Tuberculation Removal
The type of pipe commonly found in a variety of pipeline systems is the metallic pipe. Metallic pipes such as cast iron pipes are known for their longevity and overall durability. Thus, cast iron and other metallic pipes are often found in the water lines of mixed-use properties such as office buildings or apartments.
While the benefits of metallic pipelines are clear, certain issues can appear as the pipeline ages. One challenge that is unique to metallic pipelines is tuberculation.
If left untreated, a tuberculated pipeline can severely disrupt the flow of your pipeline system. This can result in emergency pipeline replacement that is both costly and time consuming.
Thankfully, replacing your pipes is not your only solution when dealing with tuberculation. Keep reading to learn what causes tuberculation and the process American Pipeline Solutions uses for tuberculation removal and prevention.
Tuberculation Removal & Prevention Services
Metallic pipelines such as cast iron and ductile iron have served as the backbone of water distribution and fire protection systems for decades. Their strength and durability are undeniable, but as these pipelines age, they face a serious challenge: tuberculation.
Tuberculation is the buildup of rust-like deposits inside the pipe walls, caused by chemical reactions between iron and naturally occurring bacteria in water. Over time, these deposits grow thicker, reduce the pipe’s internal diameter, and disrupt flow. The result is decreased pressure, reduced water quality, and in some cases, complete system blockages. Without intervention, the problem can escalate to costly and disruptive emergency pipeline replacement.
At American Pipeline Solutions (APS), we provide professional tuberculation removal and prevention services designed to restore lost capacity, extend the service life of metallic pipelines, and minimize future maintenance costs.
Why Tuberculation Matters?
In the early stages, tuberculation may go unnoticed. Water continues to flow, and the system seems to function as intended. Yet beneath the surface, nodules of iron oxide and bacterial growth begin to narrow the passageway. As the buildup progresses, property managers, municipalities, and utilities start to experience problems such as persistent low pressure, inconsistent water quality, or unexplained blockages.
What makes tuberculation particularly dangerous is its gradual nature. A pipe that was originally six inches in diameter can be reduced to little more than a single inch of usable space. This not only disrupts flow but also increases the stress on pumping systems, raises the risk of failure during high demand, and reduces overall system efficiency.
How APS Identifies Tuberculation?
Before beginning any cleaning procedure, APS performs a detailed pipeline inspection and condition analysis. Our technicians evaluate the pipeline’s age, material, and service history, then measure the degree of restriction through flow testing and pressure assessments. In some cases, video inspection or smart pigging is used to visualize the buildup and measure the remaining useful life of the pipe.
This diagnostic step ensures that our solution is tailored to the exact condition of the pipeline. By understanding the extent of tuberculation, we can determine the most effective method to restore capacity without compromising the pipe’s structural integrity.
Methods of Tuberculation Removal
APS uses a combination of proven technologies to address tuberculation, each chosen based on the severity of the buildup and the specific type of pipeline.
Mechanical Cleaning with Picote Equipment
For pipelines with heavy deposits, especially in fire suppression systems, APS relies on Picote mechanical technology. This system uses high-speed rotating chains to grind away stubborn buildup, restoring the pipe’s original diameter without damaging the surrounding metal. It is particularly effective in cases where conventional cleaning methods would fail.
Rotary Head Technology
In situations where deposits are less severe but still resistant, rotary head systems can be deployed. These tools loosen hardened tuberculation, allowing it to be flushed out of the system. Rotary cleaning is often used in conjunction with other methods to achieve a complete clean.
Pigging and Ice Pigging™
When the buildup is moderate, APS may use pipeline pigging. Traditional pigs are pushed through the pipe to clear deposits, though their effectiveness is limited in cases of severe tuberculation. For a more advanced solution, APS also offers Ice Pigging™, an innovative cleaning process that uses a slurry of ice crystals to scour the interior of the pipe. Ice Pigging™ is highly efficient, environmentally friendly, and able to restore capacity with minimal disruption to service.
Tailored Approaches for Complex Systems
Not every pipeline responds to a single method. APS frequently designs hybrid cleaning strategies that combine mechanical grinding, pigging, and flushing to deliver the best possible outcome. Our flexibility allows us to address a wide range of pipeline conditions and system designs.
American Pipeline Solutions’ Tuberculation Removal Process
The condition of the pipe was found to be heavily tuberculated. The original size of the pipe was 6”, but with the heavy tuberculation, the pipe's ID was reduced to ~1.
APS uses pigging, rotary head technology and Picote mechanical equipment to address pipeline tuberculation, especially in fire lines. Typically, pigging will not be the first method APS uses when addressing pipe tuberculation. The reason for this is because a foam pig is more likely to break apart due to the toughness of the pipe’s buildup. Instead, APS uses Picote mechanical equipment to apply a stronger force to the tuberculation buildup.
