Tina Wolff Sr. Project Engineer Malcolm Pirnie, Inc. Ft. Wayne, IN James J. Paluch Assistant Superintendent / Collection System Ops Joint Meeting of E

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1 Tina Wolff Sr. Project Engineer Malcolm Pirnie, Inc. Ft. Wayne, IN James J. Paluch Assistant Superintendent / Collection System Ops Joint Meeting of Essex & Union Counties, Elizabeth, NJ

2 Sewer Cleaning and Managing Grease Blockages Inspection & Assessment of Gravity and Pressure Pipelines September 16, 2009 Pipeline Sustainability Through Certified Inspection Financial limitations forcing do more with less Incidents where new and rehabbed pipe are dying young Man-power limitations limiting / eliminating contractor oversight Costs to repair or remove and replace pipe running more than original installation

3 Inspection as a key aspect of pipe installation and rehab Role of trained, certified inspectors in design and construction Shift toward performance based specifications Examples of value-added added inspection and lessons learned the harder way Gerhard P. Muenchmeyer, P.E. NASSCO, Inc Performance-based specifications Pipeline quality through inspector training

4 John F. Jurgens, Seattle Public Utilities, Washington Case Study The ongoing g need for quality pipeline inspection Michael D. Smith, P.E. Municipality of Bethel Park, PA Case Study CIPP inspection procedures on capital projects

5 James J. Paluch, Joint Meeting of Essex & Union Counties, NJ Case Studies Specifications & Inspection Implementing the 3 R s Water Environment Federation Collections System Committee Back to Basics and Beyond Pipeline Sustainability Through Certified Inspection

6 Introduction Products inspection, during manufacture and inspection during installation, have been part of our society for many years In some cases the government regulates products & services and what inspection is required to protect the health and safety of the consumer Public works inspectors ensure that federal, state and local government construction of new sewer & water systems, highways, bridges and dams conform to the requirements of industry standards and the contract specifications New sewer construction as well as pipeline rehabilitation requires continuous training & certification of inspectors What Can Go Wrong With New Pipeline Construction? Even after many years of industry experience, new pipeline pp installation still requires qualified inspection If the pipe installed is not as specified Possible Results: Pipe joints leaking Pipe wall leaking Structural failure Even if the pipe installed, is as specified but foundation & backfill is not as specified Possible Results: Improper line & grade Pipe becomes oval Pipe cracks or fractures Pipe fails causing a potential catastrophic pipe collapse

7 Examples of New Pipe Defects After Installation Oval Plastic Pipe Cracked Concrete Pipe Cracked Concrete Pipe Deformed Plastic Pipe Oval Plastic Pipe Cracked Concrete Pipe What Is Needed? To avoid low quality pipe installations or potential catastrophic pipe failure, a greater emphasis or re-emphasis on qualified, trained & certified inspectors including: Inspectors that are trained and certified by an industry recognized organization Training and certification requirements for new inspectors entering construction Training and certification/re-certification of experienced inspectors Performance specifications that provide detailed quality assurance inspections to be performed, by the certified inspector, during construction. New generations of construction inspectors, entering the industry, should be trained & certified rather than gaining experience only from on-the-job activities

8 What Can Go Wrong With Pipeline Rehabilitation? Pipeline rehabilitation is a relatively new industry and being technology driven can be complicated at times. To minimize what can go wrong on site, trained, qualified & certified inspector are required. When the product installation does not meet specification requirements nor pass required testing, result may be: Not meeting the engineers design requirements The formation of visual defects that t require action Excessive leakage into the pipe Catastrophic consequences of a collapsed pipe or liner backing up large amounts of flow Examples of Pipe Rehabilitation Defects Fins/Wrinkles Lifted Liner Blisters Fins/Wrinkles Disbonded Connection Hat Cracked Pipe

9 The Trenchless Industry An industry that, over the years, has grown to provide consumers greater choices on how to renew their pipeline systems The trenchless renewal industry offers the consumer technologies that are lower cost alternatives to digging and replacing aging pipelines Even though there are ASTM standards that have been developed over the years, auniform national standard has not yet been developed for many of these technologies Product quality, even though very good in some cases, will vary depending on the specification requirements, the experience of the contractor &the experience of the inspector who is verifying the installation quality Product Quality Quality trenchless technology product delivery depends on: Precise &well written detailed performance specifications Qualified & experienced contractors that are motivated to deliver consistently quality products Clearly defined quality control requirements Trained & certified inspectors that t enforce the requirements of the contract specification

