Manhole Liner Failing? The Truth 18 Years Later
Why cheaper isn’t better: How a manhole liner outperforms expectations and competitors.
The Manhole
Nearly two decades ago, a manhole serving a local authority began showing signs of serious deterioration due to discharge from a force main. Continuous aeration of the influent was producing hydrogen sulfide gas (H₂S), aggressively attacking the concrete. Left untreated, this corrosion threatened the manhole’s structural integrity and the reliability of the wastewater system.
Deterioration of the concrete manhole included cracks, soft cement, section loss, and exposed reinforcing. To address the problem without costly excavation or community disruption, the authority called on Abel Recon to trenchlessly rehabilitate the manhole in 2007.
The Trenchless Solution
Abel Recon applied Spraywall, manufactured by Sprayroq. Spraywall is a high-performance, high build, two-component polyurethane, structural liner that is completely resistant to H₂S gasses, making it the number one solution for force main discharge manholes. The thickness applied to the manhole was a structural enhancing thickness of 250 mils. Starting in the channel, working to the bench, walls, then up to chimney, Abel Recon completely sealed the existing substrate to prevent any further deterioration. A truly monolithic solution.
As authorities increasingly focus on preventing inflow and infiltration (I&I), routine system inspections are becoming a useful and beneficial tool. However, a recent manhole inspection by the authority set off some alarms. The asset owner observed what appeared to be delamination, flaking, blistering, and cracking of the liner, some questions then arose. The authority began to ask themselves: Was the Spraywall liner failing? Had Abel Recon overpromised? Or was this merely a perceived problem?
Decades Later
When the authority brought their concerns to the attention of Abel Recon, we decided to do everything we could to serve the concerns of the authority. Going into the follow-up inspections, Abel Recon wasn’t sure what to expect. The follow up included a washdown, manned entry, and thorough evaluation of the manhole and its liner.
Since Abel Recon has been partnered with Sprayroq since 2007, we are confident that high-quality materials, even in highly corrosive environments, were no match for Spraywall. Other, inferior liners often show signs of failure within 8-12 years, sometimes needing further investments. The authority also had the option to dig and replace the structure in lieu of rehabilitation. However, both options would have led to more community disruption, higher lifetime costs and repeated service delays.
The 2025 inspection confirmed exactly what Abel Recon promised the authority, long term solutions and high-quality products. The results were far better than expected, and the return on investment was clear. What might have looked like delamination, flaking, blistering, and cracking was, in fact, years of debris and build-up caked onto the liner. Once pressure washed the inspection showed that the Spraywall is still in excellent condition, with the manhole still sealed and protected from the harsh environment. It is clear Spraywall has withstood the test of time and will continue to for years to come.
The Return On Investment
The manhole was first installed in 1978, giving the authority almost 30 years of service before needing more investment. After Abel Recon’s application of Spraywall, the manhole gained at least 18 more years before any concerns arose, far exceeding the lifespan of alternative products. Furthermore, once the inspection was complete, it revealed the manhole and Spraywall have many more years of service left.
This case illustrates why authorities should prioritize high-quality and durable solutions, over cheap, short-term fixes, or even full replacement. By investing in the best materials and application methods upfront, longevity is maximized, reducing the frequency and cost of repairs. Allowing critical infrastructure to remain reliable, safeguarding public health and services. This also ensures less maintenance costs that the authority could use elsewhere, continuing to keep their system running to perfection.
In short, when it comes to protecting authorities’ assets, quality pays for itself. Spraywall and Abel Recon prove why doing it right the first time is worth every cent. Using inferior products creates more issues than it saves in monetary cost upfront. Why would any authority choose more disruption, further costs, and repeated service when they could just choose Abel Recon and Spraywall once?
