Trenchless Engineering Insights Q&A
As part of our annual Top 50 Trenchless Engineering Firms Survey, we connected with several firms to gain their insights on the current state of the trenchless engineering market and the future of this rapidly growing, multi-billion-dollar industry.
Once considered a niche discipline, trenchless engineering has expanded and evolved, driving successful projects worldwide through a wide range of innovative applications.
Contributing to this special Q&A are the following trenchless engineering firms (with their survey rankings in parentheses):
Mark Miller, national practice leader-trenchless, GeoEngineers Inc. (#38)
Jeff Maier, P.E., associate vice president-discipline lead, Dewberry (#27)
Steve Fradkin, tunneling and trenchless subsector leader, and Russell Snow, sector leader-conveyance, Stantec (#1)
Kimberlie Staheli, Ph.D., P.E., president, Staheli Trenchless Consultants Inc. (#48)
How has the role of the trenchless engineer changed/evolved over the last 10 to 20 years to where it is today?
Steve Fradkin/Russell Snow: Today, trenchless engineers are playing a much bigger role in addressing outdated infrastructure, condition assessment, and rehabilitation. According to industry research from AWWA and ASCE, this is a top concern across the water industry as American infrastructure ages — and there’s increasing emphasis on it in trenchless work. Additionally, trenchless engineers are seeing a host of new technologies, new types of equipment, and new construction methods being used in trenchless projects. Methodologies available today allow trenchless engineers and constructors to tackle ground conditions more routinely and with reduced risk than would have been the case with methodologies available in the past. This allows trenchless methods to be used in situations where they would have been excluded in the past. Finally, there is much more trenchless work today than there was 10 or 20 years ago. The good news is that we’re seeing improved programs to educate trenchless engineers so that when they enter the workforce, they have a stronger trenchless skillset than they did in the past
Jeff Maier: Engineers over the years have definitely become more sophisticated and knowledgeable of the capabilities of trenchless technologies and can design projects using a variety of methods with confidence knowing that they will result in a successful project. The industry overall has matured and many of the technologies we have available to us today in our trenchless toolbox are tried and true, and engineers can rely on these methods to provide solutions that can be delivered faster, cheaper and in a less disruptive manner than traditional open cut construction methods. Through this evolution, engineers have also become more specialized- with the best of them now considered to be subject matter experts for their respective firms. Some engineers are also now specifically focusing on rehabilitation approaches while others are focused on new installation methods, condition assessment/ inspection, geotechnical services, SUE and other niches within our industry.”
Mark Miller: For HDD projects, the trenchless engineer has had to become much more aware of regulatory requirements and provide designs that mitigate the risk of impacts resulting from inadvertent drilling fluid returns. Regulatory agencies have begun scrutinizing HDD installations more because of past project related impacts that could have been avoided with better designs and careful construction practices. Twenty years ago, nobody was completing hydraulic fracture analyses. Today, we complete them for every crossing and it requires the designer to have knowledge of geotechnical engineering to optimize their designs.
Kim Staheli: 20 years ago, the role of a trenchless engineer was primarily to educate owners and engineers on the applications of trenchless construction, providing feasibility recommendations, etc.; however, there was very little guidance on trenchless engineering or appropriate design calculations. As the industry evolved, engineers started to become more educated, largely by reading trade magazines, attendance at the NASTT No-Dig Show. In addition, engineers began development of engineering analysis procedures for many of the methods. During this time, many of the installations migrated from using performance to prescriptive specifications. The industry has evolved tremendously as the inherent risks associated with trenchless became realized in the field, accompanied with significant change orders or claims. The engineering community responded by incorporating risk analyses into the preliminary design to select the trenchless alternative that has the lowest cost-risk profile. Risk evaluation in now done on most trenchless new installations. Finally, geotechnical baseline reports were incorporated into many trenchless designs. These reports have been effective on some limited projects: however, without the use of a disputes review board, the baselines have been very problematic when a claim arises.
How has the use of design-build and other contract models impacted the role of the trenchless engineers?
Fradkin/Snow: Overall, we’re seeing a trend toward more use of alternative delivery models in the trenchless industry, but we’re seeing that across sectors and business lines at Stantec. From water to transportation to energy, the role of alternative delivery models is growing. In the past, the emphasis on alternative delivery models was primarily for larger diameter tunnels and large, complicated projects. Now these delivery models have made their way into the trenchless world as well. Depending on the model, this allows design engineers to work with contractors to prepare designs that take advantage of contractor skillsets and knowledge, and preferred methodologies and equipment. It allows the design engineer to bring their trenchless expertise where it matters most.
