Manhole Rehabilitation
The Mainstay Composite Liner is often used in a variety of applications:
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Brick and concrete manholes
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Lift stations and wet wells
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Wastewater treatment plant headworks
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Clarifiers
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Digesters
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Sumps
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Sewer pipe
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Trenches
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Paper mills
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Chemical processing plants
The following are photos of an application of the Mainstay Composite Liner at the San José Wastewater Treatment Plant in San José, CA:
 Deteriorated concrete clarifier after preparation to remove a failed existing thin film coating.
 The same surfaces after restoration with Mainstay ML-72 Sprayable Microsilica Restoration Mortar. This high strength, low shrinkage mortar can be applied at thicknesses up to 5" in a single or multiple passes, returning the structure to its original strength, shape, and appearance.
 Immediately after the ML-72 Mortar has been finished, .125" (125 mils) of Mainstay DS-5 100% Solids Epoxy Coating is applied. This high strength, 100% solids (no solvent) corrosion barrier protects the structure and prevents further corrosive deterioration.
 This structure was rehabilitated in 2004. It is still in service today.
The Mainstay® Composite Liner is a manhole rehabilitation system consisting of a high strength restoration mortar (typically Mainstay ML-72) and an epoxy corrosion barrier coating (typically Mainstay DS-5) that cure simultaneously to repair and protect brick and concrete manholes, lift stations, wet wells, and other sanitary sewer structures. The mortar is first shot onto a new or deteriorated substrate, and an epoxy topcoat is then immediately applied while the mortar is still soft. The concurrent application of these materials creates a monolithic surface that cures into a strong, highly corrosion resistant, and continuous manhole lining, free of pinholes, holidays, and voids. The mortar and topcoat are tightly bonded not only to the substrate but also to each other.
 
Product Detail Sheets:
Ancillary Manhole Rehabilitation Products:
Recommended For:
- Manhole rehabilitation
- Lift station restoration
- Wet well repair
- Wastewater treatment plant headworks
- Clarifiers
- Digesters
- Sumps
- Sewer pipe
- Trenches
- Paper mills
- Chemical processing plants
Advantages of the Mainstay Composite Liner:
 There is no wait time for the mortar to cure after it is applied to the manhole because the epoxy topcoat is applied while the mortar is still soft.- This system is specifically designed for use in moisture laden environments. Restoration mortars used in the Mainstay Composite Liner are properly applied when the surface of the concrete or brick manhole remains damp.
- Mainstay ML-72 mortar is a high-build restoration mortar that can be applied to vertical manhole surfaces up to 5" thick, often restoring the manhole substrate to its original thickness.
- Mainstay DS-5 is a 100% solids epoxy coating. It contains no solvent and may be applied to the manhole up to 125 mils in a single coat.
Product Detail Sheet:
Mainstay® ML-CA Pure Calcium Aluminate Restoration Mortar (145 KB, requires Adobe Reader)
Mortar Type:
Pure calcium aluminate cement mortar capable of withstanding corrosive environments with a pH of 1 or higher
Packaging:
Normally stocked in 65 pound bags; special packaging available
Applied Thickness:
Mainstay ML-CA mortar may be applied from 1/2" to 3" depending on the condition of the substrate. Its high-build capability allows severely deteriorated surfaces to be restored to their original substrate thickness.
Coverage:
Approximately 13 square feet per bag at 1/2"
Water Content:
Mix 1.1 gallons of water per 65 pound bag
Test Data:
- Compressive Strength per ASTM C-109: >13,000 psi at 28 days
- Flexural Strength per ASTM C-293: >1,400 psi at 28 days
- Tensile Strength per ASTM C-496: >650 psi at 28 days
- Shrinkage per ASTM C-596: 0% at 28 days at 90% relative humidity
- Bond Strength per ASTM C-882: >3,000 psi at 28 days
Suitable Applications:
Rehabilitation of deteriorated concrete structures with a pH of 1 or higher, such as:
- Brick and concrete manholes
- Lift stations
- Wet wells
Application Equipment:
Visit our Application Equipment section to learn more about the equipment needed to apply this product.
