Bridges have shaped history - not just as feats of engineering, but as lifelines connecting people, businesses, and communities by enabling seamless movement where traditional roads and railways fall short.
Yet, as traffic volumes surge and design loads grow heavier, bridges face mounting pressures that test their resilience. Many aging structures now require urgent repairs, modernization, and reinforcement to withstand the demands of today and the challenges of tomorrow.
At Sika, we specialize in durable, sustainable bridge solutions designed to extend the structure's lifespan, enhance safety, and minimize environmental impact. Whether reinforcing existing structures or designing for the future, we ensure that bridges remain strong, reliable, and built to last. Discover how our innovative solutions can safeguard the bridges of today — while building a more sustainable tomorrow.
Key Exposures Affecting Bridge Deterioration
Bridges are subjected to continuous exposure to environmental and operational stressors, each contributing to structural degradation in different ways.
A thorough understanding of these factors is essential for developing effective maintenance strategies and materials selection to allow a prolongation of the service life.
Foundation and substructure settlement
Concrete cracking and spalling
Corrosion of reinforcement and steel structures
Bearing and expansion joint failures
Failures in rail fastening systems
Water infiltrations can cause erosion of soil under foundations, abrasion of concrete elements and destabilize the ground under the foundations causing excessive movements or settlements of the structure causing cracks and reducing the load capacity of the element.
Excessive vibrations, like the ones occurring during an earthquake, or even movements caused by settlement of the ground under the foundations can shift piers and abutments causing concrete damages like cracks or spalls.
Chemical attack, salt expansion, pollutants or spillages from vehicles can reach foundations, causing cracking and weakening areas.
By their nature and locations, bridges are subjected to a wide variation of temperatures between day and night/winter and summer conditions, or between different sides or surfaces of the structure. These frequent cycles result in thermal stresses and movement in the concrete structure that can also result in cracks.
The freeze-thaw process creates stresses in the concrete matrix due to the expansion of free water in the capillary pores during freezing conditions; this can result in scaling of the surface of poor-quality concrete. This action is also greatly accelerated by the presence of chlorides in the water.
Certain aggregates in concrete react with moisture and alkalis, causing internal swelling and cracking of the concrete.
Overloading— whether from increasing traffic, inadequate design, impact damage, or seismic effects— can exceed the structural limits, leading to fatigue, deformation, or failure.
Concrete elements submerged in water, such as piers or columns, face constant erosion and abrasion from fast-moving water and suspended particles, gradually wearing away the surface.
Chlorides from de-icing salts or seawater can penetrate concrete and disrupt the passive film protecting reinforcement bars, leading to aggressive pitting corrosion.
Carbon dioxide in the air reacts with calcium hydroxide in concrete, reducing the pH and ultimately compromising steel protection as carbonation progresses inward.
Water naturally penetrates concrete through its pores. In areas with high chloride content or carbonation, this leads to corrosion of reinforcement, causing cracks and spalling.
Rubber, steel, and other joint materials degrade over time, resulting in misalignment, deformation, and performance issues.
Blocked or damaged joints allow water and debris to accumulate, accelerating corrosion and deterioration.
Leaks from failed joints or deteriorated waterproofing systems on decks can affect other bridge components below.
High stress from constant vehicle movement deforms joints and bearings, compromising bridge movement capacity.
Leaks can lead to several types of damage, including corrosion of fastening system components, reduction or complete loss of system resistance, corrosion of steel elements within the track structure and substructure, saturation of concrete with water and eventual spalling.
Failure in the electrical insulation of the rail fastening system can result in false readings from track signaling systems, induction and acceleration of electrochemical corrosion, and the generation of stray currents. These stray currents in turn, can further corrode the rail and nearby components.
Repeated dynamic loading may cause cracking in adjacent concrete areas or deformation of embedded steel elements, compromising structural integrity.
Chemical attacks may occur due to the operating conditions of rolling stock or the specific location of the fastening system, such as near fuel transfer stations, chemical plants, or train washing facilities.
A reduction in the elasticity or load-absorbing capacity of these components can result in improper load distribution, leading to increased stress and accelerated deterioration of the track system.
