A corroded sewer main in Hawthorn required relining, demanding a temporary bypass system capable of handling high sewage flows.
Key challenges included:
- Maintaining uninterrupted traffic flow across busy Power St
- Installing a 350 mm bypass pipeline in a dense urban environment
- Using an existing stormwater drain with:
- Fragile structure
- Winding profile
- Limited load-bearing capacity
- Inability to use rigid pipe systems, due to weight and installation constraints
- High risk of failure, with severe consequences if the system failed
A flexible, reliable, and low-impact solution was required.
Crusader Hose worked alongside National Pump & Energy (NPE) to implement a layflat hose sewer bypass system.
The solution included:
- 12” Waterlord® layflat hose
- Reel-based deployment system for controlled installation
- Integration with BA300 wastewater pumps
Key advantages of the system:
- Lightweight and flexible hose, suitable for fragile infrastructure
- Ability to follow the winding drain profile without modification
- No heavy machinery required, preventing structural damage
- Rapid deployment and connection, reducing setup time
- High-strength construction, ensuring safe sewage transfer
A factory visit was conducted to demonstrate:
- Hose strength and safety margins
- Secure coupling systems
- Abrasion resistance performance
This gave stakeholders confidence in the system’s reliability.
The layflat system delivered strong operational performance:
- Full pipeline deployed and connected in just 2 days
- Continuous operation for 5 days during relining works
- Flow rates: 100–300 litres per second
- Zero traffic disruption on a major urban road
- No structural damage to the stormwater drain
- Reliable performance, with no system failures
Customer feedback:
“There was no traffic flow loss across Power St during this time… the layflat hose once again proved itself as a successful alternative when poly pipe cannot be used.”
— Peter Sherwood, National Pump & Energy
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