Why Manhole Maintenance Matters
Manholes may go unnoticed by most, but they play a crucial role in the infrastructure that supports our daily lives. According to the Environmental Protection Agency (EPA), the U.S. has around 20 million manholes—roughly one for every 400 feet of pavement. These structures are more than just access points; they provide entry to sewer lines, water systems, electrical networks, and gas pipelines. Without proper maintenance, they can become a serious risk to public safety and urban efficiency.
Unfortunately, many manholes are neglected during routine maintenance, leading to significant wear and tear. About 20% of them are between 30 and 50 years old, with over 3 million in such poor condition that they require urgent repair or replacement. This neglect not only increases long-term costs but also threatens the integrity of the entire utility network.
In Pima County, Arizona, 21 manholes built in the 1940s had previously been repaired using a cementitious liner from another company. However, this solution failed over time, as the liner lost its bond with the concrete surface and began breaking off into the sewage system. This posed a serious threat to the county’s wastewater treatment operations.
To address the issue, the county turned to HJ3's innovative carbon fiber system. The process involved removing the failed liner, grinding the affected areas, and resurfacing the concrete with Quick-Set grout. Cracks were sealed using a low-viscosity polymer, and CarbonSealâ„¢ carbon fiber was applied and saturated before a vinyl ester topcoat was added to protect against future damage from hydrogen sulfide gas.
This method saved the county approximately 80% compared to the cost of replacing all 21 manholes. Moreover, the repairs were completed without closing any roads, saving months of downtime and preventing nearly 62,000 gallons of water waste that would have occurred during the production of new manholes.
By choosing a durable and cost-effective solution, Pima County ensured the continued functionality of its critical infrastructure while minimizing environmental impact and operational disruption.
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