Successfully Developing & Managing Wastewater Pipeline/ Manhole Condition Assessment & Rehabilitation Programs

Presented from a municipal perspective…

Presented byPresented by::Jeff Maier, P.E.Jeff Maier, P.E.

Metro Wastewater Reclamation DistrictMetro Wastewater Reclamation DistrictDenver, ColoradoDenver, Colorado

The challenges municipalities are facing:The challenges municipalities are facing: ASCE’s ASCE’s 2009 Report Card for America’s 2009 Report Card for America’s

Infrastructure:Infrastructure: Grade for Wastewater Infrastructure is a “D –”Grade for Wastewater Infrastructure is a “D –”

Cost effective asset management programs are Cost effective asset management programs are more important than evermore important than ever

Doing more with less is the new normalDoing more with less is the new normal

Tighter EPA & CDPHE regulationsTighter EPA & CDPHE regulations

Funding issues & aging systemsFunding issues & aging systems

The importance of condition assessment The importance of condition assessment and rehabilitationand rehabilitation

Understanding your system is vital – wastewater Understanding your system is vital – wastewater infrastructure is crumbling!infrastructure is crumbling!

Out of site, out of mind is no longer acceptableOut of site, out of mind is no longer acceptable

Critical component of successful asset management and Critical component of successful asset management and budgetingbudgeting

Regulatory compliance issuesRegulatory compliance issues

Operation & Maintenance requirementsOperation & Maintenance requirements

Knowledge about your system = good decision makingKnowledge about your system = good decision making

Benefits of effective condition assessment Benefits of effective condition assessment and rehabilitationand rehabilitation

Reduces overflows, violations & failuresReduces overflows, violations & failures

Prioritizes repair and maintenance effortsPrioritizes repair and maintenance efforts

Reduces emergency repairs or dig & replaceReduces emergency repairs or dig & replace

Modern technologies utilize trenchless condition Modern technologies utilize trenchless condition assessment and rehabilitation techniquesassessment and rehabilitation techniques

Can save a lot of money!Can save a lot of money!

Attributes of a successful condition Attributes of a successful condition assessment & rehab programassessment & rehab program

Goals and responsibilities are definedGoals and responsibilities are defined Organized & methodicalOrganized & methodical Administered by qualified staff and/or consultantsAdministered by qualified staff and/or consultants Uses available modern technologiesUses available modern technologies QA/QC is paramountQA/QC is paramount Reduces riskReduces risk Helps asset management & maintenance effortsHelps asset management & maintenance efforts Improves capital expenditure planningImproves capital expenditure planning

Condition Assessment Technologies & Condition Assessment Technologies & Management Techniques AvailableManagement Techniques Available

CCTV inspection CCTV inspection

Advanced Pipe Condition Assessment Systems Advanced Pipe Condition Assessment Systems (Redzone, Cleanflow, PPR, etc.)(Redzone, Cleanflow, PPR, etc.)

Pole Cameras Pole Cameras

Manual and Entry Inspection MethodsManual and Entry Inspection Methods

Database systems for inspection information storageDatabase systems for inspection information storage

GIS interfaces & state-of-the-art inspection softwareGIS interfaces & state-of-the-art inspection software

Consistent rating systems (NASSCO’s PACP & Consistent rating systems (NASSCO’s PACP & MACP)MACP)

Rehabilitation Technologies AvailableRehabilitation Technologies Available

Pipeline RehabilitationPipeline Rehabilitation::

CIPP Lining CIPP Lining UV-Cured CIPP LiningUV-Cured CIPP Lining SlipliningSliplining Fold & Form SlipliningFold & Form Sliplining Structural Epoxy liningStructural Epoxy lining Spiral-Wound & Panel liningSpiral-Wound & Panel lining Cementitious liningCementitious lining Trenchless Point Repair MethodsTrenchless Point Repair Methods

It’s critical to understand each It’s critical to understand each of the technologies; especially of the technologies; especially strengths & limitations.strengths & limitations.

