Combating Water Main Breaks with Carbon Fiber Solutions
As the summer approaches, cities across the northern hemisphere are bracing themselves for the challenges posed by a severe winter. This past season saw record-breaking low temperatures and heavy snowfall, and now the thawing process is exacerbating existing issues, such as flooding and pipe ruptures. Known as "water main break season," this phenomenon affects numerous regions worldwide. In Prince Albert, Saskatchewan, a persistent water main issue has flooded local streets for over a month, disrupting daily life and prompting urgent action.
The Root Causes of Water Main Breaks
The freeze-thaw cycle is a major contributor to these breaks. As the ground thaws, uneven settling occurs, shifting the soil beneath the pipes. Combined with aging infrastructure—some pipes nearing a century old—this leads to frequent breaks. In Prince Albert alone, there have been 19 breaks this season, with more anticipated. City officials are actively formulating plans to tackle these problems, acknowledging that the extreme cold put immense pressure on underground systems.
Tackling Pipe Corrosion Across North America
Corrosion in pre-stressed concrete cylinder pipes (PCCP) costs U.S. water and wastewater networks over $50 billion annually, according to a 2002 study. North America experiences approximately 850 water main breaks per day, costing over $3 billion annually in repairs. These leaks result in the loss of around 2.5 trillion gallons of drinking water yearly, accounting for roughly 17% of all water pumped in the U.S. Of this, 90% stems from corrosion-related issues tied to aging infrastructure. A 2012 Utah State University study found that 43% of U.S. water mains are between 20 and 50 years old, with another 22% surpassing the 50-year mark.
Unfortunately, nearly half of the one million miles of pipelines under American streets are nearing the end of their usable lives. Replacing them is projected to cost over $1 trillion over the next 25 years, yet funding shortages demand innovative solutions to extend the lifespan of our PCCP infrastructure.
HJ3’s CarbonSeal Carbon Fiber Solution
HJ3’s CarbonSeal carbon fiber offers a practical solution to these pressing issues. Consider a case where a coal-fired power plant faced a critical situation: a 120-inch diameter pipe, responsible for conveying water to cooling towers, developed cracks in its internal concrete lining. Water seeping through these cracks caused corrosion of the pre-stressed wires within. As these wires degraded, the pipe lost its ability to handle internal hoop stress. With replacement costs being prohibitively high, the plant chose HJ3’s CarbonSeal system to repair 750 feet of the pipe.
The CarbonSeal Repair Process
The repair began with an abrasive blast to clean the pipe’s surface, followed by injecting polyurethane foam into the leaks. After priming the surface, technicians carefully applied saturated CarbonSeal carbon fabric. A protective topcoat ensured a pinhole-free finish, making the system impermeable. Remarkably, the entire 750 feet of pipe was restored in just 11 days, regaining its capacity to withstand internal stresses. This method saved 50% compared to traditional repair techniques and slashed costs by 65% relative to replacement. Additionally, it prevented six tons of concrete from entering landfills. After eight years, the system remains robust and functional, meeting expectations. The client praised HJ3 for their invaluable support in design calculations, engineering drawings, termination details, and on-site supervision.
CarbonSeal Reinforcement Systems
If you’re dealing with the task of repairing an underground pipe and want to explore HJ3’s CarbonSeal reinforcement systems, feel free to reach out to HJ3 at [contact information].
Corrosion inside an underground water pipe
Installing HJ3's CarbonSeal fabric
HJ3 installers apply top coat to the carbon fabric
This approach not only preserves vital infrastructure but also reduces environmental impact—a win-win scenario for both cities and industries alike.
![PNM-1[1]](http://bsg-i.nbxc.com/blog/0cea1ad9232aeaed06638a149fc83342.jpeg)
