Water main breaks, also known as burst mains, are a persistent challenge for utilities, local councils, and contractors across Australia and New Zealand. Ageing pipelines made of asbestos cement, cast iron, and even early ductile iron are reaching the end of their service life, leading to more frequent failures.
Understanding why these water mains break and how to prevent water main failures is crucial for maintaining reliable water services.
Below, we explore the key causes of pipeline bursts and outline proactive strategies (including acoustic monitoring, pressure transient analysis, and IoT technology) to predict and prevent these failures.
Several factors contribute to water main breaks in the region, especially in older cast iron, ductile iron, and asbestos cement (AC) pipelines. Here are the key causes:
Aging Cast Iron and Ductile Iron Pipes: Many urban water networks installed in the early to mid-20th century still rely on cast iron (CI) pipes, with ductile iron (DI) pipes coming into use from the 1970s. Decades of service lead to material fatigue and corrosion. Cast iron is particularly brittle; external corrosion (graphitic rust) thins the pipe wall, and sudden stresses can crack the pipe. Due to this brittleness and long-term corrosion, cast iron water main breaks are common in older systems. While more flexible, ductile iron can also corrode if protective coatings fail, eventually leading to leaks or bursts. International surveys show that CI and AC pipes have some of the highest break rates as they near the end of life.
Each factor – material degradation, environmental conditions, and operational stresses – often combines. An old cast iron pipe with decades of corrosion might hold up under normal conditions but add a soil shift or a pressure spike, and it fails. Recognising these causes helps water authorities and contractors pinpoint which mains are at the highest risk of bursting.
Preventing burst mains and extending the life of ageing pipes require a proactive approach. Utilities and councils across Australia and New Zealand increasingly use predictive maintenance technologies to identify weaknesses before a break occurs.
Below are key strategies to prevent water main failures and reduce the incidence of emergency breaks:
Small leaks often precede significant water main breaks, so catching these early is critical. Active leak detection programs use acoustic sensors, hydrophone listening devices, leak correlators or inline leak detection tools to hear otherwise invisible leaks.
Regularly surveying critical pipelines with these tools allows utilities to find and fix leaks before they worsen into complete ruptures. This averts catastrophic breaks and reduces water loss (non-revenue water). Acoustic leak detection is especially beneficial on cast iron and ductile iron mains, where the “leak-before-break” phenomenon can provide a warning – studies show that cast iron pipes often start leaking before a complete rupture, offering a window for intervention.
Many councils now deploy permanent acoustic loggers on critical mains or perform online leak detection monitoring to stay ahead of bursts.
Because pressure spikes can trigger pipe failures, monitoring and controlling these transients is a powerful prevention tactic. High-frequency pressure loggers (often IoT-enabled) are installed at hydrants or pump stations to record pressure fluctuations continuously.
Pressure transient monitoring helps identify damaging events – for instance, a pump that starts too aggressively or a valve closure sending a shock wave. Once problem transients are detected, utilities can implement network calming measures. These include adjusting pump operation sequences (soft starts and stops), installing surge vessels or air valves, and training operators to open/close valves more slowly. Over time, transient data can feed into pipe failure models, as research in Australia has shown that accounting for these surges improves the predictability of failures. In practice, reducing water hammer prevents sudden bursts and minimises long-term fatigue on the pipe walls.
In many distribution networks, the baseline water pressure is higher than necessary, intensifying stress on ageing pipes. Implementing pressure management through pressure-reducing valves (PRVs) and district zoning can dramatically cut break rates. By lowering excessive pressure during off-peak times, utilities alleviate continuous strain on pipes.
For example, in one New Zealand network, pressures up to 900 kPa were reduced toward an optimal 250 kPa; this significantly reduced leakage and extended the life of the pipes and fittings. Optimised pressure not only means fewer bursts but also reduces the frequency of more minor leaks. Importantly, this can be done without impacting customer service (just reducing unnecessary over-pressure).
Many Australian and New Zealand water authorities have reported fewer main breaks after implementing intelligent pressure management systems. In short, managing pressure is a cost-effective way to prevent water main failures by tackling one of the root causes of stress.
IoT-connected devices are revolutionising how water utilities monitor asset conditions. By deploying a network of smart sensors (for pressure, flow, acoustics, water quality, etc.) across the pipeline system, operators gain real-time visibility into what’s happening inside their mains.