10 Trenchless Technology Purpose To replace or provide a significant deteriorated collection system pipelines new To provide protection against structural accelerated corrosion, I/I and exfiltration life to failure, To provide for lower maintenance and better flow characteristics after renewal To reduce long term maintenance costs All through non-excavation or low excavation means Trenchless technologies are however, sophisticated tools that rely on good engineering design, qualified contractor installation and trained inspectors to ensure quality & contract compliance Industry Misconception Of Trenchless Technology Throughout the trenchless renewal industry there is a general misconception, that trained & certified inspectors are not always required. Some of theses misconceptions include: The contractor has done this work before and should know what he is doing We don t know what we should inspect so we leave it up to the contractor We don t want to spend the extra money to have an inspector onsite all of the time If it looks good it must be installed correctly We used the same specification cat as we used on the last project it should work for this one There are many more such misconceptions that prevail throughout the industry & are used as justification for not having trained & certified inspectors on a project

11 Industry Reaction To Poor Quality Results Unfortunately, natel when the installed product quality is below the customer s expectations, the reaction is : We are not happy with trenchless pipeline renewal technologies and are considering going back to digging and replacing the old pipe LETS LOOK AT SOME INSPECTION REQUIREMENTS FOR OTHER INDUSTRIES?

12 Building Inspectors Inspect the structural quality and general safety of buildings Before construction begins, plan examiners assure compliance with building codes and confirm that they are suited to the requirements of the building site Inspectors visit the worksite before the foundation is poured After it has been completed another inspection is performed Upon completion of the project, the inspector performs a final, comprehensive inspection and issues a written report Electrical Inspectors Examine the installation of electrical systems and equipment to ensure that they function properly and comply with electrical codes and standards They visit worksites to inspect new and existing electrical systems They also inspect the installation of electrical wiring for compliance to codes Most construction projects are not approved until the electrical inspector has signed off on the work

13 Home Inspectors Conduct inspections of newly built or previously owned homes, condominiums, town homes, manufactured homes, apartments, t and at times commercial buildings Home inspection has become a standard practice in the home-purchasing process. Home inspectors are most often hired by prospective home buyers to inspect and report on the condition of a home s systems, components and structure Most banks will require it & few buyers will purchase a home without an inspection performed Public Works Inspectors Ensure that federal, state, and local government construction projects (i.e., water and sewer systems, highways, streets, and bridges) comply with contract specifications They inspect excavation and fill operations, the placement of forms for concrete, concrete mixing and pouring, asphalt paving, and grading operations Public Works Inspectors can specialize in highways, structural steel, reinforced concrete, or utilities Public works projects typically require that a trained inspector be on the project site to ensure that construction conforms to the detailed contract specifications

14 Inspector Certification By Other Industries Many states and local jurisdictions require some type of license or certification as a construction inspector Typical requirements for licensure or certification include previous experience, aminimum educational attainment level, such as ahigh school diploma, and possibly the passing of a state-approvedapproved examination Some States and municipalities have individual certification programs for inspectors, while others may require certification by applicable trade associations Current Certification Organizations The Association of Construction Inspectors (ACI), and the American Construction Inspectors Association (ACIA) provide training and certification programs Owners can access this information on-line, to verify the training and experience of a potential inspector for their project

15 What Is Needed For the Rehabilitation Industry? Uniform, performance based, specifications for the Trenchless Industry Performance specifications more focused on the quality of the delivered product and less on the installation means & methods Consistent enforcement of the contract requirements by well trained & certified inspectors Trained, certified inspectors, providing full time inspection for all critical project installation components Performance Specifications Performance specifications are the instructions to the contractor on what needs to be constructed and they are also the instructions for the inspector on what needs to be verified and tested through quality assurance Performance specifications must have clearly defined measurable performance quality control standards that are verified, in the field, by the inspector. Some examples would include: Physical Properties testing Visual inspection after installation. Chemical resistance verification Water tightness

16 Enforcement Implementation of the contract quality control requirements Written documentation of quality assurance inspections performed by a trained inspector The Trained Inspector The trained inspector is key to a successful trenchless rehabilitation project. He/she should be: Trained and knowledgeable in the product being installed Knowledgeable in quality assurance, documentation of product being installed and instrumentation to be used Ability to recognize key elements of specific product success or failure

17 Pipeline Inspector Training Requirements Inspectors should be trained & qualified in: Material inspection Installation inspection Field Processing Inspection Service reconnection inspection Quality assurance & testing Anticipated Results An inspector who is trained & certified in the CIPP technology will provide an additional resource during field construction to further ensure the success of each installation, while verifying that the customer s specified requirements and expectations are satisfied

