# UGI Utilities, Inc., Natural Gas Distribution Pipeline Explosion and Fire

- **operation:** document
- **citation:** DCA94MP003
- **title:** UGI Utilities, Inc., Natural Gas Distribution Pipeline Explosion and Fire
- **source type:** incident
- **agency:** National Transportation Safety Board
- **status:** current
- **official:** true
- **published on:** 1994-06-09
- **effective on:** 1994-06-09
- **summary:** Accident. in Allentown, PA, USA. on 1994-06-09. UGI Utilities, Inc.,. Leak/explosion/fire
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- **app url:** https://regulus.evalyn.ai/document/ntsb-case-dca94mp003
- **source url:** https://www.ntsb.gov/investigations/Pages/DCA94MP003.aspx
**body:**

NTSB investigation DCA94MP003.

Event Type: Accident

Event Date: 1994-06-09

Event City: Allentown

Event State Or Region: PA

Event Country: USA

Pipeline Operator: UGI Utilities, Inc.,

Pipeline Type: Distribution

Accident Type: Leak/explosion/fire

Completion Status: Ongoing

Tier1Name: Construction

Tier2Name: External/third-party damage

Official NTSB investigation data. NTSB findings determine probable cause and make safety recommendations; they do not adjudicate civil liability or regulatory violations.

What Happened
About 6:45 p.m. on June 9, 1994, a 2-inch-diameter steel gas service line that had been exposed during excavation separated at a compression coupling about 5 feet from the north wall of John T. Gross Towers, an eight-story retirement home operated by the Allentown Housing Authority at Allentown, Pennsylvania. The failed UGI Utilities, Inc., service line released natural gas at 55 psig pressure, and the escaping gas flowed underground to Gross Towers. The gas passed through openings in the building foundation, entered the mechanical room through floor vents, and migrated to other building floors.
An Environmental Preservation Associates, Inc., employee, who had been using a backhoe to excavate fuel-contaminated soil from the area, detected the odor of gas and heard a third-floor resident shout that she smelled a strong gas odor. The employee went to a building entrance and encountered a very strong odor of natural gas. He told his foreman, who, after having the backhoe shut down, telephoned the gas company and the housing authority, telling them of the gas odor. The foreman then instructed other employees to locate and shut off the gas line valve.
About 6:58 p.m., the natural gas that had accumulated within the building was ignited, causing an explosion. A second explosion occurred about 5 minutes later. At the time of the explosion, many of the Gross Towers and Towers East residents were out of the building. The accident resulted in 1 fatality, 66 injuries, and more than $5 million in property damage

What We Found
We determined that the probable cause of
the natural gas explosion and fire at Gross Towers in Allentown, Pennsylvania, was the failure of the management of Environmental Preservation Associates, Inc., to ensure compliance with OSHA's and its own excavation requirements through project oversight.

Contributing to the accident was the failure of the workmen from Environmental Preservation Associates, Inc., to notify UGI Utilities, Inc., that the line had been damaged and was unsupported.
Contributing to the severity of the accident was the absence of an excess flow valve or a similar device, which could have rapidly stopped the flow of gas once the service line was ruptured. Also contributing to the severity of the accident was the absence of a gas detector, which could have alerted the fire department and residents promptly when escaping gas entered the building.

What We Recommended
As a result of this investigation, we made the following new safety recommendations.

To the Research and Special Programs Administration: Require gas-distribution operators to notify all customers of the availability of excess flow valves; any customer to be served by a new or renewed service line with operating parameters that are compatible with any commercially available excess flow valve should be notified; an operator should not refuse to notify a customer because of the customer’s classification or the diameter or operating pressure of the service line. (P-96-2)

To the States and the District of Columbia.: Require gas distribution operators to install excess flow valves in all new or renewed gas service lines, when operating conditions are compatible with commercially available valves, including service lines supplying schools, churches, and other places of public assembly.(P-96-3)

