HWEA 32nd Annual Conference

March 17, 2010

Lessons Learned Planning, Design and Construction of Honolulus Sewer Rehabilitation Projects

Roy Abe, P.E. HDR|Hawaii Pacific Engineers

Mike Young, P.E. Bowers + Kubota

Stuart Ujimori, P.E. C&C of Honolulu Dept. Design & Construction

Presentation Objectives

Learn from past projects to:

Expedite projects Minimize costs Avoid problems and change orders
Make Life Easier for Everyone!

Challenges in Rehabilitating Honolulus Sewer System

Narrow/congested roads with lots of utilities Substandard 6-inch sewers Old brittle terra-cotta sewers Sags and damaged sewers due to poor soils Many sewers in groundwater 1,800 miles of sewer lines!
Many Sewer Rehabilitation Challenges!

6-inch Lines in Kalihi-Nuuanu

50% are 6-inch lines!

Terra Cotta Lines in Kalihi-Nuuanu

65% are Terra Cotta sewers!

Lessons Learned in Project Planning

Analyzing flows and pipe capacities Evaluating pipe condition and problems Dealing with 6 terra cotta lines

1. Analyze Flows and Pipe Capacities Carefully

Calibrate computer models with actual field data Sewer lines are not always clean Wet weather flow data may reflect exfiltration in leaky surcharged lines (rehabilitation reduces exfiltration, which then increases flow) Check flow splits at manholes flow model may be inaccurate Infiltration and inflow can be concentrated in one area do supplemental investigations
Try to avoid unnecessary upgrade work

Avoiding the $40 million Relief Sewer on the Kalanianaole Highway Trunk Sewer Project
Stop 1 mgd of Infiltration! Clean Trunk Sewer Upgrade Kahala WWPS

Clean Inverted Siphon

2. Determine What are the Causes of the Problems

Find the big concentrated I/I sources Check for problems outside the project area Look for downstream sags and defects that back up flow Spend extra time to clean off the old hard grease
Turn the 5-inch grease coated pipe back into an 8-inch pipe!
Fix the Easy to Fix big problems.

Solving the Kapiolani Grease Problem

Upstream Lines with Heavy Grease

Partially Collapsed Pipe Blocking Flow

3. Replacing All the 6 Terra Cotta Lines is Too Costly

Challenges with 6 lines:
Difficult to CCTV and rehab with CIPP if have more than 0.5 offset joint Often in backyard easements and narrow congested streets

Consider rehabilitating with Cured-in-Place Pipe (CIPP) if:

Slope is good (generally not much problems if greater than 1 percent) Limited spot repairs required (generally not more than three)

Lessons Learned in Sewer Design Alignment for new sewers Rehabilitating cast iron sewers Conflicts with existing utilities Improving CIPP quality Working hours Meeting deadlines Obtaining good bids

4. Consider Reconstructing Smaller Lines in the Same Location

Advantages
Less utility conflicts and unknowns Less excavation risks (such as rock) Fewer new manholes

Disadvantages
Need extensive flow bypass (but contractors do figure out a way to do it!)
Expect the Unexpected in the older areas

Utility Poles are a Pain!

Add photo

Sewer Line Under Utility Poles!

5. Corroded Cast Iron Sewers Can be Rehabilitated with CIPP

Requires removal of corrosion
Chain flail tool works well Pipe diameter wont be fully restored CIPP surface wont be smooth (but still good enough)

Need to manage risk of collapse

Monitor cleaning with CCTV watch for excessive infiltration Be ready for emergency repairs! (bypass and spot repair)

Removing Corrosion on a Cast Iron Sewer on Ala Moana Boulevard

6. Try Really Hard to Obtain Timely Approvals (Easier said than done!)
Work closely with utility and other approving agencies
Understand their concerns Be responsive to their comments Gain their trust

Consider special design to get over hurdles

Special Reinforced Concrete Jacket Detail for Water Crossing due to Inadequate Clearance

7. Improving Cured-in-Place Pipe (CIPP) Rehabilitation

Dont require CIPP liners to be thicker than necessary
Adds unnecessary cost More wrinkles and more difficult to install

Check initial work to catch problems early Check work crew qualifications (new workers) Seal annular space between liner and host pipe (stop migration of roots and infiltration) Fix heavy infiltration to ensure resin will reach curing temperature

8. Seek Extended Working Hours

Consider night work to help businesses and traffic Allow extended hours in residential areas Do traffic studies to justify extended hours
For Kalanianaole Highway trunk sewer project, DOT allowed different hours for east bound and westbound traffic and weekends.

9. Do Things to Help Meet Deadlines

Start design earlier
Negotiate design work early.

