Water main breaks can be highly disruptive, leading to water supply interruptions, property damage, and costly repairs. In North America alone, approximately 260,000 water main breaks occur every year, costing municipalities an estimated $2.6 billion annually in repairs and lost water. While some breaks are unavoidable, many can be prevented through regular inspections, proactive maintenance, and improved pipeline materials.  

1. Cold Weather & Freeze-Thaw Cycles 

In colder climates, seasonal temperature fluctuations put pipelines at higher risk of breaking. During extreme cold snaps, water can freeze inside or around pipes, expanding by 9% in volume, creating additional pressure. This stress can cause brittle pipes to crack, leading to a rupture. 

Notable Example:

In February 2025, it is stated that the probable cause of the Detroit water main leak is aging infrastructure combined with freezing temperatures.

How to Lower the Risk: 

• Use modern pipeline materials that are more resistant to freeze-thaw cycles, such as high-density polyethylene (HDPE) and PVC.  PICA’s non-metallic service solution identifies and quantifies defects in non-metallic pipes. With access through manholes, clean-outs, or ARVs, PICA’s high-resolution pipeline inspection technology can accurately size defects with great precision.
• Insulate exposed pipelines or bury them deeper below the frost line. 
• Conduct routine winter inspections to monitor vulnerable sections. 

2. Corrosion & Pipeline Deterioration 

Internal and external corrosion is a major cause of water main failures. Over time, materials like ductile iron, cast iron, and steel can deteriorate due to exposure to moisture, soil acidity, and chemical contaminants. Once corrosion weakens the pipe walls, small cracks turn into leaks, and leaks escalate into major ruptures. 

Statistic:

In the U.S., corrosion accounts for nearly 50% of water pipeline failures (EPA). 

Notable Example:

In June 2024, the City of Calgary experienced a major water main failure due to a combination of soil chemicals, minor fractures in the pipe’s outer coating, and the effects of corrosion and embrittlement, which led to wire breakage.  

How to Lower the Risk: 

• Implement a corrosion protection system, such as cathodic protection or protective coatings. 
• Conduct regular NDT (Non-Destructive Testing) inspections to identify thinning walls and corrosion spots before failures occur. PICA’s NDT provides high-resolution pipeline inspection and condition analysis using Remote Field Eddy Current (RFT/RFEC) technology, delivering precise measurements of wall thickness, detecting internal and external corrosion, cracks, and stress concentrators, and identifying critical failure locations for accurate integrity assessment of metal and pressurized concrete pipes.

3. Aging Ductile & Cast Iron Pipelines 

While cast iron pipelines (widely used before the 1970s) are extremely strong, they lack flexibility and become brittle over time. This makes them more susceptible to cracking due to ground movement or freeze-thaw cycles. Newer ductile iron pipes offer more flexibility but are thinner than cast iron and more prone to faster corrosion if left unprotected. 

Statistic:

More than 30% of North America’s water mains are over 50 years old, increasing failure risks (ASCE Infrastructure Report). 

How to Lower the Risk: 

• Replace aging cast iron pipelines with more resilient materials like PVC, HDPE, or lined ductile iron. 
• Conduct regular condition assessments using acoustic leak detection and remote field testing (RFT) to identify early signs of deterioration. 
• One RFT service application for metallic pipes is the  detection of localized corrosion in metal cylinders, even through various internal liners, for pipe sizes 3 inches in diameter and larger, in both winched and free-swimming inspection setups.

4. Soil Conditions & Ground Movement 

The acidity and moisture levels in surrounding soil can significantly impact the longevity of underground pipes. Expansive clay soils, shifting sands, and areas with high water tables can put stress on water mains. 

Statistic:

A total of 75% of utilities reported one or more areas with corrosive soil conditions. Soil-related corrosion contributes to 20-30% of water main failures in high-risk regions.  

How to Lower the Risk: 

• Apply external corrosion protection, such as polyethylene encasement or protective coatings. 
• Conduct geotechnical assessments before installation to select the best materials for specific soil conditions. 
• PICA’s RFT service technology can  assess the impact of soil acidity and moisture on underground pipes by detecting internal and external corrosion, measuring wall thickness, identifying stress concentrators, and providing accurate integrity assessments for proactive maintenance and extended pipeline longevity.

5. Construction Damage & Human Error 

Excavation, roadwork, and utility projects pose a serious risk to underground water mains. A construction crew striking a pipe can cause an immediate rupture or create microfractures that lead to future failures. 

Statistic:

Studies suggest that between 700 and 850 water main breaks occur each day in North America, causing more than $3 billion in repair costs annually. 

Notable Example:

In February 2024, Ottawa, Canada, experienced a critical water main break, prompting an emergency response and a temporary no-dig order to prevent further damage.

How to Lower the Risk: 

• Before digging, use “Call Before You Dig” services to locate water pipelines. 
• Municipalities should use GIS mapping and 3D pipeline location tools to keep accurate records of underground infrastructure. 
• See how PICA’s RFT’s inspection tools brilliantly performed in blind verification testing with AWWA C303 Bar Wrapped Pipe.

Notable Water Main Break Incidents 

• Detroit, USA (2025) – A corroded pipe failure flooded homes and required extensive emergency repairs. 
• Ottawa, Canada (2024) – A major water main burst under downtown streets, disrupting thousands of residents and businesses. 
• City of Calgary (2024)- The City experienced a catastrophic water main break in the Bearspaw South Feeder Main caused by a mix of chemicals in soil, small cracks in the pipe’s outer layer, and corrosion and embrittlement that caused wires to snap. 
• New York City (2023) – A 48-inch water main break sent millions of gallons of water into the subway system, causing transit shutdowns. 

Conclusion   

Water main breaks pose a significant challenge for cities and utilities across the globe, leading to service disruptions, property damage, and expensive repairs. These failures can strain municipal resources and inconvenience thousands of residents and businesses, particularly in regions with aging infrastructure.

However, implementing proactive maintenance strategies, conducting regular pipeline inspections, and selecting improved material selection can greatly minimize the occurrence and impact of such failures. 

By investing in modern advanced non-destructive testing (NDT) technologies, municipalities can detect early signs of wear, corrosion, and structural weaknesses before they develop into major breaks.

Additionally, integrating GIS-based pipeline monitoring systems allows utilities to track the condition of underground water networks in real time, enabling data-driven decision-making for repairs and replacements.

These modern approaches not only enhance the longevity and resilience of water infrastructure but also reduce long-term costs and ensure a more reliable water supply for future generations.