Smart Water Control in New Berlin, NY: Solving High-Pressure Runoff with Kustomflo
- PRODUCTS : KUSTOMFLO
- REALIZATION : 06/02/2025
TECHNICAL DATA
CULVERT REPLACEMENT
Location: New Berlin, NY
Installation: June 2025
PROJECT DETAILS
Distributor: Chemung Supply Co.
Contractor: Town of New Berlin
PRODUCT DESCRIPTION
Diameter: 84”
Length: 60’
Profile Information: Closed profile
Joints: Gasket
SITE CONDITIONS
Trench Depth: approximately 15’
Trench Width: 13’ to 15’ after exhuming old pipe
Backfill Material: locally supplied embedment material was a sandy gravel compacted to 90% standard proctor
Surface Material: topped off with road base material and bituminous asphalt pavement
CONTEXT
Minimizing Road Closure time & Handling high volumes of water
When the metal culvert on 104 Holmesville Hill Road in Berlin, NY collapsed—then failed again after a like-for-like replacement—the town faced recurring damage from seasonal high-pressure runoff. The deteriorating pipe caused roadway settlement and visible collapse.
The solution required two things: rapid installation to keep road closures brief, and a culvert that could manage high water volumes at the existing depth while ensuring long-term durability. Chemung Supply Company was tasked with delivering both. They contacted Soleno for a solution.
SOLUTION
Three 20-foot 84-inch diameter pipes
To address the structural and hydraulic challenges of the site, Soleno manufactured and delivered three 20-foot pipes, each with an 84-inch diameter, directly to the project location. The closed profile KUSTOMFLO pipe met the project’s scover loading requirements.
Before being lifted and carefully positioned into the trench, gaskets were applied to the spigot ends of each pipe to ensure a secure and watertight connection once pipes were connected. The pipes were then assembled sequentially in the trench. This method streamlined installation, minimized handling, and maintained the structural integrity of the pipe joints.
Moreover, Soleno efficiently delivered the product to the site within three weeks of Chemung’s initial inquiry, resulting in a completed project with only one week of road closure.
Soleno representatives were on-site to provide guidance to the contractor, ensuring smooth installation and timely project progress.
BENEFITS
Made to measure. Made to last.
The implementation of KUSTOMFLO pipes provided several key advantages that contributed to the project’s success:
- Lightweight: The KUSTOMFLO pipes are significantly lighter than traditional concrete or metal culverts, increasing maneuverability and decreasing installation time.
- Durability: KUSTOMFLO is made of HDPE, and inert material that is highly resistant to corrosion and chemical degradation, thereby providing a significantly longer useful life than concrete or steel pipes.
- Reduced Shipping Costs: Lighter pipe materials led to lower transportation expenses, reducing overall project costs.
- Improved Maneuverability: Using only a small excavator, the pipes were safer and easier to handle and position on-site, streamlining the installation process.
- Minimized Road Closure Time: Faster handling and assembly of the pipes contributed to shorter road closure periods, minimizing disruption to local traffic.
- Simplified Assembly: The pipe design allowed for quicker, more efficient assembly in the field.
- Project-Specific Flexibility: A range of pipe profile options enabled Chemung Supply Company to select the ideal solution tailored to the site’s unique trench depth and hydraulic needs.
MORE ABOUT KUSTOMFLO
Made to measure. Made to last.
KUSTOMFLO HDPE pipes are known for their robust and tailor-made piping systems designed to meet specific project requirements. The ADAPTIVE design allows optimization of the pipe profile to align with precise needs of the project or applicable standards. These HDPE pipes are engineered to customer specifications to optimize the performance of a flexible pipe. They offer versatility with hundreds of profile types and configurations with variable wall thickness, including solid wall, closed profile, and open profile options.
KUSTOMFLO
SITE CONDITIONS
The existing corrugated metal culvert on the project site exhibited significant deflection and ovalization, which resulted in roadway settlement and visible signs of collapse within the culvert. In response to these conditions, the town proposed a complete culvert removal and replacement. The priority was to find a product that could be installed quickly, minimizing road closure time. To address this, Chemung Supply Co. reached out to Soleno to confirm the availability and appropriate pipe profiles in 84-inch and 96-inch diameters.
Soleno was able to provide an 84-inch closed profile KUSTOMFLO pipe that met the project’s cover loading requirements. Moreover, Soleno efficiently delivered the product to the site within three weeks of Chemung’s initial inquiry, resulting in a completed project with only one week of road closure. Soleno representatives were on-site to provide guidance to the contractor, ensuring smooth installation and timely project progress.
TECHNICAL DATA
CULVERT REPLACEMENT
Location: New Berlin, NY
Installation: June 2025
PROJECT DETAILS
Distributor: Chemung Supply Co.
Contractor: Town of New Berlin
PRODUCT DESCRIPTION
Diameter: 84”
Length: 60’
Profile Information: Closed profile
Joints: Gasket
SITE CONDITIONS
Trench Depth: approximately 15’
Trench Width: 13’ to 15’ after exhuming old pipe
Backfill Material: locally supplied embedment material was a sandy gravel compacted to 90% standard proctor
Surface Material: topped off with road base material and bituminous asphalt pavement