CASE Study

CRITICAL DN500 POTABLE WATER PIPELINE REHABILITATION. WEST COAST DISTRICT MUNICIPALITY – SOUTH AFRICA

Location: West Coast District Municipality, South Africa

Scope: 240m of DN500mm steel potable water pipeline – 15 bar pressure rating

Technology Used: ASOE W-Series Liner (20-bar rating)

Completion Timeframe: 48 hours – no compromise

THE CHALLENGE

A vital DN500mm, 15-bar potable water pipeline supplying communities in the West Coast District suffered a catastrophic burst. The leak was not only draining thousands of litres of precious water but also flooding a local pig farming operation.

Two years earlier, Orsco had performed an emergency CIPP patch to stop the immediate loss. However, the damaged section ran deep beneath farmland, making full replacement unfeasible.

Now, the time had come for the critical second phase – a complete structural rehabilitation of 240 meters of this pressurised pipeline.

The municipality issued a strict 48-hour shutdown window. No delays. No second chances. The community’s water supply depended on it.

THE RACE AGAINST TIME

From the moment the call came in, the urgency was clear.
The Orsco team mobilised immediately from Johannesburg, driving over 12 hours straight through to Cape Town in shifts, arriving ready to start without rest.

With the clock ticking, the team began work in relentless rain and challenging weather. The trenchless rehabilitation process demanded precision – there was no room for error. Every hour counted, and every task was performed with meticulous attention to detail, even under a constant downpour.

THE SOLUTION

Lining Installation:

240 meters of ASOE W-Series 20-bar liner installed.
Designed to form a seamless, high-strength “pipe within a pipe.”
Engineered to handle high pressures and extend the pipeline’s service life for decades.

OUTCOME

Completion: Within the tight 48-hour window — despite heavy rain and fatigue from the nonstop mobilisation.
Performance: Fully restored structural integrity and sealed all existing damage.
Impact: No costly excavation, minimal disruption, and uninterrupted water supply to the community.

SUMMARY

Orsco mobilised instantly, driving over 12 hours to Cape Town and completing a 240m pipeline rehabilitation within a strict 48-hour window. Working through constant rain and fatigue, the team delivered a precision installation using ASOE W-Series liner, restoring water to the community without costly excavation. A showcase of urgency, teamwork, and innovative trenchless technology.