How to Extend the Life of Stormwater Infrastructure Without Costly Replacements

Stormwater infrastructure is vital for managing runoff and preventing flooding, but over time, storm intake boxes and drainage systems face wear and tear that can lead to significant failures. Leaks, soil erosion, and settling are common issues that, if left unaddressed, can result in expensive full-system replacements. Fortunately, modern polyurethane solutions offer an efficient and cost-effective way to extend the lifespan of stormwater systems without the need for disruptive tear-outs.

Why Storm Intake Boxes Fail Over Time

Municipalities, departments of transportation (DOTs), and infrastructure managers often encounter problems with aging stormwater systems. Some of the most common causes of failure include:

• Water Infiltration & Leaks: Over time, gaps and cracks develop in storm intake boxes, allowing water to seep into the surrounding soil. This weakens the subgrade and compromises the structural integrity of the system.
• Erosion & Washout: Improperly compacted backfill and continuous water flow can cause soil to erode around the intake structure, leading to settlement issues and further destabilization.
• Concrete Settling & Misalignment – Shifting soil and water infiltration contribute to uneven settling of storm intake tops, causing misalignment that reduces efficiency and can lead to surface failures.
• Freeze-Thaw Damage: In colder climates, repeated freeze-thaw cycles expand existing cracks and accelerate deterioration, making early intervention essential.

The Costly Alternative: Full Replacements

Traditional methods of repairing storm intake boxes often involve full removal and replacement, which can be both disruptive and expensive. Depending on the severity of damage, excavation costs, materials, and labor can push replacement costs upwards of $7,500 per intake box. Additionally, road closures and downtime can create logistical challenges for municipalities and DOTs.

A Better Solution: Polyurethane Sealing & Stabilization

Polyurethane injection technology provides a long-lasting, minimally invasive alternative to full replacement. By sealing leaks and stabilizing the surrounding soil, polyurethane solutions can restore and reinforce stormwater infrastructure at a fraction of the cost.

How Polyurethane Solutions Work

• Leak Sealing – Depending on the application, we use either dual-component polyurethane, which expands upon injection to fill cracks, gaps, and voids within the intake structure, or single-component polyurethane, which flows into fine fractures and hardens to create a watertight seal. Both options effectively prevent further water infiltration.
• Soil Stabilization – Polyurethane permeates loose soil, filling voids and binding with the subgrade to restore density and prevent future erosion. The appropriate formulation is selected based on site conditions to ensure optimal stabilization.
• Structural Reinforcement – Whether expanding or non-expanding, the polyurethane cures rapidly to strengthen the subgrade, helping storm intake boxes maintain proper alignment and long-term functionality.
• Waterproofing & Durability – Both types of polyurethane are highly resistant to water, chemicals, and environmental factors, ensuring long-term performance without degradation.

Proven Results: Case Study Example

In Solon, IA, a city faced recurring issues with storm intake boxes leaking and destabilizing the surrounding pavement. A traditional replacement would have cost $7,500 per intake, but a polyurethane application provided a long-term fix at just $2,200 to $2,800 per intake. The project successfully sealed leaks, stabilized the backfill, and restored functionality—all with minimal disruption.

Why Municipalities & DOTs Choose Polyurethane for Infrastructure Repairs

• Cost-Effective – Saves thousands compared to full replacements.
• Non-Disruptive – No excavation required, minimizing road closures.
• Fast-Acting – Cures in minutes, allowing for same-day traffic reopening.
• Long-Lasting – Prevents future settlement and erosion for years to come.

Extend the Life of Your Stormwater Infrastructure Today

If your municipality or DOT is facing storm intake failures, early intervention with polyurethane solutions can prevent costly replacements and extend the lifespan of your infrastructure. Contact Concrete PolyFix today for a consultation and see how we can help you protect your stormwater systems for the long term.