When you need to repair a manhole or large-diameter pipeline but cannot stop the flow, PlugCo’s Huge Bypass Plug (HBP) is the optimal trenchless solution.
What is the Huge Bypass Plug?
The Huge Bypass Plug is designed for sewer and drainage systems with diameters up to 2600 mm (104″), and custom models available up to 3000 mm (120″). It is constructed from hot-vulcanized SBR+NR rubber, reinforced with nylon, Kevlar, and durable fabrics. Thanks to the integrated large bypass line, it enables the water to flow by gravity without pumping.
Why Use the HBP Series?
There are many reasons why you should use the HBP Series;
- Maintain flow without pumps: Gravity-driven bypass saves pump rental costs, power, and Logistics.
- Safe manhole access: Workers can perform repairs underground while flow continues around them.
- Time-efficient setup: Inflate once, gravity handles the rest with quick deployment, minimal oversight.
- Economic impact: Typically more cost-effective than pump-and-bypass setups, especially for large diameters.
- Easy handling: Short, compact size compared to traditional plugs, simplifying transport and installation.
PlugCo: Available Models & Specifications
PlugCo offers Huge Bypass Plug models which are multi-size, covering different pipe diameters with a single model. The following table show some models that PlugCo can offer. Custom production is also available for this model.
| Model# | Nominal Size | Usage Size Range | Internal Diameter of Plug | Bypass Pipe External Diameter | Inflation Pressure | |
|---|---|---|---|---|---|---|
| Min. Dia. | Max. Dia. | |||||
| HBP200400 | 200mm-400mm (8”-16”) |
200mm (8”) |
400mm (16”) |
120mm (4,7”) |
110mm (4,3”) |
1 bar (14,5 psi) |
| HBP400800 | 400mm-800mm (16”-32”) |
400mm (16”) |
800mm (32”) |
260mm (10,2”) |
250mm (9,8”) |
1 bar (14,5 psi) |
| HBP500800 | 500mm-800mm (20”-32”) |
500mm (20”) |
800mm (32”) |
410mm (16,1”) |
400mm (15,7”) |
1 bar (14,5 psi) |
| HBP5001200 | 500mm-1200mm (20”-48”) |
500mm (20”) |
1200mm (48”) |
410mm (16,1”) |
400mm (15,7”) |
1 bar (14,5 psi) |
| HBP6001700 | 600mm-1700mm (24”-68”) |
600mm (24”) |
1700mm (68”) |
540mm (21,2”) |
530mm (20,8”) |
1 bar (14,5 psi) |
| HBP11002600 | 1100mm-2600mm (44”-104”) |
1100mm (44”) |
2600mm (104”) |
1010mm (39,7”) |
1000mm (39,3”) |
1 bar (14,5 psi) |
| HBP14003000 | 1400mm-3000mm (56”-120”) |
1400mm (56”) |
3000mm (120”) |
1350mm (53,1”) |
1340mm (52,7”) |
0,7 bar (10,15 psi) |
How to Use the Huge Bypass Plug?
For a correct use of the Huge Bypass Plug, you need to follow some instructions;
- Inspect & Measure: Identify the pipe inner diameter to choose the correct model.
- Clean Host Pipe: Remove debris, roots, silt.
- Insert Plug: Lay the deflated plug across the flow line with bypass visible.
- Inflate: Use a suitable air compressor and inflate the plug up to the instructed pressure by PlugCo. Use the Air Control Device to monitor the inflation pressure.
- Bypass Flow: Connect bypass line downstream; gravity carries flow through without interruption.
- Repair Work: Workers enter manhole and perform maintenance with zero pipeline shutdown.
- Deflate & Remove: Release air, disconnect bypass, and remove the plug.
- Inspect: Confirm structural integrity and that flow resumes normally.
Real-World Example: Russia Jobsite
In Jan 2021, PlugCo supplied two HBP1500–2600 units (1 m bypass) for a major manhole repair in Russia. Both plugs were factory-tested, certified, air-shipped, and performed effectively, maintaining flow and workspace Access.