UGI Completes Final Cast Iron Pipe Replacements, Marking System Modernization Milestone

UGI customers are now served by more durable and contemporary pipelines following the replacement of over 400 miles of cast iron infrastructure—some of which had been in the ground for well over a century.

When UGI replaced the last sections of cast iron this spring, it marked a significant milestone in company history. It took 14 years of accelerated work, by hundreds of employees, contractors and other business partners, and required the company to invest over a billion dollars into Pennsylvania’s energy infrastructure. The investment in system upgrades is how UGI will continue to deliver natural gas to customers safely and reliably for decades to come.

The replacement is the culmination of one of the largest infrastructure modernization efforts in UGI’s 144-year history, a commitment formalized in January 2013, when UGI and state regulators set a 14-year deadline to retire every mile of cast iron main. UGI finished the work nearly a year early.

UGI thanks its customers and the many communities it serves for their patience during construction, as well as the employees and contractors who continue to work tirelessly to build a safer and more resilient pipeline system.

“This milestone isn’t just about pipe in the ground. It’s about the trust our customers place in us every time they turn on a furnace or a stove,” said Hans Bell, UGI Utilities President. “Retiring our last mile of cast iron main means safe, reliable service for the homes and businesses that depend on us, and it’s a foundation we’ll keep building on as we carry that same commitment through ongoing replacement work.”

UGI’s 15-Year Journey to a Safer System

The roots of this achievement trace back to February 2011, when a break in an aging cast iron main in Allentown resulted in a tragic natural gas explosion — a moment that reshaped how UGI identifies, prioritizes, and funds natural gas infrastructure upgrades.

In the years that followed, under the oversight of the Pennsylvania Public Utility Commission (PUC), UGI charted an accelerated path forward, committing to retire every cast iron main across its system within 14 years and every bare steel main within 30 years — compressing a cast iron replacement timeline that had previously spanned half a century.

UGI’s cast iron and bare steel replacement effort began in 2012 as a 14-year, roughly $1.2 billion initiative. Since 2020, that work has expanded under two additional PUC-approved Long Term Infrastructure Improvement Plans (LTIIPs) — representing a further $3 billion investment — growing the effort into a comprehensive, proactive infrastructure modernization program. UGI crews have replaced approximately 60 to 70 miles of pipeline every construction season, with steady annual investment that keeps making the system safer for the customers it serves.

Staying the Course Through a Pandemic

Momentum was tested in 2020, when the COVID-19 pandemic disrupted construction schedules, supply chains, and daily life. Rather than pause, UGI’s crews adapted.

The company introduced new field safety protocols — staggered and rotated shifts, single occupant field vehicles, dispatch-from-home practices, and enhanced personal protective equipment — to keep construction moving while safeguarding employees and communities.

Even with nearly two months of pandemic-related inactivity that year, UGI still replaced almost 72 miles of cast iron and bare steel main — meeting its commitment to regulators and keeping its modernization timeline on track. It was a clear signal that the safety of UGI’s communities would remain the top priority — pandemic or not.

A Modern System, Measurable Results

UGI’s ongoing investments have delivered results: hazardous leaks are down nearly 60% since 2015, and methane emissions due to pipe materials are more than 90% lower since 1999. Over the same period, the scale of UGI’s operations has more than doubled, supporting significant job and economic gains. Those gains reflect both the direct and indirect economic impact of contractor, supplier, and vendor spending, as well as the broader value customers realize through access to affordable natural gas.

“The real measure of this program isn’t the list of pipe segments we replaced. It’s that our customers can now count on a system built almost entirely of modern materials — and that’s the kind of reliability this work was always meant to deliver,” said Hans, who has been a part of the program’s leadership team since its outset — including as Vice President of Engineering and Operations Support and as Chief Operating Officer.

What Comes Next

Reaching this milestone doesn’t mean the modernization work is done. UGI’s replacement program now turns its attention to the system’s remaining bare steel mains, with a target of full replacement by 2041. The systems, processes, and partnerships built over the last 15 years — with skilled contractors and PUC oversight — position UGI well to keep its momentum going.

This fall, UGI marked the completion of cast iron retirement with a company-hosted event that brought together employees, contractors, lawmakers, local leaders, and regulators. The event reflected on this milestone and looked ahead to future replacement efforts.