The City of McKinney had received occasional complaints regarding potable water clarity and low pressure concerns over the past 9 years. The city has miles of unlined cast iron water mains more than 65 years in age which have been experiencing internal corrosion. Temporary solutions had been employed including maintenance flushing of mains and installation of water filters at meter boxes to minimize the effects on rusty water burdened homeowners. However, complaints continued to increase with as many as 140 discolored water complaints in a four month period.

In January 2007, the City Council approved additional funding through its Capital Improvements Projects budget to initiate a multi-phase replacement of the deteriorating water mains. Harlyn Farrell, Water Superintendent for the City of McKinney, evaluated various methods of replacement and renewal and in July 2007, an additional contract was entered with CuraFlo Spincast Services to rehabilitate an additional 14,000 feet with an epoxy lining throughout the identified area.

The majority of pipes were located along the roadway under asphalt and concrete. Required excavations were reduced due to not having to gain access to the pipe at the service location for reopening the connection. The mains also ran along the front of the properties and in some cases in the rear yards between properties. Excavation was made possible at either end of the street, in the roadway or common areas to gain access to the pipe and avoid any excavation on private properties or driveways. Epoxy lining avoided the removal of boundary fencing and walls, excavating newly laid concrete driveways, extensively landscaped areas or in rear gardens, accomplishing a primary goal of minimizing social impact and disturbance of surrounding infrastructure and environment.

Although no major incidents were encountered during construction, various problems arose causing schedule changes at short notice. These problems included: inability to obtain shut downs, additional connections coming into the main to be lined, water sample failures, equipment breakdowns, even a customer Christmas party. Due to the flexibility of the CuraFlo system, and the cooperation of the City, crews worked to alter the lining lengths or amount of linings per day to reduce customer disruptions and maintain overall project scheduling.

This is a three year multi-phased project with an October 2009 completion target. The City Council approved $1 million per year for 3 years. Based on historical in-house line replacement data and estimated per foot costs from trenchless contractors, an average cost of $45 per foot was budgeted. As of January 2008, 24,800 feet of the estimated 68,000 feet has been completed.