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Approach

U.S. Department of Energy–supported, 3-year, multi-million-dollar project focused on gas distribution mains. The approach automates construction of a regulation-compliant, stand-alone internal replacement pipe (IRP) inside legacy mains using trenchless methods. It integrates smart structural coatings, new integrity/inspection tools, and 3D geospatial maps combining pipeline, adjacent-utility, leak, and coating-deposition data. A performance-based framework is used to establish pipe-replacement criteria and to validate a 50-year design life for IRP systems.

Results

A validated design basis demonstrates a 50-year design life for innovative IRP systems that do not rely on the host pipe. Clear performance criteria and acceptance thresholds for pipe replacement are established to meet utility and regulatory requirements. Prototypes and test datasets are produced for smart coatings, integrity/inspection tools, and integrated 3D mapping of mains and nearby infrastructure. Progress is shown toward a total cost target of $0.5–$1.0M per mile, inclusive of service disruptions.

Implications

Utilities can rehabilitate leak-prone legacy mains faster and with less excavation, reducing methane emissions and improving public safety. The performance criteria provide a repeatable, standards-ready pathway to specify and qualify IRP technologies across projects. Smart coatings and integrated mapping enhance long-term monitoring, risk prioritization, and lifecycle asset management. Achieving the cost target supports large-scale deployment and accelerates backlog reduction nationwide.