From Rust to Robust: A CFRP Trenchless Triumph in Penstock Repair

Abstract

Penstocks form the backbone of hydropower generation, channeling high-pressure water from reservoirs to turbines with minimal energy loss. Their design and integrity are critical to the reliable delivery of peak electrical demand. As these assets age, maintaining structural performance while minimizing environmental impact becomes increasingly complex— particularly when they are located in environmentally sensitive and logistically challenging areas. This paper presents the trenchless structural renewal of a 1941 steel riveted penstock in Banff National Park, Alberta, Canada, using Carbon Fiber Reinforced Polymer (CFRP). The project showcases the integration of innovative construction methods, stringent quality control, and environmental stewardship to restore full pressure capacity and extend service life without the need for open-cut replacement.