High-Rise Sanitary Pipe Rehabilitation
FEATURED PROJECT
Mixed-Use High-Rise | Downtown Chicago
Epoxy Pipe Lining & Plumbing | Occupied 60-Story Building
Althoff Industries partnered with NuFlow Midwest to rehabilitate deteriorated sanitary piping within an occupied 60-story mixed-use high-rise in downtown Chicago.
By combining cured-in-place pipe lining with selective traditional pipe replacement, the project team restored difficult-to-access piping while minimizing demolition, protecting surrounding building systems, and limiting disruption to residential and commercial occupants.
EXISTING CONDITION & pIPE CLEANING PROCESS
Before - Deteriorated Existing Pipe
Pipe Cleaning & Preparation
Pipe Cleaning & Preparation
LINING PROCESS
Coordinating Pipe Lining Work
Liner Preparation
Liner Installation
Completed Lined Pipe
Project Overview
The building contains 24 floors of commercial office space and 35 residential floors. Cast-iron residential lateral lines and kitchen sanitary mains had developed severe corrosion, buildup, deterioration, and leaks.
Many of the affected pipes were located above finished commercial spaces or intertwined with electrical systems, HVAC equipment, fire-protection piping, ductwork, and other critical building infrastructure. Certain sections were also encased in concrete near the building’s gym and pool areas.
Althoff Industries and NuFlow Midwest developed a coordinated rehabilitation plan that used cured-in-place pipe lining for inaccessible piping and conventional replacement where the existing lines could be reached without excessive disruption.
THE CHALLENGE
Replacing the deteriorated piping through conventional methods would have required extensive demolition and the temporary removal or relocation of surrounding mechanical, electrical, and fire-protection systems.
The work also had to be performed inside a fully occupied high-rise. Commercial offices needed to remain operational, and shutdowns affecting residents had to be carefully scheduled and communicated.
Limited access, multiple pipe sizes, branch connections, cleanouts, concrete-encased piping, and the building’s dense infrastructure required detailed planning and a flexible installation strategy.
THE SOLUTION
Althoff Industries and NuFlow Midwest evaluated the piping system to determine which sections could be rehabilitated through cured-in-place pipe lining and which accessible sections were better suited for traditional replacement.
Before lining, the affected pipes were cleaned, inspected, and prepared to receive the liner. The project team then used a combination of pull-in-place lining, gap-method installations, and mechanical reinstatement techniques to restore the inaccessible sanitary lines.
Pre-lined cast-iron piping was also installed in selected mechanical-room locations. This approach provided the durability of a lined system while allowing those accessible sections to be installed using conventional plumbing methods.
Work was coordinated around detailed shutdown schedules to limit inconvenience to residents and allow the building’s commercial tenants to remain operational.
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PROJECT SCOPE
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Rehabilitation of more than 1,100 linear feet of existing sanitary piping
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Installation of liners in pipe sizes ranging from 4 inches through 15 inches
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Approximately 510 feet of 4-inch piping
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Approximately 265 feet of 5-inch piping
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Approximately 105 feet of 6-inch piping
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Approximately 75 feet of 8-inch piping
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Approximately 85 feet of 10-inch piping
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Approximately 100 feet of 15-inch piping
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Installation of approximately 200 feet of pre-lined 6-inch and 8-inch cast-iron piping
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Installation of approximately 30 pre-lined 4-inch cast-iron cleanouts
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Pipe cleaning, preparation, and camera inspection
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Pull-in-place and gap-method liner installation
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Mechanical reinstatement of branch connections
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Selective conventional pipe replacement
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Coordination of resident notifications and scheduled shutdowns
THE RESULT
The completed project restored deteriorated sanitary piping throughout the high-rise without requiring widespread demolition or the dismantling of adjacent building systems.
Commercial office spaces remained operational throughout the work, while carefully planned shutdowns minimized the impact on residents. The combined use of cured-in-place pipe lining, pre-lined piping, and selective replacement provided a practical solution for the building’s complex conditions.
Completed over approximately two to three months, the project reduced disruption, avoided substantial restoration work, and extended the useful life of critical sanitary piping. No subsequent problems with the rehabilitated piping had been reported when the project results were documented.
This project demonstrates how Althoff Industries can work with specialized technology partners to solve complex piping problems in occupied facilities through detailed planning, careful coordination, and minimally disruptive rehabilitation methods.