To the UGI Utilities, Inc.:
Require that people handling emergency calls determine whether escaping gas is likely to enter a structure, and if so, require that the information be quickly conveyed to “911.” (Class II, Priority Action) (P-96-4)
Modify its excavation-damage prevention program to include the review and close monitoring of any proposed excavation near a gas service line, including any line with unanchored compression couplings, that is installed near a building and that, if damaged, might endanger public safety significantly. (P-96-5)
Instruct members of local governments and contractor groups in its service area about the threat to public safety posed by a gas line that is unsupported or damaged, and emphasize the importance of reporting such information immediately to the facility owner. (P-96-6)

To Environmental Preservation Associates, Inc.: Instruct its employees on actions to take when buried facilities, such as gas lines, are unsupported or damaged; such actions should include alerting local response agencies and residents of threatened buildings, initiating evacuations, and notifying facility owners. (P-96-7)

To the Governor of the Commonwealth of Pennsylvania:
Require any person or entity that excavates to participate in the State's excavationdamage prevention program.(P-96-8)
Designate a single State agency responsible for the State's excavation-damage prevention program; give the agency the power to levy administrative penalties. (P-96-9)
Require each contractor to outline the area of the proposed excavation before asking the facility operators to mark the locations of their facilities.(P-96-10)

To the City of Allentown:
Instruct fire and other city inspectors to advise facility owners, such as gas companies, immediately about any suspected damage to their buried facilities or any lack of structural support. (P-96-11)
Require as an excavation-permit condition that the excavator instruct his workmen in how to help members of the public in the immediate vicinity of an emergency, how to notify the local response agencies and the owner of a damaged facility, and how to evacuate anyone who might be in danger. (P-96-12)

To the International Association of Fire Chiefs: Urge its members to instruct their inspectors to report observed or suspected damage to a buried facility, including lack of support, to the owner immediately.(P-96-13)

To the Department of Housing and Urban Development: Require the installation of excess flow valves in new and renewed gas services to buildings that the Department has approved for Federal rent subsidies. (P-96-14)

PAR-96-01
<<<PAGE 1>>>

PB96-916501
NTSB/PAR-96/01
NATIONAL
TRANSPORTATION
SAFETY
BOARD
WASHINGTON, D.C. 20594
PIPELINE ACCIDENT REPORT
UGI UTILITIES, INC., NATURAL GAS DISTRIBUTION
PIPELINE EXPLOSION AND FIRE
ALLENTOWN, PENNSYLVANIA
JUNE 9, 1994
/
B(-)
,, ,—, ‘
6652
-------

<<<PAGE 2>>>

Abstract: On June 9, 1994, a 2-inch-diameter steel gas service line that had been exposed during
excavation separated at a compression coupling about 5 feet from the wall of a retirement home
in Allentown, Pennsylvania. The escaping gas flowed underground, passed through openings in
the building foundation, migrated to other floors, and exploded. The accident resulted in 1
fatality, 66 injuries, and more than $5 million in property damage.
In its investigation of this accident, the Safety Board identified safety issues relating to pipeline
excavation damage prevention and rapid shut down of failed gas service lines.
As a result of its accident investigation, the National Transportation Safety Board issued safety
recommendations to the Research and Special Programs Administration, the Sates and the
District of Columbia, UGI Utilities, Inc., Environmental Preservation Associates, Inc., the
Governor of the Commonwealth of Pennsylvania, the city of Allentown, the International
Association of Fire Chiefs, the Department of Housing and Urban Development, the Allentown
Housing Authority, the Associated General Contractors, and the National Utility Contractors
Association.
The National Transportation Safety Board is an independent Federal agency dedicated to promoting
aviation, railroad, highway, marine, pipeline, and hazardous materials safety. Established in 1967,
the agency is mandated by Congress through the Independent Safety Board Act of 1974 to
investigate transportation accidents, determine the probable causes of the accidents, issue safety
recommendations, study transportation safety issues, and evaluate the safety effectiveness of
government agencies involved in transportation. The Safety Board makes public its actions and
decisions through accident reports, safety studies, special investigation reports, safety
recommendations, and statistical reviews.
Information about available publications may be obtained by contacting:
National Transportation Safety Board
Public Inquiries Section, RE-51
490 L'Enfant Plaza, S.W.
Washington, D.C. 20594
(202) 382-6735
Safety Board publications may be purchased, by individual copy or by subscription, from:
National Technical Information Service
5285 Port Royal Road
Springfield, Virginia 22161
(703) 487-4600

