Regeneration and reinforcement of metal culvert

A Ductal® Shotcrete application

You are looking for a quick, economical and long-lasting solution for the renovation of metal culvert that are damaged by corrosion. But traditional techniques reduce the diameter of the work and require heavy work sites. A better solution is presented to you: the new Ductal® UHPC Shotcrete with very high durability. What are the advantages? Reduced work times, preserved circulation dimensions and well-protected templates and thresholds.

 
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In the scope of your infrastructure maintenance and surveillance, the renovation of metal culvert is a real technical and economic challenge. How can these structures be restored at a low cost and as quickly as possible, while respecting technical requirements such as the conservation of speed? The problem becomes even more urgent because a corroded duct can cause major disruptions for the stability of works over time.

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Traditional techniques: solutions by default

Until now, three technical principles were possible: traditional sprayed concrete, poured concrete and lining with GRP (Glass-Reinforced Plastics). These three methods have advantages as well as many disadvantages including:

  • Long and heavy preparation work: placement of framework and metal connectors (traditional sprayed concrete) / installation of a casing (poured concrete) or channeling by a special convoy of prefabricated modules (GRP pushing) for large diameters.
  • Damage of works' characteristics: reduction of diameters (15 to 30 cm for concrete), creation of thresholds to be arranged to provide for passage of machines and wildlife.

Now there is another solution: Ductal®!

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Ductal® UHPC Shotcrete: the global response to your specific issues

The result of research by LafargeHocim R&D teams and Freyssinet, this new Ductal® Shotcrete solution represents a technological break in the field of UHPCs. It is the only one on the market that can be applied directly to vertical walls or vaults by spraying.

An application facilitated for exceptional durability

In the reinforcement of metal culvert, the application of Ductal® shotcrete does not require any extensive preparatory work besides a quick cleaning of the works by simple sandblasting. The time periods of your work sites are drastically reduced, which allows you to limit the time when works are closed.

Applied by spraying directly onto metal walls, thin layers of Ductal® Shotcrete (less than 6 centimeters), provide a rapid and durable regeneration and reinforcement of the infrastructure. This solution has the advantage of not altering the characteristics of works while ensuring that they are returned to new, almost identical, condition.

Due to its qualities of durability, its resistance to damage from chemicals and weather and from collisions and abrasion, it guarantees effective and long-lasting renovations.

Finally, renovation with Ductal® Shotcrete prevents waste. On a duct with a diameter of 2.5 meters, a 60 mm layer is sufficient (versus 15 to 30 cm for sprayed or poured concrete). Therefore, the geometry of the culvert is completely protected and the reduction of their diameter is extremely low, less than 2% for a nozzle with a 2.5 m diameter.

 

Advantages of choosing Ductal® Shotcrete

 
  • Simpler work sites

    • Reduction of work times by teams due to Foreva® spraying technique

    • Conservation of the Hydraulic Template and Thresholds

    • Protection of Circulation Dimensions

    • No transformation of initial characteristics of the duct (diameter, speed, template)
  • Works restored

    • Durability of the new structure

     

    • Resistance to damaging agents (chlorines), abrasion, collisions and freezing-thawing cycles

     

    • Secured infrastructures for vehicles and agricultural machines

     

    • Respect for ecological continuity
 

Therefore, the Ductal® solution lifts every constraint and obstacle posed by regular solutions. This is real technological and economical progress.

 

Ductal® Shotcrete: a validated and controlled innovation

  • A mechanical qualification of the material and its spraying in a laboratory and on a demonstratorA mechanical qualification of the material and its spraying in a laboratory and on a demonstrator
  • Solution awarded by call for innovative projects by the CIRR (Comité Routes et Rues [Roads and Streets Committee]) in 2016
  • Development assisted by the Centre d'études des tunnels   (CETU) ([Tunnels Studies Center], technical validation) with the technical support of the l'Institut français des sciences et technologies des transports, de l'aménagement et des réseaux (IFFSTAR)
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Innovation: Ductal® Shotcrete, the first sprayed UHPC

Innovation: Ductal® Shotcrete, the first sprayed UHPC

The Ultra-High Performance Fiber-Reinforced Concrete (UHPC) product line Ductal® has expanded with a new formula that is applied by spraying on vertical walls, vaults and complex structures. This technological breakthrough offers new competitive solutions for engineers and construction contractors.