If you’ve ever wondered who the go-to problem solvers are behind some of Charleston’s most complex water and wastewater projects, look no further than Alan Townsend, PE and Forest Suggs III, PE. With decades of experience between them, these two embody what makes Hussey Gay Bell’s partnership with Charleston Water System (CWS) so successful: deep technical expertise, creative problem-solving, and an unwavering ability to rise to any challenge.

From installing massive water lines across Charleston Harbor to troubleshooting emergency pipe failures on a barge, Alan and Forest have seen — and fixed — it all. Their work isn’t just about engineering; it’s about trust, relationships, and a willingness to roll up their sleeves when it matters most. Simply put: when Charleston Water System calls, Alan and Forest answer.

In this interview, they share stories from the field, reflect on how infrastructure has evolved over the past 30 years, and offer a glimpse into what’s next for water and wastewater solutions in the Lowcountry.

1.   Can you tell us how Hussey Gay Bell first became involved with Charleston Water System (CWS)?

Our relationship with Charleston Water System (CWS) dates to the late 1980s, when Gus Bell played a pivotal role in fostering the initial connection. During this period, Gus’s strong industry relationships and technical expertise positioned Hussey Gay Bell as a trusted partner for CWS’s growing infrastructure needs. We began providing design services for the utility around that time, establishing the foundation for what has become a decades-long partnership.

Early notable projects included our involvement in the development of Daniel Island and collaborations with the Guggenheim Foundation, both of which showcased our ability deliver innovative solutions for high-profile initiatives. Gus also authored a Preliminary Engineering Report (PER) that provided critical recommendations for future system improvements.

These efforts, supported by then General Manager Tony Maglione, were instrumental in advancing several key initiatives and solidifying our role as a long-term partner to CWS.

2. The deep sewer tunnel replacement program has been a major focus of our work with CWS. How did our team initially become involved with that program?

In the mid-1990s, our already-strong relationship with CWS positioned us as a natural fit when they sought partners for this critical infrastructure initiative. At that time, CWS introduced us to Black & Veatch, with whom we began collaborating as a consultant on the program.

Our team became actively involved in the tunnel replacement program, supporting the design and coordination efforts needed to modernize and expand the city’s failing wastewater tunnel conveyance infrastructure. The BV/HGB Team designed and managed the construction of a new Ashley River Sewer Tunnel (March 2003-2005), Cooper River Sewer Tunnel (2004-2008), Daniel Island Sewer Tunnel Extension (2007-2009), West Ashley Sewer Tunnel and Influent Pump Station (2010-2020) and the West Ashley Sewer Tunnel Extension (2021- Present) which is currently in construction. Over the last 22 years, our role has grown in both scope and complexity, with each successive phase reinforcing our reputation as a reliable, innovative, and solutions-oriented partner. The success of this program has been a testament to the collaborative trust between our team, CWS, and other key stakeholders, and it remains one of the most impactful infrastructure programs in our Charleston portfolio.

3. Looking back, what types of infrastructure design and installation techniques was CWS utilizing at the time, and how have those methods evolved?

In the early days of our work with Charleston Water System, infrastructure design and installation relied heavily on a mix of traditional and emerging methods. At that time, we promoted directional drilling to extend water transmission mains to Daniel Island, Sullivans Island, Isle of Palms, James Island, Mount Pleasant and West Ashley. While trenchless technologies like directional drilling were just beginning to gain traction, the industry still relied heavily on conventional “open cut” installation for most projects.

Directional drilling quickly became a preferred approach, particularly in sensitive or hard-to-reach areas where minimizing surface disruption was critical. This method of construction has allowed us to design and construct large diameter (24 to 40-inch) water mains with lengths over 5,200 linear feet under rivers and marshes with no impact to the environmentally sensitive features. Over the years, the evolution of trenchless methods, improved materials, and enhanced equipment capabilities have transformed how we design and construct. Conventional tunnel boring machine (TBM), micro tunneling, slip lining and pipe bursting were other trenchless technologies that were utilized on the wastewater tunnel replacement projects. Today, these advancements allow for greater precision, efficiency, and environmental stewardship, ensuring that CWS’s system upgrades and expansions are completed with minimal impact to the surrounding communities and ecosystems.