<<<PAGE 3>>>

UGI UTILITIES, INC., NATURAL GAS
DISTRIBUTION PIPELINE
EXPLOSION AND FIRE
ALLENTOWN, PENNSYLVANIA
JUNE 9, 1994
PIPELINE ACCIDENT REPORT
Adopted: February 26, 1996
Notation 6652
NATIONAL
TRANSPORTATION
SAFETY BOARD
Washington, DC 20594

<<<PAGE 4>>>



<<<PAGE 5>>>

CONTENTS
EXECUTIVE SUMMARY
INVESTIGATION
The Accident
Postaccident Events ...
Community Response..
Police
Fire
Medical
Housing Authority.
Preaccident Events........
Injuries
Medical and Pathological
12
Pipeline Damage
12
Postaccident Site Inspection.
12
Other Damage
13
Personnel
14
Pipeline System Information..
15
System Ownership
15
Gas Service Line History..
15
Applicable UGI Operations ...
16
EFVs
16
Excavation-Damage Prevention Plan.
17
Emergency Plan..
19
Employee Training for Emergencies..
19
Emergency Preparedness...
20
Housing Authority
21
Operations
21
Emergency Preparedness.
21
EPAI Procedures
22
Drug and Alcohol Policy.
22
Health and Safety Program
22
Regulations and Oversight
23
Pennsylvania
24
Damage-Prevention Statute.
24
Pipeline Safety Oversight..
25
OSHA Requirements
27
Excavation-Damage Prevention..
27
Postaciens isis and insper and inforeme...
27
29
29
Pipe Inspection
Gas Leakage Tests......
29
iii

<<<PAGE 6>>>

Metallurgy ............................................................................................................. 29
Phone Records....................................................................................................... 30
ANALYSIS ................................................................................................................... 31
Exclusions ................................................................................................................... 31
The Accident ................................................................................................................... 31
Emergency Response......................................................................................................... 32
Human Performance and EPAI Workcrew ....................................................................... 32
General .................................................................................................................. 32
Training ................................................................................................................. 34
Preaccident Events ................................................................................................ 35
UGI Operations and Procedures........................................................................................ 35
General .................................................................................................................. 35
Excavation-Damage Prevention............................................................................ 35
Damage Notification ............................................................................................. 36
Rapid Shutdown of Failed Service Lines.............................................................. 36
Pennsylvania’s Pipeline Safety Operations ....................................................................... 37
Premarking Proposed Excavations........................................................................ 37
Excavation-Damage Prevention Program ............................................................. 38
Housing Authority Standards ............................................................................................ 38
Detection of Released Gas .................................................................................... 38
Rapid Shutoff of Failed Service Lines .................................................................. 39
Rapid Shutdown of Failed Service Lines.......................................................................... 40
Excavation-Damage Prevention........................................................................................ 44
CONCLUSIONS ................................................................................................................... 47
PROBABLE CAUSE ................................................................................................................... 48
RECOMMENDATIONS .............................................................................................................. 49
APPENDIX A: Investigation and Hearing.................................................................................... 53
APPENDIX B: Rapid Shutdown of Failed Service Lines............................................................. 55
APPENDIX C: Time Line of Events ............................................................................................ 79
APPENDIX D: September 28, 1995, Letter to RSPA from Safety Board.................................... 83
APPENDIX E: Gas Piping Technical Committee Excavation Damage Prevention Guidelines
iv

