Carbon Fiber for Manhole Repair

The Critical Role of Manhole Maintenance

Manholes may not be the most glamorous part of our infrastructure, but they play a vital role in keeping our cities running smoothly. According to the Environmental Protection Agency (EPA), there are about 20 million manholes across the United States—roughly one for every 400 feet of pavement. These structures are more than just access points; they provide entry to essential utilities like sewer systems, water lines, electrical networks, and gas pipelines. Proper maintenance is key to ensuring public safety and the long-term health of urban environments. Unfortunately, many manholes are neglected during routine maintenance, leading to serious issues over time. It’s estimated that 20% of U.S. manholes are between 30 and 50 years old, with over 3 million in such poor condition that they require urgent repair or replacement.

In Pima County, Arizona, 21 manholes built in the 1940s had previously been repaired using a competitor's cementitious liner, which eventually failed. As the material degraded, it lost adhesion to the concrete, causing pieces to fall into the sewage flow and potentially damaging the wastewater treatment system. To address this, the county needed to remove the failed liner, reinforce the structure, and protect it from hydrogen sulfide gas, which can cause severe corrosion. The repair process involved grinding the damaged surfaces, resurfacing with Quick-Set grout, sealing cracks with a low-viscosity polymer, and applying CarbonSealâ„¢ carbon fiber. A vinyl ester topcoat was then added to shield the system from future damage caused by gas exposure.

HJ3’s carbon fiber solution proved to be a game-changer. Not only did it save the county around 80% in costs compared to replacing all 21 manholes, but it also allowed repairs to be completed without closing roads. This meant no traffic disruptions, 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, long-lasting repair method, Pima County was able to extend the life of its critical infrastructure while protecting public health and the environment.

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