The water now enters more than 2 million miles of underground transmission and distribution lines. Some of the nation's oldest pipes were laid in the 19th century, and pipes laid after World War II have an average lifespan of 75 to 100 years, so many of even the newer segments are reaching, or have reached, the end of their design life.7
A 2023 Utah State University survey of 802 utilities, covering about 400,000 miles of mains, found cast iron still makes up 23% of pipe, with 86% of it over 50 years old. Cast iron had the highest failure rate of the common materials, 28.6 breaks per 100 miles per year, against an overall average of 11.1; across the United States and Canada that works out to roughly 260,000 water main breaks a year.8
What happens inside the pipe is the point of this page. EPA describes how poor corrosion control leaves thick corrosion layers or tubercles and scale, and corrosion-related sediment; these deposits accumulate organic sediments that act as a habitat and nutrients for bacteria, and corrosion tubercles can contain more coliform bacteria than finished water.9
Loose sediment accumulates in the low-velocity zones, dead ends and reservoirs of a distribution system. It is made of silt, dirt and organics from the source, minerals such as iron and manganese, corrosion by-products, and cell debris that grows and detaches inside the pipes; if it remains loose, it may travel within the distribution system due to changes in flow velocity and/or direction.10 That is why a main break, a hydrant opened for firefighting or flushing, or a pressure swing can send brown water down the street. Flushing is also how utilities deliberately scour pipe surfaces and remove loose sediment, biofilm and scale; depending on the velocity, it can loosen and mobilize sediment in the pipe without fully removing it.11