customized flow control, and even extreme weather conditions during installation.
Q: Did the facility have to shut down during installation?
A: No. Installation was completed while the facility remained fully operational, with zero unplanned downtime.
Q: What equipment helped NuFlow Indy scale into large-diameter mainline work?
A: NuFlow Indy invested in the Trelleborg Mainline UV PowerLight Pro system, which supports projects up to 72 inches in diameter and provides greater control in the field through its integrated KAESER blower.
Q: Why is large-diameter mainline rehabilitation important for industrial facilities?
A: Large-diameter mainline rehabilitation allows facilities to restore critical underground infrastructure without the disruption, cost, and operational impact of full excavation and replacement.
Q: What does this project say about NuFlow Indy’s capabilities?
A: It demonstrates NuFlow Indy’s ability to execute complex large-diameter UV CIPP installations in industrial environments and shows their readiness to pursue larger municipal and industrial opportunities.
Q: What is the broader takeaway from this case study?
A: The case study shows that trenchless rehabilitation can deliver reliable, efficient performance at scale when paired with the right equipment, skilled crews, and strong operational coordination.