Ageing infrastructure is a widespread problem across Germany. Many bridges are coming under pressure as they near the end of their lifespan amid rising traffic volumes. Bridge upgrade and replacement projects often prove contentious due to the associated transport congestion and resulting journey delays, which can severely impact the health of the local and regional economy.

As part of a pilot project, Arup has developed a modular bridge system for Straßenbau Nordrhein-Westfalen, the North Rhine-Westphalian road construction company, that cuts construction time on site by more than half, down to sixteen weeks from an initial estimate of about twelve months.  

The modular bridge system, designed to keep construction-related traffic disruption to a minimum while shaving months off a project timeline, has now been used for the first time to replace two 1960s road bridges near Werne - Stiegenkamp and Nordbecker Damm.

Keeping the network flowing: offsite production minimises traffic disturbance

Both bridges were designed with modular components, which enabled the relocation of large parts of the construction process to remote production facilities: since numerous components could be prefabricated offsite, construction times on site were significantly reduced, helping avoid traffic chokeholds. 

The new prefabricated bridge system was designed so that the existing foundations can remain in the ground reducing the need for lengthy – and potentially costly - demolition and complex earthworks. Overall, construction time on site could be cut by as much as 70 percent to around sixteen weeks from an original estimate of about twelve months. 

3D design helps optimise use of resources

Modular structures require particularly exact design, allowing only for minor adjustments on site. To address this, Arup has designed a detailed 3D model for the various construction phases reflecting the changing ground conditions and ensuring an efficient and highly precise design execution.

Many of the modules were made of high-performance concrete and pre-cast in a factory. This high-performance material is more stable than conventional concrete, allowing for slimmer bridges and a more sustainable and efficient use of materials overall which will positively impact cost-control during construction.

Our innovative modular bridge design system was designed to adapt to different bridge designs, both in terms of form as well as in terms of geological factors. 

Assembly of a modular bridge

The modular bridge system minimises traffic disruption and significantly reduces project timelines