Quick Overview of Sika Bridge Solutions
Foundations
Main exposures
Aggressive soils or water infiltration due to erosion, ground settlement, seismic activity
Main causes of deterioration
Chemical attack from aggressive soil particles, salt expansion, erosion/ abrasion, concrete cracking from excessive movement
Sika solutions
- Protective sheets: Sika® Index
- Protective membranes: SikaProof® A+
- Structural injections, soil stabilization: SikaInject®, Sikadur®
Piers
Main exposures
Temperature variations, chloride exposure (marine or de-icing salts), weathering, traffic impacts, vibrations
Main causes of deterioration
Surface scaling due to erosion, abrasion, salt expansion, cracking from movement or loads, carbonation, vandalism
Sika solutions
- Concrete repair and protection systems: Sika MonoTop®, SikaEmaco®, Sikagard®, SikaInject®, Sikadur®, Sika® FerroGard®, Sikalastic®
- Structural strengthening systems: Sika® CarboDur®, SikaWrap®
Bearings
Main exposures
Loads, water infiltration from damaged joints, chemical pollutants
Main causes of deterioration
Overloading, corrosion, failure of anchors or bearing zones
Sika solutions
- Grouting and fixing systems for the replacement: Sikadur®-42+ series, Sikacrete® UHPC range, SikaGrout®-340+
- Bearings: Wabo® bearings
Girders/ beams
Main exposures
Temperature variations, de-icing salts, marine environments, water ingress, traffic actions and vibrations
Main causes of deterioration
Scaling, erosion, salt expansion, de-icing salts, freeze/thaw cycles, impacts, cracking from loading or fatigue, carbonation
Sika solutions
- Concrete repair and protection systems: Sika MonoTop®, SikaEmaco®, Sikagard®, SikaInject®, Sikadur®, Sika® FerroGard®, Sikalastic®
- Structural strengthening systems: Sika® CarboDur®, SikaWrap®
- Structural crack repair: Sikadur®
Decks
Main exposures
Temperature variations, de-icing salts, marine environments, water ingress, traffic actions and vibrations, pollutants
Main causes of deterioration
Scaling, erosion, salt expansion, corrosion of reinforcement bars, freeze/thaw cycles, impacts, cracking from loading or fatigue, carbonation, chemical attacks
Sika solutions
- Concrete repair and protection systems: Sika MonoTop®, SikaEmaco®, Sikagard®, SikaInject®, Sikadur®, Sika® FerroGard®, Sikalastic®
- Structural strengthening systems: Sika® CarboDur®, SikaWrap®
- Structural crack repair: Sikadur®
- Deck waterproofing systems: Sikalastic®, Sika® Index
Joints
Main exposures
Weathering, excessive movements, traffic loads, pollutants due to de-icing salts or spillages from vehicles, settlements, water ingress due to leaking joints
Main causes of deterioration
Ageing of the elastomeric elements, cracking of the nosing material, excess of traffic loads, corrosion of metallic elements, breaks due to excessive movements, vandalism
Sika solutions
- Complete joint systems: Wabo® joints, Sikaflex® PRO-3 Purform®, Sikadur-Combiflex® System
- Nosing systems: WaboCrete®, Sikacrete® UHPC range, SikaEmaco® T 1400 FR
Abutments / wing walls
Main exposures
Temperature variations, de-icing salts, marine environments, water ingress, traffic actions and vibrations, pollutants
Main causes of deterioration
Scaling, erosion, salt expansion, de-icing salts, freeze/thaw cycles, impacts, cracking from loading or fatigue, carbonation, vandalism
Sika solutions
- Concrete repair and protection systems: Sika MonoTop®, SikaEmaco®, Sikagard®, SikaInject®, Sikadur®, Sika® FerroGard®, Sikalastic®
- Structural strengthening systems: Sika® CarboDur®, SikaWrap®
- Structural crack repair: Sikadur®
- Soil stabilization or waterproofing: SikaInject®
Ancillary elements, e.g. street lamps, hand rails, traffic lights
Main exposures
Loads, vehicles, temperature variations, weathering, vibrations and other settlement movements, human actions
Main causes of deterioration
Traffic impact damages, corrosion, aging, cracking due to settlements,
vandalism
Sika solutions
- Grouting and fixing solutions: Sika AnchorFix® range, Sika FastFix®-136 Road, SikaEmaco® T 1200 PG, SikaGrout® range
- Protection: Sikagard®
Sidewalks/ maintenance lanes
Main exposures
Loads, vehicles, temperature variations, weathering, vibrations and other settlement movements, human actions, pollutants
Main causes of deterioration
Traffic impacts and spillages, erosion, excessive loads, corrosion, aging, corrosion, concrete cracking
Sika solutions
- Paving range: Sika FastFix® range, Sikafloor® solutions, Sikacrete® UHPC range
- Structural crack repair: SikaInject® and Sikadur® range
- Waterproofing systems: Sikalastic®, Sika® Index
Rail systems for railway bridges
Main exposures
Loads, vibrations and dynamic loads, settlements, displacement of ballast, car traffic in road intersections, pollutants
Main causes of deterioration
Wearing, corrosion due to stray electric currents, excessive movements, fatigue of components, erosion, wear, chemical attack
Sika solutions
- Fixing and grouting systems: Sika® Icosit® KC range, Sikadur® range, SikaGrout® range
- Electrical insulation system: Sika® Index, Sika® Icosit® KC
- Ballast bonding systems: Sika® Icosit® KC Trackfix
- Sealing systems: Sika® Icosit® KC, Sikaflex®
Predictive methods
Main exposures
Corrosion and carbonation
Main causes of deterioration
Corrosion of reinforcement bars
Sika solutions
- Monitoring system: DuraMon sensors
1. Concrete Technology
Concrete structures such as bridges can be exposed to a broad range of forces and strains, starting internally with mechanical stresses resulting from the construction type and extending to various external attacks. Enormous stress on the concrete include such factors as extreme hot or cold temperature conditions and fluctuations, aggressive water or chemicals, continually rolling, abrading or pulsating strains on surfaces, or even in extreme cases the impact of fire. Therefore, a highly durable concrete is necessary for the construction or repair of a bridge.
