As summer approaches, many cities in northern regions are facing the consequences of a severe winter. Record low temperatures and heavy snowfall have left infrastructure under immense pressure, and now, as the weather warms up, we're seeing the effects of melting snow and frequent water main breaks. This time of year is commonly known as "water main break season," and it's a recurring issue that affects communities across the globe. In Prince Albert, Saskatchewan, a persistent water main break has been flooding the streets for over a month, causing inconvenience and disruption.
One of the primary causes of these breaks is the freeze-thaw cycle. As the ground thaws, it can cause uneven settling, putting stress on underground pipes. Combined with aging infrastructure—some of which is nearly 100 years old—this creates a perfect storm for water main failures. In Prince Albert alone, there have been 19 water main breaks this season, with more expected in the coming weeks. City officials are working to develop a long-term plan to manage these issues, acknowledging that the extreme cold last winter put significant strain on the entire underground system.
Corrosion is another major problem, especially in pre-stressed concrete cylinder pipes (PCCP). A 2002 study estimated that corrosion costs U.S. water and wastewater systems over $50 billion annually. On average, there are 850 water main breaks every day in North America, leading to repair costs exceeding $3 billion each year. Leaking pipes also result in the loss of about 2.5 trillion gallons of drinking water annually—equivalent to roughly 17% of all water pumped in the U.S. Alarmingly, 90% of this loss is due to corrosion in aging infrastructure.
In fact, almost half of the one million miles of pipelines beneath American streets are nearing the end of their useful life. Replacing them could cost over $1 trillion over the next 25 years, but funding is limited. That’s why innovative solutions like HJ3’s CarbonSeal carbon fiber system are becoming increasingly important.
HJ3’s CarbonSeal offers a reliable and cost-effective way to repair damaged pipes without the need for full replacement. A notable example was a cracked water pipe at a coal-fired power plant. The internal concrete lining of a 120-inch diameter pipe had developed cracks, allowing water to seep in and corrode the pre-stressed wires inside. Faced with the high cost of replacing the entire 750-foot section, the plant chose to use HJ3’s CarbonSeal system for the repair.
The process involved cleaning the pipe surface with an abrasive blast, injecting polyurethane foam into leaks, priming the area, and then applying the CarbonSeal fabric. A protective top coat was added to ensure a waterproof finish. The entire repair was completed in just 11 days, saving 50% compared to other methods and 65% compared to full replacement. Plus, it prevented six tons of concrete from going to landfills. The system has been performing well for eight years, meeting all expectations.
The client praised HJ3 for the support provided throughout the project, including design calculations, engineering drawings, and on-site supervision. If you’re dealing with a similar challenge, HJ3’s CarbonSeal reinforcement system may be the solution you need.
For more information or to discuss your specific situation, reach out to HJ3 today.
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