Hydrovac for New Utility Installation Projects
8-step process guide with equipment, safety, and cost information.
Utility installation using hydrovac encompasses the excavation required to install new underground pipes, conduits, cables, and related infrastructure in areas where existing buried utilities are present. This includes trenching for new utility runs, excavating for manholes and vaults, and creating service connections to existing systems.
Hydrovac utility installation is the standard approach in congested urban and suburban environments where underground utility networks are dense and often poorly mapped. The non-destructive process protects existing infrastructure while enabling efficient installation of new services, reducing project risk and insurance costs.
The complete utility installation process typically involves multiple hydrovac applications including potholing for pre-construction verification, slot trenching for the new utility run, and daylighting at connection points to existing systems. Coordinating these activities efficiently is key to cost-effective hydrovac utility installation.
Step-by-Step Process
Design and Permitting
Review utility installation plans, obtain excavation permits, and file 811 locate requests for all utilities in the project area.
Pre-Construction Potholing
Pothole at all planned crossing points and connection locations to verify exact positions of existing utilities and resolve any design conflicts.
Trench Excavation
Excavate the utility trench using hydrovac to the specified depth and width. Maintain grade control and protect existing utilities at all crossings.
Bedding Preparation
Place bedding material in the trench bottom per specification. Verify proper grade and alignment for the new utility.
Utility Placement
Install the new pipe, conduit, or cable in the prepared trench. Make connections at tie-in points to existing systems.
Testing
Perform required testing on the installed utility: pressure testing, vacuum testing, CCTV inspection, continuity testing, or other specifications.
Backfill and Compaction
Backfill the trench in lifts with approved material, compacting each lift to specified density. Install warning tape above the new utility.
Surface Restoration
Restore pavement, sidewalks, landscaping, or other surface materials to match existing conditions and meet permit requirements.
Equipment Recommendations
- Mid-size to large hydrovac truck based on trench volume
- Multiple nozzle types for different soil conditions
- Grade control equipment (laser, string line)
- Compaction equipment for backfill operations
- Pipe cutting and joining tools specific to the utility type
Safety Considerations
- ⚠Verify all existing utility locations before and during trenching
- ⚠Follow OSHA trenching standards for trench safety
- ⚠Implement traffic control for work in or near roadways
- ⚠Coordinate shutdowns with utility owners for connection work
- ⚠Test new installations before placing into service
Cost Factors
- ●Linear footage of new utility to install
- ●Trench depth and width requirements
- ●Number and complexity of utility crossings
- ●Bedding and backfill material specifications
- ●Surface restoration requirements (asphalt, concrete, landscape)
- ●Testing and inspection requirements
- ●Permit fees and traffic control costs
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