In the first step in the APS’ tuberculation removal process, technicians shut down the pipeline flow. With the pipeline out of operation, the APS team gains access to it to begin the tuberculation cleaning process. This typically involves the removal of a section of the pipeline, a flange or a 90-degree bend.
Next, the APS team will set up the Picote mechanical equipment. The Picote machine is plugged into a wall socket or an on-site generator provided by APS. Once the Picote machine is ready, the tuberculation removal process can begin.
During the removal process, APS places a bucket under the pipe being cleaned to catch runoff and broken up tuberculation. When the pipe has been thoroughly cleaned, APS will place the removed pipeline sections back into place. The pipes are then flushed to ensure any remaining tuberculation that wasn’t removed in cleaning is flushed out of the pipeline.
The results of the pipe after cleaning using the Picote machine. The pipe was cleaned and all tuberculation was removed.
What Causes Tuberculation?
What makes tuberculation unique to metallic pipelines is found in how it forms. Tuberculation is the result of chemical reactions in metallic pipes such as cast iron and ductile iron pipes.
Tuberculation forms when bacteria found in a pipeline’s water reacts to the iron found in the pipeline’s inner walls. As a result, tuberculation buildup begins to form on the inside of the pipeline.
Initially, a property manager may not notice any significant impact from tuberculation in their pipeline’s performance. Over time, this buildup grows thicker and eventually disrupts the flow of the pipeline.
What Types of Pipes Need Tuberculation Removal?
Tuberculation is typically found in older pipeline systems. Pipelines that were originally built and installed in the 1950s to the 1970s begin showing signs of tuberculation today.
Examples of the types of pipes that APS has experience in removing tuberculation include the following:
Cast Iron
Ductile Iron
Fire-Lines
Water Lines
Water & Force Mains
This is by no means an exhaustive list of the types of pipes that APS can clean tuberculation out of. Customers are encouraged to contact APS to discover the appropriate pipeline cleaning solution for their needs.
Are There Preventative Measures to Stop Tuberculation?
One way to ensure your pipelines are not tuberculated in the future is to simply replace them. However, this is a costly and overall inefficient solution. While your new pipes will not be tuberculated now, they will face the challenge of tuberculation in the future.
Instead of replacing your pipelines when they become tuberculated, there are preventative measures you can take.
Once your pipelines have been cleaned of tuberculation, APS can internally coat your pipelines. APS’ internal coating process involves applying a thin epoxy coating, used by the experts at NASA, to your pipeline’s interior. Without coating the interior of your pipeline, you will need to address tuberculation every five years. Conversely, a coated pipeline can operate tuberculation free for up to 50 years!
Preventing Tuberculation from Returning
Cleaning is only the first step in protecting metallic pipelines. Without additional measures, tuberculation will inevitably reform over time. APS provides a proven prevention strategy by applying an internal epoxy coating to cleaned pipelines.
This thin lining creates a barrier between the water and the pipe wall, eliminating the chemical reaction that causes tuberculation. The coating we use is NSF-61 certified, making it safe for potable water systems, and has been tested in demanding environments such as aerospace engineering.
Pipelines left uncoated may require re-cleaning within five years, while coated systems can remain tuberculation-free for several decades. In many cases, this process extends a pipeline’s service life by 50 years or more, making it one of the most cost-effective preventative solutions available.
Where Tuberculation Is Most Common?
Tuberculation is typically found in older pipeline systems. Pipelines that were originally built and installed in the 1950s to the 1970s are beginning to show signs of tuberculation today.
Examples of the types of pipes that APS has experience in removing tuberculation include the following:
Cast Iron
Ductile Iron
Fire-Lines
Water Lines
Water & Force Mains
This is by no means an exhaustive list of the types of pipes that APS can clean tuberculation out of. Customers are encouraged to contact APS to discover the appropriate pipeline cleaning solution for their needs.
Why Choose APS for Tuberculation Solutions?
APS combines decades of industry expertise with advanced technology to deliver reliable results. As a member of the Pigging Products and Services Association (PPSA), we operate at the highest standard of safety and performance. Our nationwide reach allows us to support projects of any scale, while our flexible approach ensures that every client receives a customized solution.
Most importantly, APS delivers cost-effective results. Instead of replacing aging infrastructure, we help property owners, municipalities, and industrial operators restore and protect their pipelines for the long term.
Restoring Flow, Protecting the Future
Tuberculation doesn’t have to mean costly replacement or prolonged downtime. With American Pipeline Solutions, you have a partner that can restore lost capacity, protect water quality, and extend the life of your infrastructure.
Contact APS today at (201) 525-0088 to schedule a consultation and learn how our tuberculation removal and prevention services can keep your pipelines operating at peak performance.
Are you looking for an efficient solution for your tuberculated pipelines?
Contact the team at American Pipeline Solutions to learn how our tuberculation removal and prevention processes can help.
