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
• 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
• 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
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

BENEFITS OF PIPE BURSTING
• Economic Benefits
• Social Benefits
• Environmental Benefits

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

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

https://www.youtube.com/watch?feature=pl
ayer_detailpage&v=VgD2kVzNE64

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

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

• 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

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
• Environmental Impact of AC Pipe
Rehab Technologies Study
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

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

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

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

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

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

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

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

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

ACTIVE HAZARDOUS WASTE SITES

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

• Introduction
• Environmental Impact of AC Pipe Rehab
Technologies Study
QUESTIONS

Pipe Bursting

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