Abstract
Current infrastructure management frameworks typically involve replacing bridges at the end of their intended service duration or when significant structural deficiencies arise, resulting in high costs and environmental impacts. Novel structural-strengthening methods using ultra-high-performance fiber-reinforced cementitious composite (UHPFRC) have allowed the preservation of hundreds of bridges in several countries. Their service duration has been extended, and their performance has been improved to match that of a new structure. Examining the Swiss federal network (3903 bridges), it is found that interventions using the UHPFRC method are feasible on more than 99.7% of structures, demonstrating that the structural intervention can be technically applied to most bridges in this network. On the given case study, systematically applying the UHPFRC method would lead to savings of up to 7.7 MtCO2eq, and 18.5 billion CHF over the next 80 years compared to current engineering practice. This study highlights the significant potential of systematically implementing the UHPFRC method for sustainable and cost-effective infrastructure management.
Data availability
The input datasets (i.e., bridge condition data) used in this study are not publicly available due to confidentiality agreements with bridge owners. However, datasets generated and analyzed during the study (i.e., bridge replacement scenarios, cost and carbon savings, and case study results) are available from the corresponding author upon request. Source data are provided with this paper.
Code availability
Carbon and cost-saving potential algorithms are available as Supplementary Code 1.
References
Sánchez-Silva, M., Frangopol, D. M., Padgett, J. & Soliman, M. Maintenance and operation of infrastructure systems: review. J. Struct. Eng. 142, F4016004 (2016).
Yanweerasak, T., Pansuk, W., Akiyama, M. & Frangopol, D. M. Life-cycle reliability assessment of reinforced concrete bridges under multiple hazards. Struct. Infrastruct. Eng. 14, 1011–1024 (2018).
Bocchini, P., Frangopol, D., Ummenhofer, T. & Zinke, T. Resilience and sustainability of civil infrastructure: toward a unified approach. J. Infrastruct. Syst. 20, 04014004 (2014).
Biondini, F. & Frangopol, D. M. Life-cycle performance of deteriorating structural systems under uncertainty: review. J. Struct. Eng. 142, F4016001 (2016).
Barone, G., Frangopol, D. M. & Soliman, M. Optimization of life-cycle maintenance of deteriorating bridges with respect to expected annual system failure rate and expected cumulative cost. J. Struct. Eng. 140, 04013043 (2014).
Zhang, G., Liu, Y., Liu, J., Lan, S. & Yang, J. Causes and statistical characteristics of bridge failures: A review. J. Traffic Transp. Eng. Engl. Ed. 9, 388–406 (2022).
Bertola, N. & Brühwiler, E. Risk-based methodology to assess bridge condition based on visual inspection. Struct. Infrastruct. Eng. 0, 1–14 (2021).
Ye, C., Kuok, S.-C., Butler, L. J. & Middleton, C. R. Implementing bridge model updating for operation and maintenance purposes: examination based on UK practitioners’ views. Struct. Infrastruct. Eng. 18, 1638–1657 (2022).
Brühwiler, E. Framework to engineer existing bridges for sustainability, validated by applications. Struct. Infrastruct. Eng. 1–15 https://doi.org/10.1080/15732479.2025.2453485 (2025).
Habel, K., Viviani, M., Denarié, E. & Brühwiler, E. Development of the mechanical properties of an ultra-high performance fiber reinforced concrete (UHPFRC). Cem. Concr. Res. 36, 1362–1370 (2006).
Du, J. et al. New development of ultra-high-performance concrete (UHPC). Compos. Part B Eng. 224, 109220 (2021).
Graybeal, B. A. Material Property Characterization of Ultra-High Performance Concrete. https://rosap.ntl.bts.gov/view/dot/38714/ (2006).
Yu, R., Spiesz, P. & Brouwers, H. J. H. Mix design and properties assessment of ultra-high performance fibre reinforced concrete (UHPFRC). Cem. Concr. Res. 56, 29–39 (2014).
Shi, C. et al. A review on ultra high performance concrete: Part I. Raw materials and mixture design. Constr. Build. Mater. 101, 741–751 (2015).
Wang, D. et al. A review on ultra high performance concrete: Part II. Hydration, microstructure and properties. Constr. Build. Mater. 96, 368–377 (2015).
Yoo, D.-Y. & Banthia, N. Mechanical properties of ultra-high-performance fiber-reinforced concrete: a review. Cem. Concr. Compos. 73, 267–280 (2016).
Hung, C.-C., El-Tawil, S. & Chao, S.-H. A review of developments and challenges for UHPC in structural engineering: behavior, analysis, and design. J. Struct. Eng. 147, 03121001 (2021).
