MWRAs Heath Hill Water Main Rehabilitation Project
with the Innovative Use of Trenchless Technologies
By Michael Pelletier, P.E.,* Peter A. Richardson, P.E.,** Milan Horbaczewski, P.E.,*** and
Kevin OBrien, P.E.****
Presented April 1, 2009
Abstract
The Heath Hill Section 52 Phase 2 project
consisted of rehabilitating 2 miles of an 80-year
old, 54-inch diameter steel water main in Brookline
and Boston for the MWRA. The pipeline had
experienced leaks from corrosion and is a critical
component of MWRAs transmission system.
Detailed pipeline and environmental assessments
were conducted and trenchless technologies were
used to develop a sustainable rehabilitation approach.
A combination of conventional and reinforced
cement-mortar lining, as well as sliplining and an
innovative Integrated Corrosion Protection System
were implemented to overcome the challenges of
construction work in Route 9, residential properties,
Hellenic College, and wetlands.
Introduction
Project Description
The Heath Hill Section 52 Phase 2
Rehabilitation Project consisted of design and
construction services for more than 2 miles of
water transmission main in Brookline and Boston
for the Massachusetts Water Resources Authority
(MWRA). Section 52 is a 54-inch diameter steel
water main with a mixture of riveted and welded
*Senior Associate, Green International Affiliates, Inc.,
Westford, MA
**Vice President, Green International Affiliates, Inc.,
Westford, MA
***Senior Program Manager, Massachusetts Water
Resources Authority, Chelsea, MA
****Director, Massachusetts Water Resources
Authority, Chelsea, MA
140 Journal NEWWA June 2010
seams and joints that was constructed in 1927-
1928. The pipeline extends from the Chestnut Hill
High Service Pumping Station located on Beacon
Street in Boston, through Brookline, and then back
into Boston where it connects to MWRA's Section
19 at the Arborway in Jamaica Plain (See Figure1).
In addition to being a major water transmission
main for the MWRA's Southern High Service
Area, Section 52 is one of the primary supply mains
for the two booster pump stations that service the
Authority's Southern Extra High Service System.
Prior to the Phase 2 Rehabilitation project, this
critical pipeline had already exceeded its design
life and was experiencing leaks from corrosion.
In 1997, approximately 800 linear feet of Section
52 located in Heath Hill Road was replaced due
to excessive leaks and corrosion. The remaining
11,500 linear feet was rehabilitated under the
Phase 2 project, which was completed in 2007.
Design Issues and Challenges
The pipeline route presented a number of
design issues and challenges as follows:
Abutters and Mature Street Trees: Roadways
along a large portion of the pipeline route are
residential streets with healthy mature shade trees.
Trench excavation near root systems of these large
trees would have likely caused damage to them.
Maintain Service to Newton Street Pump
Station: MWRA Sections 19, 76 and 96 are all
fed by Section 52. Section 19, as well as either
76 or 96, had to remain in service at all times
during the project, such that Section 52 had to be
rehabilitated in two phases.
Michael Pelletier, P.E., Peter A. Richardson, P.E., Milan Horbaczewski, P.E.,
and Kevin OBrien, P.E.

Figure 1. Locus plan showing recommended rehabilitation segments and sensitive receptors.