<<<PAGE 7>>>

EXECUTIVE SUMMARY
About 6:45 p.m. on June 9, 1994, a 2-inch-diameter steel gas service line that had
been exposed during excavation separated at a compression coupling about 5 feet from
the north wall of John T. Gross Towers, an eight-story retirement home operated by the
Allentown Housing Authority at Allentown, Pennsylvania. The failed UGI Utilities, Inc.,
service line released natural gas at 55 psig pressure, and the escaping gas flowed
underground to Gross Towers. The gas passed through openings in the building
foundation, entered the mechanical room through floor vents, and migrated to other
building floors.
An Environmental Preservation Associates, Inc., employee, who had been using a
backhoe to excavate fuel-contaminated soil from the area, detected the odor of gas and
heard a third-floor resident shout that she smelled a strong gas odor. The employee went
to a building entrance and encountered a very strong odor of natural gas. He told his
foreman, who, after having the backhoe shut down, telephoned the gas company and the
housing authority, telling them of the gas odor. The foreman then instructed other
employees to locate and shut off the gas line valve.
About 6:58 p.m., the natural gas that had accumulated within the building was
ignited, causing an explosion. A second explosion occurred about 5 minutes later. At the
time of the explosion, many of the Gross Towers and Towers East residents were out of
the building. The accident resulted in 1 fatality, 66 injuries, and more than $5 million in
property damage.
The National Transportation Safety Board determines that the probable cause of
the natural gas explosion and fire at Gross Towers in Allentown, Pennsylvania, was the
failure of the management of Environmental Preservation Associates, Inc., to ensure
compliance with OSHA's and its own excavation requirements through project oversight.
Contributing to the accident was the failure of the workmen from Environmental
Preservation Associates, Inc., to notify UGI Utilities, Inc., that the line had been damaged
and was unsupported.
Contributing to the severity of the accident was the absence of an excess flow
valve or a similar device, which could have rapidly stopped the flow of gas once the
service line was ruptured. Also contributing to the severity of the accident was the
absence of a gas detector, which could have alerted the fire department and residents
promptly when escaping gas entered the building.
v

<<<PAGE 8>>>

In its investigation of this accident, the Safety Board identified safety issues
relating to pipeline excavation damage prevention and rapid shut down of failed gas
service lines.
As a result of its accident investigation, the Safety Board issued safety
recommendations to the Research and Special Programs Administration, the Sates and the
District of Columbia, UGI Utilities, Inc., Environmental Preservation Associates, Inc., the
Governor of the Commonwealth of Pennsylvania, the city of Allentown, the International
Association of Fire Chiefs, the Department of Housing and Urban Development, the
Allentown Housing Authority, the Associated General Contractors, and the National
Utility Contractors Association.
vi

<<<PAGE 9>>>

INVESTIGATION
The Accident
About 6:45 p.m. on June 9, 1994, a 2-inch-
diameter steel gas service line that had been
exposed during excavation separated at a
compression coupling1 about 5 feet north of the
north wall of the John T. Gross Towers (Gross
Towers), an eight-story retirement home. Gross
Towers, located at 14th and Allen Streets (1339
Allen Street), is one of several subsidized-rent
residence buildings operated by the Allentown
Housing Authority (housing authority) in
Allentown, Pennsylvania. Towers East, a 13-story
building that is connected to Gross Towers, is also
a rent-subsidy building for senior citizens that is
operated by the housing authority. (See figure 1.)
The separated service line, which was
owned by UGI Utilities, Inc., (UGI) released
natural gas at 55 psig pressure. The escaping gas
flowed underground to Gross Towers, where it
passed through openings in the building’s
Figure 1. Accident Location
foundation and filled the space beneath the
mechanical room, which served as a combustion
air intake reservoir for boilers. (See figure 2.) Gas then entered the mechanical room through
openings in the floor. The gas then migrated to the building’s other floors through an adjacent
tower that housed the boiler exhaust stacks, through a trash chute, and through floor openings for
electrical and other building services.
At the same time, a backhoe operator, an employee of the Environmental Preservation
Associates, Inc., (EPAI), was removing fuel-contaminated soil from the excavation site and
detected the odor of gas coming from the building. He heard a woman in a third-floor apartment
shout to him about a heavy gas odor. The loader, another EPAI employee, opened a
1A compression coupling joins lengths of pipe by applying mechanical pressure through a gasket to the end surfaces
of pipe lengths sufficient to retain the pipe lengths against movement for a specific internal gas pressure and to seal the
joint against gas leakage. If the forces on the pipe are expected to be greater than the retaining capability of the coupling,
the pipes are to be anchored or otherwise prevented from moving out of the coupling.

