Securing America’s Water Infrastructure Through Carbon Fiber Pipe Repair
As the warmer months approach, water consumption spikes nationwide, bringing with it challenges for underground pipelines. Milwaukee’s Department of Public Works has been confronting issues related to corrosive and cracked pipes, which have led to temporary plant closures and a staggering repair bill close to $2 million.
A Recent Pipe Emergency and Expensive Repairs
Just last month, a critical 72-inch Pre-Stressed Concrete Cylinder Pipe (PCCP) started leaking water between the Texas Avenue and Howard Avenue treatment facilities. This leak forced the Texas Avenue plant to shut down, and the Howard plant also stopped operations due to reliance on water supplied by the Texas Avenue pumping station. The leak was traced back to two 5/8-inch cracks, which were quickly addressed. However, further inspection revealed multiple areas along the 250-foot pipeline showing similar corrosion concerns. In response, the city decided to use a carbon fiber lining to repair the entire corroded section of the pipe. This innovative carbon fiber solution provides excellent corrosion resistance and long-term durability, offering a more sustainable and lasting fix than traditional repair methods.
The Growing Challenge of Leaky Pipes in the U.S.
Leaky pipes are a major concern in the U.S., causing the loss of approximately 7 billion gallons of drinking water daily. As our aging infrastructure continues to deteriorate, the reliability of these systems diminishes. While regular maintenance and pipe replacement are planned and budgeted for, unexpected emergency repairs can be significantly more expensive—up to three times the cost of routine work. The American Society of Civil Engineers (ASCE) gave America’s drinking water infrastructure a disappointing “D†rating in their 2013 report card, emphasizing that much of our infrastructure is nearing the end of its operational lifespan. Emergency repairs on PCCP pipes have become a recurring problem across the country.
Revolutionizing Pipe Repair with Carbon Fiber Technology
In Florida, a county’s water and sewer system encountered an urgent situation when a large-diameter PCCP pipe began corroding and leaking. Previous repairs on several sections, including three 54-inch and four 48-inch diameter pipes, used a composite product that eventually delaminated, allowing moisture to seep into the concrete and damage the prestressing steel wires. Severe corrosion weakened the pipe’s structural integrity, making it unable to maintain its required operating pressure of 150 psi.
HJ3’s carbon fiber pipe repair system was selected to restore the pipe to its original strength and prevent future corrosion. The affected pipe sections were thoroughly prepared by removing all loose concrete, dust, and coatings. They were then primed and wrapped with CarbonSeal™ carbon fiber inside the pipe, ensuring complete joint coverage.
Economic and Environmental Benefits of Carbon Fiber Repairs
Using the CarbonSealâ„¢ system, the damaged pipe was successfully repaired in just a few days, avoiding costly downtime. The pipeline was restored to its original operating pressure, eliminating the need for ongoing maintenance. This carbon fiber repair saved the county over $1 million compared to replacement costs while significantly reducing environmental impact. By opting for this solution, the county prevented 5 tons of concrete waste and 1 ton of steel waste from entering landfills. Additionally, it reduced CO2 emissions by 12 tons, conserved 50,000 kWh of energy, and saved 60,000 gallons of water.
Discovering Sustainable Pipe Repair Solutions
If you’re dealing with corroded PCCP pipes that require repair and want to learn more about HJ3’s carbon fiber systems, contact our project managers today at [insert contact information].
â€
A cracked pipe flooding Milwaukee's streets
â€
Corroded PCCP pipes leak trillions of gallons of water annually
â€
Interior view of a corroded pipeline
Corrosion at the failure point of a previous repair attempt
An installer applying CarbonSeal to the pipe's interior
