Bridge Superstructures & Decks

........Lower Maintenance, Cost-effective throughout its Life

In 2006, an extruded aluminum deck was constructed for the Kentucky State Road 974 bridge over Howard Creek in Clark County, Ky. The aluminum deck weighs approximately 80 percent less than the steel reinforced concrete deck it replaced, which permitted increasing the load limit for trucks crossing the bridge.

Aluminum bridge decks are 80 percent lighter than concrete, offering increased bridge width and capacity without the need to strengthen the supporting bridge elements. Corrosion-resistant aluminum bridge decks require no painting and minimal maintenance, and are better suited than steel or concrete where de-icing chemicals are used. Aluminum allows for rapid, cost-effective construction. In comparison, concrete typically requires extensive formwork and cure time. Downtime for a bridge receiving an aluminum deck is a fraction of the time needed for concrete. Low-temperature toughness makes aluminum ideal for bridges and other highway structures in colder climates.

Aluminum has a long record of performance for new, rehabilitated, and temporary bridges in the U.S. and Europe. Bridges in North America with aluminum decks or superstructures were first built in the 1940s. Over 50 aluminum bridges have been built in Europe, and that number increases yearly. Since aluminum is lighter than steel and concrete, does not rust or need painting or protective coatings, and lowers maintenance and installation time—and hence lowers cost—aluminum has distinct advantages over other materials.

Aluminum is an ideal material to add width without increasing weight to the substructure and decks of load-restricted bridges, historic bridges, movable bridges, and bridges with narrow roadways. Because seismic forces are directly proportional to weight, aluminum is also excellent for seismic retrofitting of bridges.

New aluminum deck systems are shop-fabricated, welded, and have multivoid extruded bridge deck panels with a shop-applied wearing surface to speed construction. Prefabricated aluminum deck panels can be installed faster than other systems and require no field welding.