<<<PAGE 10>>>

—
B NORTH WALL OF
~ GROSS TOWERS
GAS
METER
GAS SERVICE
RISER
m
x
z
r
1ST FLOOR z
x PARKING LOT
L
SPACE UNDER x
MECHANICAL ROOM x COMPRESSION
x COUPLINGS GAS SERVICE LINE
x
\~n a-r 80UlH N~
GAS
MAIN
L O C A T I O N F O R E F V HAD IT BEEN INSTALLED
v -
4FT. 11 IN.
Figure 2. Schematic of Gas Service Line

<<<PAGE 11>>>

side door to the building that led to the boiler room and encountered a very heavy gas odor that
"took my breath away." He told his foreman of his observation, and the foreman told the backhoe
operator to shut off the machine.
The foreman said that he then went to his pickup truck and, using his cellular phone,2
called the gas company and the housing authority, telling them that he was excavating near the
gas line and smelled gas. He stated that he next made three attempts to phone "911." He said that
each time he called, there was no answer. He said he then moved his truck to another spot in the
parking lot in case the phone signal to his cellular phone was being blocked. He said that at the
new location he again tried unsuccessfully to call "911."
According to the UGI’s records, the foreman's call was answered at 6:48 p.m. by UGI's
Central Gas Control at Reading, Pennsylvania. According to the UGI’s records, the foreman said
that there was a gas leak at 1337 (Allen Street) Gross Towers in Allentown and that the gas line
had been hit during digging. (The foreman acknowledged telling the UGI that he was digging
near the gas line and had detected the odor of gas, but said that he did not tell the UGI that he had
"hit" the gas line.) At 6:52, the UGI received a second call, which was apparently from the
foreman. The call was recorded as "Cust [customer] just called back, said they definitely hit gas
line and broke it." The UGI's procedures did not require Gas Control to notify the Allentown fire
department or any other emergency-response agency of either report about the release of gas
because the caller did not indicate there was an imminent threat; consequently the fire department
was not called.
According to the housing authority’s records, the foreman called the housing authority at
6:55 and was connected to the after-hours answering service. The answering service’s records
show that the foreman advised that "they [the EPAI] were digging and they think they got the gas
line." At 7:06, according to the answering service, the foreman's message was relayed to one of
the housing authority's maintenance employees, who promptly went to Gross Towers.
The records of both the UGI and the housing authority of the foreman’s calls do not show
that he said anything about detecting a strong odor of gas within the building.
While he was making the calls, the foreman said, he instructed the operator and the loader
to trace the gas line back toward Utica Street until they found the shutoff valve. They found the
valve near the north edge of the parking lot, but were unable to close it. They lacked the
necessary tools to operate the below-ground valve. (Later, when the fire department
representatives arrived, the EPAI workmen did not tell them they had been unable to close the
valve.)
2Details of the calls to and from the foreman's telephone appear later in the report.
3

<<<PAGE 12>>>

About 6:50, the UGI telephoned its on-call serviceman for the Lehigh Division, which
includes the Allentown area, who was at his residence about seven blocks from Gross Towers.
At 6:55, he left for Gross Towers.
The foreman's calls to Gas Control were relayed electronically to the Lehigh Division
Office, which is staffed by two employees. When the office received the report, an alarm
sounded to tell the office employees that the message was urgent. One of the employees
radioed a construction and maintenance crew that was working about 7 to 8 miles north of
Gross Towers. He directed the crew to respond to the emergency.
About 6:58, the natural gas within the building was ignited by one of several possible
sources common in apartment buildings, such as the electrical arcs that are created when an
electrical appliance or a piece of
equipment is turned on or off. The EPAI
employees stated that after the initial
explosion, a second one occurred about 5
minutes
later.
After the
second
explosion, they observed fire within the
building. The loader said that he thought
the explosion and fire originated in the
area of the boiler room.
At the time of the explosion,
many of the residents of Gross Towers
and Towers East were out of the
building, either attending a nearby Bingo
game, walking around the adjacent
shopping center, or sitting on the front
lawn at the entrance of the building.
which was on the south side.
Postaccident Events
A UGI employee at 12th and
Gordon Streets, about 2 1/2 blocks from
Gross Towers, was
in his truck
Figure 3. Back of Gross Towers after Accident
completing work reports when he heard
an explosion and saw a cloud of dust
rising into the air. Although he was not on call to respond to emergencies, he began driving in
the direction of the dust cloud and radioed his dispatcher to find out whether he had received a
report on the explosion. The dispatcher replied that a gas release had been reported and that a
serviceman was en route. The employee arrived at Gross Towers about 7:03. About a minute

