Hot Tapping Services

With over 25 years of experience, we specialize in hot tapping—also known as live taps—on water mains, forced sewers, chilled water, and glycol lines nationwide. Hot tapping is an advanced and efficient approach to connecting with existing pipelines without requiring a complete system shutdown.

It delivers significant advantages, such as substantial cost savings by avoiding interruptions and precise control through valve insertions, which create new valve-controlled access points for targeted isolations without disrupting system flow. This enables emergency repairs or upgrades while maintaining full flow elsewhere. Additional benefits include environmental protection by reducing water waste and contamination, enhanced safety by minimizing excavation risks, and compatibility with a wide range of pipe materials.

What is Hot Tapping?

underground pipeline with the hot tap drill setup and ready to go.

Hot tapping, often called live tapping in water utilities or pressure tapping in other industries, is a specialized technique for creating new connections to existing pipelines while keeping them fully operational and under pressure. This process involves securely attaching a tapping machine to the pipeline, then drilling or cutting a hole into it without interrupting the fluid flow or depressurizing the system. It’s especially valuable for adding branches, installing valves, or conducting maintenance on pressurized systems like water mains, gas lines, and industrial pipelines, helping to avoid costly downtime and ensure uninterrupted service.

For a detailed step-by-step guide, including when to use it, check out our Hot Tapping Explained: What It Is and When to Use It article.

Why Choose Hot Tapping?

Hot tapping, particularly among municipalities, provides significant benefits over traditional shutdown methods:

No System Interruption
Service continues while work is performed!
Cost Savings: By keeping systems live, hot tapping eliminates the labor, planning, and downtime associated with draining and repressurizing pipelines—delivering a faster, more economical solution.
Enhanced Control: Hot tapping creates new valve-controlled access points on live pipelines, allowing targeted isolation without disrupting system flow.. This precision allows for emergency repairs or upgrades while maintaining full flow across the rest of the system.
Environmental Benefits: Because the line stays pressurized, hot tapping prevents water loss and reduces contamination risks. It’s a cleaner, more sustainable alternative that supports modern water conservation standards.
Improved Safety: Hot tapping minimizes excavation and surface disruption, reducing risks for crews and the surrounding environment. With less trenching and confined-space exposure, workers operate in safer, more controlled conditions.

Interested in how this compares to line stopping? Check out our detailed article Line Stopping vs. Hot Tapping: Choosing the Right Pipeline Solution.

A hot tap service in motion. drilling out the pipeline section for the valve insertion.

We perform hot taps on most pressurized pipeline materials, including:

Ductile Iron
Cast Iron
Steel
PVC
HDPE
Copper

Our technicians also work on systems carrying:

Potable Water
Sewer & Wastewater
Glycol & Chilled Water
Brackish Water
Compressed Air

A hard hat that is typically worn by the Watertap Inc. crew for safety during a hot tapping pipeline procedure.

Suitability and Safety

Live tapping is suitable for various pipe diameters and materials, including asbestos concrete, C900, carbon steel, cast iron, ductile iron, HDPE, and pre-stressed concrete. Modern live tapping equipment includes advanced safety features to prevent accidental leaks or damage during the operation.

Emergency Response Capability

Watertap Inc. provides hot tapping services 24 hours a day, 7 days a week, ensuring immediate response to urgent situations like pipeline leaks or unexpected failures. Our rapid deployment process allows for quick setup and execution, creating valve-controlled access points to quickly isolate issues without a full shutdown. This is ideal for high-pressure scenarios up to 15,000 psi, where maintaining continuous flow is critical.

Frequently Asked Questions (FAQs)

Is Hot tapping safe?

Yes, hot tapping is safe when performed by experienced technicians using advanced equipment. It reduces the need for extensive excavation and minimizes the risk of accidents and injuries.

What types of pipelines can be hot tapped?

Hot tapping can be performed on various pipeline materials, including asbestos concrete, C900, carbon steel, cast iron, ductile iron, HDPE, and pre-stressed concrete.

How does hot tapping compare to traditional shutdown methods?

Hot tapping is more efficient and cost-effective than traditional shutdown methods. It eliminates the need for system-wide shutdowns, reduces water wastage, and minimizes the risk of contamination.

What’s the difference between hot tapping and wet tapping?

Wet tapping is often used for non-pressurized or lower-risk systems like potable water, while hot tapping handles pressurized lines with volatile fluids. However, in water utilities, the terms are sometimes used interchangeably.

Can hot tapping be done on large-diameter pipes?

Yes, hot tapping is feasible for pipes from 1/2 inch up to 24 inches or more, depending on pressure and wall thickness.

Why Choose Watertap Inc.?

Experience: With over 25 years of industry experience, Watertap Inc. has the knowledge and skills to perform hot tapping efficiently and safely. Our seasoned professionals are adept at handling various pipeline systems and conditions, ensuring high-quality workmanship.
State-of-the-Art Equipment: We utilize the latest tools and technology to ensure precision and reliability in every hot tap operation. Our advanced equipment allows us to perform hot taps with minimal disruption and maximum safety, adhering to the highest industry standards like ASME codes.
Commitment to Customer Satisfaction: Our focus on clear communication, timely project completion, and exceptional workmanship ensures that we build long-term relationships based on trust and reliability. We strive to exceed customer expectations by providing tailored solutions and outstanding service.