Challenge
During maintenance at a project site, a pedestrian was injured when stepping onto a cast iron meter cover that dislodged and flipped vertically, exposing the opening of the meter box. The installation paired an HDPE meter box with a cast iron cover that was not designed for use together, creating excessive lateral movement and instability.
Technical Analysis & Recommended Approach
Back Municipal Consulting conducted a technical review and identified critical deficiencies:
- Component Mismatch – The HDPE meter box and cast iron cover were not compatible by design. The cover lacked proper cleats or webbing to prevent lateral shifting.
- Improper Installation & Inspection – The cover was not secured to the box. Safe installation would have required a properly sized HDPE cover, an oversized cast iron cover seated beyond the rim, or a bolted riser system.
- Violation of Standards & Practices – Placement of the meter box in a pedestrian pathway without protective measures violated accepted utility practices requiring accessibility without creating hazards.
- Oversight Failures – The unstable condition should have been detected at installation or during subsequent inspections. Reliance on a material supplier did not relieve the utility of its responsibility to ensure safe, compatible equipment.
Outcome & Industry Implications
BMC concluded the incident was entirely preventable. Key lessons for the industry include:
- Always verify component compatibility during design and installation.
- Conduct thorough inspections at commissioning and throughout service life.
- Consider pedestrian traffic patterns when siting meter boxes and covers.
- Train staff to recognize and correct unsafe conditions before they result in injury.
BMC’s Role
As an expert consultant, BMC provided engineering analysis and testimony demonstrating how mismatched components, inadequate inspection, and poor siting practices created the failure. Referencing ASTM standards, NASSCO inspection protocols, and accepted utility practices, BMC reinforced the importance of proper design, installation, and QA/QC oversight in preventing such incidents.