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MWRAs Heath Hill Water Main Rehabilitation Project with the Innovative Use of
Trenchless Technologies
Route 9 Crossing: Section 52 crosses under
Route 9, which has an Average Daily Traffic
volume of over 52,000 vehicles. The pipeline has
several vertical bends allowing it to pass beneath
other utilities at approximately 15 feet below the
road surface. The pipe is also encased in concrete
in this location, making pipe replacement in the
same trench impractical.
Wetland/Environmental Impacts: Section 52,
between Sears Road and Goddard Avenue, is located
beneath a significant wetland system and stream
crossing, such that open cut pipe replacement
would have caused significant wetland disturbance.
Easements through Private Property: Section
52 passes through a number of residential properties.
The old MDC easement that the pipeline was
constructed in had not been maintained and
residents had installed fences and landscape features
over or along the pipeline, making access difficult.
Project Goals
MWRA established the following goals for
the Section 52 Phase 2 project:
1. Provide redundancy to the Southern High
Service System
2. Maintain water supply to the Southern Extra
High Service System during construction
3. Rehabilitate appurtenances to improve
operation and maintenance of the pipeline
4. Provide hydraulic capacity to meet present
and future needs for its service area
5. Improve dewatering operations in order to
drain any pipe segment in six hours or less
6. Minimize impacts to abutting properties and
the general public during rehabilitation
142 Journal NEWWA June 2010
7. Minimize impacts to the environment during
construction
8. Acquire remaining permanent easements
along Section 52 within public Right of Ways
9. Complete design and construction on
schedule and within budget
Project Team
Green International Affiliates, Inc, (Green)
Westford, MA served as the prime consultant
for this project under MWRA Contract No.
6288 working with MWRA's Engineering and
Construction Division. Green was responsible
for project administration, rehabilitation design,
permitting, traffic remediation, and construction
administration services. The project team also
included a number of highly qualified design
subconsultants and contractors as follows:
Weston & Sampson Engineers, Inc. (WSE),
Peabody, MA, had lead responsibility for the
geotechnical investigation/hazardous material
program and also for wetland services.
GEI Consultants, Inc. (GEI), Woburn,
MA supported Green and WSE relative
to Geotechnical Investigations, including
excavation stability and groundwater control.
CorrTech, Inc. Hopkinton, MA had lead
responsibility for the corrosion assessment of
the existing pipeline and recommendations
for future corrosion protection.
Other support subconsultants included: Howe
Surveying Associates, Inc., Timelines, Inc.
(Historic Assessment), and Conover & Company
Communications, Inc. (Public Relations).
J. D'Amico Inc., Randolph, MA was the
general contractor for the project. They were
the low bidder and were subsequently awarded
MWRA Construction Contract No. 5194.
 Michael Pelletier, P.E., Peter A. Richardson, P.E., Milan Horbaczewski, P.E.,
and Kevin OBrien, P.E.

W. Walsh Company, Inc., Attleboro, MA the extent of corrosion on the inner pipe wall as
was the specialty cleaning and cement-mortar shown in Photo 1. These internal inspections
lining subcontractor for the project. were considered to be representative of the entire
pipeline length because water quality is consistent
Project Cost and Schedule over the length of the pipeline.
Design services began on September 10, 2002
and bids for the project were received on December
20, 2005. Green estimated the construction cost
to be $8.26 million and J. D'Amico's bid was
$7.59 million. Construction began in February,
2006 and the Section 52 pipeline was brought
completely back in service in August, 2007, four
months ahead of schedule. The balancing change
order at project closeout resulted in a credit to
MWRA of $63,750.60.

Discussion of Pipeline Assessment

The key to the success of this project was
the thorough pipeline assessment that was
undertaken during preliminary design. The
pipeline assessment ensured that the contract
documents were complete and included the proper
rehabilitation techniques for different pipeline
segments, avoiding costly change orders. The
pipeline assessment included a hydraulic modeling Photo 1. SEGMENT 1 & 2: Internal physical
analysis, which involved development of modeling inspection and cement-mortar lining.
scenarios and parameters. Simulations were run on
the Authoritys water distribution system model to In addition, a structural analysis was performed
analyze the effects of the rehabilitation techniques. on a coupon taken from the Section 52 pipeline and
a Closed Circuit Television (CCTV) inspection
A critical part of the pipeline assessment was the was performed by MWRA's Operations Division
external pipe inspections performed by CorrTech. along 1,200 linear feet of pipe. Lastly, a thorough
environmental assessment was performed relative
Nine (9) large test pits were excavated in order to
to hazardous materials, traffic, wetlands, and
expose and analyze 1% of the pipeline exterior.
mature shade trees on residential streets.
The inspections included measuring depths
of surface pitting, taking ultrasonic thickness
measurements and performing a statistical analysis
Results of Rehabilitation Design
to determine the probability of future leaks. Soil Based on the results of the field testing
corrosivity, stray current and pipeline electrical work, the corrosion evaluation, the structural
continuity were also analyzed. In addition to the evaluation and the hydraulic analysis, the existing
external inspections, portions of the pipeline were pipeline was divided into six segments with varied
dewatered and two 50-foot long detailed internal pipe conditions and future corrosion potential.
pipe inspections were also performed to determine Specific levels of rehabilitation were proposed for

Journal NEWWA June 2010 143

MWRAs Heath Hill Water Main Rehabilitation Project with the Innovative Use of
Trenchless Technologies

each segment according to the condition of the

pipeline and its environment. Applying specific
rehabilitation methods to different segments
reduced the overall project cost and environmental
impact when compared to complete pipeline
replacement. Segment specific rehabilitation also
allowed hydraulic capacity to be maximized, as it
would have been reduced by sliplining the entire
length of pipeline.

