Why Manhole Maintenance Matters: A Vital Part of Urban Infrastructure
Manholes are often overlooked by the general public, but they play a crucial 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 serve as access points for sewer lines, water systems, electrical grids, and gas pipelines. Without proper maintenance, they can become a major source of problems, affecting both public safety and environmental health.
Unfortunately, many manholes are neglected during routine maintenance, leading to serious deterioration over time. It's estimated that around 20% of manholes are between 30 and 50 years old, with more than 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 cementitious liner, which eventually failed. As the material deteriorated, it lost its bond with the concrete, causing pieces to fall into the sewage system and risk damaging the county’s wastewater treatment facilities. To address this, the manholes were stripped of the failed liner, reinforced, and protected from Hydrogen Sulfide Gas—a common and corrosive issue in sewer environments.
The repair process included grinding the interior surfaces, resurfacing with Quick-Set grout, and sealing cracks with a low-viscosity polymer. Then, CarbonSealâ„¢ carbon fiber was applied and saturated, followed by a vinyl ester topcoat to provide long-term protection against further damage.
Using HJ3’s carbon fiber system, Pima County saved an impressive 80% compared to the cost of replacing all 21 manholes. Additionally, the project avoided road closures, saving months of disruption and preventing nearly 62,000 gallons of water from being wasted during the production of new manholes.
This case highlights how innovative materials and smart maintenance strategies can extend the life of aging infrastructure while saving money and resources. It also underscores the importance of regular inspection and timely intervention to keep our underground systems safe and functional.
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