Pipe Bursting

Casselberry Asbestos Cement Pipe Bursting Project:

Moving Forward by Leaving it Behind

Tuesday, July 8, 2014 Florida Public Works Expo

•Introduction •Casselberry pipe bursting project •Benefits of pipe bursting •History of Asbestos •Asbestos fibers during rehabilitation •Compliance with NESHAP •Environmental Impact of AC Pipe Rehab Technologies Study •Mitigation of future exposure risk •Resistance to AC pipe bursting

AGENDA

• City incorporated in 1940 • Municipal utility provider • Urban Orlando area • 27,000 residents • 55,000 water customers • 7.8 square mile area • 3 water treatment plants • 1 wastewater plant • 71 pump stations • 215 miles of water main • 150 miles of gravity sewer

INTRODUCTION

• Killebrew’s dedicated field staff stayed mostly the same for all 4.5 years of construction

• Killebrew’s management staff worked very well with City staff and inspector

• CPH provided a fantastic, dedicated and knowledgeable Professional Engineer inspecting the project for the entire duration

INTRODUCTION – SUCCESSFUL TEAM

• Introduction • Casselberry pipe bursting project • Benefits of pipe bursting • History of Asbestos • Asbestos fibers during rehabilitation • Compliance with NESHAP • Environmental Impact of AC Pipe Rehab

Technologies Study • Mitigation of future exposure risk • Resistance to AC pipe bursting

AGENDA

CASSELBERRY REPLACEMENT PATH

• Casselberry potable water distribution network is 215 miles

• Prior capital improvement plan included $300,000 per year for pipe replacement which equals less than 1 mile of pipe replacement per year

• Pipe bursting technology was used; however not enough capital investment to be sustainable

Entire network replaced in 215 years!

UNREALISTIC COMMODITY RATES • Compare cost of filling an average size swimming pool

(10,000 gallons) with Casselberry potable water with many other commodities in the marketplace

• $32 to fill with Casselberry water

• $10,000 to fill with bottled water from the grocery store

• $23,700 to fill with soda from a 2L bottle

• $35,000 to fill with milk

• $40,000 to fill with gasoline

• $100,000 to fill with bottled beer

• $320,000 to fill with brand name coffee shop

• $2,200 with topsoil from Home Depot in 40 pound bags

CASSELBERRY PROJECT SUMMARY • Pipe bursting of 35 miles (184,800

lf) of asbestos cement (AC) pipe

• Project specifically targeted AC pipe replacement (pipe was selected because of age and failure rate)

• $10 M from the federal government ($6.5 M in grants)

• Question applicability of NESHAP to pipe bursting of AC pipe

CASSELBERRY PROJECT SUMMARY

• Casselberry Project received over $10 million in grant/loan funding, $6.5 million in grants

• American Recovery and Reinvestment Act – “Shovel Ready” requirement

– No permit required by FDEP for pipe bursting up to 2 pipe size larger

– Project can be designed from GIS records, minimized design performed in-house

• Administered through the State Revolving Loan Fund Program with the Florida Department of Environmental Protection

CASSELBERRY PROJECT IMPLEMENTATION

• Utilized HDPE pipe because of its flexibility and strength

• Standard mechanical joints and stiffeners for all connections

• Previous pilot test used FPVC but it failed through rapid crack propagation

CASSELBERRY PROJECT IMPLEMENTATION

• Bypass pumping eliminated through accepted outages

• 300-400 lf per day of bursting production

• 2-3 month project duration for urban neighborhoods minimizes resident impact

CASSELBERRY PROJECT NON-INVASIVE TO RESIDENTS • Replace one to two City blocks in

a single work day • Residents are out of water for

only a work day or less • Minimal Excavations compared to

open-cut or directional boring • Reduces restoration costs and

time • Reduces time construction

crews are present in front of residents

CASSELBERRY PROJECT NON-INVASIVE TO RESIDENTS

• Maintains same pipe alignment • Pipe testing (swabbing, pressure testing,

chlorination and sampling) is performed prior to its installation • Residents do not see crews along their front

yards for testing of the pipe line

CASSELBERRY PROJECT NON-INVASIVE TO RESIDENTS

• Pipeline is activated immediately upon installation via bursting – No “wait time” for • Record drawing preparation • Pipe testing • Regulatory clearance

• An additional reduction of construction presence to residents

CASSELBERRY PROJECT

CASSELBERRY PROJECT FLORIDA LEADS THE WAY

• April 27, 2011 FDEP Secretary writes Atlanta EPA Regional Administrator supporting the use of pipe bursting – Environmentally superior to removing the old pipe

