About The Facility
This manufacturing facility is a major commercial aircraft assembly and delivery site located in the Southeastern region of the US. As one of the largest employment centers in the state, the campus plays a critical role in aerospace manufacturing operations and relies on strict industrial water quality management protocols to protect both product integrity and workforce safety.
The Problem
During a period of active construction, the facility faced an increased risk of building water system disruption, a common but often underestimated threat to water quality. Routine microbial water testing of water used in aircraft processes detected elevated levels of Pseudomonas, raising immediate health, safety, and regulatory compliance concerns.
Further investigation into the facility’s plumbing infrastructure and hot water systems uncovered red clay sediment inside multiple water heaters. This sediment indicated that nearby construction activity likely caused underground pipe disturbances, pressure fluctuations, or debris infiltration. These conditions created an environment favorable to microbial growth in water systems, which shows how construction projects can directly impact water safety and compliance if not proactively managed.
IWC's Approach
To mitigate risk and restore water quality, the facility partnered with IWC to conduct a remediation of the affected potable water system. During the remediation process, the hot water storage tank was isolated and drained, revealing significant sediment accumulation and discoloration that supported findings from the root cause investigation.
A full-system disinfection was then performed using a hyperchlorination process. Disinfectant solutions were injected directly into the building’s incoming water supply and circulated throughout the potable water system. Water quality specialists verified that disinfectant residuals reached all distal outlets, including sinks, showers, safety stations, hose bibs, and aircraft water fill pits. The system was maintained at elevated disinfectant levels for several hours in accordance with industry sanitization protocols before being thoroughly flushed and tested to restore normal operating conditions.
Following remediation, the facility implemented point-of-use (POU) water filters on outlets in affected areas as an additional layer of protection against bacteria and sediment. These filters provide an immediate physical barrier while supporting ongoing microbial control efforts and are replaced on a routine schedule to maintain performance.
The facility also launched an enhanced water management and monitoring program that included routine microbial testing, disinfectant residual verification, fixture flushing procedures, and preventive maintenance for hot water equipment. Recommendations included regular draining and flushing of hot water storage tanks to reduce sediment buildup, periodic pathogen testing, and continued oversight in alignment with industry water management guidance.
The Results
- Implemented point-of-use filtration and enhanced water quality monitoring, resulting in consistently safe and compliant water conditions across the campus.
- Ongoing microbiological testing and regulatory compliance monitoring have confirmed all parameters remain within acceptable limits, with no recurrence of elevated Pseudomonas levels.
- These sustained results demonstrate the effectiveness of a structured industrial water management plan in protecting critical manufacturing operations.
Conclusion
This case study demonstrates how construction activity can quickly compromise building water systems and increase the risk of waterborne pathogens in industrial environments. By conducting a thorough root cause investigation, implementing point-of-use filtration, and strengthening its water quality monitoring and compliance program, the facility not only resolved the immediate issue but also enhanced the long-term resilience of its industrial water management system.
Today, the campus maintains reliable, compliant water quality standards, while supporting operational continuity, and regulatory compliance.