These devices send continuous data (via cellular, NB-IoT or LoRaWAN networks) to central dashboards. Utilities and councils in Australasia use IoT sensors to get instant alerts of anomalies. For instance, a sudden pressure drop can indicate a pipe burst, while unusual pressure oscillations might flag a developing issue that requires intervention.
Flow meters and acoustic sensors can catch silent leaks or bursts as they happen, enabling a rapid response. The real-time data allows a shift from reactive to proactive maintenance. Another example is using our AquaNRW intelligent water loss management software to identify potential issues before they escalate and get early warnings of pressure or flow irregularities to fix problems prior to failure .
IoT analytics can feed machine-learning models that predict which pipes will likely fail next based on patterns. In summary, a “smart” water network with connected sensors helps utilities pinpoint stress on pipes 24/7 and respond immediately – a game changer for preventing significant water main breaks in the field.
In addition to high-tech monitoring, traditional condition assessment remains vital for preventing breaks. Utilities prioritise critical water main inspections (especially large-diameter or high-consequence pipes).
Techniques such as electromagnetic scanning, ultrasonic wall thickness testing, CCTV internal inspection, and even newer methods like dynamic response testing (from Kenwave) can reveal the extent of corrosion or degradation in iron and AC pipes.
Some water agencies take coupon samples or use core drilling to directly measure the remaining wall thickness of cast iron or AC pipes. Asset managers can plan targeted renewals by assessing which pipe segments are most deteriorated – replacing or relining the weakest sections before they burst. For asbestos cement pipes, councils in Australia have developed models to predict remaining life based on factors like pressure, age, and water chemistry. When high-risk pipes are identified, a proactive renewal program can swap them out controlled (or rehabilitate them with liners) instead of waiting for an emergency.
For example, Urban Utilities in Queensland recently replaced nearly 8 km of AC water mains from the 1920s–1950s as part of a planned renewal program. Likewise, some NSW utilities prioritise AC pipe replacements in areas with high failure rates.
Rehabilitation is another option: lining old cast iron or AC pipes with epoxy, PVC liners, or cement mortar can restore structural integrity and reduce internal corrosion, thus preventing breaks and extending pipe life.
In summary, knowing the condition of your assets and renewing aging pipes on schedule is one of the most direct ways to prevent water main failures.
By combining these strategies, water authorities, councils, and their contractors can dramatically reduce the incidence of burst water mains.
A holistic approach might involve using IoT sensors and acoustic devices to monitor the network continuously, applying pressure management to calm the system, and scheduling targeted condition assessments on the highest criticality pipeline assets. The result is fewer emergency repairs, lower water losses, and more reliable service for the community.
Ageing water infrastructure doesn’t have to mean an epidemic of water main breaks.
For Australian and New Zealand utilities and councils, the key is understanding why water mains break – from corroded cast iron and decaying asbestos cement to summer droughts and pressure spikes – and then acting on that knowledge.
Proactive measures like leak detection, pressure transient monitoring, smart IoT sensors, and strategic pipe renewals empower agencies to fix weaknesses before a main bursts.
These preventive strategies not only reduce water main failures but also save money and minimise disruptions by addressing issues on a planned schedule rather than in crisis mode.
By investing in modern predictive maintenance and smarter water network management, utilities can significantly reduce burst mains and ensure a resilient water supply system for years to come.
The message is clear: understanding the causes and taking action early is the best recipe for keeping the water flowing and avoiding the costly consequences of water main breaks.
If you require any information on managing your ageing buried pipe network, or wish to discuss possible options to improve asset intelligence or help prioritise replacements, please contact us today.
As water scarcity intensifies and ageing infrastructure poses increasing challenges, traditional water management methods are no longer sufficient.
Utilities need innovative solutions to manage water networks more effectively, efficiently, and sustainably.
Smart water technology is transforming the water sector, enabling utilities to monitor, predict, and respond to issues in real-time.
By leveraging advanced data-driven tools, smart water systems offer unparalleled insights, helping utilities shift from reactive responses to proactive management.
Let’s explore the benefits of smart water technology, the steps for successful implementation, and the challenges utilities may encounter—along with how Aqua Analytics can help overcome them.
Implementing smart water technology provides measurable improvements, including:
Advanced leak detection systems pinpoint leaks faster, minimising water loss.
By integrating IoT-enabled sensors and real-time monitoring, utilities can identify even small, hard-to-detect leaks, significantly reducing unaccounted-for water.
These systems also allow for trend analysis, helping utilities predict and address problem areas before leaks occur.
Predictive maintenance and operational efficiency reduce costly emergency repairs and downtime.
