ICF(Insulated Concrete Form) Bracing
AASHTO LRFD & Eurocode 3 Box Girder Steel Bridge | Prefabricated Steel Box Girder Solutions
We specialize in the R&D, prefabrication and export of high-performance box girder steel bridges, engineered to meet the stringent requirements of global infrastructure projects. Our box girder steel bridges adopt closed-section box structures, delivering superior torsional rigidity, bending resistance and fatigue performance compared to traditional beam bridges. Fully compliant with AASHTO LRFD, EN 1993-2 and AS 5100 standards, our products are prefabricated in ISO 9001-certified factories, with precision welding and strict quality control, ensuring reliable performance for permanent, semi-permanent and heavy-load applications. We provide end-to-end engineering solutions, from FEA-based structural design to on-site erection supervision, tailored to the unique geological, load and environmental conditions of each overseas project.
Design Standards & Calculation
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● Complies with AASHTO LRFD 2020 (including vehicular load HL-93), EN 1993-2 (Eurocode 3 for bridges), AS 5100.6 (Steel Bridges) and AWS D1.5 (Bridge Welding Code). - ● Structural analysis via Finite Element Analysis (FEA) software (ANSYS/Abaqus) to optimize section design, verify load-bearing capacity, torsional stiffness and fatigue resistance.
- ● Load calculation covers dead load, live load, wind load, seismic load (per local code) and temperature stress, ensuring structural safety under extreme conditions.
Structural Configurations
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✅Single-Box Single-Cell Girder: Suitable for spans 10–40m, ideal for urban overpasses and light-duty industrial bridges. - ✅Single-Box Multi-Cell Girder: For spans 40–80m, enhanced torsional rigidity, suitable for highway bridges and heavy-load applications.
- ✅Double-Box Girder: For spans 60–100m, distributed load evenly, applicable to long-span river-crossing and viaduct projects.
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✅Orthotropic Steel Deck (Optional): Integral with box girder, lightweight, high load-bearing capacity, suitable for long-span and high-traffic bridges.
Design Advantages
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👍Closed box section minimizes torsional deformation, ensuring stability under asymmetric loads. - 👍Streamlined cross-section reduces wind resistance and aerodynamic vibration (critical for long-span bridges).
- 👍Prefabricated integral/segmental design reduces on-site construction time and environmental impact.
- 👍Optimized welding details (full penetration welds, fillet welds with fatigue reinforcement) extend service life.
Raw Materials & Quality Assurance
Primary Structural Steel
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✅ASTM A709 Gr.50/Gr.70: American standard high-strength bridge steel, with minimum yield strength 345MPa (Gr.50) / 485MPa (Gr.70), excellent weldability and fatigue resistance. - ✅S355JR/S460: European standard EN 10025-3 low-alloy steel, compliant with EN 1993-2, suitable for heavy-load and long-span structures.
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✅Q355B (GB/T 1591 Low Alloy High Strength Structural Steel): Universal export-grade steel, yield strength 355MPa, cost-effective and compatible with global standards.
Auxiliary Materials & Components
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✅High-strength bolts: 10.9S grade, compliant with ASTM A325/A490, for bolted connection of girder segments. - ✅Welding consumables: AWS E7018/E8018 electrodes, matching base metal grade, ensuring weld strength ≥ base metal strength.
- ✅Anti-corrosion materials: Epoxy zinc-rich primer, polyurethane topcoat, hot-dip galvanizing (HDG) materials (ASTM A123).
Quality Control & Certification
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👉Material Inspection: Chemical composition analysis, mechanical property testing (tensile, bending, impact) for all raw materials, with MTC (Material Test Certificate) provided. - 👉Welding Quality Control: Pre-welding qualification test, in-process welding supervision, post-welding ultrasonic flaw detection (UT), magnetic particle inspection (MT) for critical welds, complying with AWS D1.5.
- 👉Dimensional Inspection: Precision measurement of girder dimensions, straightness, and assembly tolerance, ensuring compliance with design drawings.
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👉Certifications: ISO 9001, ISO 14001, OHSAS 18001, and product certification compliant with destination country standards.
