Carbon Fiber for Manhole Repair

Why Manhole Maintenance Matters

Manholes are often overlooked in everyday life, yet they play a crucial role in the functioning of modern cities. 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 essential utilities like sewer systems, water lines, electrical grids, and gas pipelines. Without proper maintenance, these critical components can deteriorate, leading to costly repairs and potential safety hazards. Unfortunately, many manholes are neglected during routine maintenance, which accelerates their decline. About 20% of them are between 30 and 50 years old, with over 3 million in such poor condition that they require urgent attention. This neglect can lead to structural failures, leaks, and even dangerous situations for workers and the public. In Pima County, Arizona, 21 manholes built in the 1940s had previously been repaired using a cementitious liner, but it eventually failed. The liner lost adhesion, causing pieces to fall into the sewage system and damage processing equipment. To fix this, the county had to remove the damaged liner, reinforce the structure, and protect it from hydrogen sulfide gas, a common byproduct in sewers that can corrode concrete. The repair process involved grinding the surface, resurfacing with Quick-Set grout, sealing cracks with a low-viscosity polymer, and applying CarbonSeal™ carbon fiber. A vinyl ester topcoat was then added to shield the structure from further damage caused by hydrogen sulfide exposure. This solution not only saved the county 80% in costs compared to replacing all 21 manholes but also avoided road closures, saving months of downtime and preventing nearly 62,000 gallons of water waste that would have occurred during the production of new manholes. By investing in smart, long-term solutions, cities can ensure the continued reliability of their infrastructure while protecting both people and the environment.

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