A detailed Rehabilitation Alternative Selection

Process Flow Chart was developed to select the
appropriate rehabilitation method for each segment.
The recommended levels of rehabilitation were
based on the American Water Works Association
(AWWA) Manual M28 Rehabilitation of Water
Mains, 2nd Edition (2001), as follows: Class I
linings (Non-Structural); Class II and III linings
(Semi-Structural); and Class IV (Fully-Structural or
Structurally Independent) linings (or replacement).
The flow chart for one of the representative
Photo 2. SEGMENT 4 & 5: Sliplining new 48
segments is shown in Figure 2. Per M28, the type diameter steel pipe near mature shade trees and
of rehabilitation methods used for each segment, as estate properties.
shown in Figure 1, were as follows:

SEGMENT 1: Cement-mortar lining with a In addition to using trenchless technologies,

double-pass thickness to cover rivets (Class I)
SEGMENT 2: Segmental sliplining new 36
dia. steel pipe (short pieces) with welded joints
(Class IV)
SEGMENT 3 Phase I: Pipe replacement
with new direct-buried 54 dia. steel pipe (by
MWRA)
SEGMENT 4 & 5: Sliplining new 48 dia.
steel pipe with welded joints (Class IV) as
shown in Photo 2.
SEGMENT 6: Reinforced cement-mortar
lining with multiple passes to cover rivets
(Class II and III)
some new pipe sections were also installed by open-
cut methods to complete the rehabilitation, improve
interconnections and modify the alignment.
An Integrated Corrosion Protection System
(ICPS) was developed and implemented for the
rehabilitation of Section 52, using techniques
that are normally reserved for new pipes only.
Corrosion protection materials were integrated
into many aspects of the design details to create
a stronger barrier against future corrosion. The
ICPS included the following items:
Insulating Flange Assemblies were designed
and used instead of restrained insulating
couplings. The flange assemblies are
approximately 2-feet long and were bolted

144 Journal NEWWA June 2010

 Michael Pelletier, P.E., Peter A. Richardson, P.E., Milan Horbaczewski, P.E.,
and Kevin OBrien, P.E.

together above ground, maintaining the
integrity of the insulator gasket. The insulators
were tested before installation and in the
trench. The self-restrained assemblies were
then lowered into place and connected with
welded butt straps in order to accept minor
pipe deflection angles. The assemblies work
better than couplings because they did not
require an additional restraining harness with
tie rods, which can come in contact with the
pipe and short-circuit the insulator.
welded in place. During the design phase, it was
determined that the 15-foot change in elevation
under Route 9 could develop enough hydrostatic
pressure during the grout injection process to collapse
the new steel liner pipe if it was not protected.
Therefore, the Contract Documents required the
contractor to "charge" or fill the new slip-lined pipe
with water prior to injecting grout into the annular
space in order to counteract the grout pressure.
The segmental sliplining and grouting operation is
shown in Photo 3 and Figure 3.

Grout with a corrosion inhibitor was used to

fill the annular space between the new slip-
lined pipe and the existing pipe for the first
time on an MWRA project. The atomizing
inhibitor provides a barrier between the new
steel and the old steel, reducing the potential
for corrosion.

Concrete encasement with a corrosion

inhibitor was used to protect sections of
new direct buried pipe that were removed
for internal access points, as well as around
insulating flange assemblies and around
connections of slip-lined pipe with new direct
buried pipe. Heat shrink sleeves were also
used at each end of new pipe segments to
prevent future corrosion from stray current.

Sacrificial anodes were used in addition to

tape wrapped pipe on new pipe sections and
also added to one section of existing pipe Photo 3. SEGMENT 2: Segmental sliplining and
(Segment 3) to supplement the system. annular space grouting under Route 9.

The biggest challenge of the project was
successfully completing the complex work under
Route 9. This crossing was accomplished by
segmental sliplining, which uses short can
sections of steel pipe approximately 3 to 5 feet
long to negotiate sharp bends. Each 36 diameter
"can" was carefully lowered and maneuvered into
position with special rigging and then internally
Cement-mortar lining, reinforced with welded
wire fabric (WWF) was used for the segments of
pipe that were in fair condition, but where the
surrounding soil environment had the potential
to develop corrosion holes in the future. Use of
reinforcement prevents cracking of the lining as it
makes the lining self supporting (semi-structural).
Placing reinforced cement-mortar lining on a

Journal NEWWA June 2010 145

MWRAs Heath Hill Water Main Rehabilitation Project with the Innovative Use of
Trenchless Technologies

Figure 2. Rehabilitation Alternative Selection Process Flow Chart

146 Journal NEWWA June 2010

 Michael Pelletier, P.E., Peter A. Richardson, P.E., Milan Horbaczewski, P.E.,
and Kevin OBrien, P.E.

