Custom Cutting Technology for Challenging Geology
In De Soto, Kansas — at a site near a former munitions plant — Iowa Trenchless was tasked with installing sewer lines across an area with highly unstable soil conditions.
Initial plans called for using a TBM to install a 36-inch sewer beneath Kill Creek. However, geotechnical exploration revealed loose cobbles, gravel, and groundwater, making manned TBM operation unsafe and potentially damaging to the creek.
Iowa Trenchless engineered a custom, innovative solution.
Step 1 — Establishing a Safe Guided Path
A 12-inch pilot casing was installed using a Vermeer Axis guided bore system to create a precise alignment through the unstable geology.
Step 2 — Developing a Custom Cutting Head
In partnership with the Michael Byrne Group, Iowa Trenchless designed a specialized rigid cutterhead featuring:
- Heavy-duty carbide rock-cutting teeth
- Dual radial/thrust bearings positioned fore and aft of the cutterhead
- A built-in swivel system for smoother steering under load
- Compatibility with the 12-inch guidance casing
This custom head enabled two guided drives — each over 200 feet — to cut through bedrock while staying on an exact line and grade.
Team Recognition
Key personnel included Superintendent Brandon Derry, Foremen Jon Kile and Kyle Spoon, and crew members Lucas Lathrop, Daniel Jensen, Ryan Sanderville, and Jacoby Winters.
President Jason Clark praised the collaboration:
“It’s always gratifying to see a plan come together so effectively.”
The final result delivered both safety and accuracy on a complex crossing once believed to be too geologically unstable for trenchless installation.
