Employee Spotlight
Darl Schifer, our Machine Shop Supervisor and a Marine veteran with nearly 30 years at Michael Byrne Mfg., showcases the significance of our new machine shop and the in-house production of our B16 gearboxes.
Mixed Ground Nightmare Becomes Sewer Success
Jason Clark and his team at Iowa Trenchless recently encountered a unique challenge while completing a complex bore for high-precision sanitary sewers in De Soto, Kansas. The project involved installing twin sewer lines near the site of an old munitions plant, where the geological conditions were expected to be primarily shale bedrock. However, once the work began, the team discovered that the bore path passed through a more intricate geological profile, including cobble, sand, gravel, and water. This unexpected complexity required a thorough reevaluation of the original excavation plan to ensure the project’s success.
The primary challenge arose from the unexpected geological conditions encountered during the boring process. The presence of cobble and gravel, alongside water and low overburden, rendered the initial plan to utilize a traditional Tunnel Boring Machine (TBM) unsafe for manned operations. This situation posed significant risks concerning both the accuracy of the bore and the safety of the crew. To address these challenges, Iowa Trenchless installed a 12-inch pilot casing using a guided bore system. This system was designed to maintain precision while navigating through the challenging geological formations. However, as the project progressed, the crew encountered more difficult ground conditions than initially anticipated, including cap rock and geological inconsistencies that compromised the effectiveness of their traditional guided boring setup.
To maintain the accuracy of the pilot bore while excavating to the required diameter for the casing, the team devised a novel approach. They conceptualized a connection between the lead bearing and a heavy-duty cutting head equipped with soft rock cutting teeth. This design incorporated a thrust/radial bearing positioned behind the cutting head, which provided additional support for the auger stem.
In collaboration with the Michael Byrne Group, the Iowa Trenchless team designed and manufactured a custom trenchless swivel featuring a mounted rigid head with hard teeth, capable of penetrating the bedrock efficiently.
Sewer Success Continued
This custom tool was utilized in two drives exceeding 200 feet, where it effectively bored through both hard rock and clay, achieving the required precision and accuracy that had previously seemed unattainable.
The implementation of the specialized cutting head proved to be a critical factor in the project’s success. Jason Clark, president of Iowa Trenchless, noted “The specialty head worked exactly as we had planned. All credit and congratulations for a successful project go to the Michael Byrne folks and Iowa Trenchless teams. It’s always rewarding when a plan comes together as effectively as this one did.”
The project concluded with the successful installation of the sanitary sewers, meeting all specified accuracy and safety standards. Iowa Trenchless expressed their gratitude for the specialized equipment provided by the Michael Byrne Group, emphasizing the collaborative effort that led to this successful outcome. Clark stated, “The guys deserve the credit, and we hope to use this head again in the future.” Clark had many good things to say about both the tenacity of the Iowa Trenchless crew (particularly Brandon Derry and Jay Klein) and the customer service of the Michael Byrne Group. “They were the right people to partner with for both speed and quality”
Project Overview
Location: Munition plant De Soto, KS
Utility: Gravity Sewe
Diameter & Length: Twin 38” casings, 200+ ft Casing: Hobas pipes
GC: Kissick Construction
Iowa Trenchless
This Month’s Feature Product
D72 – 1.5
Looking to make a statement your customers won’t forget? Impressive and powerful the D72-1.5 provides class-leading power and performance for 72” machines. The 250 HP Tier 4 engine and MBM B-16 Gearbox combined with high-strength carbon steel frames and tracks won’t disappoint you on the large diameter bores.
Machine Specs
| Machine | D72 – 1.5 |
| Diameter | 72″ |
| Horsepower | 250 HP |
| Thrust | 1,475,914 lbs |
| Max Torque | 252,277 ft-lbs |
| Gear Box | Michael Byrne B13-B16 |
| Operating Weight* | 55,470 lbs |
