Engineering stronger bridges through smarter materials

Innovative, domestically produced materials are optimizing bridge infrastructure and reducing long-term maintenance demands

By Andy Foden and Ted Zoli | HNTB

As much of the U.S. bridge inventory reaches or surpasses its intended design life, transportation agencies face a pivotal moment. Thousands of structures, many built between the 1950s and 1970s, operate under increased traffic volumes, load demands and environmental conditions. To maintain safety, reliability and economic vitality, agencies are searching for rehabilitation and replacement programs that can deliver longer-lasting performance, reduce life cycle costs and meet rising expectations for speed and resilience.

Innovative, domestically produced materials are available now and are already demonstrating superior performance, longer service life and reduced maintenance demands in the field. Ultra-high-performance concrete (UHPC), internally cured (IC) concrete and quenched and self-tempered (QST) steel, in particular, are enabling agencies to deliver bridges with higher strength-to-weight ratios, improved durability and enhanced constructability.

When paired with collaborative delivery models and informed stakeholder coordination, agencies can leverage these materials to modernize infrastructure in ways that are both technically advanced and operationally efficient, advancing the long-term resilience and sustainability of transportation networks.

A new toolbox for accelerated, stronger and more resilient bridges

The following materials can transform an agency’s approach to bridge infrastructure, helping to address specific, persistent challenges, from cracking in decks to the limitations of field-placed concrete joints, while supporting broader goals such as sustainability, resilience and life cycle efficiency.

• Internally cured (IC) concrete: By embedding curing water directly into the concrete matrix, IC concrete reduces early-age shrinkage and cracking, which is a common issue in traditional decks. States, like New York, have adopted it as a standard after demonstration projects showed significantly less cracking and better long-term performance when compared to conventional high-performance concrete.
• Quenched and self-tempered (QST) steel: By post-processing standard rolled sections, QST steel offers higher strength and toughness without requiring custom metallurgy. The lighter, shallower profiles also ease installation and improve hydraulic performance — key advantages for rapid bridge replacements. For example, Louisiana Department of Transportation used QST steel on rural bridge replacements following Hurricane Ida.
• Ultra-high-performance concrete (UHPC): UHPC offers exceptional strength and impermeability, making it ideal for field-cast connections in prefabricated bridge systems. UHPC joints can exceed the performance of adjacent precast members, supporting longer service life and greater structural integrity. Its use is enabling broader adoption of modular components, streamlining delivery and reducing long-term maintenance. In addition to connections, a number of states have leveraged UHPC for bridge deck overlays, steel girder end repair and deck joint elimination using link slabs to extend structure life and reduce closure times. With the recent publication of the AASHTO LRFD Guide Specifications for Structural Design with Ultra-High-Performance Concrete, UHPC is also becoming more established as a material for primary structural elements such as girders and deck systems to provide longer spans, shallower depths and lighter loads on the substructure.

Turning innovation into everyday practice

Successfully integrating new materials into bridge programs requires coordinated action across agencies, designers and contractors — supported by a clear strategy for implementation, knowledge transfer and sustained investment. The following strategies can support the implementation of innovative materials:

• Project Champion: A dedicated advocate within the agency or project team can accelerate adoption by maintaining focus on the innovation’s benefits, navigating approval processes and aligning stakeholders around common objectives. Champions often help secure funding, coordinate training and ensure lessons learned are carried forward to future projects, turning one-off successes into repeatable practice.
• Partnerships and shared guidance: Collaborations with academic institutions, industry consortia and federal partners are accelerating the development of practical design and construction guidance. Many successful projects have leveraged FHWA’s Every Day Counts program, an initiative that deploys proven but underutilized innovations to save time, reduce costs and stretch resources. Shared research, nonproprietary specifications and open-source tools are helping agencies evaluate, procure and implement new materials with greater confidence and consistency.
• Pilot projects as proving grounds: Demonstration projects play a critical role in validating material performance under real-world conditions. They allow teams to test constructability, refine installation techniques and develop standard details, while reducing perceived risk. These demonstrations also can help build institutional knowledge, creating templates and precedents that can accelerate adoption across an agency’s program.
• Flexible delivery to enable innovation: Alternative delivery models such as design-build and CM/GC encourage early, integrated decision-making between engineers, contractors and material suppliers. This alignment enables teams to identify opportunities for innovation during the planning and design phases, optimize material sourcing and adapt quickly during construction, all of which are essential when working with new or evolving technologies.

Together, these approaches are helping agencies move beyond experimentation, laying the groundwork for broader adoption and long-term impact of innovative materials.

Transforming bridges through smarter materials and strategies

As demands on bridge infrastructure increase, so do the tools and technologies available to meet them. Proven, high-performing materials are already reshaping how agencies build, preserve and modernize critical structures. These innovations aren’t theoretical; they’re field-tested, cost-effective and available today. By accelerating their adoption through strategic investment and cross-sector collaboration, agencies can deliver safer, stronger bridges that stand the test of time.