Innovation: Sustainable cable duct covers with GRP reinforcement

Klaus Köhler Beton- und Fertigteilwerk GmbH presents a groundbreaking solution for infrastructure: cable duct covers with non-metallic reinforcement made of glass fibre rods („Tec Bar“). This innovation replaces conventional steel reinforcement with a corrosion-free, durable and resource-saving system – and has the potential to bring about lasting change across the entire precast concrete industry. The project was realised in close cooperation with CG Tec Carbon und Glasfasertechnik GmbH, with project management provided by Rothycon Carbon Bewehrung. Within just 1.5 years, the project progressed from initial discussions to series production – including certification by Deutsche Bahn. The cable duct covers have been in series production since April 2024. Extensive tests at two independent testing institutes confirm their technical performance and practical suitability. As a member of the CU Bau specialist network, Köhler Beton is clearly positioning itself as a pioneer for sustainable solutions in precast construction. The combination of materials is remarkable: non-metallic reinforcements often develop their full performance potential in high-strength concretes. Here, however, a standard concrete of class C30/37 was used – proof of its broad applicability and cost-effectiveness.

Innovative Feature

Corrosion-free, durable reinforcement (100–200 years)

Significant CO₂ reduction (250–400 kg vs. 1,800 kg for steel)

Series production and DB certification market readiness achieved

Ergonomic advantage: bars are not cold better working conditions

Added value for products, processes, and technology

Products: Cable duct covers with GRP reinforcement replace steel no rust problems, longer service life, easier handling

Processes: Series production possible in existing production lines, no expensive conversions

State of the art: Steel alternative with up to 80% less CO₂, two to three times longer service life, can be used with standard concrete

Technical and ecological advantages

Technology: Break resistance up to 2 t wheel load

CO₂: 250–400 kg

Service life: 100–200 years, corrosion-free

Ecological balance: savings in energy (48 MJ) and emissions (2.72 kg CO₂ equivalent per kg)

Ergonomics: No cold hands when handling the bars

Practical application: Series production since April 2024, compatible with C30/37.

Degree of innovation and market potential

This solution is a game changer for precast concrete construction and rail infrastructure. It combines sustainability, cost-effectiveness and practicality. Series production and approval by Deutsche Bahn mean that it is already ready for the market. The innovation opens up new perspectives for precast plants, infrastructure operators and the entire industry – both ecologically and economically.