REINFORCEKiT® STRUCTURE, Corroded trolleybus poles – Europe
Composite solution for structural repair
Overview
In June 2025, 3X ENGINEERING (3X) specialists performed 9 reinforcements on trolleybus poles severely damaged by corrosion. These structures are located in the city center. To restore their structural integrity, the REINFORCEKIT® STRUCTURE composite repair system was applied.
Results
Hardness measurements, conducted 6 to 20 days post-repair, validated all repairs. All tested products met 3X hardness requirements. These repairs are designed for a minimum 20-year lifespan minimum.
 Defect type |
Severe corroded structures |
Details |
Poles (trolleybus) - 9 units - various shapes |
Location |
Europe |
3X Product type |
REINFORCEKIT® STRUCTURE |
SCOPE OF WORK
Damaged poles have various shapes: 8 octogonal shapes and 1 round specific shape with 2 cables on both sides. REINFORCEKIT STRUCTURE is a tailor-made composite repair system that enables to adapt to various designs. Repair designs were developed using finite element analysis (FEA) to ensure optimal structural performance. Initially, lead paint was removed and the concrete base was disbursed.
Focus here is on the specific round shape with cables on both sides:
- Surface preparation & hygrometric conditions control: Surface preparation was carried out with Bristle Blaster machine to achieve adequate roughness (minimum 60-micron surface profile). Hygrometric conditions were checked to confirm compliance with application standards. Acetone was then used to clean the surface of any dust.
- 3X resin & metal inserts installation: 3X epoxy resin was firstly applied at the base to seal the concrete/beam interface. Custom-designed metal inserts (here made of 2 half shells), tailored to fit the specific geometry of the pole, was then installed. These inserts were fixed using 3X filler and secured with ratchet belts until the filler cured completely.
- Composite wrapping reinforcement: A first layer of 3X resin was applied on the entire surface to ensure optimal adhesion and impregnation. The structure was then reinforced with six layers of Kevlar® tape impregnated with epoxy resin to restore its mechanical performance.
- Impact & UV protection: The repaired area was covered with a specific coating to provide long-term durability and protection against UV exposure and mechanical impacts.