Rehabilitation Technologies AvailableRehabilitation Technologies Available

Manhole RehabilitationManhole Rehabilitation::

Epoxy Coating/ LiningEpoxy Coating/ Lining Poly-Urea Coating/ LiningPoly-Urea Coating/ Lining Urethane Coating LiningUrethane Coating Lining Calcium Aluminate MortarCalcium Aluminate Mortar Cured in Place LinersCured in Place Liners Fiberglass InsertsFiberglass Inserts HDPE Manhole InsertsHDPE Manhole Inserts Cementitious LiningCementitious Lining Polymer MortarsPolymer Mortars

Metro Wastewater’s Interceptor & Manhole Metro Wastewater’s Interceptor & Manhole Condition Assessment & Rehab ProgramCondition Assessment & Rehab Program

Systematic, consistent, & cost-effect Systematic, consistent, & cost-effect approach to assessing & rehabilitating approach to assessing & rehabilitating

pipe and manhole conditionspipe and manhole conditions

In-house developed programIn-house developed program

Collaborative effort between Collaborative effort between Engineering, Comprehensive Planning, Engineering, Comprehensive Planning, and Operations & Maintenance (O&M) and Operations & Maintenance (O&M) Departments Departments

Balances operational, financial, and engineering Balances operational, financial, and engineering needsneeds

Metro Wastewater’s Interceptor & Manhole Metro Wastewater’s Interceptor & Manhole Condition Assessment Program Condition Assessment Program

Pipes inspected mainly by using CCTV Pipes inspected mainly by using CCTV In-house CCTV using MWRD crewsIn-house CCTV using MWRD crews 5-category pipe condition rating system 5-category pipe condition rating system 3-category manhole condition rating system3-category manhole condition rating system Manholes surface & entry inspected Manholes surface & entry inspected Utilizes advanced condition assessment Utilizes advanced condition assessment

technologiestechnologies

Program utilizes customized database system Program utilizes customized database system and GIS interfaceand GIS interface

Defined Departmental Roles & WorkflowDefined Departmental Roles & Workflow

O&M DepartmentO&M Department – Televise pipelines (CCTV), inspect – Televise pipelines (CCTV), inspect manholes/ structures, enter inspection info into manholes/ structures, enter inspection info into database, initial condition ratingdatabase, initial condition rating

Engineering DepartmentEngineering Department – Review CCTV footage, – Review CCTV footage, follow-up inspection of manholes, assign final follow-up inspection of manholes, assign final condition rating, generate prioritization list & reports, condition rating, generate prioritization list & reports, design & manage rehabilitation project, research new design & manage rehabilitation project, research new technologiestechnologies

Comprehensive PlanningComprehensive Planning – Review rehabilitation – Review rehabilitation prioritization lists & reports, update & manage prioritization lists & reports, update & manage Capital Expenditure ScheduleCapital Expenditure Schedule

Interdepartmental Cooperation & Responsibility: Interdepartmental Cooperation & Responsibility: Results in successful in-house condition assessment Results in successful in-house condition assessment and rehabilitation program.and rehabilitation program.

Program Components: CCTV InspectionProgram Components: CCTV Inspection CCTV video inspections: CCTV video inspections:

Minimum of 10% of pipe Minimum of 10% of pipe segments annuallysegments annually

10 year video cycle for entire 10 year video cycle for entire interceptor system interceptor system

CCTV work performed in-house CCTV work performed in-house by O&M Department crews by O&M Department crews

In-house CCTV ensures consistency, eliminates In-house CCTV ensures consistency, eliminates scheduling issues, & ultimately saves moneyscheduling issues, & ultimately saves money

Customized 5-category rating system Customized 5-category rating system

Program Components: CCTV Review, Program Components: CCTV Review, Condition Rating Classification & ReportingCondition Rating Classification & Reporting

5-category CCTV review criteria developed in-5-category CCTV review criteria developed in-house house

Rating criteria based on reinforced concrete pipe Rating criteria based on reinforced concrete pipe (RCP) conditions, but can be applied to all pipe (RCP) conditions, but can be applied to all pipe materialsmaterials

Rating system is comparable to NASSCO’s Rating system is comparable to NASSCO’s Pipeline Assessment & Certification Program Pipeline Assessment & Certification Program (PACP), but meets specific needs of MWRD(PACP), but meets specific needs of MWRD

Specific definitions of each category define Specific definitions of each category define rehabilitation urgency and time frame for rehabilitation urgency and time frame for rehabilitation completionrehabilitation completion

