Consolidated Mutual Water Company Pipe-Bursting Waterline Replacement Program Using 56,000 LF of Fusible C-900® Pipe

The Consolidated Mutual Water Company (Consolidated) distributes approximately 4 billion gallons of water annually to 90,000 residents in Lakewood, Wheat Ridge, and unincorporated portions of central Jefferson County, Colorado. Treated water is delivered through about 400 miles of pipelines and over 20,000 tap connections in a service area of approximately 27 square miles. After building a state-of-the-art membrane treatment plant, Consolidated decided to improve the quality of distributed water further by modernizing their existing water main rehabilitation methods.

Consolidated's distribution system dates back as far as 1926 when the original company was formed from four smaller, well-based systems. Through decades of additions, expansions, and reorganizations, Consolidated has remained committed to providing the highest quality water to its customers through a reliable distribution system. Since the mid-50's, Consolidated has budgeted money annually for water main replacement and upgrades of other aging infrastructure. Consolidated has historically used the open-cut installation process in its water main replacement program. As the cost of open-cut installation continued to rise, including paved street restoration, Consolidated began evaluating alternative methods for water main replacement.

Pipeline Details and Project Summary

Owner: Project: Location: Pipe: Installation: Upsizing: UGSI Contact:

The Consolidated Mutual Water Company Pipe Burst Waterline Replacement Phase I & II Lakewood, CO (2010-2011) 56,000 LF 4", 6" and 8" DR18 Fusible C-900® Pipe Bursting, self performed by utility 4" lines to 6" and 6" lines to 8" Steve Austin (303) 563-9467 saustin@undergroundsolutions.com

After evaluating and testing a variety of equipment, piping products, and installation methods, Consolidated decided to proceed with a pipe bursting program to replace 23,000 LF of water pipelines, beginning in April 2010, in a service area with antiquated and undersized lines. Consolidated selected Fusible PVC™ pipe as the replacement pipe based on its corrosion resistance, ease of connection, and its ability to upsize old cast iron distribution lines while minimizing soil displacement due to its smaller pipe OD versus other pipe options.

Consolidated is trained and certified to fuse Fusible PVC™ pipe. They use McElroy fusion equipment and pipe bursting equipment from TT Technologies. Consolidated enlisted the technical assistance when they initiated their pipe burst installation program and have been fully self performing the installations with excellent efficiency ever since. The first phase of the project started on April 26, 2010, and was completed on September 10, 2010, with minimal disruption to customers and traffic. The project was a success and resulted in significant savings versus traditional open-cut replacement. The 2011 phase of the project will be complete by October with even greater savings.

Mike Queen, President of Consolidated, stated: "We saved $1.3 million using pipe bursting instead of the open-cut method on the first phase. Consolidated is replacing 33,000 feet of waterlines this year (2011)with another 41,000 feet planned for 2012 using pipe bursting and we anticipate the same cost saving results." Consolidated has also used Fusible PVC™ pipe for open-cut installation of new 8" and 12" waterlines at a new development and a golf course in its service area, as well as for a 16" emergency slipline under West Colfax Avenue.

Pipe Fusion	Temporary Service Line	Fused Pipe String & Roller
Bursting Entry Pit	Expander Head Entering Pipe	Cast Iron Pipe Fragments
Service Connection Pits	Minimal Asphalt Restoration	Completed Project