Product Detail Sheet:
Mainstay® ML-10 Hydraulic Cement Mortar (134 KB, requires Adobe Reader)
Mortar Type:
Proprietary mixture of hydraulic cements and fillers
Packaging:
Normally stocked in 50 pound pails
Mixing:
Mainstay ML-10 Mortar is mixed by adding just enough water to form a viscous lump with the consistency of modeling clay.
Suitable Applications:
To repair flowing, seeping, or weeping leaks in brick or concrete sanitary sewer structures such as:
- Manholes
- Lift stations
- Wet wells
Product Detail Sheet:
Mainstay® DS-4 100% Solids Epoxy Coal Tar Coating (142 KB, requires Adobe Reader)
Coating Type:
Black, 100% solids, two-component epoxy coal tar coating
Packaging:
Normally stocked in 4.5 gallon, two-component kits; special packaging available
Applied Thickness:
50 to 125 mils (0.050" to 0.125") in one or two coats, depending on the application
Coverage:
Approximately 16 square feet per gallon at 100 mils; approximately 72 square feet per kit at 100 mils. Allowances should be made for waste.
Mix Ratio:
Mix 1 part A to 2 parts B by volume
Working Time:
Approximately 45 minutes at 90 degrees Fahrenheit
Suitable Applications:
Use as a topcoat over Mainstay ML-72 Sprayable Microsilica Mortar for the rehabilitation of severely deteriorated concrete structures or as a stand alone product on steel surfaces with a pH of 1 or lower. Some applications include:
- Brick and concrete manholes
- Lift stations
- Wet wells
- Wastewater treatment plant headworks
- Clarifiers
- Digesters
- Sumps
- Sewer pipe
- Trenches
- Pulp and paper mills
- Chemical processing plants
Application Equipment:
Visit our Application Equipment section to learn more about the equipment needed to apply this product.
Product Detail Sheet:
Mainstay® DS-5 100% Solids Epoxy Coating (144 KB, requires Adobe Reader)
Coating Type:
100% solids, two-component epoxy coating
Packaging:
Normally stocked in 4.5 gallon, two-component kits; special packaging available
Applied Thickness:
50 to 125 mils (0.050" to 0.125") in one or two coats, depending on the application
Coverage:
Approximately 16 square feet per gallon at 100 mils; approximately 72 square feet per kit at 100 mils. Allowances should be made for waste.
Mix Ratio:
Mix 2 parts A to 1 part B by volume
Working Time:
Approximately 45 minutes at 80 degrees Fahrenheit
Suitable Applications:
Use as a topcoat over Mainstay ML-72 Sprayable Microsilica Mortar for the rehabilitation of severely deteriorated concrete structures or as a stand alone product on steel surfaces with a pH of 1 or lower. Some applications include:
- Brick and concrete manholes
- Lift stations
- Wet wells
- Wastewater treatment plant headworks
- Clarifiers
- Digesters
- Sumps
- Sewer pipe
- Trenches
- Pulp and paper mills
- Chemical processing plants
Application Equipment:
Visit our Application Equipment section to learn more about the equipment needed to apply this product.
Product Detail Sheet:
Madewell® 806 Flexible Joint & Manhole Chimney Seal (172 KB, requires Adobe Reader)
Coating Type:
100% solids, two-component flexible epoxy coating
Packaging:
Normally stocked in 2 gallon, two-component kits; special packaging available
Applied Thickness:
Typically 1/4", depending on the application
Coverage:
To seal the interior circumference of a 2 foot diameter manhole frame/chimney, Madewell 806 is typically applied at a thickness of 250 mils (1/4") thick by 8" wide. When applied in this way, one 2 gallon kit will normally treat three manhole frames.
Mix Ratio:
Mix 1 part A to 1 part B by volume
Working Time:
Approximately 20 minutes at 80 degrees Fahrenheit
Suitable Applications:
- Seals the joint between the chimney and frame on brick and concrete sanitary sewer manholes
- Used on expansion joints in concrete slabs, bridges, garages, decks, balconies, etc.
Product Detail Sheet:
Madewell® 1103 100% Solids Epoxy Coal Tar Coating (141 KB, requires Adobe Reader)
Coating Type:
100% solids, two-component epoxy coal tar coating
Packaging:
Normally stocked in 4.5 gallon, two-component kits; special packaging available
Applied Thickness:
20 to 30 mils (0.020" to 0.030") in one coat, depending on the application
Coverage:
Approximately 80 square feet per gallon at 20 mils; approximately 360 square feet per kit at 20 mils. Allowances should be made for waste.
