UNDER REVIEW — As part of its preliminary design on a project to replace cast iron and galvanized pipe in Weirton’s distribution system, the Weirton Area Water Board has been working with Thrasher Engineering to map such lines still in use in the city. -- Craig Howell

WEIRTON — Last year, the Weirton Area Water Board was ordered to design and implement a project to replace all cast iron and galvanized lines in the city’s water distribution system, following an investigation into widespread outages and boil orders in early 2025.

Now, officials have an idea of what such a project will cost.

Since the order was issued last summer by the West Virginia Public Service Commission, the Water Board has been working with Thrasher Engineering on a preliminary engineering report for the project, which includes early designs and costs.

Part of those plans included taking a count of the number, type, and distance of each pipe in the system.

“We’ve got the mapping prepared,” Jesse Alden, project manager for Thrasher, said. “We have finalized the inventory.”

According to Alden, the inventory notes approximately 500,000 linear feet, or approximately 95 miles, of cast iron or galvanized pipe, with a replacement cost of close to $190 million.

“That estimate is all based on the mapping we have and the Street View from Google Earth,” Alden said, noting such lines are spread throughout the city. “It’s pretty extensive across the system.”

A field verification study will be implemented in the coming months to verify those lines and assist with establishing a better cost estimate, but officials anticipate it being close to the current estimate.

Ward 6 Councilman Anthony Rocchio, who serves as an ex officio member of the board, asked if any potential rate increase had been established to fund the project.

“It’s not funny,” he said. “You have to throw it on the residents.”

Utilities Director A.D. “Butch” Mastrantoni explained the board is hoping for assistance on the project, whether through state or federal grants, loans or other funding programs, to cut down on any local costs, but it will be some time before any of that can be determined.

Alden, though, said there are several such programs for which Weirton doesn’t qualify because of the ratio between the city’s median house income and water rates. He said they will look at every avenue available to the board as the process moves forward.

“Every funding program has its requirements,” he said.

Board member Joe Paolo asked about the likelihood of receiving federal assistance, given the Water Board received $22.47 million in Congressionally Directed Spending as part of the funding package for the water treatment plant expansion project, and other funding for the wastewater treatment plant project for the Sanitary Board.

“We had a hell of a lot of help on those projects,” Paolo said. “Would they be willing to come back at that kind of level?”

Ben Erste, of the Brooke-Hancock-Jefferson Metropolitan Planning Commission, noted there are processes remaining before the board can even begin seeking such financial aid.

Officials also have to determine how to approach dividing up the project; whether to bid everything out as one complete package, or whether to offer separate bids based on geographic areas of the city.

Board member Ronnie Jones emphasized the importance of replacing 2 inch lines, which officials previously have explained makes up the majority of the distribution system.

“That’s the one that needs to be done,” Jones said.

Not all lines in the system will be in need of replacement.

Mastrantoni explained the Water Board has had a line replacement program, implemented 10 years ago, which was designed to take a phased approach by addressing some of the worst areas of the city, as funds were available.

“The replacement of those lines was done with PVC,” Mastrantoni said.

The water board has to have its final preliminary engineering report submitted to the state by June, with estimates of being able to begin the bidding process in December 2027, begin construction in June 2028 and complete construction in June 2029.

In its order last summer, the PSC gave the board a five-year window to have the project complete.