Completing a Challenging 60-In. Steel Casing Auger Bore Across Hwy 72
In the heart of Limestone County, Alabama, a major infrastructure project has been completed with precision, power, and persistence. Price Road Boring Inc., a veteran in the trenchless construction industry since its inception in 1989, recently wrapped up a highly technical auger bore under Highway 72 in Athens, Alabama — a 210-lf crossing through solid limestone rock.
The mission: to install a 60-in. diameter, 0.625-in. wall steel casing to house a 42-in. fiberglass reinforced plastic (FRP) gravity sewer pipe. The job, contracted by Apel Machine & Supply Co., Inc., demanded not only experience but specialized equipment capable of handling both the scale and geological challenges of the bore.
Taking on Limestone Rock with Confidence
Limestone is no joke. Known for its abrasive, unyielding nature, full-face limestone presents a significant challenge in trenchless construction. For this particular project, the bore needed to traverse underneath a busy section of Hwy 72 — a key east-west artery in north Alabama. With traffic flow and surface disruption concerns, open-cut trenching was off the table. The solution? Auger boring — and a powerful one at that.
Price Road Boring, Inc. brought in their heavy hitter: a Michael Byrne D60-1.5. Known for its brute torque and dependable performance, the D60-1.5 was the clear choice for a drive of this size and length in tough geological conditions.
To complement the machine, Price Road Boring rented Michael Byrne 60-in. and 54-in. augers, equipped with 5-in. hex connections in lieu of utilizing their own 60-in. augers to withstand the torque necessary to push through the hard rock. The hex drive configuration was critical — offering greater rotational force and resistance to stress cracking under high torque loads, ensuring the augers stayed engaged and aligned during the push. This decision was made because of past experience with large diameter long drives with Michael Byrne Augers in similar ground conditions.
December Start
The bore kicked off on Dec. 2, 2024, under the guidance of Price Road Boring Inc.’s superintendent David Price, who has more than 36 years of experience in the tunneling and auger boring industry and has a three-person crew, made up of Tyler Armstrong, Dexter Moates and Braydon Vineyard.
Once the pit was excavated and shoring was installed, the team began the methodical process of launching the casing. The first few feet of the drive are always the most critical, especially when working in rock. Alignment, face stability, and machine calibration must all be dialed in perfectly.
“The first day went off without a hitch,” said Superintendent David Price from Price Road Boring Inc. “We were seeing solid contact with the rock face and the equipment was performing flawlessly. The Michael Byrne machine was biting into the limestone like it was built for this — because it was.”
Indeed, the Michael Byrne D60-1.5 is designed for projects just like this — long, large-diameter bores in difficult soils. Its robust design provides high torque and low RPMs, ideal for slow, deliberate progress through solid rock without overheating or stressing components.
Equipment That Exceeded Expectations
Throughout the project, the weather was not a friend. Abnormally cold temperatures, wet conditions and snow made working conditions difficult for these southern boys. “That white stuff from the sky belongs up north. We are not built for this,” said Price.
However, the synergy between the machine and auger setup made working in tough conditions bearable and played a major role in keeping things on track — literally and figuratively. “They are not built for this,” said Price, noting that the augers maintained excellent alignment and cutting efficiency throughout the bore. The 5-in. hex augers with 1-in. wall tube minimized slippage and wear, allowing for continuous excavation without frequent stops for equipment inspection or changeout.
“Performance-wise, the equipment exceeded our expectations,” said Tommy Sander, president of Price Road Boring, Inc. “We anticipated needing to make adjustments due to the grade requirements. With the rapid retrieval system equipped on the Michael Byrne D60-1.5, stripping the augers to adjust the guide shoes was accomplished fast and efficient keeping us on schedule.”
The team monitored line and grade closely throughout the bore using laser guidance and regular casing measurements to confirm alignment. Despite the density of the limestone, progress remained consistent, thanks in large part to the power of the D60-1.5 and the cutting efficiency of the Byrne augers.
A Clean Win for Trenchless Technology
This bore marks another successful project in Price Road Boring Inc.’s growing list of complex trenchless crossings. By leveraging powerful equipment, experienced operators, and sound engineering practices, they were able to complete a technically demanding project without delays, safety issues, or surface disruptions to the heavily trafficked Hwy 72.
The installed steel casing will now serve as a protective conduit for the new 42-in. FRP gravity sewer pipe — part of an ongoing infrastructure improvement project for the region. FRP is known for its corrosion resistance and long service life, making it an ideal material for municipal sewer applications.
Looking Ahead
Projects like this highlight the continued importance of auger boring in the utility and sewer construction industry — especially when faced with hard geological conditions and the need for precision.
“It’s all about having the right machine for the job,” said a representative from Michael Byrne Mfg. “The D60-1.5 is built for rock, for torque, and for getting the job done. The gearbox made by Michael Byrne Mfg is designed for auger boring with heavy-duty thrust and radial bearings. We’re proud to support contractors like Price Road Boring who push the limits of what’s possible in trenchless installation.”
As trenchless methods continue to grow in popularity due to their minimal environmental footprint and reduced disruption, equipment reliability becomes even more critical. This successful crossing in Athens, Alabama, stands as a testament to that principle — when you match skilled contractors with reliable equipment, you get results.
Jim Weist is president of Michael Byrne Mfg.