The development and production of innovative concrete mix designs using special admixtures has been a core Sika business since 1910. Our technology and high-quality products have been continuously developed during this century of experience. Sika provides the most complete range of admixture technologies and products for the efficient replacement of highly durable concrete.
Increasing the durability of concrete by using:
SikaControl® SRA to minimize shrinkage of concrete
SikaControl® AER to increase the frost and freeze/thaw resistance
SikaFume® silica fume to increase the density of the matrix
Sika® FerroGard® corrosion inhibitor to prevent the corrosion of steel reinforcement
Sika® Antisol® for controlled curing of the concrete for significantly enhanced durability
SikaFiber® for increasing the ductility, tensile strength and resistance to concrete spalling in high temperatures
High early strength concrete for reduced closure times is achieved by:
High range water reduction and plasticizing with Sika® ViscoCrete® and SikaPlast® technology, to provide enhanced strength development and precisely controlled concrete workability
Hardening or set acceleration to speed up the hydration process using SikaRapid® technology
Casting concrete with maximum flowability for specific periods of time without the need for vibration by the addition of:
Sika® ViscoCrete® and Sika ViscoFlow® technology for highly flowable and workable concrete with optimized raw material usage, based on powerful water reduction with extended workability time
Sika® Stabilizer VMA for improved stability of the self compacting concrete, even with inferior quality aggregates
SikaFume® silica fume to provide increased density and durability of the matrix, with enhanced fresh concrete stability
Two-component, structural epoxy bonding agent Sikadur®-32 to bond fresh concrete to hardened concrete
2. Concrete Repair & Strengthening
Repairing damaged concrete is one of the primary requirements in the maintenance of concrete bridges. Localized spalling or full surface scaling of concrete surfaces has to be repaired with durable concrete repair materials. A sound and correctly repaired concrete substrate is also the basic requirement for any additional waterproofing, protection or strengthening systems to be applied.
Sika provides an extensive range of thoroughly tested and proven repair materials and systems, based on various technologies to meet specific requirements. These include bonding and corrosion protection primers, hand- and machine-applied repair mortars (suitable for vertical and overhead applications), semi-fluid mortars for efficient deck repairs, and surface levelling/protection mortars. Additionally, Sika has pioneered the development of carbon fiber-reinforced polymer structural strengthening systems.
Thanks to years of research and decades of hands-on experience, Sika has developed a fully comprehensive product range to restore and rehabilitate concrete bridges in a durable and sustainable way.
Sika MonoTop®-1010 one-component cement-based product providing high resistance to water and chloride penetration, reduced carbon footprint
SikaTop® Armatec® 110 EpoCem® three-component, high-performance corrosion protection primer based on epoxy-cement technology
Sika MonoTop®/ SikaEmaco®/ Sikacrete® high-performance cement-based repair mortars for hand or machine application with reduced carbon footprint options
Sika® CarboDur® epoxy resin-based strengthening systems using carbon fiber and other composite materials
Strengthening of reinforced concrete structures with SikaWrap® fiber fabrics
Sikadur®/ SikaInject® two-component, solvent-free, low viscosity epoxy resins with structural properties
3. Protective Coatings & Corrosion Mitigation
To improve the performance and durability of reinforced concrete surfaces on bridge structures, additional protection systems are frequently required, particularly in refurbishment situations. Concrete protection systems for bridges are designed to greatly reduce damage to the concrete surfaces, to stop or reduce the rate of steel reinforcement corrosion and prevent significant structural damage.
