Working on a water pipeline inside a narrow mountain canyon is no easy task. 

So, in November 2023, when Denver Water needed to replace a section of pipe in Waterton Canyon, they called in a helicopter to deliver the goods from the sky.

The challenge: Remove a section of pipe 6 feet long, 5 feet in diameter and weighing 2 tons — tucked up next to a cliff. 

The pipeline is a common site for visitors who hike and bike up the Denver Water service road in the popular recreation area.

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The pipeline in Waterton Canyon feeds water from the South Platte River to Denver Water’s Marston Treatment Plant. The section of pipe that needed to be replaced, called an expansion joint, had been leaking and needed to be replaced.

“Expansion joints are critical parts of above-ground pipelines exposed to the elements,” said Lance Paplow, a senior project inspector at Denver Water.

“As the air temperature fluctuates, the expansion joint absorbs the expansion and contraction of the pipe to help avoid shearing, buckling or cracking. The expansion joint works much like the shock absorbers on a car or bike.”

It takes all kinds of skills to deliver a clean, safe water supply to 1.5 million people. Learn more at denverwater.org/Careers.

Due to the difficulty accessing the section of pipe via a narrow road tucked next to the cliff and across the river, Denver Water’s contractor, Garney Inc., called in a specialized helicopter used for lifting large objects in challenging locations.

The helicopter’s first task was removing the existing expansion joint, part of the original pipeline installed in 1912. 

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It was a challenging task. The helicopter had to approach the pipeline and descend into the canyon. Once in place, the pilot hovered over the pipeline, with a cable dangling about 100 feet below the helicopter.

Workers on the ground, in communication with the pilot, grabbed the cable and hooked a strap wrapped around the pipe. 

Once attached, the pilot lifted the old pipe from its resting place for more than 100 years. The mission continued as the pilot needed to gain enough elevation to clear some power lines and reach a safe altitude to turn around. He then flew the pipe section to the mouth of the canyon to exchange the old section for a new one.

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With the new section of pipe dangling under the helicopter, the pilot flew over the river flowing through the canyon and got into position. 

There was no room for error as the pilot slowly lowered the helicopter into the canyon. With the helicopter’s rotors about 50 feet from the canyon wall, any mistake could be disastrous.

Thanks to the skilled pilot and crews on the ground, the new pipe was successfully lowered into place. 

“These types of construction projects take months of planning,” said Ryan Haas, a senior project inspector at Denver Water. 

“The pilot has to evaluate the wind, temperature, weight of the pipe and needed fuel load, and then execute the flight safely in a challenging environment.”

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The pilot’s mission complete, he flew away as workers connected the new expansion joint to the existing pipeline.

Since the installation work was completed in November, Waterton Canyon has experienced a wide range of temperatures and weather. 

The new expansion joint is working properly and has seen about 1 inch of movement. It’s designed to be able to handle about 9 inches of expansion and contraction of the pipe during the temperature swings.

“It’s not often we need a helicopter to move our pipes,” said Jim Light, project engineer for Denver Water. “It was impressive to watch the team in action delivering the expansion joint with such precision in a tight space.”

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Know before you go. Denver Water reminds visitors to Waterton Canyon that the road up the canyon is used to access Denver Water facilities and infrastructure and will be closed from time to time. Check for updates on possible closures at denverwater.org/Waterton and on Denver Water’s social media channels.