With smart water technology, utilities can schedule maintenance based on pipeline conditions rather than fixed intervals, preventing failures and reducing the costs associated with reactive repairs.
Automated systems also cut down on labour expenses tied to manual inspections.
Real-time data allows for better planning and response strategies.
By leveraging AI-driven analytics, utilities can prioritise critical areas in their networks, allocate resources effectively, and model scenarios to prepare for potential risks.
This ensures faster decision-making in emergencies and optimises day-to-day operations.
By conserving water resources and optimising energy usage, utilities align with environmental goals.
Smart water technology enables utilities to track their environmental impact more accurately, from carbon emissions tied to energy use to water saved through efficient management.
These insights empower utilities to meet sustainability benchmarks and comply with environmental regulations more effectively.
Implementing smart water technology doesn’t happen overnight, but breaking the process into clear, manageable steps can make the journey much smoother.
We recommend you follow these steps when implementing smart water technology:
By following these steps, you can ensure a seamless transition to smarter, more efficient water network management.
With the right tools and a clear plan, your network will be better equipped to tackle today’s challenges and prepare for tomorrow’s demands.
At Aqua Analytics, we specialise in implementing smart water technologies tailored to the specific needs of utilities and councils. Our services include:
As a trusted partner for water utilities and councils across Australia and New Zealand, Aqua Analytics brings unparalleled expertise to smart water technology implementation.
Our smart water management solutions include:
Our commitment to reducing water loss, improving operational efficiency, and enabling sustainable practices has established us as industry leaders.
Whether you’re looking to modernise your water network, optimise resources, or reduce NRW, Aqua Analytics delivers solutions that drive measurable results.
Contact us today to learn how smart water technology can transform your water network.
Have you ever wondered how important water management is for our daily lives and the environment? The precision in managing and distributing water across cities hinges significantly on properly calibrating hydraulic models. This intricate process ensures that every drop of water reaches its destination efficiently and sustainably. In this blog, we’ll explore why understanding and implementing hydraulic model calibration in water networks is indispensable.
Hydraulic model calibration fine-tunes the predictive capabilities of water distribution systems. This calibration ensures that the models accurately reflect real-world conditions, thus improving the reliability of the water distribution analyses.
Optimising the performance of water distribution systems through hydraulic model calibration enhances operational efficiency and ensures reliability across the network. Regular calibration helps identify and rectify discrepancies between model predictions and actual system behaviours, thereby optimising the functionality of the entire network.
This proactive approach allows utilities to manage pressures. It flows more effectively, reduces instances of pipe bursts or overflows and ensures that water reaches all end-users with consistent quality and quantity.
Moreover, a well-calibrated hydraulic model can significantly aid in the planning and implementing system expansions or upgrades, making it a critical practice for maintaining a robust and efficient water distribution infrastructure.
Efficient hydraulic models are crucial for detecting leaks and potential failures in the network. This not only saves water but also reduces costs associated with water loss. Understanding system performance is critical for the design and implementation of District Metered Areas (DMAs).
Sustainability in water management is crucial for resource conservation and environmental protection. Calibrated hydraulic models play a significant role in achieving these goals.
Enhancing emergency response readiness is a critical aspect of managing water distribution systems, and hydraulic model calibration plays a pivotal role in this process.
With calibrated hydraulic models, water utilities and councils are equipped to quickly and accurately assess and respond to various emergencies, such as pipe failures, contamination events or sudden changes in demand due to environmental factors.
These models provide a reliable framework to simulate and predict different scenarios, ensuring the water supply remains secure and manageable under adverse conditions. This readiness protects the public and the environment and maintains the integrity and resilience of the water infrastructure.
The future of water network infrastructure lies in the ability to predict and preempt issues before they escalate. Here’s how hydraulic model calibration aids in this process:
Calibrating hydraulic models of water networks is a strategic imperative that enhances system accuracy, efficiency and sustainability while ensuring cost-effectiveness and emergency preparedness.
With the high stakes, prioritising hydraulic model calibration in your water management strategy is essential.
At Aqua Analytics, we focus on providing cutting-edge smart water solutions that enhance the efficiency and sustainability of water management systems. Our approach to hydraulic model calibration is designed to improve your water networks’ accuracy and efficiency while contributing to more cost-effective environmental practices. We own and operate a large fleet of IoT flow and pressure loggers to assist with turn-key model calibration projects across Australia and New Zealand.
Explore our services to see how they align with your water management objectives. Contact us today for more details on how we can support your infrastructure needs.
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