Restoring Pipeline Integrity Without Excavation Kokosing Construction | I-271 Infrastructure Project Study

The Challenge

As a division manager at Kokosing Construction, Kevin Blankenship oversees underground utility support, inspections, and quality assurance. On a major I-271 project, his team encountered a critical issue: significant pipe deflection exceeding allowable tolerances.

When deflection reaches unacceptable levels, projects do not just slow down, they stop. All above-ground work, including paving and asphalt operations, must come to a halt until the issue is resolved.

Traditionally, the only solution would be excavation and full pipe replacement. This approach is not only disruptive, damaging completed surfaces and project timelines, but can also cost hundreds of thousands to millions of dollars depending on site conditions. In many cases, especially late in project phases, excavation is simply not feasible.

Hear from Kevin about this project

> The Solution

Instead of resorting to destructive methods, Kokosing turned to rerounding technology.

On the I-271 project, the team successfully rerounded 280 feet of 42-inch pipe that had over 15% deflection, bringing it back within tolerance and allowing it to pass a 5% mandrel test.

The rerounding process proved both precise and effective:

  • Restored the pipe to a true circular shape
  • Maintained structural integrity with no wall damage or buckling
  • Recompacted surrounding backfill, reinforcing long-term stability

> Why It Worked

Rerounding offered a trenchless alternative that aligned with the industry’s shift away from excavation-heavy repairs. While not a one-size-fits-all solution and requiring proper backfill conditions and site access, it delivered exceptional results in this scenario.

Equally important was the trust built over time. After more than a decade of working together, Kokosing values the provider’s transparency, knowing they will give honest guidance on whether a pipe can be repaired or if another solution is needed.

The Result

By choosing rerounding, Kokosing avoided a costly and disruptive excavation, kept the project moving, and preserved completed infrastructure.

The biggest impact is peace of mind.

Knowing there is a reliable, cost-effective alternative to large-scale excavation changes how teams approach underground challenges, saving time, money, and unnecessary rework.