4. Out of all the CWS projects you’ve been a part of, which stands out as your favorite or the most complex? Why?

Alan: One of my favorites was an early directional drilling project that involved installing a 24-inch water main across Charleston Harbor from James Island to Fort Sumter and from Fort Sumter to Sullivan’s Island. Working in a marine environment presented unique challenges and required extensive planning and coordination with each municipality, State and Federal governments. It was a groundbreaking project for its time and showcased how emerging techniques could be successfully applied in difficult conditions.

Forest: I really enjoyed a smaller emergency project involving the joint failure of the 24-inch subaqueous HDPE water main at Fort Johnson that provided water service to Sullivan’s Island and Isle of Palms. Those areas temporarily lost water service, and we were holding daily “war room” meetings with CWS to strategize and troubleshoot solutions. It was a high-pressure situation, but also incredibly rewarding. CWS trusted us to assist in resolving the issue, and ultimately, we raised the 20-foot-deep pipeline onto a barge to make the repair and reinstalled it. The entire experience was a great demonstration of teamwork, quick thinking, and problem-solving under pressure. The project won the Engineering Excellence Award from the American Council of Engineering Companies in 2010.

5. Horizontal directional drilling (HDD) has been a key technique used in our projects. Why is this method so successful in coastal areas, and what are its key benefits and risks?

HDD is particularly well-suited for coastal regions because it allows us to cross large water bodies and install pipelines with minimal disruption to sensitive environments, wetlands, and developed areas. Over the years, advancements in technology and equipment have greatly improved efficiency, enabling the installation of larger-diameter steel and HDPE pipes with greater precision, reliability and cost effectiveness.

While HDD offers significant benefits, including reduced surface disturbance and faster project timelines, it is not without risks. Challenges such as inadvertent drilling fluid returns, or “frac-outs,” can occur, but with proper planning, geotechnical analysis, and construction oversight of bore hole reaming and pipeline pullback pressures, these risks are effectively managed. When executed correctly, HDD remains one of the most efficient and environmentally responsible methods for coastal infrastructure installation.

6. Regional Water Supply and the Sewer Tunnel Extension projects are part of a larger program. How has Hussey Gay Bell supported CWS in achieving its long-term infrastructure goals?

The population growth in the Charleston metro area has resulted in significant demand for water not only in CWS’s service area but adjacent municipalities. CWS obtains its water from nearby surface freshwater sources and doesn’t rely on ground water. Some of the adjacent municipalities utilize ground water as their primary supply source and the long-term dependability of this resource is not sustainable. Consequently, they have been motivated to purchase water from CWS. As a result, over the past 28 years Hussey Gay Bell has supported CWS on expanding and connecting the adjacent communities to their water supply infrastructure to meet increasing demands and to ensure long-term system reliability and redundancy.

On the wastewater side, the Ashley, Cooper and West Ashley Sewer Tunnel replacement projects addressed a severely deteriorating tunnel system that was at risk of collapse which would have resulted in severe consequences to the safety and health of the public. By constructing the new tunnels wastewater flow conveyance systems, reliability and operational efficiency for the entire peninsula of Charleston is now in place for the next century.

With more than three decades of collaboration, Hussey Gay Bell has developed an in-depth understanding of CWS’s infrastructure and priorities, uniquely positioning us to anticipate challenges, deliver innovative solutions, and help achieve the utility’s long-term goals for the Charleston region.

7. Are there any emerging technologies or design approaches you believe will shape the next generation of water and wastewater projects in the region?

In Charleston, our primary challenges are centered on water distribution as we are fortunate to have an adequate regional water source. For those municipalities that still rely upon groundwater as a source, many of the emerging technologies we see are focused on water treatment and reuse. While some communities adopt water recycling out of necessity, Charleston’s focus remains on maintaining efficient, reliable systems and proactively addressing aging infrastructure.