Figure 3. SEGMENT 2: Profile of segmental sliplining a 36 diameter steel pipe through multiple horizontal
and vertical bends of the existing 54 diameter pipe under Route 9.

Journal NEWWA June 2010 147

MWRAs Heath Hill Water Main Rehabilitation Project with the Innovative Use of
Trenchless Technologies
riveted steel pipe created new challenges during
the design and construction phases. Several
layers of cement-mortar lining were used to build
up sufficient thickness over the rivets before the
WWF was placed. The WWF cage was rolled up,
installed, expanded and welded together inside
the pipe before the final layers of cement lining
were placed. The reinforced cement-mortar lining
provided for a larger final internal pipe diameter
when compared to sliplining, and thus provided
the hydraulic capacity that MWRA required (at
a lower cost than sliplining or replacement). The
installation of the reinforced cement-mortar lining
is shown in Photo 4.
Photo 4. SEGMENT 6: Reinforced cement lining
with welded wire fabric cage.
A Health and Safety Plan (HASP) was
developed for this project to protect the
contractors workers and the engineers inspectors.
The level of care executed on the HASP for this
project exceeded those prepared for previous
MWRA water main projects because of the
confined space entry requirements. Access inside
large diameter buried pipelines was needed to
perform rehabilitation work, as well as inspections.
All work inside the Authoritys water main was
conducted in compliance with OSHA 29 CFR
1910.146 Permit-Required confined space entry
148 Journal NEWWA June 2010
requirements. Specific requirements were included
in the Contract Documents for the contractor to
prepare and follow a site specific Confined Space
Entry (CSE) Plan combined with their HASP.
Access manholes for new pipe closure pieces
and man-ways on half-cap access pieces of existing
pipe were included in the design for use during
construction. These access points were 2-feet in
diameter and located at each end of pipe sections
being lined. Once the final pieces of pipe were
welded back in place, these man-ways provided
for convenient, safe CSE access for the contractors
and inspectors while they completed welding,
lining and final inspection work inside the pipe.
An independent, qualified CSE Rescue Team
was designated by the Contractor and kept up to
date of the progress of work at all times in case of
emergencies.
Summary
MWRA allowed the design team to
thoroughly explore trenchless technology options
in order to extend the life of the existing pipeline,
thereby reducing costs, environmental impacts,
neighborhood disruption and unnecessary waste
of water resources. Multiple rehabilitation
methods were selected ranging from non-
structural rehabilitation (i.e. cleaning and cement-
mortar lining) to full structural rehabilitation
(i.e. sliplining). Segmental sliplining was used to
negotiate vertical bends under Route 9. Reinforced
cement-mortar lining was used for areas where the
pipe condition was fair but the pipe environment
was more corrosive. The major innovative features
of the project included the Integrated Corrosion
Protection System, Segmental Sliplining through
deep-buried vertical bends and the use of reinforced
cement-mortar lining over riveted steel pipe.
A thorough pipeline assessment and
engineering analyses were critical to ensuring
complete Contract Documents and minimal
 Michael Pelletier, P.E., Peter A. Richardson, P.E., Milan Horbaczewski, P.E.,
and Kevin OBrien, P.E.

change orders during construction. Engineering
enhancements for the MWRA as a result of this
project include the Rehabilitation Alternative
Selection Process Flow Chart, the innovative
corrosion protection measures and the HASP
Planning. Complaints and neighborhood issues
were minimized during construction by keeping the
public informed about the work during all phases
of the project through neighborhood meetings
and notices. The perception by abutters and the
public during construction was that rehabilitation
projects using trenchless technologies will
minimize impacts to the environment compared
to installing new pipe.
The multiple rehabilitation methods used on the
project, combined with work under Route 9, work
through residential properties in Brookline, work
through Hellenic College, work under wetlands,
and having to maintain water supply to customers
at all times made this a complex project. However,
the project was completed ahead of schedule,
under budget, and with minimal complaints or
neighborhood issues, while being located in a
residential section of Brookline where abutters'
expectations for quality work were extremely high.
MWRA was able to re-establish its easements and
provide redundancy to their system with minimal
environmental impact.

Journal NEWWA June 2010 149