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Currently, there are many structurally-deficient and obsolete bridges in the US highway system. The expected cost for repair and replacement is enormous; therefore, more cost-effective materials and construction methodology must be sought. Reynolds Metals Company formed a vertical consortium to develop and market a cost-effective, innovative, lightweight, corrosion resistant aluminum bridge deck system based on hollow aluminum shapes that could be welded together in the shop to form deck panels. Panels would be shipped to the construction sites for final assembly, which uses connections along longitudinal edges. These deck panels would replace conventional steel or concrete panels. An epoxy-gravel wearing surface would be applied to the top side of the deck to provide a durable, skid-resistant surface. However, before this deck system could be widely utilized, the overall structural integrity had to be fully demonstrated. Reynolds Metals Company and Oak Ridge National Laboratory (ORN L) entered in a Cooperative Research and Development Agreement (CRADA) to conduct a number of fundamental investigations into potentially critical technical areas over approximately a four-year period

Development of Aluminum Bridge Deck System with Reynolds Metals Company