18 Inspector Certification Available for The Rehabilitation Industry NASSCO Certification Programs Inspector Training & Certification Program (ITCP) for Cured-In-Place Pipe (CIPP) Inspector Training & Certification Program (ITCP) for Pipe Bursting (Available Spring 2010) Inspector Training & Certification Program (ITCP) for Manhole Rehabilitation (Available Mid Year 2010) Summary WHETHER ITS NEW PIPELINE CONSTRUCTION OR PIPELINE REHABILITATION, THE TRAINED & CERTIFIED INSPECTOR IS A MAJOR FACTOR IN ACHIEVING A QUALITY INSTALLED PRODUCT

19 Thank You Gerhard Gerry P. Muenchmeyer, P.E. Technical Director NASSCO Tel Questions?

20 THE ONGOING NEED for INSPECTION John Jurgens Seattle Public Utilities Seattle, WA Growth of a City The Denny Regrade Approximately 1.6 million cubic yards of material were removed

21 This photo, taken around 1930, shows a scow dumping 600 cubic yards of dirt. Setting the Standard The process of preparing specifications much more than copying standard specifications from previous projects. Specific to each unique project, site and conditions Clearly stating unacceptable options minimizes misunderstandings and legal actions during the bidding and construction process.

22 Setting the Standard beyond paper The designer NEEDS to communicate to the field inspector the assumptions made during the design of the project. Inspectors NEED to verify that the application of appropriate materials is in accordance with design assumptions to achieve to ensure long, useful life of the rehabilitation efforts. Lessons Learned the Hard Way

23 Laterals not Bypassed Lesson Learned: It is important to thoroughly document the location and description of all features and conditions. Improper Resin Curing Lesson Learned: Understand the curing requirement of the product being used

24 Poor Robotic Lateral Connections Lesson Learned: Require and verify that experienced persons perform key work Are warranty inspections needed? Lesson Learned: Insure a 12 month inspection takes place.

25 Spot Repair Interface Lesson Learned: Product should be tight against host pipe Flawed CIPP Design and Installation Lesson Learned: Not all problems can be avoided but they can be compounded

26 Annual Space Grouting Lesson Learned: The inspector needs to verify all gauges are working, sometimes we now require them to be certified. Liner Removal Lesson Learned: Removal of a product can cost more than the initial installation

27 Private Contractors Lesson Learned: Installing contractors must have appropriate training and successful experience with the methods used. Summary Specifications provide the base for a successful installation ti Communication between designers and inspectors are key to: Understanding critical design aspects Transferring knowledge from design to construction Update and revise processes

28 THE ONGOING NEED for INSPECTION John Jurgens Seattle Public Utilities Seattle, WA Questions?

29 CIPP Inspection Procedures on Capital Projects A Case Study Michael D. Smith, P.E. Municipality of Bethel Park, PA Objective Demonstrate the need for high quality inspections during capital sanitary projects

30 Bethel Park General Background Located about 10 miles south of Pittsburgh Area of 12.1 square miles Population of 34,000 Manager and municipal council Annual Budget of $30,128, 635 Bethel Park General Background Claim to Fame Birthplace of the Whiskey Rebellion Burial place of artist, Andy Warhol

31 Bethel Park Sanitary Sewer System Consists of approximately, 221 lineal miles Over 34% of BP conveys sewage to a regional facility About 66% of BP conveys sewage to BP s own plant BPMA owns all of the facilities The Municipality of BP provides O&M Recent Capital Projects Projects were driven by pressure from regulators to; Address local wet weather issues, and Meet the requirements of the Administrative Consent Order (ACO)

32 Recent Capital Projects BPMA Response to regulatory pressure In 2004 funded $8 million for to reduce wet weather flows, and identified approximately100,000 LF of trenchless rehabilitation work Scope INITIAL CIPP PROJECT 12,664 LF of 8 CIPP 195 LF of spot repairs 60 wye replacements Contract value of work- $888, Total cost at closing -$1,031, Translates to a final cost of $81.43 per ft.

