Causes of Ironwork Failure

Ironwork failures on the highway network are unfortunately all too common. In a landmark study, Scott Wilson Kirkpatrick found that on principal routes, over 50% of manholes fail within just two years of installation or reinstatement.

So why does this happen?

Extensive research and field evidence have identified three primary failure modes—each of which contributes to premature deterioration, safety risks, and increased maintenance costs.

failed road gully
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multiple failures around highway ironwork

The Problem with Traditional Repairs

Traditional ironwork reinstatement methods fail repeatedly—leading to escalating costs, safety risks, and legal exposure.

In a study of over 1,500 failed highway ironwork installations, every single case involved multiple points of failure, including:

  • Bedding mortar breakdown

  • Poor packing or shimming

  • Deteriorated brickwork

  • Cracked or unstable surface surrounds

  • Damaged or misaligned ironwork

These failures fall into three critical categories:

1) Structural, 2) Financial & 3) Litigation

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