<<<PAGE 13>>>

later, the UGI on-duty serviceman arrived. The two men met with the fire department's
emergency onscene coordinator and received his approval to shut off the gas line.
The UGI employees made their way through the debris to the rear of Gross Towers,
where a natural gas-fed fire burned from the back of the mechanical room. They located the
shutoff valve, near Utica Street, and, about 7:15, closed it. As a precaution, they also closed the
service-line valves at two gas meters just north of Gross Towers and then helped the emergency-
response personnel. The fire in the mechanical room, which had spread through building utility
chutes up to the fourth floor, died out from lack of fuel.
Postaccident surveys of 115 residents show that three Towers East occupants, in units
108, 408, and 902, had smelled gas immediately before the explosion and that two other
occupants had smelled gas shortly before the explosion while they were in the mail room on the
first floor. The occupant of unit 108 stated that he had reported the gas odor to "911," but after
the explosion.
Community Response
Police--At 6:58,3 a policeman working an extra job at a store at 14th and Allen Streets
heard a loud explosion and radioed that information to the city’s Communication Center. He then
ran to Gross Towers and, to avoid the flames, entered the building through the windows to the
right of the front entrance. As he entered, several bystanders apparently followed him in and
helped escort survivors out. Within minutes, a second, smaller explosion occurred within the
building. The officer told the people who were helping him to put any injured residents on the
front lawn as close as possible to the corner of 14th and Allen Streets and to take uninjured
residents to the corner of Madison and Allen Streets, an empty parking lot.
Other police officers arrived from areas within a mile of Gross Towers. They helped
transport handicapped and elderly people from the stairways and, after putting on self-contained
breathing apparatus, did a room-by-room search for victims and survivors. When the officer who
had been the first to arrive decided that enough people were working to efficiently evacuate the
building, he began to triage the injured. As more officers arrived to help remove victims from the
building, he stayed outside to direct arriving emergency medical-service units. A total of 50
police officers, 8 members of the police reserves, and 12 fire police officers responded to the
incident.
Fire--When the Communication Center alerted the fire department, at 6:59, it dispatched
three engine companies, one aerial unit, and one command car. When they arrived, the
emergency onscene coordinator (coordinator), an assistant fire chief, learned that occupants were
trapped by heavy smoke on the seventh floor and that several residents were trapped in an
3His call was the first to reach the Communication Center. The Center received its second call 45 seconds later. It
came from a customer at a nearby restaurant.
5

<<<PAGE 14>>>

elevator. After UGI personnel shut off the valve, emergency-response personnel searched each
floor to ensure that all residents had been evacuated.
The fire department used the city's mass casualty incident plan, and the coordinator used
the fire department's incident command system. The command post was established on the front
lawn of Gross Towers at 7:03; and at 7:04, the emergency-response staging area and emergency
shelter were established at the Allentown Fairgrounds, about 1/2 mile southwest of Gross
Towers, where approximately 200 residents and 150 family members were helped. At 7:21, a
MedEvac helicopter was requested to transport burn victims. Buses were requested at 7:40 to
transport victims to the shelter at the fairgrounds, and by 7:49, the preliminary search of Gross
Towers for victims was complete. The last injured resident was transported to a local hospital at
8:45.
Throughout the emergency, local agencies worked with each other to provide food and
shelter for the displaced residents. The agencies included the housing authority; the Allentown
police, emergency medical-services, and public-works departments; the Lehigh Valley County
Emergency Management Administration; the American Red Cross; the Pennsylvania Power and
Light Company; and the UGI.
Medical --The Communication Center notified Allentown's emergency medical services
at 6:59, and it dispatched two Allentown and three Cetronia emergency medical-services units.
The first medical unit arrived at Gross Towers at 7:03. The total time for triage was 1 1/2 hours.
A total of 15 emergency medical-services agencies dispatched 35 vehicles, including one
MedEvac helicopter. The injured people were transported to seven area acute-care hospitals.
Housing Authority--The housing authority's answering service called the EPAI foreman
at 7:03, telling him that the housing authority had been notified of his 6:55 report. The housing
authority’s executive director arrived at Gross Towers about 7:25. He directed the identification
and relocation of the more than 300 residents and the site security operations. Additionally, 30 to
40 other housing authority employees were notified and went to Gross Towers to help.
Preaccident Events
The housing authority decided to eliminate potential future fuel-leak problems by
removing a buried tank at Gross Towers and two more that were no longer needed at other
locations. The authority receives approximately $3 million in grant funds for stock modernization
each year from the U.S. Department of Housing and Urban Development (HUD), and the
authority used a portion of the money to pay for removing the tanks.
6

