Dedicated and sustainable – Cable duct covers with nonmetallic reinforcement contribute to a low-carbon infrastructure

In this presentation, Lars Lehmann, Managing Director of Klaus Köhler Beton- und Fertigteilwerk GmbH, explains how nonmetallic reinforcement can be used in concrete structures and what its benefits are in terms of implementing a low-carbon infrastructure. In a Deutsche Bahn infrastructure project, inexpensive glass-fiber-reinforced plastic (GFRP) was used for the first time instead of conventional reinforcing steel. This project demonstrates how successful collaboration can drive innovation. GFRP bars were sourced from CG TEC Carbon und Glasfasertechnik GmbH, and the project was coordinated by Rothycon Carbon Bewehrung.

Ready for series production in just 1.5 years, including Deutsche Bahn certification

Cable duct covers have been in series production since April 2024, and tests conducted by two independent organizations confirmed their market readiness. As a member of the CU Bau industry network, Köhler Beton is pioneering sustainable infrastructure and precast solutions. Even though nonmetallic reinforcing materials often only reach their full potential in high-strength concrete, a standard C30/37 concrete was used in this project, which proved their fitness for purpose and suitability for series production.

Key benefits:

Structural performance: 2-ton wheel load capacity in the post-fracture state

Sustainability: carbon footprint of 250–400 kg (vs. 1,800 kg for steel)

Service life: 100–200 years, no corrosion

Environmental footprint: energy savings (48 MJ) and lower emissions (2.72 kg CO₂eq/kg)

Ergonomics: Reinforcing bars are not cold, which is why employees’ hands do not get cold.

Practical advantage: works with C30/37 standard concrete, not just high-strength concrete

This is a real game changer for sustainable concrete construction in rail infrastructure. Carbon and glass-fiber reinforcing materials are market-ready and unlock enormous economic and environmental potential for infrastructure and precast construction.