– More cost effective than conventional open-cut

– Reduces landfill space consumption with old pipe

– Pipe bursting has less impact on communities



AGENDA

BENEFITS OF PIPE BURSTING

• Economic Benefits

• Social Benefits

• Environmental Benefits

BENEFITS OF PIPE BURSTING ECONOMIC BENEFITS

• Reduced design and survey costs

• In Florida, pipe bursting does not require a permit and the new pipe can be two sizes larger than the existing pipe

• In developed urban areas, restoration costs can easily exceed pipeline costs

• Reduced third party utility relocation costs

• Less risk equals fewer change orders

BENEFITS OF PIPE BURSTING SOCIAL BENEFITS

• Dramatically reduced construction schedule reduces impact to residents/customers

• Minimized excavations reduces impact to established urban landscaping

• Pipe bursting can replace 300+ linear feet of pipe between 8:30 am and 3:30 pm, some residents don’t even notice impact

Happy Customers = Happy City Hall

BENEFITS OF PIPE BURSTING

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BENEFITS OF PIPE BURSTING ENVIRONMENTAL BENEFITS

• Reduced excavation minimizes environmental footprint

• Reduced carbon dioxide emissions from less machinery and shortened construction schedule

• Pipe bursting is found to reduce greenhouse gas emissions over traditional open cut by 75-90%

• Reduces infrastructure congestion



AGENDA

HISTORY OF ASBESTOS Naturally occurring mineral fiber Attractive attributes

•Fire and chemical resistance •Flexible, long, thin fibrous shape •High strength

Use noted as early as Ancient Greece Use of asbestos supported nationwide during the early 20th century Navy was #1 consumer of asbestos during the first half of the 20th century Knowledge of inhalation dangers solidified by 1950’s

ASBESTOS MINING AND MANUFACTURING OPERATIONS • Large asbestos deposits are rare but found

in North America and Europe in the late 19th century

• Use of asbestos encouraged by developing nations and increasing wealth

• First commercial use as insulation in 1860 • Incorporation of asbestos fibers in cement

was developed in 1931 – Used in pipes, wallboard and siding

ASBESTOS MINING AND MANUFACTURING OPERATIONS • Workers for large companies like Johns-

Manville and Owens Corning encountered greatest occupational risk

• Asbestos miners • Asbestos weavers • Maritime industry workers building Navy fleet

MANUFACTURED PRODUCTS CONTAINING ASBESTOS • Fibrous insulation - #1 health hazard

– Sprayed in, blown in and electrical • Roofing Shingles • Floor and Ceiling tiles • Brake pads • Paints, plasters, mastics, adhesives & tape • Gaskets • Packing materials • Fire blankets and curtains • Boiler insulation – US Navy • Asbestos cement pipe

•Estimates upwards of 630,000 miles of AC pipe installed in North America

– Includes potable, force main and stormwater •AWWA Buried No Longer doesn’t clearly estimate amount of AC pipe but does estimate cost to rehabilitate •Geographically focused in Southeast, Southwest •Population growth rate can be utilized in combination with increase in use (1940-1970) to estimate service areas with greater quantities

AMOUNT OF INSTALLED AC PIPE



AGENDA

• Keep the AC pipe wet • Don’t saw cut the AC pipe to

release fibers • Utilize a snap cutter on the

AC pipe

AWWA WORK PRACTICES FOR AC PIPE

• Casselberry and Killebrew, Inc. performed an extensive Negative Exposure Assessment on the pipe bursting project

• Results indicated levels of asbestos under the limits set by OSHA

ASBESTOS FIBERS DURING REHABILITATION

• EPA currently believes AC pipe that has undergone the mechanical process of pipe bursting SHOULD BE SUBJECT TO NESHAP.

• RACM is defined as friable asbestos material or non-friable ACM that will be or has been subjected to sanding, grinding, cutting, or abrading or has crumbled, or been pulverized or reduced to powder in the course of demolition or renovation operations

IS AC PIPE FRIABLE AFTER BURSTING?

RACM is regulated AC pipe that can be further reduced to powder by hand



AGENDA

NATIONAL EMISSIONS STANDARDS FOR HAZARDOUS AIR POLLUTANTS • Promulgated in 1972

• Part 61 governs 7 key air pollutants

– Asbestos, Beryllium, Mercury, Vinyl Chloride, Benzene, Arsenic, Radon/radionuclides

• Requires an Act of Congress to change

• Does not provide adaption for technology development

• Does allow for an Administrator Approved Alternate as approved process different from regulations

NESHAP COMPLIANCE

• Does it apply? • If so, why and how

• 260 LF exemption (can be less in some states) • Asbestos content > 1% (AC pipe can be up to