Charron, J.-P., Denarié, E. & Brühwiler, E. Permeability of ultra high performance fiber reinforced concretes (UHPFRC) under high stresses. Mater. Struct. 40, 269–277 (2007).
Toutlemonde, F. et al. Long-term material performance checked on the world’s oldest UHPFRC road bridges at Bourg-Lès-Valence. In Proc. RILEM-fib-AFGC Int. Symposium on Ultra-High Performance Fibre-Reinforced Concrete, UHPFRC, 265–274 (RILEM Publications SARL, 2013)
Li, J., Wu, Z., Shi, C., Yuan, Q. & Zhang, Z. Durability of ultra-high performance concrete—a review. Constr. Build. Mater. 255, 119296 (2020).
Brühwiler, E. UHPFRC technology to enhance the performance of existing concrete bridges. Struct. Infrastruct. Eng. 16, 94–105 (2020).
Brühwiler, E. & Denarié, E. Rehabilitation and strengthening of concrete structures using ultra-high performance fibre reinforced concrete. Struct. Eng. Int. 23, 450–457 (2013).
Graybeal, B. et al. International perspective on UHPC in bridge engineering. J. Bridge Eng. 25, 04020094 (2020).
Bertola, N., Schiltz, P., Denarié, E. & Brühwiler, E. A review of the use of UHPFRC in bridge rehabilitation and new construction in Switzerland. Front. Built Environ. 7, 155 (2021).
Xue, J. et al. Review of ultra-high performance concrete and its application in bridge engineering. Constr. Build. Mater. 260, 119844 (2020).
Zhou, M., Lu, W., Song, J. & Lee, G. C. Application of ultra-high performance concrete in bridge engineering. Constr. Build. Mater. 186, 1256–1267 (2018).
Brühwiler, E. About the process of technology transfer from research to engineering practice. Struct. Infrastruct. Eng. 21, 1872–1882 (2025).
Schranz, B. et al. Strengthening and prestressing of bridge decks with ribbed iron-based shape memory alloy bars. Eng. Struct. 241, 112467 (2021).
Madaj, A. & Mossor, K. Evaluation of external prestressing as a strengthening method for existing concrete bridges. Struct. Eng. Int. 29, 412–416 (2019).
Zou, X., Lin, H., Feng, P., Bao, Y. & Wang, J. A review on FRP-concrete hybrid sections for bridge applications. Compos. Struct. 262, 113336 (2021).
Feng, S., Xiao, H., Liu, R. & Liu, M. The bond properties between ultra-high-performance concrete and normal strength concrete substrate: Bond macro-performance and overlay transition zone microstructure. Cem. Concr. Compos. 128, 104436 (2022).
Huang, Y., Grünewald, S., Schlangen, E. & Luković, M. Strengthening of concrete structures with ultra high performance fiber reinforced concrete (UHPFRC): a critical review. Constr. Build. Mater. 336, 127398 (2022).
Bentz, D. P. et al. Influence of substrate moisture state and roughness on interface microstructure and bond strength: slant shear vs. pull-off testing. Cem. Concr. Compos. 87, 63–72 (2018).
Beushausen, H., Höhlig, B. & Talotti, M. The influence of substrate moisture preparation on bond strength of concrete overlays and the microstructure of the OTZ. Cem. Concr. Res. 92, 84–91 (2017).
Brühwiler, E. UHPFRC technology for the extension of the service duration of bridges. in Bridge Maintenance, Safety, Management, Digitalization and Sustainability 158–166 (CRC Press, 2024).
Brühwiler, E. & Bastien Masse, M. Strengthening the Chillon viaducts deck slabs with reinforced UHPFRC. In IABSE Conference Geneva 2015 ‘Structural Engineering: Providing Solutions to Global Challenges’ 1171 (IABSE, Geneva, Switzerland, 2015).
El Jisr, H., Moreillon, L. & Menétrey, P. Strengthening of the riddes viaduct through UHPFRC-based rehabilitation. Struct. Eng. Int. 0, 1–9 (2023).
Bertola, N. J. & Brühwiler, E. Transforming the Static System of Prestressed Concrete Bridges Using UHPFRC. J. Bridge Eng. 30, 05025005 (2025).
Hajiesmaeili, A., Pittau, F., Denarié, E. & Habert, G. Life cycle analysis of strengthening existing RC structures with R-PE-UHPFRC. Sustainability 11, 6923 (2019).
Brochellaz, L., Laurencet, P. & Brühwiler, E. Renforcement au CFUP du pont de Bramois sur le Torrent de Verbier. In 3ème Journée Suisse du BFUP, 25–36 (Fribourg, Swizterland, 2019).