Program Components: CCTV Review, Program Components: CCTV Review, Condition Rating Classification & ReportingCondition Rating Classification & Reporting

GoodGood – No rehab at this time, maintain 10 yr cycle – No rehab at this time, maintain 10 yr cycle

FairFair – No rehab at this time, maintain 10 yr cycle – No rehab at this time, maintain 10 yr cycle

Fair-Poor Fair-Poor – Rehab may be necessary (5-10 yrs) – Rehab may be necessary (5-10 yrs)

PoorPoor – Rehab is necessary (2-5 yrs) – Rehab is necessary (2-5 yrs)

Very PoorVery Poor – Rehab needed ASAP (0-2 yrs) – Rehab needed ASAP (0-2 yrs)

PipelinePipeline Rehabilitation report cost estimates based Rehabilitation report cost estimates based on condition ratings of Fair-Poor, Poor, and Very Poor on condition ratings of Fair-Poor, Poor, and Very Poor only.only.

Program Components: Program Components: Manhole/ Structure InspectionManhole/ Structure Inspection

Manhole surface & entry inspection examples:Manhole surface & entry inspection examples:

Program Components: Manhole/ Structure Program Components: Manhole/ Structure Condition Rating Classification & ReportingCondition Rating Classification & Reporting

GoodGood – No rehab at this time, maintain 10 – No rehab at this time, maintain 10

year inspection cycleyear inspection cycle

FairFair – No rehab at this time, maintain 10 year – No rehab at this time, maintain 10 year

cycle, monitor as neededcycle, monitor as needed

PoorPoor – Rehabilitation is necessary (1-3 yrs) – Rehabilitation is necessary (1-3 yrs)

Program Components: GIS MappingProgram Components: GIS Mapping

Example GIS Map & Legend

Program Components: Interceptor Program Components: Interceptor Infrastructure System Database (IIS)Infrastructure System Database (IIS)

CCTV & Manhole inspection data CCTV & Manhole inspection data maintained real-time in IIS databasemaintained real-time in IIS database

IIS database developed in-house IIS database developed in-house Oracle based systemOracle based system Manages inspection data, physical Manages inspection data, physical

pipe & manhole info, and GIS systempipe & manhole info, and GIS system Streamlined condition assessment program Streamlined condition assessment program Access searchable pipe & manhole/ structure Access searchable pipe & manhole/ structure

condition informationcondition information

Program Components: Program Components: Supplemental Pipe Coring ActivitiesSupplemental Pipe Coring Activities

Core drill sampling on selected pipe segmentsCore drill sampling on selected pipe segments Coring used to confirm remaining pipe thicknessCoring used to confirm remaining pipe thickness Candidates for coring are pipe segments that may Candidates for coring are pipe segments that may

be rated in either category (i.e. fair-poor or poor)be rated in either category (i.e. fair-poor or poor) Coring work done by outside contractorCoring work done by outside contractor Info entered into IIS database, compare to existing Info entered into IIS database, compare to existing

data & reevaluate current condition ratingdata & reevaluate current condition rating Samples used to verify & check CCTV rating Samples used to verify & check CCTV rating

systemsystem

Research & DevelopmentResearch & DevelopmentNew Condition Assessment TechnologiesNew Condition Assessment Technologies

Ongoing research of non-destructive methods to Ongoing research of non-destructive methods to determine pipe condition & wall thicknessdetermine pipe condition & wall thickness

Laser profiling, sonar systems, & Laser profiling, sonar systems, & combo assessment technologies combo assessment technologies (RedZone, CleanFlow. PPR)(RedZone, CleanFlow. PPR)

Will replace supplemental coring Will replace supplemental coring

Will help improve rehabilitation Will help improve rehabilitation prioritizationprioritization

CCTV will still provide majority CCTV will still provide majority of inspection information of inspection information (CCTV ~90%, new method ~10%) (CCTV ~90%, new method ~10%)

Research & DevelopmentResearch & DevelopmentTesting & Product EvaluationTesting & Product Evaluation

MWRD’s 6-Step Manhole/ ConcreteMWRD’s 6-Step Manhole/ Concrete Rehabilitation Product Evaluation ProgramRehabilitation Product Evaluation Program In-house developed programIn-house developed program Evaluates products and applicatorsEvaluates products and applicators Helps ensure QA/QCHelps ensure QA/QC

