What Is Underground Utility Construction​?

In this blog, we will explore the concept of underground utility construction, discuss the process, share tips and tricks, and introduce lean methodologies that can improve efficiency and success in the field.

What Is Underground Utility Construction?

Underground utility construction involves the installation, repair, or upgrading of essential underground utilities such as water supply, wastewater collection, stormwater drainage, natural gas distribution, telecommunications, electricity distribution, and sometimes heating and cooling systems. Throughout my career, I’ve had the privilege of working with numerous underground utility contractors, particularly excavating contractors. There is a standard process that works every time. In fact, if you’re interested, feel free to reach out to me, and I can provide a presentation or examples on how to excel in underground utility construction, whether you’re a civil contractor, grading contractor, or utility contractor.

Characteristics of the Best Underground Utility Contractors

The most successful underground utility contractors have certain characteristics in common:

1. Solid Business Systems: Many use EOS (Entrepreneurial Operating System) to keep their leadership teams aligned and committed to excellence.
2. Standard Processes: They have well-defined processes for dealing with common challenges.
3. Continuous Training: They ensure that their team is always learning and improving.
4. Field Walks: Monthly field walks help to ensure that everything is being implemented correctly.

These contractors typically achieve a gross profit margin of 15-30%. If you’re not seeing these numbers, it’s likely you’re missing out on some key strategies.

How to Plan & Design Installations for Underground Utilities

Effective planning and design are crucial for a successful project. Contractors need to:

• Collaborate with designers on potholing, modeling, and routing.
• Develop a high-level project plan, including scheduling, zone maps, and profiles.
• Create logistics maps, grading drawings, and strategies for handling soil.

A comprehensive plan also includes a budget, risk/opportunity register, and procurement log for early ordering of necessary materials.

How to Present & Review Plans for Underground Utilities

Once the team has won the project, it’s essential to hold a “stand and deliver” or risk review meeting. This allows the project team to review the plan, schedule, zone maps, logistics plans, and procurement logs. This step ensures that potential problems are addressed early and that everyone is aligned.

Importance of Examining Soil Conditions

Before beginning, it’s critical to assess the soil conditions. This includes boring tests, test pits, and checking for potential dewatering issues. Soil quality directly impacts excavation success and can make or break a project. I recall a story about my great-grandfather, who worked in Southern California. He was called in to recover a project where miles of trench kept collapsing due to sandy soil. His solution was to work in smaller segments, backfilling and securing the trench each day, which prevented further collapses.

Important Reminders When Installing Underground Utilities

When installing utilities, use a quality checklist to ensure accuracy with elevations and fixtures. Double-check every step, particularly during compaction, to avoid costly rework later.

How to Check Connection & Integration

It’s important to test systems for leaks or other issues before backfilling or paving. Catching problems early can save significant time and resources later.

Developing a Testing & Inspection Process

The best contractors have crews with three essential tools:

1. Quality Checklists: Reviewed every morning.
2. Layout Sheets: Used to double-check inverts and elevations.
3. As-Built Records: Kept up to date to prevent rework.

Ensure you’re inspecting as you go and conducting pressure tests, flow checks, and line inspections.

Important Reminders for Backfilling

Backfilling should be done with the right materials and densities to prevent settlement or future issues. Ensure that your team is meeting all safety standards.

Importance of Ensuring Safety on the Project Site

Safety is always the top priority. A good underground utility contractor ensures a safe environment for workers through continuous training, mentoring, and field inspections.

Key Lean Concepts to Remember

To excel in underground utility construction, consider these lean principles:

1. One-Piece Flow: Focus on completing one section at a time rather than tackling multiple areas simultaneously.
2. Avoid Busyness: Don’t mistake activity for productivity. Efficiency is key.
3. Reduce Waste: Train your team to identify and eliminate waste.
4. Daily Improvements: Continuously look for ways to enhance productivity and minimize waste.

Final Thoughts

By following these guidelines—planning effectively, training your team, ensuring safety, and embracing lean concepts—you can achieve great success in underground utility construction.