Put some pressure on reviewing agencies but be nice to them! Focus on getting the traffic control plans approved Dont forget DCABs approval Check and obtain required easements Prepare archaeological monitoring plans if necessary Dont forget the NPDES Construction Activity permit (if more than one acre)

10. Getting Better Bids

Avoid year-end avalanche of projects being bid out Break large projects into smaller ones
Many small contractors are competitive, hungry and competent $4 to $8 million per project seems to be a good range Consider separating out easier open trench work from specialty work (microtunneling and work in groundwater)

HWEA 32nd Annual Conference

March 17, 2010

Lessons Learned Construction of Honolulus Sewer Rehabilitation Projects

focused on Kalihi-Nuuanu Sewer Rehabilitation Project

Mike Young, P. E. Bowers + Kubota Consulting

Too Many Aloha Shirts & Hard Hats Standing Around!

Presentation Outline
1. Description of the Kalihi-Nuuanu Sewer Rehabilitation Project 2. The Lessons Learned = The challenges and issues encountered during construction are what teach the lessons
o o Hope that the designers can consider these lessons to improve future designs Help other CMs to effectively deal with these challenges and issues if or when encountered

3. Ideas to consider for making Open Cut Trench Work Easier in the Future

What are you talking about?!?

1. Kalihi-Nuuanu Sewer Rehabilitation Project

About Project (Short Description):
Approximately 19,500 linear feet (3.7 miles) of sewer lines, ranging from 6 to 12 inches in diameter were installed or replaced via open-cut trenching throughout the Lower Nuuanu and Kalihi Areas 9 separate phases/contracts with six different contractors awarded contracts Total Contracted Construction Amount is approximately $51 Million Currently 6 of the 9 phases are substantially complete or being closed out (about 80% of the overall work complete)

Wow, thats a lot of sewer pipe!

2. Lessons Learned Challenges and Issues Encountered

Utility Locate and Record Drawing information sometimes incorrect or records not available
This can create costly bids and dangerous situations in the field Do the research and go through the proper utility reviews Include Descriptions of Critical Underground System information on the plans Verify that Contractor Calls for Utility Locates and for a Utility Inspector as Required
Contractor can appropriately prepare for encountering the utility Contractor can be held responsible for damage to the utility

Digging in the Dark!

Utility Locate and Record Drawing information sometimes incorrect or records not available
Contractors hoe-ram penetrated *Major Underground Utility System not located per record drawings

*Specialized System causing repairs that cost over $1 Million and caused our contractor to pull off job for several months

2. Lessons Learned Challenges and Issues Encountered

Work in Easements presents unusual/difficult situations
Public Relations Work is very important (Can we start during design). This project was a rush. Consider Bid Items for Specific Restoration Work (In this contract the work is incidental to other items)

Youre going to do what in my yard!

Work in Easements presents unusual/difficult construction situations

Lima Street in Upper-Kalihi

Work in Easements presents unusual/difficult construction situations cont.

Booth Road in Pauoa Area

Work in Easements presents unusual/difficult construction situations cont.

Booth Road in Pauoa Area

Work in Easements presents unusual/difficult construction situations cont.

Akahi Street in Upper-Kalihi

Existing Deteriorated Sewer Line to be Replaced

Work in Easements presents unusual/difficult construction situations cont.

2. Lessons Learned Challenges and Issues Encountered

Utility Conflicts, Tight Fits, and Damage to the sewer system from other Utilities
Boring of holes for Utility Poles, and installation or concrete jacketing of other utilities are sometimes the culprit of damage to the Citys sewer system Tight Utility Crossings even more tight due to upsizing of new line Ask the question of whether it is feasible to put the pipe back in the same location

Easier said than done!

Utility Conflicts, Tight Fits, and Damage to the Sewer System from other Utilities
School Street at Stillman Lane

Utility Conflicts, Tight Fits, and Damage to the Sewer System from other Utilities
Pulaa Lane in Downtown Kalihi

Utility Conflicts, Tight Fits, and Damage to the Sewer System from other Utilities
Pulaa Lane in Downtown Kalihi

Utility Conflicts, Tight Fits, and Damage to the Sewer System from other Utilities
Pulaa Lane in Downtown Kalihi

Utility Conflicts, Tight Fits, and Damage to the Sewer System from other Utilities
Pulaa Lane in Downtown Kalihi

Utility Conflicts, Tight Fits, and Damage to the Sewer System from other Utilities
Kuakini Street

3. A Few Ideas for Making the Work Easier in the Future

Seek Permitting for Night Work in Commercial and Industrial Areas
Noise a Factor Contractor can work with minimal traffic impacts and inconvenience to public Contractor can work more efficiently

Produce Accurate Record Drawings

Push Contractors (with CM verification) to maintain and provide accurate record drawings Consider requiring contractors to provide Record Drawings in CAD

Consider walking the site with a CM or Contractor

HWEA 32nd Annual Conference

March 17, 2010