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Donald McwayneGood team members always offer budget in time and answer questions with patience, great job! -
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Long Span Prefabricated Box Girder Steel Bridge for Expressway & Municipal Crossing
| Place of Origin | China |
|---|---|
| Brand Name | FASEC |
| Certification | ISO 9001; EN 1090-1 FPC; CE; AWS CWI; AISC IBR/ABR |
| Model Number | Steel Girder Bridge |
| Minimum Order Quantity | 100 MT |
| Price | USD 1,000-1,500/MT |
| Packaging Details | Sea Freight (Container/Bulk Vessel) |
| Delivery Time | 30-60 Days |
| Payment Terms | L/C, D/A, D/P, T/T |
| Supply Ability | 5,000-15,000 MT/Year |
Product Details
| Design Standard | AASHTO LRFD | Welding Standard | AWS D1.5M |
|---|---|---|---|
| Deck Type | Orthotropic Steel Deck / Concrete Composite Deck | Corrosion Protection | Hot-dip Galvanizing (ASTM A123), Epoxy Coating, Weathering Steel |
| Field Connection | ASTM A325/A490 High-strength Bolts / AWS D1.5M Field Welding | NDT Inspection | 100% UT For FCM Welds; MT/PT As Required |
| Customization | Customized To Project Requirements (span, Width, Load, Site Conditions) | Applications | Expressway Crossings, Municipal Urban Crossings, Highway Ramps, Pedestrian Bridges, Port Bridges |
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| NDT Inspection |
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Product Description
The Long Span Prefabricated Box Girder Steel Bridge is a high-performance steel bridge superstructure, specially designed for expressway and municipal crossing projects requiring long clear spans, fewer intermediate piers and fast construction. Featuring a closed trapezoidal box structure with outstanding torsional rigidity and load-bearing capacity, this bridge realizes single long spans of 50m–100m+, effectively simplifying foundation construction and reducing civil engineering costs. All modular components are fully prefabricated in factory and quickly assembled on-site, perfectly suitable for river crossing, railway crossing, existing highway renovation and urban intersection reconstruction projects with strict time and traffic control requirements.
Long Span Design Philosophy
Our long-span bridge design balances structural strength, overall stiffness and self-weight efficiency to achieve optimal spanning performance:
- Optimized Span-to-Depth Ratio: Girder depth controlled at 2.5m–5.5m to realize high stiffness-to-weight ratio for stable long-span operation.
- Variable Depth Structure: Girders adopt variable depth design for spans over 70m — thicker at supports to resist maximum bending moment, thinner at mid-span to reduce dead load.
- Orthotropic Steel Deck: Adopts orthotropic steel deck for ultra-long-span projects to lower self-weight and maximize spanning efficiency.
- Full Composite Action: Factory pre-welded shear studs realize reliable composite cooperation with concrete deck to enhance overall stiffness and reduce deflection.
- High-Strength Material: Adopts ASTM A709 HPS 70W high-performance steel to achieve lighter structure and longer span without sacrificing structural strength.
- Infinite Fatigue Design: All structural details comply with highway cyclic load standards to ensure long-term fatigue resistance under high traffic flow.
- Wind & Seismic Resistance: Aerodynamic box section reduces wind load; seismic design strictly follows AASHTO LRFD for high-risk seismic zones.
Key Technical Specifications
| Parameter | Specification / Range |
|---|---|
| Span Configuration | Single span: 50m–120m; Continuous total length: up to 300m+ |
| Bridge Width | 8m–28m (2–8 traffic lanes + safety shoulders) |
| Girder Depth | 2.0m–5.5m (constant / variable depth customizable) |
| Steel Grade | ASTM A709 (50, 50W, HPS 50W, HPS 70W) |
| Design Standard | AASHTO LRFD (HL-93 live load, fatigue, wind and seismic load) |
| Welding Standard | AWS D1.5M Bridge Welding Code |
| Deck Type | Orthotropic steel deck / Concrete composite deck with shear studs |
| Corrosion Protection | Weathering steel, epoxy paint system, ASTM A123 hot-dip galvanizing |
| Field Connection | High-strength bolted splices / AWS D1.5M field welding |
| Design Life | 75–100+ years |
Structural Performance & Mechanical Advantages
Box girder structure is the most preferred solution for long-span crossing projects with exclusive mechanical advantages:
- Excellent Torsional Rigidity: Closed box section effectively resists torsion force, suitable for curved bridges, skew crossings and uneven multi-lane load distribution.