Maier: Design-build and other alternative project delivery methods have certainly opened up more opportunities for trenchless engineers to provide best value solutions that are both creative and collaborative. Alternative project delivery allows for design and construction using more of a team approach that can be very effective and efficient, if used properly. These approaches can also be beneficial for more complex projects where some unknowns can still exist, and different aspects of the engineering design process can happen concurrently.
Miller: Most of our trenchless projects are completed under the typical design-bid-build model for energy clients. We have not seen any projects using the design-build contract model for these clients. Several years ago, we completed a large design project with almost 20 HDD installations where our pipeline client was a using the EPC model. From our perspective there wasn’t any significant difference on that project vs. our typical design-build projects. Where we see design-build being used most is when a contractor is awarded a project with 30 percent design drawings and they are required to complete final designs and perform the calculations. We work for some contractors to complete the installation force and stress calculations along with hydraulic fracture analyses.
Staheli: The shift to alternative contracting mechanisms is not without issues. The biggest problem is the lack of training with the engineers. Many owners are doing their first alternative delivery project and are not familiar with the process, relying on the Engineer to walk them through the process. As such, many firms are designing alternative delivery projects as if they were a design-bid-build, diminishing any of the benefits of using alternative delivery. Many owners are not aware how expensive the use of an alternative contracting can be. Many owners also believe that using alternative delivery methods shield them from claims. However, differing site conditions remain a hurdle for the trenchless community. Differing site conditions claims will get passed to the owner, resulting in trenchless claims that the owner was trying to avoid.
How has the role of technology impacted the work that trenchless design firms do vs. even 10 years ago?
Fradkin/Snow: As we mentioned, the technology is much more advanced today than it was a decade or two ago. For example, slurry machines are better equipped to handle variable conditions and match ground conditions because of continued advancements in machine technology and slurry additives. We are also seeing more advanced technology around condition assessment and leak detection. Some of the latest technologies that we’re using includes:
Acoustic sensors, which help with leak and air pocket detection in large diameter pipes.
Remote monitoring and satellite-based techniques, which have emerged as valuable tools for proactive leak detection and structural integrity assessment in pipeline systems.
Additionally, integrating machine learning and artificial intelligence into water infrastructure can help predict failures and better manage water assets. We expect the role of AI and machine learning to increase in the coming years.
Maier: Trenchless technologies in general have matured a lot over the years, and through this growth and innovation, well established design methods, robust industry standards and quality assurance practices are now in place for many of the technologies that are commercially available. With this, the design process for engineers has really become more procedural in nature using these now well-established practices, allowing for a broader cross section of engineering professionals to successfully design and manage the more everyday types of projects. At the same time, technological advancements in our industry have also expanded the envelope of what is possible with trenchless construction, allowing engineers and contractors to push the limits of different materials, methods, and installations, advancing the industry even further. This is evident with the amazing engineering feats we see each year with the trenchless project of the year submissions. As trenchless technologies gain more acceptance and an increased market share in the underground construction industry, these trends will continue providing a conducive environment for strong growth on the engineering design side.
Miller: Wireless communications have improved significantly which allows for good voice and data communication between field engineers and project managers back in the office. This is extremely helpful to address issues when they arise. We’ve developed custom HDD design and hydraulic fracture analysis software that integrates well with our CAD systems enabling our engineers and CAD designers to work together and streamlines the design and CAD processes. We also use tablet-based GIS software when completing a site reconnaissance that can be sent to and utilized by our clients and other team members.
Staheli: The technology is advancing so quickly that it is absolutely necessary to continue educating engineers over time. The rate of advance in the trenchless sector increases over time. The innovation is largely by the contractors who are trying to solve problems in the field. Engineers without field experience lose their “expertise” quickly as the trenchless industry moves forward. There is a huge need for engineers to actually see the projects and understand the vital design elements. There are many projects that go to bid with an unbuildable design, massively increasing the incident of claims.
How would you describe the state and direction of the worldwide trenchless market today?
Fradkin/Snow: The trenchless market, especially in North America, is robust—and continuing to grow. There is a lot of opportunity in this market. The industry is positioned for transformation through the application of new technologies like AI and machine learning.
Staheli: The trenchless market in the U.S. is moving so quickly that there are not enough qualified engineers to design the trenchless project. In addition, the contractors have increased staffing by a significant margin to meet the market demands. As such, the contractor’s employees are more inexperienced due to the volume of work available. This has led to an increasing incidence of claims.