<<<PAGE 15>>>

The housing authority solicited contract proposals from three engineers who it believed
capable of the work. The authority selected the least-cost proposal. The owner and principal of
the selected engineering firm (consultant) was a mechanical engineer registered as a professional
engineer in Pennsylvania. He had had some experience in removing buried tanks and was aware
of, but not thoroughly knowledgeable about, the excavation safety requirements of the
Occupational Safety and Health Administration (OSHA), a part of the U.S. Department of Labor
that establishes safety standards to protect workers. The consultant did not seek advice or support
from an engineer qualified in structures and soils engineering.
The consultant prepared plans, dated November 17, 1993, for removing the tanks. The
plans consisted of a drawing showing the layout of the three sites and a work specification
document applicable to all three. The drawing showed the approximate location of the buried
fuel tanks but did not show the locations of other buried facilities even though it was known that
Gross Towers had a buried natural gas line. The plan and specifications included among other
provisions, the following ones:
• The pavement in areas to be excavated was to be saw cut before the tanks
were removed.
• All work was to be performed in accordance with the latest requirements of
the Pennsylvania Department of Environmental Resources and the U.S.
Environmental Protection Agency.
• Bidders were to examine the specifications, drawings, and the construction
sites. In signing the contract, the successful bidder was to be considered as
having made a reasonable attempt to ascertain the nature and location of the
work and to learn of the general and local conditions that could affect the
work and its costs. In signing the contract he was also to be considered as
having acknowledged that he was as knowledgeable of the character, quality,
and quantity of surface and subsurface materials or obstacles to be
encountered as was reasonable after inspecting the site. He was to notify the
housing authority promptly, before conditions were disturbed, of subsurface or
latent physical conditions at the site that differed materially from those
indicated.
• The consultant was to be allowed to visit the work site, inspect it, and issue
written reports to the housing authority on observed deficiencies.
• The contractor was to ensure that no laborer or mechanic was required to work
in surroundings or under conditions that were hazardous or dangerous to
his/her safety as determined under OSHA safety and health standards. The
contractor was to protect the lives, health, and safety of other people, to
prevent damage to property, materials, supplies, and equipment, and to comply
with regulations and standards of 29 CFR 1926.
7