Severe Wastewater Analysis Test (SWAT)Severe Wastewater Analysis Test (SWAT) Evaluates coating/lining effectiveness & longevity in Evaluates coating/lining effectiveness & longevity in

severe wastewater headspace environments severe wastewater headspace environments Laboratory and real-life test comparisonsLaboratory and real-life test comparisons Accelerated test chamber & electrical impedance testsAccelerated test chamber & electrical impedance tests

Long-term Capital Expenditure PlanningLong-term Capital Expenditure PlanningInterceptor PipesInterceptor Pipes

Assumes pipes will be rehabilitated with CIPP lining for Assumes pipes will be rehabilitated with CIPP lining for cost estimating purposescost estimating purposes

Other rehab methods considered during design (slip Other rehab methods considered during design (slip lining, fold & form, epoxy-lined, etc.)lining, fold & form, epoxy-lined, etc.)

Cost estimates based on past MWRD rehab projectsCost estimates based on past MWRD rehab projects

Historical CIPP cost data for pipe sizes 8”-60”Historical CIPP cost data for pipe sizes 8”-60”

Current MWRD CIPP cost estimate data (installed price):Current MWRD CIPP cost estimate data (installed price):

8”- 30” = $3.75 per in/ft8”- 30” = $3.75 per in/ft31” – 41” = $4.50 per in/ft31” – 41” = $4.50 per in/ft42” – 60”+ = $6.00 per in/ft42” – 60”+ = $6.00 per in/ft

Long-term Capital Expenditure PlanningLong-term Capital Expenditure PlanningManholes/ StructuresManholes/ Structures

Assumes manholes will be Assumes manholes will be be rehabilitated with epoxy be rehabilitated with epoxy coating/lining for cost coating/lining for cost estimating purposesestimating purposes

Other rehab methods Other rehab methods considered during design considered during design (other coating/liner types, (other coating/liner types, CAM, fiberglass, HDPE)CAM, fiberglass, HDPE)

Cost estimates based onCost estimates based on past MWRD rehab projectspast MWRD rehab projects

Prioritization for Pipe & Manhole Prioritization for Pipe & Manhole Rehabilitation Projects Rehabilitation Projects

Pipe segments rated “very poor” will be repaired on priority Pipe segments rated “very poor” will be repaired on priority basis (i.e. next available rehab project)basis (i.e. next available rehab project)

Adjoining “poor” segments will be added when shared Adjoining “poor” segments will be added when shared bypass pumping cost savings can be realized bypass pumping cost savings can be realized

Assumed that only 75% of “poor” and “fair-poor” rated Assumed that only 75% of “poor” and “fair-poor” rated pipes will ever reach “very poor” conditionpipes will ever reach “very poor” condition

Projected timing for when pipe segment or manhole will Projected timing for when pipe segment or manhole will deteriorate and reach “poor” or “very poor” is considereddeteriorate and reach “poor” or “very poor” is considered

Manholes rated as “poor” will be repaired on priority basis Manholes rated as “poor” will be repaired on priority basis (i.e. next available rehab project)(i.e. next available rehab project)

10-year Capital Expenditure Schedule updated 10-year Capital Expenditure Schedule updated accordinglyaccordingly

ConclusionsConclusions A well-run Condition Assessment & Rehabilitation A well-run Condition Assessment & Rehabilitation

Program provides a systematic, consistent, & cost-Program provides a systematic, consistent, & cost-effective approach to asset managementeffective approach to asset management

Supports long term capital expenditure planningSupports long term capital expenditure planning

Effective in forecasting future maintenance needs, Effective in forecasting future maintenance needs, prioritizing resource allocation, and costs based on prioritizing resource allocation, and costs based on inspection & condition assessment ratingsinspection & condition assessment ratings

Reduces potential overflows, violations & failuresReduces potential overflows, violations & failures

Utilizes trenchless technologyUtilizes trenchless technology

Can save a lot of money!Can save a lot of money!

QuestionsQuestions??

Jeff Maier, P.E.Jeff Maier, P.E.Metro Wastewater Reclamation DistrictMetro Wastewater Reclamation District

Denver, ColoradoDenver, Colorado303-286-3285303-286-3285