Successfully Developing & Managing Wastewater Pipeline/ Manhole Condition Assessment & Rehabilitation Programs Presented from a municipal perspective… Presented by: Jeff Maier, P.E. Metro Wastewater Reclamation District Denver, Colorado

The challenges municipalities are facing:  ASCE’s 2009 Report Card for America’s Infrastructure: Grade for Wastewater Infrastructure is a “D –”  Cost effective asset management programs are more important than ever  Doing more with less is the new normal  Tighter EPA & CDPHE regulations  Funding issues & aging systems

The importance of condition assessment and rehabilitation  Understanding your system is vital – wastewater infrastructure is crumbling!  Out of site, out of mind is no longer acceptable  Critical component of successful asset management and budgeting  Regulatory compliance issues  Operation & Maintenance requirements  Knowledge about your system = good decision making

Benefits of effective condition assessment and rehabilitation  Reduces overflows, violations & failures  Prioritizes repair and maintenance efforts  Reduces emergency repairs or dig & replace  Modern technologies utilize trenchless condition assessment and rehabilitation techniques  Can save a lot of money!

Attributes of a successful condition assessment & rehab program  Goals and responsibilities are defined  Organized & methodical  Administered by qualified staff and/or consultants  Uses available modern technologies  QA/QC is paramount  Reduces risk  Helps asset management & maintenance efforts  Improves capital expenditure planning

Condition Assessment Technologies & Management Techniques Available  CCTV inspection  Advanced Pipe Condition Assessment Systems (Redzone, Cleanflow, PPR, etc.)  Pole Cameras  Manual and Entry Inspection Methods  Database systems for inspection information storage  GIS interfaces & state-of-the-art inspection software  Consistent rating systems (NASSCO’s PACP & MACP)

Rehabilitation Technologies Available Pipeline Rehabilitation:  CIPP Lining  UV-Cured CIPP Lining  Sliplining  Fold & Form Sliplining  Structural Epoxy lining  Spiral-Wound & Panel lining  Cementitious lining  Trenchless Point Repair Methods It’s critical to understand each of the technologies; especially of the technologies; especially strengths & limitations. strengths & limitations.

Rehabilitation Technologies Available Manhole Rehabilitation:  Epoxy Coating/ Lining  Poly-Urea Coating/ Lining  Urethane Coating Lining  Calcium Aluminate Mortar  Cured in Place Liners  Fiberglass Inserts  HDPE Manhole Inserts  Cementitious Lining  Polymer Mortars

Metro Wastewater’s Interceptor & Manhole Condition Assessment & Rehab Program  Systematic, consistent, & cost-effect approach to assessing & rehabilitating pipe and manhole conditions pipe and manhole conditions  In-house developed program  Collaborative effort between Engineering, Comprehensive Planning, and Operations & Maintenance (O&M) Departments  Balances operational, financial, and engineering needs

Metro Wastewater’s Interceptor & Manhole Condition Assessment Program  Pipes inspected mainly by using CCTV  In-house CCTV using MWRD crews  5-category pipe condition rating system  3-category manhole condition rating system  Manholes surface & entry inspected  Utilizes advanced condition assessment technologies Program utilizes customized database system and GIS interface

Defined Departmental Roles & Workflow  O&M Department – Televise pipelines (CCTV), inspect manholes/ structures, enter inspection info into database, initial condition rating  Engineering Department – Review CCTV footage, follow-up inspection of manholes, assign final condition rating, generate prioritization list & reports, design & manage rehabilitation project, research new technologies  Comprehensive Planning – Review rehabilitation prioritization lists & reports, update & manage Capital Expenditure Schedule Interdepartmental Cooperation & Responsibility: Results in successful in-house condition assessment and rehabilitation program. Interdepartmental Cooperation & Responsibility: Results in successful in-house condition assessment and rehabilitation program.

Program Components: CCTV Inspection  CCTV video inspections: Minimum of 10% of pipe segments annually  10 year video cycle for entire interceptor system  CCTV work performed in-house by O&M Department crews  In-house CCTV ensures consistency, eliminates scheduling issues, & ultimately saves money  Customized 5-category rating system

Program Components: CCTV Review, Condition Rating Classification & Reporting  5-category CCTV review criteria developed in- house  Rating criteria based on reinforced concrete pipe (RCP) conditions, but can be applied to all pipe materials  Rating system is comparable to NASSCO’s Pipeline Assessment & Certification Program (PACP), but meets specific needs of MWRD  Specific definitions of each category define rehabilitation urgency and time frame for rehabilitation completion

Program Components: CCTV Review, Condition Rating Classification & Reporting Good – No rehab at this time, maintain 10 yr cycle Good – No rehab at this time, maintain 10 yr cycle Fair – No rehab at this time, maintain 10 yr cycle Fair – No rehab at this time, maintain 10 yr cycle Fair-Poor – Rehab may be necessary (5-10 yrs) Fair-Poor – Rehab may be necessary (5-10 yrs) Poor – Rehab is necessary (2-5 yrs) Poor – Rehab is necessary (2-5 yrs) Very Poor – Rehab needed ASAP (0-2 yrs) Very Poor – Rehab needed ASAP (0-2 yrs) Pipeline Rehabilitation report cost estimates based on condition ratings of Fair-Poor, Poor, and Very Poor only.