<<<PAGE 16>>>

• The contractor was to protect from damage all existing improvements and
utilities at or near the work site.
• The contractor was to employ a competent supervisor who would be
responsible for all the construction practices and workmanship of all people
employed by the contractor or subcontractor so that the contractor, rather than
the consultant, would be obligated to exercise responsible control over the
construction practices and workmanship.
• Side slopes of excavations were to comply with local codes, ordinances, and
requirements of agencies having jurisdiction. Shoring and bracing, which was
to be supplied by the successful bidder, would be required where sloping was
not possible. Excavation sides were to be maintained in safe condition until
completion of backfilling.
The consultant stated in the specifications that he would review the on-site work in
process to identify deficient conditions or instances of noncompliance with the contract’s
requirements. His contract with the housing authority called for him to attend the preconstruction
meeting with the successful bidder and to conduct periodic job conferences to ensure that the
work was performed in accordance with the contract.
In February 1994, using the consultant's plan and specifications, the housing authority
advertised for bids to remove each of the buried fuel tanks and to replace one tank. The fuel tank
at Gross Towers was an 8,000-gallon one buried beneath the north parking lot and used to store
heating fuel. The housing authority’s executive director served as the contracting officer on
construction procurement, and its construction coordinator had project oversight responsibility to
ensure that the work was completed. The executive director had worked for the housing authority
for 33 years, of which he had spent 4 in his present position. He had had no construction
experience. The construction coordinator had worked for the housing authority for 15 years and
had been involved with construction before being employed by the housing authority.
The EPAI won the contract to remove the tank at Gross Towers. According to the
minutes of the meeting that was held when the contract was signed, such matters as compliance
with the U.S. Department of Labor standards regarding payrolls were discussed. OSHA job
safety requirements were not discussed, and the consultant did not attend.
On May 18, the EPAI obtained a permit from Allentown to remove the tank at Gross
Towers. The permit issued by the building department, which is staffed to perform building-
construction inspections, did not require on-site inspection by a building inspector because no
building construction was involved. Also, the Building Officials and Code Administrator’s
(BOCA’s) building code adopted by the city did not require or recommend on-site inspections of
excavation work. However, the permit was forwarded to the fire department for action
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because the city requires on-site safety inspections of work that includes the handling of
flammable liquids.
At 1:26 p.m., on May 19, an EPAI employee told the Pennsylvania one-call notification
center4 that it planned to begin excavating at Gross Towers at 8:00 a.m. on May 23. He said the
purpose was to remove an underground storage tank in the rear parking lot of the housing
authority, and he noted that the proposed excavation would be 12 feet deep. The notice center
disseminated the information to its member facility operators. The EPAI did not identify the
approximate location of the proposed excavation with white paint, as is now done in some States,
nor was it required to do so.
On May 23, the housing authority issued the EPAI a Notice to Proceed. The notice stated
that the EPAI was to "carefully [note] and fulfill the requirements of the general conditions
relative to the submittal and approval of Workmen's Compensation and Manufacturers' and
Contractors' Public Liability Insurance." No mention was made of OSHA safety standards. The
housing director and the consulting engineer recognized that the site drawings did not include
information on the locations of buried facilities and that they were depending on the contractor
identifying the locations by notifying the excavation-damage notification system so that the
facility owners would mark the locations before excavation was begun. Even though there were
provisions for the consultant to oversee the work project, he did not.
When they received the EPAI’s excavation notice, the UGI's Lehigh Division5 employees
checked the UGI’s records for the address the EPAI had given for Gross Towers and concluded
that the address should have been given as 1339 Allen Street. At 2:25 p.m. on May 19, a UGI
employee telephoned the EPAI, using the telephone number the EPAI had given the one-call
center, and left a recorded message that the UGI had a gas service line to Gross Towers. At 8:21
a.m. on May 20, a UGI employee marked the location of the service line on the asphalt paving
with yellow spray paint. He did not talk with any EPAI employees about the gas line’s location as
none were at Gross Towers while he was there.
On May 23, the EPAI moved its equipment to the Gross Towers north parking lot. It
removed the asphalt paving in the area to be excavated and began removing the soil above the
tank. The foreman evaluated the soil being excavated as OSHA Type A, which is cohesive soil
with an unconfined compressive strength of 1.5 tons per square foot. (OSHA’s postaccident
evaluation indicated that a visual evaluation of the soil should have shown that it was OSHA
Type C, which is a cohesive soil with an unconfined compressive strength of 0.5 ton or less per
square foot.)
4A one-call notification center is one part of an overall excavation-damage prevention program that is used by
excavators for communicating with buried-facility operators about planned excavations to allow the facility operators to
mark the locations of their facilities in the area of planned excavation.
5UGI's Lehigh Division is responsible for the gas system and its operations in Allentown, Bethlehem, Easton, and
adjacent areas.
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<<<PAGE 18>>>

While an Allentown fire inspector was inspecting the EPAI's work, he saw the
excavation's west sidewall slide into the excavation, exposing the gas line, which was about 3
to 4 feet west of the
tank. The collapsed
sidewall removed the
soil support from about
30 feet of the gas line,
causing it to sag. (See
figure 4.)
The fire inspector
said that he questioned
the EPAl foreman about
the need to secure the
gas line. He said that the
foreman told him that
the condition presented
no problem because the
gas line was
an all
welded system. (The
foreman later stated that
based on his experience,
Figure 4. Gas Service Line after Explosion
he bel
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