Permalok® HDD Joint Powers Award-Winning Champlain Hudson Power Express Project
Trenchless Technology Magazine has awarded the Champlain Hudson Power Express (CHPE) Terrestrial Trenchless Crossings its 2025 Project of the Year – New Installation, recognizing the groundbreaking project’s exceptional scale, technical complexity, and forward-thinking innovation. This recognition highlights a milestone achievement in modern trenchless construction and the pioneering application of Permalok® HDD pipe technology in one of the most ambitious renewable energy infrastructure undertakings in North America.
A Landmark in Renewable Energy Construction
The CHPE project, designed and led by Kiewit Infrastructure, represents a major step forward in delivering clean, renewable hydropower to New York City. Spanning approximately 339 miles, the transmission line is a critical component in the region’s effort to transition toward sustainable energy sources, reduce carbon emissions, and increase grid reliability.
To complete the project’s final terrestrial segment, Kiewit and its trenchless subcontractor, Michels Corporation, faced a formidable challenge: executing a horizontal directional drill (HDD) beneath the East River in one of the most densely developed and logistically constrained urban environments in the United States. The team’s solution marked a historic first — the use of Permalok® HDD pipe to complete a major HDD crossing under the East River.
Engineering Excellence with Permalok® HDD Joint
For this crucial section of the project, Northwest Pipe Company supplied more than 10,000 feet of 20-inch steel casing pipe, each featuring its patented Permalok® HDD Joint. This innovative system revolutionizes HDD installation by replacing traditional welded joints with a weld-free, press-fit connection, allowing for faster assembly, enhanced alignment accuracy, and improved safety in the field.
The dual 5,100-foot HDD crossing was executed as a record-length push installation, a remarkable engineering feat considering the challenging riverbed geology and the dense urban infrastructure surrounding the worksite. Michels Corporation utilized 170 thirty-foot pipe segments, which were cartridge-loaded from the rig side — a method made possible by the compact design of the Permalok® joint system.
This approach eliminated the need for field welding and long pipe string-outs, both of which are typically difficult or impossible in tight city work zones. By reducing on-site fabrication and minimizing the footprint of construction activities, the team was able to maintain a high level of safety and efficiency while minimizing disruption to surrounding communities.
Overcoming Urban Construction Challenges
Performing a complex HDD crossing in New York City presents a host of logistical challenges — from limited staging space to heavy regulatory oversight and the presence of existing underground utilities. Traditional HDD methods often require extended laydown areas for welding and stringing pipe sections before insertion. However, the Permalok® system’s cartridge-load design enabled crews to adapt to the space-constrained conditions without compromising the integrity or speed of the installation.
This capability proved to be a decisive factor in maintaining project schedules and controlling costs. It also showcased how advanced trenchless technologies can make large-scale infrastructure projects more feasible in urban environments, where minimizing disruption and maximizing efficiency are paramount.
Innovation Meets Sustainability
Beyond its engineering significance, the CHPE project aligns closely with the growing emphasis on sustainable infrastructure development. Once operational, the Champlain Hudson Power Express will deliver 1,250 megawatts of clean hydropower from Quebec to New York City — enough to power more than one million homes.
By incorporating advanced trenchless techniques, the project minimized surface disturbance, reduced environmental impact, and avoided the need for extensive open-cut excavation. The use of Permalok® HDD pipe further enhanced these sustainability goals by streamlining installation, reducing emissions associated with field welding, and improving worker safety.
Collaboration Drives Success
The successful completion of this milestone project underscores the power of collaboration among industry leaders. Kiewit Infrastructure provided overall project management and engineering oversight, Michels Corporation brought its world-class trenchless installation expertise, and Northwest Pipe Company delivered cutting-edge product innovation through its Permalok® HDD Joint system.
Together, these teams overcame formidable technical and environmental challenges to deliver a solution that not only met but exceeded the project’s performance expectations. The result is a durable, efficient, and environmentally responsible infrastructure asset that will serve as a model for future renewable energy transmission projects.
Industry Recognition and Future Implications
Trenchless Technology Magazine’s recognition of CHPE as the 2025 Project of the Year – New Installation validates the project’s impact on the future of underground construction. It stands as a testament to how innovation in materials and methods — like the Permalok® HDD Joint — can redefine what is possible in the trenchless industry.
As urbanization continues to expand and the demand for sustainable energy infrastructure grows, the need for efficient, space-conscious, and environmentally sensitive construction techniques will only intensify. Projects like CHPE demonstrate that with the right combination of engineering vision and technological innovation, even the most challenging conditions can be met with success.
A Proud Partnership
Northwest Pipe Company takes immense pride in contributing to this award-winning achievement. The company’s Permalok® HDD Joint continues to set new standards for performance, safety, and efficiency in trenchless applications across North America and beyond.
In a statement reflecting the company’s commitment to innovation and partnership, Northwest Pipe expressed its congratulations:
“We are proud to have supplied our Permalok® HDD Joint for such a transformative and technically challenging project. This recognition from Trenchless Technology Magazine is a testament to the dedication and expertise of Kiewit, Michels, and the entire CHPE team. We extend our sincere congratulations to everyone involved in this extraordinary accomplishment.”
The Champlain Hudson Power Express stands as a symbol of what can be achieved when engineering innovation, sustainability, and collaboration come together — and the success of its Permalok® HDD installation will continue to inspire the trenchless industry for years to come.