12%) • Will it be crumbled, pulverized, or reduced to

powder • EPA currently believe NESHAP applies to pipe

bursting AC pipe, industry does not • States vary with regulation practices

NESHAP COMPLIANCE – 5 KEY STEPS

1. Notice Submit 10 days prior to work (61.145(b))

2. Emission Control during work (61.145(c) / 61.150)

3. Control Public Access 2’ of cover or fencing (61.151 / 61.154)

4. Deed Notation for site after work is complete (61.151(e))

5. Notice Prior to Digging Up Site 45 days before digging up the site (61.154(j) / 61.1(d))

• Introduction • Casselberry pipe bursting project • Benefits of pipe bursting • History of Asbestos • Asbestos fibers during rehabilitation • Compliance with NESHAP • Environmental Impact of AC Pipe

Rehab Technologies Study • Mitigation of future exposure risk • Resistance to AC pipe bursting

AGENDA

ENVIRONMENTAL IMPACT OF AC PIPE REHAB TECHNOLOGIES • EPA commissioned study on the environmental impacts of various AC pipe rehabilitation technologies through the Water Research Foundation

• Water RF Project #4465 selected the Battelle Institute and Dr. John Matthews and Ryan Stowe to perform AC pipe rehabilitation technology studies

• Collection of available data

• Field verification of available technologies

ENVIRONMENTAL IMPACT OF AC PIPE REHAB TECHNOLOGIES Water RF Project #4465 data collection provided:

• Renewal options for AC pipe • Dig and replace (open cut) • Abandon-In-Place • Cured-In-Place Pipe (CIPP) • Spray-In-Place Pipe (SIPP) • Pipe Bursting

UK has already conducted this research and approved pipe bursting as preferred method

ENVIRONMENTAL IMPACT OF AC PIPE REHAB TECHNOLOGIES • Casselberry’s project was the field test for Water RF Project #4465

• Preliminary findings confirm absence of asbestos fibers as NEA previously conducted by Killebrew and Casselberry concluded

• Final report expected to be released in 2014



AGENDA

MITIGATION OF EXPOSURE RISK

• NEA performed on Casselberry’s project clearly denotes no exposure to workers during rehabilitation

• 3 key future exposure situations

• Utility crossings

• Resident/home owner excavation

• Future rehabilitation/replacement of new HDPE pipe

MITIGATION OF EXPOSURE RISK UTILITY CROSSINGS

• Occur when other utility companies are required to perform work around remaining AC pipe fragments

• Utility companies will not perform extensive excavation within a few inches of the new HDPE pipe

Reality is all work performed will be below the 260 linear feet threshold set forth by NESHAP

MITIGATION OF EXPOSURE RISK RESIDENT EXCAVATION

• Resident installing new tree or other will not excavate to water main depth for extended length

• Casselberry utilizes special locate flags that will generate questions

Reality is all work performed will be below the 260 linear feet threshold set forth by NESHAP

MITIGATION OF EXPOSURE RISK REPLACEMENT OF HDPE PIPE

• Utility provider performing AC pipe bursting must acknowledge the risk of future work required around AC pipe fragments

• Emergency repairs will be below the 260 linear feet threshold set forth by NESHAP

• Focused HDPE pipe replacement will occur after HDPE pipe has expelled its service life

• Reality is all work performed will be below the 260 linear feet threshold set forth by NESHAP



AGENDA

RESISTANCE TO AC PIPE BURSTING

• AC pipe bursting projects can only be performed with all parties acknowledgement of process

• Right-of-way controllers approval

• Casselberry only owns R/W for 30% of streets where AC pipe is located

• Local Environmental Regulators approval

• General public approval

RESISTANCE TO AC PIPE BURSTING UNCLEAR APPLICATION OF NESHAP

• Active Hazardous Waste Site • One year of air monitoring

• Signs above site every several hundred feet

• In-active Hazardous Waste Site • Record notation to deed to property

• Problem: Public right-of-way has no deed

• After significant discussion and demonstration of pipe bursting, EPA suggested use of the Administrator Approved Alternate

RESISTANCE TO AC PIPE BURSTING ACTIVE HAZARDOUS WASTE SITES

RESISTANCE TO AC PIPE BURSTING PIPE BURSTING SITES

ADMINISTRATOR APPROVED ALTERNATE

• Clean Air Act requires an act of Congress to change

• When presented with the Casselberry project, EPA applauded the environmental benefits of pipe bursting

• EPA in Washington suggested industry pursue an Administrator Approved Alternate

• No Administrator Approved Alternate approved to date

• No format for submitting Administrator Approved Alternate

CONCLUSIONS

• Pipe bursting is a safe method of trenchless AC pipe replacement

• Current and future exposure risk is mitigated

• AC pipe bursting can occur now and meet all requirements of NESHAP

• > 630,000 miles of AC pipe is reaching the end of its useful life

• There are many economical, social and environmental benefits of pipe bursting



QUESTIONS

Government & Nonprofit

Pipe Bursting