Short Span Steel Bridges 
Whiteside County (IL) Selects Steel Bridge Solution for Short Lead Time
Russ Renner had a decision to make. The Whiteside County Engineer (IL) needed to replace an existing bridge this summer, while maintaining traffic flow in both directions. In addition, he needed a solution that would last at least 100 years, was efficient to install, and had a short fabrication lead time.
After reviewing the various solutions and consulting with Keith Brandau, Chastain & Associates, a decision was made. Russ selected a press-brake tub girder (PBTG) for the 4-lane wide by 105 foot long bridge replacement project near Rock Falls, Illinois.
Whiteside County Engineer, Russ Renner, PE, SE., discusses the composite 8” Precast Concrete Deck on 18” Valmont® U-BEAM TM Tub Girders that were used for the Howland Creek Bridge Replacement project.
Valmont U-BEAM
The PBTG, manufactured by Valmont and called the U-BEAM, is an innovative bridge solution that uses a performance-proven cold bending method. Cold-bent steel tub girders meet all AASHTO LRFD requirements and are approved for both state DOT and FHWA funded projects.
The girders can be hot-dip galvanized to protect from corrosion and vastly reduce maintenance needs.
The bridge will be fabricated within Valmont’s new facility in Jasper, TN, featuring a 60 foot long automated press brake, automated shear stud welding, and cold rolling machinery for camber.
The Valmont U-BEAM consists of a steel plate formed by cold bending with a press brake. A single row of shear studs is applied to the top flange by an automated stud welder.
Bolted Splice Connection
Since this project is over 60 feet, the Whiteside County bridge must be fabricated in 2 pieces. The structure can then be joined either by shop welding, or by a bolted splice. According to Valmont, a bolted splice connection has several advantages for PBTG applications:
- All elements can be hot-dipped galvanized.
- Elements can be shipped in pieces on standard trailers.
- Bolted splices are typical steel construction elements that all steel bridge erectors know how to assemble.
The PBTG was built in 2 phases in order to maintain traffic in both directions during construction.
The 71 foot long Evans Mill Road press-brake tub girder bridge, located in Peoria IL, features a bolted splice connection.
Download Project Plans Download Project Specs
Illinois First PBTG, Champaign County
This is not the first PBTG to be installed in Illinois. In September 2021, Champaign County completed the installation of the first prefabricated PBTG in the state of Illinois. The bridge, also manufactured by Valmont, provided a $2.00-per-square-foot savings by using steel instead of an alternative precast-prestressed concrete deck beam structure.
Jeff Blue, P.E., County Engineer for Champaign County, discussed the project in the following video:
Contact Information
Steel Fabricator
Guy Nelson, P.E., S.E.
Business Development Director – North American Structures
Valmont Industries, Inc.
28800 Ida Street
Valley, NE 68064
616.813.8514
Email: Guy.Nelson@valmont.com
Website: https://www.valmontstructures.com/products-solutions/traffic-mass-transit/bridge-systems
Product Specialist
Melissa Islam
The Will Group
Email: mislam@thewillgroup.com
Website: https://www.twginfrastructuresolutions.com/bridges
Bridge Owner
Russ Renner, PE, SE
County Engineer
Whiteside County Illinois
200 East Knox Street
Morrison, IL 61270
(815) 772-7651
Email: WCHighway@Whiteside.org
Website: https://www.whiteside.org/departments/highway.html
Bridge Owner
Jeff Blue, P.E.
County Engineer
Champaign County Highway Department
1605 E. Main St.
Urbana, IL 61802
217.384.3800
Email: jblue@co.champaign.il.us
Website: https://www.co.champaign.il.us/highway/highway.php
What are Press Brake Tub Girders?
Press-brake-formed tub girder (PBTG) is a new technology for short span bridge applications. It consists of modular galvanized shallow trapezoidal boxes fabricated from cold-bent structural steel plate (watch fabrication video). A concrete deck is recommended to be precast on the girder and the modular unit can be shipped by truck to the bridge site.
The system utilizes standard plate widths (based on availability) and is optimized to achieve maximum structural capacity, with most of the steel in the bottom flange and increased torsional stiffness. It is a closed system, since the girder is closed at the bottom. It is versatile for multiple-deck options.
The system utilizes Accelerated Bridge Construction practices, since it:
- Can be installed in one or two days
- Is modular, allowing the use of a precast deck
- Is cost-effective―as much as 1/3 less than a standard concrete girder structure
- Is simple to fabricate, requiring very little welding.
The Short Span Steel Bridge Alliance has developed standardized plans using standard plate sizes (60”, 72” 84”, 96”, 108”, 120”). The designs were developed to achieve maximum structural capacity and are available to use in the free-to-use, web-based design tool eSPAN140.
The press-brake-formed tub girder system is open source.
Case Study
Steel in Action: On-Demand Steel Bridge Video Series
Watch this four-part, on-demand video series featuring expert-led case studies on cost-effective, resilient short span bridge projects—now available with downloadable presentation materials.
Press Brake & Folded Plate
New Specs, New Opportunities for Press-Brake Tub Girders
Valmont Structures developed a summary outlining how the new AASHTO 10th Edition Bridge Design Specifications impact the use of press-brake tub girders (U-BEAMS) in bridge construction.
Press Brake & Folded Plate
Press-Brake Tub Girder Delivers Modern Upgrade for Historic Alabama County Bridge
After over 80 years of wear from daily traffic, the Parkwood Road Bridge was upgraded with Valmont’s U-BEAM™ system to enhance safety and streamline construction.