Mix Ratio:
Mix 2 parts A to 1 part B by volume
Working Time:
Approximately 45 minutes at 100 degrees Fahrenheit
Suitable Applications:
Use as a topcoat over Mainstay® ML-72 Sprayable Microsilica Restoration Mortar for the rehabilitation of severely deteriorated concrete structures or as a stand alone product on steel surfaces with a pH of 1 or lower. Some applications include:
- Brick and concrete manholes
- Lift stations
- Wet wells
- Wastewater treatment plant headworks
- Clarifiers
- Digesters
- Sumps
- Sewer pipe
- Trenches
- Pulp and paper mills
- Chemical processing plants
Application Equipment:
Visit our Application Equipment section to learn more about the equipment needed to apply this product.
Total Area (ft2):
Mortar Requirements
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Epoxy Coating Requirements
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Mortar & Coating Combined
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Notes:
- For round manholes, square footage is computed: π * D * V, where D = nominal-diameter in feet and V = vertical depth in feet. No adjustments are made for items such as cone shape, etc.
- Mortar requirements are based on a mortar density of 120 lb. per cubic foot. For round manholes, mortar cubic footage requirements are computed: π * [(D / 2) 2 - (D / 2 - T / 12)2] * V, where T = mortar thickness in inches and the other variables are as defined above. No adjustments are made for items such as waste, irregular surface profile, cone shape, etc. The number of bags of mortar is rounded as selected, and the total lbs. required is computed from the number of bags and the bag capacity (65 lbs.).
- For round manholes, 100% solids epoxy coating requirements in gallons are computed: π * [(D / 2) 2 - (D / 2 - T / 1000 / 12)2] * V * 123 / 231, where T = coating thickness in mils and the other variables are as defined above. No adjustments are made for items such as waste, etc. The number of kits required is rounded as selected, and the total gallons required is computed from the number of kits and the chosen kit size.
- Contact Madewell Products Corporation for current mortar & coating cost information.
- The computation of selling price is simply the product of the material cost times the chosen cost multiplier(s). No adjustment is made for other costs (labor, equipment, fuel, transportation, supervision, overhead, etc.) and related mark-ups that should properly be considered when determining a final selling price for a project.
- The computational results shown on this page are rendered gratis and are provided "as is" without warranty of any kind, either express or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. By accessing and using this page, you agree that the entire risk as to the quality and performance of the computational results is with you. Should the computational results prove defective, you assume the cost of all necessary servicing, repair or correction. In no event will Madewell Products Corporation, or any other party, be liable to you for damages, including any general, special, incidental or consequential damages arising out of the use or inability to use the computational results (including but not limited to losses sustained by you or third parties), even if Madewell Products Corporation or any other party has been advised of the possibility of such damages.
Product Detail Sheet:
Mainstay® ML-PF Pure Fused Calcium Aluminate Restoration Mortar (146 KB, requires Adobe Reader)
Mortar Type:
Pure calcium aluminate cement mortar containing 100% pure fused calcium aluminate aggregate capable of withstanding corrosive environments with a pH of 1 or higher.
Packaging:
Normally stocked in 65 pound bags; special packaging available
Applied Thickness:
Mainstay ML-PF mortar may be applied from 1/2" to 3" depending on the condition of the substrate. Its high-build capability allows severely deteriorated surfaces to be restored to their original substrate thickness.
Coverage:
Approximately 11.5 square feet per bag at 1/2"
Water Content:
Mix 1 gallon of water per 65 pound bag
Test Data:
- Compressive Strength per ASTM C-109: >16,000 psi at 28 days
- Flexural Strength per ASTM C-293: >1,800 psi at 28 days
- Tensile Strength per ASTM C-496: >775 psi at 28 days
- Shrinkage per ASTM C-596: 0% at 28 days at 90% relative humidity
- Bond Strength per ASTM C-882: >3,000 psi at 28 days
Suitable Applications:
Rehabilitation of deteriorated brick and concrete structures with a pH of 1 or higher, such as:
- Brick and concrete manholes
- Lift stations
- Wet wells
Application Equipment:
Visit our Application Equipment section to learn more about the equipment needed to apply this product.
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