The Barbazan Culvert Rehabilitation project marked the first field application of spray-applied Ultra-High Performance Fiber-Reinforced Concrete (UHPFRC) for strengthening a corrugated steel culvert. Developed through a collaborative effort between Freyssinet, LafargeHolcim, and French transportation research agencies, the innovative solution restored structural capacity, minimized traffic disruption, and extended the service life of the culvert while maintaining existing clearances. The project demonstrated how thin layers of UHPFRC can provide durable, long-term infrastructure rehabilitation with significantly less material than conventional repair methods.

 

  • Owner
    VINCI Autoroutes, ASF (Autoroutes du Sud de la France)
  • Project Completion Date
    September 2020
  • Partners of the project
    UHPFRC supplier: LafargeHolcim

Expanding the Possibilities for UHPFRC

UHPFRC dry-sprayed application Freyssinet USA

Ultra-High Performance Fiber-Reinforced Concrete (UHPFRC) has a unique combination of high compressive and tensile strength, ductility, impact resistance, abrasion resistance, freeze-thaw durability, and protection against chloride intrusion makes it an ideal material for structural repairs designed to last 50 to 100 years.

Traditionally, UHPFRC applications were limited to cast-in-place or precast construction because the material’s self-leveling properties made it difficult to apply to vertical, inclined, or overhead surfaces.

The development of a spray-applied UHPFRC system transformed those limitations, creating new opportunities for rehabilitation and strengthening projects across a wide range of infrastructure assets.

This breakthrough resulted from a partnership between LafargeHolcim, which developed the specialized UHPFRC mix, and Freyssinet, which engineered the application process and equipment necessary to place the material efficiently in the field.

The collaboration also included support from transportation research organizations in France, helping validate the technology for the rehabilitation of corrugated steel culverts.

First Application on
Corrugated Steel Culverts

The first implementation of the spray-applied UHPFRC system focused on repairing and strengthening corroded corrugated steel culverts beneath a highway. The project was funded through an innovation initiative supported by the French Ministry for Environmental Transition. Development and validation of the system involved three major phases.

1- Adapting the Material and Equipment

Because conventional UHPFRC is designed as a self-consolidating material, a new formulation was required to allow pumping and spraying onto vertical and overhead surfaces.

LafargeHolcim Ductal developed the modified concrete mix, while Freyssinet designed the field equipment required for batching, pumping, and spray application. The result was a practical construction process capable of delivering consistent quality in challenging environments.

 

2-Validating Structural Design Methods

The second phase focused on confirming the structural performance of the rehabilitation system and establishing reliable design methodologies.

Freyssinet constructed a full-scale testing program using corrugated steel pipe sections reinforced with spray-applied UHPFRC. Load testing measured structural response under increasing loads and documented deformation behavior.

Additional bending tests were performed on sprayed corrugated panels to gather detailed performance data and refine engineering calculations for future projects.

 

3- Verifying Performance in the Field

The final stage involved selecting a real-world project site to demonstrate the technology under actual construction conditions.

Engineers chose a deteriorated corrugated steel culvert and rehabilitated it using a thin UHPFRC lining with an average thickness of approximately 2.4 inches (6 centimeters). Despite the relatively thin application, the material provided substantial structural strengthening while preserving the semi-flexible behavior of the original structure.

Because only a thin layer was required, the repair minimized reductions in interior clearance and maintained hydraulic capacity for water conveyance where applicable.

Efficient and Durable Rehabilitation

The exceptional mechanical properties of UHPFRC make it possible to reduce material quantities by approximately two-thirds compared to traditional reinforced concrete strengthening methods.

This reduction delivers several significant advantages:

  • Shorter construction schedules
  • Reduced material transportation and site logistics
  • Lower environmental impact
  • Less disruption to roadway users
  • Preservation of existing clearances and flow capacity
  • Extended service life with reduced maintenance requirements

These benefits make spray-applied UHPFRC an attractive alternative for upgrading aging infrastructure while minimizing operational impacts.

 

Mobile UHPFRC Production Unit

To support field applications, Freyssinet developed a compact mobile batching and pumping system specifically designed for UHPFRC projects.

The portable unit can be rapidly deployed and delivers precise quality control while supporting pumping distances of up to 328 feet (100 meters). The system improves productivity and allows UHPFRC rehabilitation projects to be performed efficiently in remote or constrained sites.

Barbazan Culvert Reinforcement with Spray-Applied UHPFRC | Freyssinet

Barbazan Culvert Project

In September 2020, Freyssinet used this mobile production system to rehabilitate the Barbazan farm-access culvert beneath the A64 Highway near Tarbes in southwestern France.

Approximately 99 tons of spray-applied UHPFRC were installed during the project. The corrugated steel culvert measures approximately 194 feet in length and 14.4 feet in diameter.

Construction was completed over a four-week period, successfully demonstrating the effectiveness of spray-applied UHPFRC as a structural rehabilitation solution for deteriorated steel culverts.

 

Future Applications

The success of the Barbazan project has opened the door to a wide variety of potential applications for spray-applied UHPFRC. The technology can be used to strengthen, protect, waterproof, and extend the service life of infrastructure assets such as:

  • Dams
  • Canals
  • Tunnels
  • Arches and vaults
  • Marine structures
  • Retaining structures
  • Water treatment facilities

While UHPFRC materials typically carry a higher upfront cost than conventional concrete, projects often realize lower overall lifecycle costs. Reduced material requirements, faster installation, fewer maintenance interventions, and significantly longer service life can provide substantial long-term value when compared to traditional repair solutions.

Contact Freyssinet Today!

Thank you for your interest in Freyssinet, Inc. To discuss a specific project, sign up for our newsletter, schedule a presentation, or request other information, please fill out the form below and we will contact you shortly.

  • This field is for validation purposes and should be left unchanged.
  • *Mandatory fields