33 INITIAL CIPP PROJECT Notable Costs $19, for legal and expert witness $100, for construction phase management and inspections INITIAL CIPP PROJECT Planned Schedule Originally 120 days Actual Schedule Bid in August 2006 Closed out March 2009

34 INITIAL CIPP PROJECT March Contractors CCTV inspection reveals no defects. September Municipality performs maintenance CCTV inspection that reveals approximately 400 defects Post Mortem No mandatory pre-bid Limited QA/QC and Work Plan submittals No minimal installation requirements No material testing requirements No certifications required Lack of familiarity with ASTM 1216 requirements and testing methods Relied on contractor for quality control without documented proof

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38 Education Actions Learned about the products and processes that were being specified Developed contacts with experts Attended NASTT Good Practices Course Attended NASSCO s Inspector training Found out what other entities are doing with respect to rehab Actions Specification changes Performance based integrated ASTM 1216 Mandatory pre-bid Contractor must meet minimum installation quantities Required 3rd party materials testing results Required Submittals Certifications Work Plan and Quality Control Plan Estimated curing times Thickness design calculations

39 Actions Field Inspections - Procedures Visually inspect liner prior to installation and document Wet out sheets must be provided prior to installation of each liner Monitor and record temperature and pressure during installation Collect samples and have them tested for ASTM parameters Review post installation CCTV Perform independent maintenance CCTV inspection during warranty Rationale Field Inspections Why are we doing all this? Hold contractors accountable Get what we paid for Identify the cause of catastrophic or wide-spread problems Identify the responsible party Document what and where was done for the future

40 McLaughlin Run Phase III Results Scope 9,023.9 LF of 8, 15, and 18-inch CIPP LF of spot repairs 46 wye replacements Contract value of work- $707, Total cost at closing -$827, Translates to a final cost of $78.37 per ft. McLaughlin Run Phase III Results Planned Schedule Originally 120 days Actual Schedule 1 year because of non CIPP defects Punch list had 4 items

41 McLaughlin Run Phase III Results Notable Costs Insignificant legal costs $39, for design In Summary Customize spec for job Know the process and the materials Spec out and review submittals The inspector should be well trained Require materials testing Review post install DVDs Perform a warranty CCTV inspection Implement a quality program step by step

42 Questions? Specifications & In spec tion ( Implementing the 3 R s ) James J. Paluch, C- 4 LCSO Assistant Superintendent / Collection System Operations Joint Meeting of Essex & Union Counties Elizabeth, New Jersey

43 JMEUC Operates the Edward P. Decker Secondary Wastewater Treatment Plant MGD Rated Capacity: 85 Avg Daily Flow: 67 Avg Storm Flow: 126 JMEUC Collection System consists of : Original trunk and supplementary sewer lines which capture flow from an area of 65 square miles Represents two paralleling trunk sewers: Over 43 miles long (All gravity) Original trunk built ( ) Supplementary trunk built ( ) Pipe sizes: 10-inches to 81-inches Pipe Materials: Brick, VCP, RCP

44 Case Study # 1 B & B ( Bedding & Backfill ) Location

45 The Project Removal of Backfill from Trench

46 The First R R EADING Become thoroughly familiar with your Project & it s spec ific requirements Specifications always call for appropriate / select backfill Read your specifications & follow through

47 Case Study # 2 When Things Go Udderly Wrong Location

48 The Project The Problem

49 The Quick-Fix The Source

50 The Source The Repair

51 The Second R W R ITING Make certain your Plans & Specifications are complete and site-specific ifi Don t rely on generic / boiler-plate specs Write your specifications to reflect your specific project / research, not hearsay

52 Case Study # 3 P B & J (Pipe Bursting & Justification) Location

53 The Challenge Planning and Design Phase Alternative Analysis Pipe Bursting Alternative Evaluation Static and Pneumatic Pipe Bursting Construction Materials for Consideration Budgetary Pipe Material Only Cost Comparison Pipe Bursting Alternatives Specific for this Project Cured-In-Place Pipe Alternative Evaluation Recommendations

54 IPBA Guideline Specification for the Replacement of Mainline Sewer Pipes by Pipe Bursting The Project The Third R

55 A R ITHMETIC Proper Planning & Design + Performance-Based Specifications + Certified / Trained Inspectors = A successful pipeline construction / rehabilitation project Questions?

56 Q & A Session Tina Wolff, P.E., Malcolm Pirnie Jim Paluch, Joint Meeting of Essex & Union Counties, NJ Gerhard P. Muenchmeyer, P.E., NASSCO John F. Jurgens, Seattle Public Utilities, WA Michael D. Smith, P.E., Bethel Park, PA Recognize a divide often exists between design and construction inspection can bridge the divide Training and using skilled inspectors protects t communities investments and contributes to optimizing the life of the pipe

57 Performance based specification focuses on end-product, leaving means and methods to the contractor It is always easier and less expensive to do it right the first time