Challenging WV Transmission Station Pipeline Job on 58-Degree Slope Uses TerraThane by U.S. Company, NCFI Polyurethanes



MOUNT AIRY, NC—A recent pipeline job at Dominion Resource’s extraction/fractionation plant in Pine Grove, WV presented some pretty hairy challenges. First the pipeline was to be laid on a 58-degree hillside. Trucks, excavators, and other equipment had to be wenched up the slope and held in place by cables attached to heavy equipment. Secondly, it was the rainy season, so erosion of the freshly turned earth was a major concern.

Chad Corbin’s company, All Seasons Foam and Coatings Services, Sanger, TX, was chosen to create pipeline pillows and trench breakers for the project. “We took one look at it and, when most companies might have thrown up their hands or declined the job, we felt right at home,” says Corbin. “They laid 1,400 feet of pipe on a 58-degree slope. That’s steep. We had to cable the excavator and our spray rig, wench it up the hill, and secure it to two or three dozers while we worked.”

Corbin says his company selected TerraThane geotechnical polyurethane foam system by NCFI to meet the challenge. “TerraThane is a great product. Polyurethane foam is far superior to sand breakers. Water eats through the sand breakers and the sand escapes and erodes over time. Polyurethane foam breakers bond with the earth, and water doesn’t have an effect on them. They’re easier to apply and they last.”

Corbin says they use NCFI foam because, “unlike others foams we’ve tried and seen used, TerraThane doesn’t char inside, doesn’t smoke when you spray it, or get crusty inside. It’s the highest quality product on the market.” He adds, “Their (NCFI’s) technical support people are dedicated to our success. They are always on call when we’re on a job. We can call them any time and they help us do the best job for our customers. You don’t find that very often and it makes a big difference on our bottom-line.”

Pat Burchett, TerraThane product manager for NCFI, says the WV job is an excellent example of why foam systems are replacing sand breakers. “Less labor is required, there is less chance of injury as compared to handling sandbags, allows for quicker construction and provides time savings. Our system is formulated for low exothermic heat and tested per ASTM test procedures for strength values and dimensional stability. It’s a two component polyurethane foam designed for great lift thicknesses without scorching or splitting during field applications.”

The Dominion Transmission plant processes and stores natural gas liquids (NGLs): propane, normal butane, isobutane, and natural gasoline. They extract, fractionate, store, transport and market to various end user markets including propane retailers, refineries, petrochemical facilities, and aerosol companies.




All Seasons serves the continental U.S. from its headquarters in Sanger, TX, and offers residential, commercial and geotechnical foam systems. The company is a recognized leader in pipeline trench breakers, pads and pillows and specializes in challenging geotechnical applications. For more information call (877) 420-7575 or visit



NCFI, headquartered in Mt. Airy, NC since 1964, manufactures polyurethane foam chemical systems for spray foam-in-place insulation (SPF), roofing, geotechnical application, marine floatation, packaging, specialty molding, and many other uses. The company also offers a complete line of flexible foams for furniture seating, transportation seating, bedding, carpet underlay, and packaging. NCFI also has manufacturing plants in Hickory, N.C., Dalton, GA., and Salt Lake City, UT. To learn more about NCFI please