Sameer, H. et al. Environmental assessment of ultra-high-performance concrete using carbon, material, and water footprint. Materials 12, 851 (2019).
Randl, N., Steiner, T., Ofner, S., Baumgartner, E. & Mészöly, T. Development of UHPC mixtures from an ecological point of view. Constr. Build. Mater. 67, 373–378 (2014).
Lande, I. & Terje Thorstensen, R. Comprehensive sustainability strategy for the emerging ultra-high-performance concrete (UHPC) industry. Clean. Mater. 100183 https://doi.org/10.1016/j.clema.2023.100183 (2023).
Habert, G., Denarié, E., Šajna, A. & Rossi, P. Lowering the global warming impact of bridge rehabilitations by using Ultra High Performance Fibre Reinforced Concretes. Cem. Concr. Compos. 38, 1–11 (2013).
Fan, J., Huang, W., Wang, H., Adams, M. P. & Bandelt, M. J. Multi-physics simulation–driven assessment of environmental and cost performance in ultra-high performance concrete (UHPC) bridge deck under local climate effects. Eng. Struct. 343, 121029 (2025).
Bertola, N., Küpfer, C., Kälin, E. & Brühwiler, E. Assessment of the environmental impacts of bridge designs involving UHPFRC. Sustainability 13, 12399 (2021).
Shao, Y., Parks, A. & Ostertag, C. P. Carbon footprint between steel-reinforced concrete and UHPC beams. J. Struct. Eng. 149, 06023001 (2023).
di Summa, D., Parpanesi, M., Ferrara, L. & De Belie, N. A holistic life cycle design approach to enhance the sustainability of concrete structures. Struct. Concr. 24, 7684–7704 (2023).
Dong, Y. Performance assessment and design of ultra-high performance concrete (UHPC) structures incorporating life-cycle cost and environmental impacts. Constr. Build. Mater. 167, 414–425 (2018).
Bertola, N., Kälin, E. & Brühwiler, E. Environmental and Life-Cycle Cost Evaluation of a Composite Timber-UHPFRC Bridge. In Third International Interactive Symposium on Ultra-High Performance Concrete 2023, Vol. 3 (Iowa State University Digital Press, Wilmington, Delaware, USA, 2023).
Federal Roads Office (FEDRO). https://www.astra.admin.ch/astra/en/home.html.
Federal Road Office (FEDRO). RAPPORT SUR L’ÉTAT DU RÉSEAU DES ROUTES NATIONALES 2023. 56 https://www.astra.admin.ch/astra/fr/home/themes/routes-nationales/reseau/rapport-d-etat-des-routes-nationales.html (2024).
Collings, D. The carbon footprint of bridges. Struct. Eng. Int. 32, 501–506 (2022).
Collings, D. & Murthy, S. An update on bridge carbon footprint data. Proc. Inst. Civ. Eng. Bridge Eng. 1–21 https://doi.org/10.1680/jbren.23.00032 (2024).
Archer-Jones, C. & Green, D. Carbon targets for bridges: a proposed SCORS-style rating scheme. Struct. Eng. 99, 14–18 (2021).
Orr, J., Gibbons, O. & Arnold, W. A brief guide to calculating embodied carbon. Struct. Eng. 98, 22–27 (2020).
KBOB, K. der B. L. der öffentlichen B. Ökobilanzdaten im Baubereich. https://www.kbob.admin.ch/kbob/de/home/themen-leistungen/nachhaltiges-bauen/oekobilanzdaten_baubereich.html (2024).
Swiss Society of Engineers and Architects. Règlement concernant les prestations et honoraires des ingénieurs civils—SIA 103. (SIA Zürich Publisher, 2020).
Bertola, N. & Brühwiler, E. Transforming the static system of prestressed concrete bridges using UHPFRC. J. Bridge Eng. 30, 05025005 (2025).
Yu, R. et al. Sustainable development of Ultra-High Performance Fibre Reinforced Concrete (UHPFRC): Towards to an optimized concrete matrix and efficient fibre application. J. Clean. Prod. 162, 220–233 (2017).
Brühwiler, E. et al. Strengthening the Chillon viaducts deck slabs with reinforced UHPFRC. in IABSE Symposium Report Vol. 105, 1–8 (International Association for Bridge and Structural Engineering, 2015).
Adey, B., Hajdin, R. & Brühwiler, E. Effect of common cause failures on indirect costs. J. Bridge Eng. 9, 200–208 (2004).
Tran, H., Robert, D., Gunarathna, P. & Setunge, S. Estimating cost of bridge closure for bridge network rehabilitation priorities. J. Constr. Eng. Manag. 150, 04024071 (2024).
