Large-Diameter HDPE Tailrace Replaces Costly Elevated Steel Design

Application: Tailrace for Run-of-the-River Hydropower Plant

The Challenge: The original design for this critical hydropower tailrace called for a traditional, elevated steel pipeline to convey high-volume water from the powerhouse back to the river. This approach faced two major problems: the immense cost of fabricating and structurally supporting a large, above-ground steel system, and the certainty of perpetual maintenance due to external corrosion and coating requirements. The client needed a permanent, cost-effective, and low-maintenance alternative.

The Krah USA Solution:

Krah USA partnered with the project team to replace the elevated steel design with a custom-engineered, direct-buried HDPE pipeline.

• Cost Efficiency: Switching to Krah's structured-wall HDPE immediately eliminated the significant expense of the steel structure, including foundations, supports, and required anti-corrosion treatments.

• Installation Logistics: The lightweight nature of the HDPE pipe—compared to heavy steel—enabled a much faster and safer installation. Sections were easily transported to the remote site and joined using leak-free electro-fusion welding, allowing for quick burial with minimal environmental impact.

• Long-Term Value: The HDPE pipe is inherently corrosion-proof and does not require external maintenance, offering the client a 100-year asset with dramatically reduced lifecycle costs compared to maintaining an elevated steel pipe.

• Hydraulic Excellence: The smooth interior maintains high flow efficiency, which is vital for the optimal performance of the run-of-the-river facility.

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The Impact:

Krah USA provided a superior, bury-ready solution that achieved significant capital cost savings, dramatically sped up the construction timeline, and delivered a permanent, zero-maintenance tailrace system essential for the facility’s long-term renewable energy operations.