A labyrinth of water main pipes lie underneath the city of Hastings. They stretch for miles and no one can see them.
But this world, 5 feet beneath the streets, covered in sand and soil, transporting water from the city to home, is causing a slew of problems.
The pipes are breaking at an abnormally high rate, threatening to flood streets and chewing a hole in the city budget.
“It is unusual for a water system our size to have as many water breaks as we have. I can’t believe it, really,” City Manager Sarah Moyer-Cale said.
This winter, seven water mains, so far, have broken in Hastings. Last year, 17 broke.
The problem has existed for decades. Mayor David Tossava started with the city's Department of Public Service nearly 40 years ago. Even then, he said, water main breaks plagued the city. Forty years later, they still do.
DPS Director Travis Tate calls it the biggest issue facing the department.
And the problem isn’t going anywhere, according to Ron Brenke, executive director of the American Council of Engineering Companies of Michigan.
“You can’t stick your head in the sand and expect this problem to just go away. It’s not going to go away,” Brenke said. “They’re going to have more water breaks, if it doesn’t get fixed.”
How they break
When a water main pipe cracks, water comes streaming out, filling the trench, until the trench can hold no more.
Then the water will start to trickle above ground. Sometimes it will come through cracks in pavement or the grass behind the curb. But there’s always water somewhere.
“It’s like a stream going down a hill,” Tate said.
Within a few hours of notification, the department will have people at the site of the water. Normally it takes four people – a dump truck, an excavator and a suction cup-like Vactor to fix a water main. It doesn’t matter what DPS staff is doing at the time. Water main breaks come first.
“[The water main breaks] make operations less effective because they may plan their day one way and, when there’s water main break, you got to go take care of that,” Moyer-Cale said.
If a water main isn’t treated right away, it could flood a road or a basement. In 2009, a water main break in Warren opened up a sinkhole, ate a van and shut off the water to a shopping center. In Flint, it took a year to find a water main break, leading to more than $800,000 in lost water in 2012. Lansing this past year lost nearly 650 million gallons of water from breaks – nearly 10 percent of its water, Brenke said.
To solve the problem, DPS workers start by digging out the trench to reach the water main. Then they will cover the crack with a stainless-steel repair clamp, halting the flow.
The clamps save the city time and money. They use a clamp and keep the water running, which maintains positive pressure and keeps bacteria out of the pipes.
But taking care of water main breaks still costs a substantial amount of time and money. From start to finish, the repair can take up to eight straight hours. Workers may grind through the early hours of a night, soaked in water in freezing temperatures, to finish the job. It’s not easy, DPS Superintendent of Streets and Construction Rob Neil said.
“Sometimes it’s midnight. Sometimes 2, 3, 4 o’clock in the morning,” Neil said. “And that’s taxing on our guys, because if it snows while we’re doing the water main, then we have to pull guys off the water main and start plowing.”
After stopping the water, the crew refills the trench with sand and, a week or so later, when they receive asphalt, they’ll repair the road and pour asphalt.
The process is not cheap. A repair clamp, new asphalt and overtime can cost the city between $5,000 and $10,000.
But that's pennies compared to the millions of dollars it will take to replace the cracking pipes.
Why they break
A number of factors normally contribute to a rash of water main breaks.
Most water main breaks happen during the winter from temperature change and frigid temperatures, Brenke said. When the ground freezes, it expands, putting additional pressure and weight on the pipes, causing them to move.
“All the snow melts. And, once the frost starts giving way, that water seeps down into the ground and then we get these hard freezes again,” he said. “That’s when [the ground] expands and starts to move things.”
Then the older pipes will crack.
Many of the pipes in those clustered sections of Tate’s maps are older – some as much as 80 years or older. They are made of cast iron, making them less flexible and more susceptible to cracks.
The breaks also have to do with the trenches. When the water mains were built, excavators dug out a hole to hold the pipes. Tate said they normally fill the trenches with sand. But some of them hold clay-based soil.
Sand lets the water easily flow through the ground around the pipe. Clay-based soil, on the other hand, holds the water, pressing down on the pipes and expanding when it freezes.
Communities across Michigan are running into the same issue. Hastings, Brenke said, is a small sample “of what’s going on throughout Michigan and, quite honestly, throughout the U.S.”
In an assessment of the state’s drinking water system, the American Council of Engineering Companies of Michigan, where Brenke works, gave the state a “D” grade.
“It’s a big problem that is basically out of sight, because it’s below the ground,” Brenke said of water infrastructure. “It’s not like the roads or the bridges; when they start crumbling, everybody sees them. But when a water main is leaking because it’s 100 years old or 75 years old, nobody pays attention to it until it breaks.”
Finding a solution
When asked how the city plans to solve its water main issue, DPS Director Tate gestures across his office to a pile of table-sized posters. “Well, I want to show you this map over here,” he said.
It’s a map of the city. Almost every street is covered in colors and shapes – brown blocks, green dots and X’s. The map illustrates all of the issues DPS faces, and the X’s represent water main breaks from 2011 to 2022.
There are about 80 X’s on the map. Many come in clusters. There’s a group along M-43 highway between Woodlawn Avenue and the city limits. There’s another near Hastings Mutual in the northeast part of the city. There’s a few more on West Clinton and Marshall streets next to the high school, and another along East Clinton Street, stretching from South Hanover to East State streets.
The special map, created by an engineer at Prein&Newhof, is part of the city’s capital improvement plan, which focuses on infrastructure improvements that require a large sum of money. Brenke said asset management projects like this are essential. They identify problems, helping city officials understand these infrastructure issues. It then allows the city to communicate the need for money to replace pipes the public cannot even see.
“You have to educate the community members,” he said. “Be transparent. Let them know the current situation that you’re in, and I think most people, if they understand what needs to be done and they have the data to back it up, I think they’d be more willing to pitch in and help.”
There’s just one issue – the city does not have the funds to replace every water main in its geographical boundaries.
But they can focus on the hot spots – the cluster of blocks with lots of water main breaks. As part of the capital improvement plan, Tate said he plans to spend the next five years replacing the pipes in those high-risk locations. In their place, the department will lay down new ductile iron pipes and fill the holes with sand.
“If it broke in one place, it will break in another,” Moyer-Cale said. “We’re targeting areas that have repeated water main breaks that continue to cost us thousands of dollars every time something breaks there.”
Still, Tate estimated the price tag for fixing the hot spots would amount to millions of dollars. And the city doesn’t have millions of dollars to put toward water main repairs.
There are a few different ways Hastings could get funding for its water mains, Brenke said. It could raise residents' water bills, for example, but this is often difficult in rural communities.
“In cities, there are more people to pay for it because the cities are usually more densely populated,” he said. “In rural areas, there’s less population so the rates may seem higher because there are less people to pay for it.”
Before making any decisions, city officials will wait to receive the finalized capital improvement plan, which Prein&Newhof will present at the city council’s March 28 meeting. By then, they will have a better idea of how much the project will cost and how they would be able to fund it.
Currently, Moyer-Cale said they do not have any plans to raise the water bills for residents. Instead, they will most likely focus on applying for United States Department of Agriculture and Drinking Water State Revolving Fund loans – providing perhaps millions of dollars on a low-interest rate without a large burden on the public.
Regardless, the city needs to find money somewhere and it needs to do something, officials said. Putting a clamp on leaking pipes might work for right now.
But it won’t work forever. Pipes will continue age and they will continue to break.
“You can’t keep putting a Band-Aid on it for the solution,” Tate said. “Eventually, you got to just rebuild.”