Haber, Z. B., McDonagh, M., Foden, A. & Sadasivam, S. Ultra-High Performance Concrete (UHPC) Overlays: An Example of Lifecycle Cost Analysis [Tech Note]. (Federal Highway Administration (FHWA), USA, 2022). https://rosap.ntl.bts.gov/view/dot/64952.
Yuan, Y., Wu, C. & Jiang, X. Experimental study on the fatigue behavior of the orthotropic steel deck rehabilitated by UHPC overlay. J. Constr. Steel Res. 157, 1–9 (2019).
Jun, Z. 2024 Highlights of UHPC Developments in China. White Hub https://www.white-hub.com/innovation-sustainability/2024-highlights-uhpc-developments-china (2025).
Technical Leaflet on UHPFRC: Materials, Design and Application (SIA 2052). 48 (Société suisse des ingénieurs et des architectes (SIA), SIA Zürich Publisher, 2016).
Finkbeiner, M., Inaba, A., Tan, R., Christiansen, K. & Klüppel, H.-J. The new international standards for life cycle assessment: ISO 14040 and ISO 14044. Int. J. Life Cycle Assess. 11, 80–85 (2006).
Sjöström, C. et al. Implementation of the European Construction Products Directive via the ISO 15686 standards. In Proc. 9th Conference of Durability of Building Materials and Components, Brisbane 2002 (CSIRO Publishing, 2002).
European Standards. Sustainability of construction works—Environmental product declarations—Core rules for the product category of construction products (includes Corrigendum: 2021). https://doi.org/10.31030/3294005 (2022).
Jalaei, F., Zhang, J., Ayuk, N. M. & McLeod, C. Environmental life cycle assessment (LCA) for design of climate-resilient bridges—a comprehensive review and a case study. Int. J. Constr. Manag. https://www.tandfonline.com/doi/abs/10.1080/15623599.2024.2304479 (2025).
DIN EN ISO 14044. https://doi.org/10.31030/3179656 (2021).
Wernet, G. et al. The ecoinvent database version 3 (part I): overview and methodology. Int. J. Life Cycle Assess. 21, 1218–1230 (2016).
Brühwiler, E., Oesterlee, C. & Redaelli, D. Béton Fibré Ultra Performant: Concevoir, Dimensionner, Construire. 3ème Journée d’étude, 24 Octobre 2019. 196 https://www.heia-fr.ch/media/vmvibli0/gesamt-tagungsband-uhfb-2019.pdf (2019).
Brühwiler, E. “Structural UHPFRC”: Welcome to the post-concrete era! in International Interactive Symposium on Ultra-High Performance Concrete 1–16. https://doi.org/10.21838/uhpc.2016.key (Iowa State University Digital Press, Des Moines, Iowa, USA, 2016).
Cesare, M. A., Santamarina, C., Turkstra, C. & Vanmarcke, E. H. Modeling bridge deterioration with Markov chains. J. Transp. Eng. 118, 820–833 (1992).
Marsili, F. et al. Abschätzung Der Restnutzungsdauer von Brückenbauwerken Durch Entwicklung Und Erprobung Hybrider Modelle, 264 (ENDURE Network publisher, 2024)
Habert, G. et al. Environmental impacts and decarbonization strategies in the cement and concrete industries. Nat. Rev. Earth Environ. 1, 559–573 (2020).
Acknowledgements
The authors are thankful for the data and input provided by Dr. Dimitrios Papastergiou and Charles-Henry Demory (Federal Roads Office FEDRO) and Dr. Marian Ralbovsky (Austrian Institute of Technology).
Author information
Authors and Affiliations
Contributions
N.B., C.K., and E.B. contributed to the conceptualization of the study. N.B. and C.K. performed the analyses. N.B. developed the code and drafted the manuscript. All authors reviewed and approved the final version.
Corresponding author
Ethics declarations
Competing interests
The authors declare no competing interests.
Peer review
Peer review information
Nature Communications thanks Pamela Haverkamp, Gabriel Sas and Helder Sousa for their contribution to the peer review of this work. A peer review file is available.
Additional information
Publisher’s note Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Source data
Rights and permissions
Open Access This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License, which permits any non-commercial use, sharing, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if you modified the licensed material. You do not have permission under this licence to share adapted material derived from this article or parts of it. The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by-nc-nd/4.0/.
About this article
Cite this article
Bertola, N., Küpfer, C. & Brühwiler, E. Environmental and economic benefits of UHPFRC intervention in bridge management for the Swiss network. Nat Commun (2026). https://doi.org/10.1038/s41467-026-69103-x
Received:
Accepted:
Published:
DOI: https://doi.org/10.1038/s41467-026-69103-x