- High Lateral Stability: Inherent structural stability greatly reduces temporary bracing demand during erection and long-term service.
- High Strength-to-Weight Ratio: Supports longer spans with thinner sections, improves vertical clearance and lowers approach road gradient requirements.
- Uniform Load Distribution: Optimized cross-section structure ensures even stress distribution and improves material utilization rate.
- Structural Redundancy: Multi-box and multi-cell design provides redundant load paths, improving safety for fracture-critical components.
- Aerodynamic Performance: Streamlined box structure reduces wind resistance and vortex vibration, adapting to coastal and open-area long-span bridge environments.
Prefabrication & Installation Strategy
We adopt professional modular prefabrication and systematic erection scheme to solve long-span bridge construction difficulties:
- Reasonable Module Segmentation: Divided into 12m–20m standard modules to fit international transportation and hoisting limits.
- Full Pre-assembly Factory Production: Stiffeners, diaphragms, shear connectors and access hatches are fully pre-installed in factory.
- Fast On-site Assembly: High-strength bolted connection enables weather-independent, fast and inspectable on-site installation.
- Diversified Erection Methods: Support crane lifting, incremental launching and barge hoisting according to actual site conditions.
- Minimum Traffic Disruption: Over 90% factory prefabrication greatly shortens on-site construction period.
- Parallel Construction: Foundation work and steel bridge fabrication proceed simultaneously to compress overall project cycle.
- Precision Camber Design: Pre-set professional camber to offset dead-load deflection and ensure accurate final bridge profile.
Fabrication & Quality Assurance – AWS D1.5M Certified
All bridge modules are manufactured in AWS D1.5M certified workshop with full standardized quality control:
| Quality Aspect | Our Standard |
|---|---|
| Welding Compliance | Full compliance with AWS D1.5M Bridge Welding Code |
| Production Personnel | AWS-certified welders & CWIs full-shift supervision |
| Tension Weld Inspection | 100% UT (Ultrasonic Testing) |
| Fillet Weld Inspection | MT / PT non-destructive testing as required |
| FCM Standard | Clause 12 compliance, enhanced inspection & Charpy V-notch test |
| Material Traceability | Complete MTRs (Mill Test Reports) for all steel materials |
| Dimensional Control | Laser precision measurement for camber, alignment and assembly tolerance |
| Third-Party Inspection | Available for SGS, BV, TÜV independent inspection |
| Technical Documents | Complete quality dossier: WPS/PQR, NDT reports, as-built drawings |
Lifecycle Considerations – Built for Decades
Our long-span steel bridges are designed for long-term stable operation and low maintenance:
- Long Service Life: Standard design life of 75–100+ years with routine maintenance.
- Maintenance-Free Option: A709 weathering steel forms natural anti-corrosion patina, suitable for inaccessible crossing projects.
- Convenient Inspection Design: Equipped with internal access hatches and ventilation system for daily inspection and maintenance.
- Permanent Fatigue Resistance: Structural details meet infinite fatigue life standards for long-term high-frequency traffic load.
- Expandable Structure: Reserved margin for future road widening, pipeline crossing and load upgrade.
- Eco-Friendly Material: 100% recyclable steel material reduces whole-life environmental impact.
Application Scenarios
Ideal for various long-span crossing infrastructure projects:
- Expressway Crossings: Over rivers, valleys and existing road networks to ensure smooth traffic operation.
- Municipal Urban Crossings: Cross railways, metro lines and dense urban areas with less land occupation.
- Highway Interchange Ramps: Suitable for curved and skew long-span bridge structures.
- Large-Span Pedestrian Bridges: Aesthetic long-span walkways over urban expressways.
- Port & Industrial Bridges: Heavy-load long-span access bridges for industrial zones and railway yards.
- Bridge Renovation & Replacement: Fast-installation solution for emergency bridge renewal projects.
Conclusion – Spanning the Distance, Delivering the Future
The Long Span Prefabricated Box Girder Steel Bridge for Expressway & Municipal Crossing integrates advanced long-span structural design, standardized factory prefabrication and efficient on-site construction. It solves the construction difficulties of large-span river and road crossing projects, reduces foundation investment and minimizes traffic disruption. Fully compliant with AASHTO LRFD and AWS D1.5M international standards, it delivers stable, durable and low-maintenance infrastructure solutions.
Submit your project parameters including span, width, load standard and site constraints. Our engineering team will provide customized conceptual design, span optimization, budget estimate and construction schedule within a short time.
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