Program Components: Manhole/ Structure Inspection Manhole surface & entry inspection examples:

Program Components: Manhole/ Structure Condition Rating Classification & Reporting Good – No rehab at this time, maintain 10 year inspection cycle year inspection cycle Fair – No rehab at this time, maintain 10 year cycle, monitor as needed cycle, monitor as needed Poor – Rehabilitation is necessary (1-3 yrs)

Program Components: GIS Mapping Example GIS Map & Legend

Program Components: Interceptor Infrastructure System Database (IIS)  CCTV & Manhole inspection data maintained real-time in IIS database  IIS database developed in-house  Oracle based system  Manages inspection data, physical pipe & manhole info, and GIS system  Streamlined condition assessment program  Access searchable pipe & manhole/ structure condition information

Program Components: Supplemental Pipe Coring Activities  Core drill sampling on selected pipe segments  Coring used to confirm remaining pipe thickness  Candidates for coring are pipe segments that may be rated in either category (i.e. fair-poor or poor)  Coring work done by outside contractor  Info entered into IIS database, compare to existing data & reevaluate current condition rating  Samples used to verify & check CCTV rating system

Research & Development New Condition Assessment Technologies  Ongoing research of non-destructive methods to determine pipe condition & wall thickness  Laser profiling, sonar systems, & combo assessment technologies (RedZone, CleanFlow. PPR)  Will replace supplemental coring  Will help improve rehabilitation prioritization CCTV will still provide majority of inspection information (CCTV ~90%, new method ~10%)

Research & Development Testing & Product Evaluation  MWRD’s 6-Step Manhole/ Concrete Rehabilitation Product Evaluation Program In-house developed program In-house developed program Evaluates products and applicators Evaluates products and applicators Helps ensure QA/QC Helps ensure QA/QC  Severe Wastewater Analysis Test (SWAT) Evaluates coating/lining effectiveness & longevity in severe wastewater headspace environments Evaluates coating/lining effectiveness & longevity in severe wastewater headspace environments Laboratory and real-life test comparisons Laboratory and real-life test comparisons Accelerated test chamber & electrical impedance tests Accelerated test chamber & electrical impedance tests

Long-term Capital Expenditure Planning Interceptor Pipes  Assumes pipes will be rehabilitated with CIPP lining for cost estimating purposes  Other rehab methods considered during design (slip lining, fold & form, epoxy-lined, etc.)  Cost estimates based on past MWRD rehab projects  Historical CIPP cost data for pipe sizes 8”-60”  Current MWRD CIPP cost estimate data (installed price): 8”- 30” = $3.75 per in/ft 31” – 41” = $4.50 per in/ft 42” – 60”+ = $6.00 per in/ft

Long-term Capital Expenditure Planning Manholes/ Structures  Assumes manholes will be be rehabilitated with epoxy coating/lining for cost estimating purposes  Other rehab methods considered during design (other coating/liner types, CAM, fiberglass, HDPE)  Cost estimates based on past MWRD rehab projects past MWRD rehab projects

Prioritization for Pipe & Manhole Rehabilitation Projects  Pipe segments rated “very poor” will be repaired on priority basis (i.e. next available rehab project)  Adjoining “poor” segments will be added when shared bypass pumping cost savings can be realized  Assumed that only 75% of “poor” and “fair-poor” rated pipes will ever reach “very poor” condition  Projected timing for when pipe segment or manhole will deteriorate and reach “poor” or “very poor” is considered  Manholes rated as “poor” will be repaired on priority basis (i.e. next available rehab project)  10-year Capital Expenditure Schedule updated accordingly

Conclusions  A well-run Condition Assessment & Rehabilitation Program provides a systematic, consistent, & cost- effective approach to asset management  Supports long term capital expenditure planning  Effective in forecasting future maintenance needs, prioritizing resource allocation, and costs based on inspection & condition assessment ratings  Reduces potential overflows, violations & failures  Utilizes trenchless technology  Can save a lot of money!

Questions? Jeff Maier, P.E. Metro Wastewater Reclamation District Denver, Colorado