Technical Specifications (Customizable)
Specification Item
Range & Details
Single Span Length
10m – 100m (multi-span configurable for longer distances)
Deck Width
3.5m – 14m (single lane: 3.5–4.5m; double lane: 6.0–8.0m; multi-lane: 8.0–14.0m)
Girder Height
0.8m – 4.0m (varies with span and load requirements)
Steel Plate Thickness
Web: 8mm – 20mm; Flange: 12mm – 25mm; Deck Plate: 10mm – 16mm
Design Load
AASHTO LRFD HL-93 vehicular load, 5.0kPa pedestrian load, industrial equipment load (customizable)
Fatigue Life
≥ 2 million load cycles (per AASHTO LRFD fatigue criteria)
Service Life
75 years (permanent structure, with regular maintenance)
Connection Method
Bolted (high-strength bolts) + field welding (full penetration welds for segmental connection)
| Specification Item | Range & Details |
|---|---|
| Single Span Length | 10m – 100m (multi-span configurable for longer distances) |
| Deck Width | 3.5m – 14m (single lane: 3.5–4.5m; double lane: 6.0–8.0m; multi-lane: 8.0–14.0m) |
| Girder Height | 0.8m – 4.0m (varies with span and load requirements) |
| Steel Plate Thickness | Web: 8mm – 20mm; Flange: 12mm – 25mm; Deck Plate: 10mm – 16mm |
| Design Load | AASHTO LRFD HL-93 vehicular load, 5.0kPa pedestrian load, industrial equipment load (customizable) |
| Fatigue Life | ≥ 2 million load cycles (per AASHTO LRFD fatigue criteria) |
| Service Life | 75 years (permanent structure, with regular maintenance) |
| Connection Method | Bolted (high-strength bolts) + field welding (full penetration welds for segmental connection) |
Core Performance Advantages
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👍Superior Torsional Stiffness: Closed box section design provides 3–5 times higher torsional rigidity than I-beam bridges, eliminating lateral deformation under asymmetric loads. - 👍Excellent Fatigue Resistance: Optimized welding details and high-quality steel materials ensure compliance with AASHTO LRFD fatigue standards, suitable for high-traffic and heavy-load scenarios.
- 👍Heavy-Load Capacity: Designed for HL-93 vehicular load and industrial heavy equipment, with reserve capacity for future traffic growth.
- 👍Low Life-Cycle Cost: Durable anti-corrosion system and minimal maintenance requirements reduce long-term operational costs.
- 👍Rapid Erection: Factory prefabricated integral/segmental girders, on-site assembly with modular connection, shortening construction period by 30% compared to cast-in-place structures.
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👍Terrain Adaptability: Suitable for complex terrains (rivers, valleys, urban areas) with minimal foundation requirements, reducing civil engineering costs.
Anti-Corrosion System (Tailored to Environment)
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👉Land/Urban Environments: Hot-Dip Galvanizing (HDG, ASTM A123) + Epoxy Zinc-Rich Primer (80μm) + Polyurethane Topcoat (60μm) – service life ≥ 30 years. - 👉Coastal/Marine Environments: Epoxy Asphalt Coating (heavy anti-corrosion, 300μm) + HDG – resists salt spray, humidity and marine organism adhesion, service life ≥ 40 years.
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👉Industrial Environments: Anti-chemical corrosion coating system, resistant to acid-base and industrial fumes.
Surface Treatment Process
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✅Shot blasting (SA 2.5 grade) to remove rust and oxide scale, ensuring coating adhesion. - ✅Primer application (epoxy zinc-rich) within 4 hours of shot blasting to prevent re-rusting.
- ✅Intermediate coat and topcoat application, with thickness inspection and adhesion testing.
- ✅Special treatment for weld seams, bolt holes and edges to avoid corrosion weak points.
Application Scenarios
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✅Urban highway overpasses, interchanges and flyovers - ✅Long-span river-crossing and valley-crossing highway bridges
- ✅Industrial viaducts, plant access bridges and heavy-equipment passages
- ✅Rural and urban permanent road bridges (heavy-load, long-span)
- ✅Temporary bridge replacements during infrastructure renovation (semi-permanent)
- ✅Coastal and marine bridge projects (with heavy anti-corrosion treatment)
One-Stop Export Engineering Services
We provide comprehensive, professional export services to ensure smooth project execution for overseas clients:
- ✅Custom Engineering Design: FEA-based structural design, detailed construction drawings, load calculation reports and local code compliance verification.
- ✅Precision Prefabrication: ISO 9001-certified factory production, robotic welding (for key seams), strict dimensional and quality control.
- ✅Material & Quality Certification: MTC for raw materials, welding certification, non-destructive testing (NDT) reports and product compliance certificates.
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👉Professional Ocean Packaging:
- Integral girders: Waterproof film + anti-rust paper + steel strapping + wooden pallet fixation, end protection against collision.
- Segmental girders: Sealed packaging, labeled with assembly sequence, anti-rust and shockproof treatment.
- Small components (bolts, sealants): Waterproof wooden cases, classified labeling.
- ✅Global Logistics & Trade Terms: Flexible terms (FOB, CIF, DAP), full logistics tracking, customs clearance documentation support.
- ✅On-Site Technical Support: Professional engineers provide on-site erection supervision, welding guidance and quality inspection, ensuring compliance with design requirements.
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✅After-Sales Service: 5-year structural warranty, long-term technical consultation, maintenance guidance and spare parts supply.
Partner With Us for High-Performance Box Girder Bridges🤝
As a leading manufacturer and exporter of box girder steel bridges, we combine advanced engineering design, precision production and professional export services to deliver reliable, standard-compliant solutions for global infrastructure projects. Our team of experienced engineers and technicians is dedicated to customizing products that meet your specific span, load, and environmental requirements. Contact us today to obtain a detailed FEA design proposal, technical specification sheet and competitive quotation for your box girder steel bridge project!
