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Overlay

Withstand the test of time. 

Fast track your construction process and reduce the amount of material needed for your structure with this thixotropic technology — guaranteeing maximized life span and minimized maintenance over time.

This cast-in-place dense UHPC composition presents a cement-based matrix with a very low void ratio, making it impermeable to carbonation and alkali reactivity, and preventing the penetration of aggressive chemical agents into the applied layers (preventing rebar corrosion), even under heavy stress from road traffic and deicing chemicals.

Ductal® overlay provides a durable and impermeable layer against chlorides and can also structurally strengthen an existing bridge deck. It is an efficient rehabilitation method to extend the service life and to enhance the long-term durability performance in a cost-effective way.

Ductal® overlay offers an optimized solution that protects, strengthens and waterproofs at the same time while saving considerable time during construction.

01 - What it is

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Ductal® Overlay includes both thixotropic and self-compacting consistencies that increase the range of applications (slopes up to 15% and horizontal surfaces applications) while providing speed of construction.

Thanks to its unique combination of ultra high mechanical properties and bending behavior, Ductal® overlay can be used in very thin layers to increase the structure’s bearing capacity, thus reducing the added dead load and extra weights, resulting in reduced material and labour needs.

02 - Implementation

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Add a highly protective, durable, low maintenance layer to new and existing concrete surfaces with Ductal® Overlay, adding protection, strength, durability, waterproofing and resistance to chemicals to any project.

The solution’s implementation can be performed easily with reduced minimal down time, which diminishes risks related to planning and execution deadlines.

03 - Benefits

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  • New overlay
  • Bridge deck rehabilitation and protection
  • Industrial/warehouse floor slab protection
  • Building slab strengthening and repair

04 - Applications

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Discover our projects

The Honghe Suspension Bridge between Honghe Hani and Yi Autonomous Prefecture in Yunnan Province, South of China was completed within 35 days.

The Chillon Viaducts have been reinforced by an Overlay of Ductal® UHPC. Thanks to its mechanical characteristics and its durability properties, Ductal® was the only material able to provide an efficient retrofitting preserving the bearing capacity of the bridge, a lower maintenance cost and a quick retro commissioning of an important axis of the Swiss highway network. The two Chillon...

In 1951, the Delaware Memorial Bridge was opened to traffic allowing commuters to navigate over the Delaware River on a 3,650 ft (1,112 m) long state-of-the-art suspension bridge. The structure is a twin suspension bridge crossing the Delaware River. This roadway is a major artery which carries I-295 from New Jersey to Delaware. This is a toll road where any...

The Commodore Barry Bridge spans over the Delaware River from Chester PA to Bridgeport NJ. Originally constructed in 1969 and named after the Revolutionary War Hero from Philadelphia John Barry. This bridge is a cantilever truss bridge which was commonly built during those times.

A new life for an emblematic structure: The Kanderviadukt was stabilised using a protective coat of Ductal®.

In partnership with Iowa State University and Iowa State DOT, with participation from Wapello and Buchana counties in Iowa, this project was the first to implement overlay application of UHPC using automated paver system brought by Walo from Europe.

State Route 141 over I95 interchange rehabilitation was commenced in 2019 and expected to be fully completed by Spring 2022. Several crossing structures within this interchange utilized precast panels and required UHPC for all the connections.

Deformation of the concrete rolling surface, structural deficit in terms of puncture resistance, sloping terrain (5% gradient) ... the equation to be solved for the repair of the covered car park at the Saas-Fee ski resort was arduous. Ductal® took up the challenge and developed an innovative product meeting all these constraints.

The Gardner River Bridge, with its impressive dimensions and historical significance, posed unique challenges for rehabilitation. To address these challenges, our Ductal Holcim US Engineered Solutions Team developed cutting-edge UHPC Technologies, leveraging materials made in the USA. This commitment to innovation and excellence allowed us to optimize our approach, ensuring durability and sustainability in bridge preservation and repair.

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