Maier: The trenchless market is strong in all sectors right now and continues to grow in a healthy manner. Acceptance of trenchless technologies worldwide continues to gain momentum, with better understanding of the advantages that these construction approaches bring when compared to traditional methods. In my opinion, the market has shown that it can do well regardless of economic challenges and political climate, as the inherent advantages of trenchless technologies allow for more economical, more environmentally friendly, faster, and less disruptive alternatives for addressing the needs of underground infrastructure worldwide. With trenchless, municipal entities and other users can simply accomplish more work in a more effective manner using less money, which is a big win. Out of sight, out of mind is no longer an acceptable way of thinking when it comes to our underground infrastructure. Continued focus on education and awareness are keys in continuing these positive trends for our industry, both domestically and internationally.
What are the most concerning or impactful challenges facing trenchless engineers today?
Fradkin/Snow: One of the biggest challenges facing trenchless engineering companies today is the ability to hire enough staff. The trenchless world is no different from the general engineering world in this regard. Although education and training in this field has improved, there’s a shortage of talent coming out of schools, and that translates to a shortage of labor. Despite the large amount of trenchless work in North America, it’s still a pretty small community of practitioners. When you combine this scarcity with growing needs in trenchless and the increase in opportunities, it leaves us with some concern about how we move forward. Another challenge that individual engineers face is keeping up with the ongoing advances in technology. We need to be well-versed in this evolving landscape so we can continue to deliver exceptional projects and design cost-effective solutions
Maier: A significant challenge with today’s trenchless engineers is the need to really understand the technologies that are available in the trenchless toolbox and know that there is no such thing as a one size fits all solution. Engineers must understand the problem, understand the potential solutions available, and understand that there are limits to any technology. Ask a lot of questions and do not rely solely on internet searches when trying to find technical information, as misinformation certainly exists out there… and be sure to pursue educational opportunities in this sector wherever possible. Don’t be complacent and don’t forget sound engineering principles when designing projects. That said, there is a shortage of engineers out there and we as an industry need to encourage students to choose engineering and/or trenchless construction as a career path. We need to do our best to help pave the path for development of the future leaders in our industry.
Staheli: With the rapid growth of trenchless, many engineers design a project, relying on information from published papers conferences that they have attended, or introductory classes. These people may have introductory knowledge; however, they do not have the wisdom to manage the trenchless design risks. Many do not even know what specific risks apply to trenchless, or that the trenchless portion of a pipeline project carries the highest risk of installation. There is a need for engineers with field experience that can speak to the risks that occur, how the risks are mitigated in construction, and the costs associated with risk mitigation. In addition, when the owner is not aware of the potential risks on the project, the relationship between the owner, contractor, and engineer deteriorates quickly. Many of these projects result in claims and litigation.
How would you describe the growth of trenchless engineering over the years?
Fradkin/Snow: We would describe the growth as promising. Here at Stantec, we’ve seen exciting, sustained growth in trenchless engineering in recent years. We know this is a market that continues to become more sophisticated, innovative, and essential throughout North America. Our trenchless team is growing, and it is a core market for our clients and our business.
Maier: In my opinion, growth of the trenchless industry sector over the years has been strong and steady, and the future outlook and growth trends continue to look strong as well. Trenchless engineering will continue to grow in parallel with other areas of the industry in general, as good quality engineering is essential to making sure that trenchless installations are going to work and are done right- whether it be rehabilitation, new installations, or other specific applications. Trenchless engineers are gaining more and more knowledge and experience with the various technologies, and to engineering firms in general, trenchless design represents a continued robust growth opportunity for their business model that allows them to deliver effective, innovative, and economical solutions for clients. Compared to other aspects of the underground utility world, trenchless represents a fast-moving sector of an otherwise relatively slow-moving industry. The benefits of trenchless technology are clear, and this sector will continue to gain market share in the utility construction industry that I believe will continue to outpace other sectors for the foreseeable future. There is a lot of need out there, and with limited resources available to bring our underground infrastructure up to par, trenchless technology and advancements within this sector will play a significant role in helping make this happen.
Miller: The trenchless engineering field has really matured over the years with projects becoming more complex and contractor capabilities expanding to successfully complete them. The increasing use of trenchless installations has also created a new specialty field in the engineering consulting world, offering an entirely new career path for engineers.
Staheli: The trenchless industry has grown remarkably over the last 15 years; however, the growth has been beyond amazing since COVID. The number of projects that require trenchless installation is increasing at a ridiculous pace. There are very few trenchless engineering firms that do not have a significant backlog of work. This is likely impacted by the infrastructure bill and the number of projects that were put on hold during COVID, all of which have been released for engineering or construction during the time since the pandemic.
Sharon M. Bueno is editor of Trenchless Technology.
