Prefabricated Bridge Elements and Systems in Japan and Europe

FHWA-PL-05-003

The aging highway bridge infrastructure in the United States is being subjected to increasing traffic volumes and must be continuously renewed while accommodating traffic flow. The traveling public demands that this rehabilitation and replacement be done more quickly to reduce congestion and improve safety. Conventional bridge reconstruction is typically on the critical path because of the sequential, labor-intensive processes of completing the foundation, substructure, superstructure components (girders and decks), railings, and other accessories. New bridge systems are needed that will allow components to be fabricated offsite and moved into place for quick assembly while maintaining traffic flow. Depending on the specific site conditions, the use of prefabricated bridge systems can minimize traffic disruption, improve work zone safety, minimize impact to the environment, improve constructibility, increase quality, and lower life-cycle costs. This technology is applicable and needed for both existing and new bridge construction. The focus of this initiative is on conventional, routine bridges that make up the majority of the bridges in the United States.

To obtain information about technologies being used in other industrialized countries, a scanning study of five countries was conducted in April 2004. The overall objectives of the scanning study were to identify international uses of prefabricated bridge elements and systems, and to identify decision processes, design methodologies, construction techniques, costs, and maintenance and inspection issues associated with use of the technology. The scanning team, therefore, was interested in all aspects of design, construction, and maintenance of bridge systems composed of multiple elements fabricated and assembled offsite. The elements consisted of foundations, piers or columns, abutments, pier caps, beams or girders, and decks. Bridges with span lengths in the range of 6 to 40 meters (m) (20 to 140 feet (ft) were the major focus, although longer spans were of interest if a large amount of innovative prefabrication was used.

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