Sika provides a wide range of tested and well proven concrete protection systems based on different technologies including hydrophobic impregnations, impregnations, rigid and elastic surface coatings, galvanic anodes, and surface applied corrosion inhibitors. All of these Sika products and systems fully comply with various standards and regulations.
Sika® FerroGard®-903 Plus organic, cost-effective service life extension against carbonation
Sikagard®-8500 CI one-component, dual-phase, surface-applied corrosion inhibitor for long-term protection against both carbonation and chloride induced corrosion
Sika® FerroGard®-300’s Duo anode with initial current applied to it- for stronger cathodic protection
Sika® FerroGard®-500’s Patch sacrificial anode to prevent ‘halo’ effect connected to rebar during patch repair
Sikagard®-675 W ElastoColor acrylic resin-based waterproof coating offering excellent carbonation protection
Sikagard®-5500 highly elastic, crack-bridging, waterproof concrete protection
Sikagard® anti graffiti system: Sikagard®-850 Primer, Sikagard®-850 Activator and Sikagard®-850 Clear semi-matt, permanent protection system which allows cleaning with cold low water pressure or just with cold water and a cloth or scrubbing brush
Sikagard® silane and siloxane based hydrophobic systems to repel water on concrete and other mineral surfaces
4. Expansion Joint & Bearing Replacement
Bridges are complex and demanding structures. There are many joints that need waterproofing, from simple saw cut contraction joints to exposed movement and connection joints. These joints are exposed to thermal movement, constant vibrations, extreme weathering, mechanical impact from the traffic and chemical impact from spillage or de-icing.
Sika offers a complete selection of customized expansion joint systems tested and with a well proven track record. Additionally, we provide a comprehensive range for fixing and bedding road and rail elements required for durable, safe use of the bridge.
Wabo® high performance customizable joints systems designed to absorb bridge movements
WaboCrete® II two-component polyurethane header with specialty aggregate used to absorb and disperse traffic impact loads
Emcrete II flexible, rapid setting, self-leveling, impact-absorbing elastomeric concrete used to fill blockouts, impact-absorbing backfill nosing, patching potholes and spalls on concrete roadways and bridges
SikaGrout®-340+ one-component cementitious grouting mortar with shrinkage compensation and high strength development suitable for dynamic loads
Sikadur®/ SikaFlow® high performance precision resin grouts based on various chemistries for high durability and excellent mechanical strengths, used to secure elements for proper alignment and transmission of static and dynamic loads induced by vibrations or seismic actions
Sika FastFix®/ SikaEmaco® cementitious rapid-hardening bedding and fixing mortar for road maintenance works
5. Waterproofing & Drainage Enhancements
Given the open nature of bridge decks, it’s crucial to prevent water ingress. Proper waterproofing of the deck is essential to prevent water damage and extend the structure's lifespan. This protection also safeguards critical areas beneath, ensuring a safe and reliable environment for all users.
Sika offers a complete range including liquid-applied membranes (LAM) which are highly elastic and flexible polymeric systems, bituminous sheets and cementitious polymer-modifed mortars that meet all the latest quality standards.
Sika® Index bituminous waterproofing membrane sheets for bridge deck waterproofing
Sikalastic®-851 polyurethane-based, multi-layered waterproofing system suitable for mastic and hot rolled asphalt schemes, certified under ETAG 033 and BBA HAPAS
Sikalastic® Bridge 5000 polyurethane-based, multi-layered waterproofing system suitable for mastic and hot rolled asphalt schemes, certified under ETAG 033
Sikalastic®-2304 polyurethane-based, multi-layered waterproofing system suitable for mastic asphalt schemes
Sikalastic®-2302 polyurethane-based, multi-layered waterproofing system suitable for hot-rolled asphalt schemes
Sikalastic®-6100 FX one-component, flexible and lightweight cementitious waterproofing mortar with crack bridging properties
6. Grouting & Fixing for Structural Integrity
Remedial work on concrete bridge structures often include the requirement for void filling, fixing and sealing or bedding and grouting with free-flowing materials. Typical examples are concrete repairs using formwork, high precision grouting under bridge bearing plates, or for cable duct grouting. Additionally, flowable resin and cement grouts are used to fix manholes or other steel frames and equipment, where rapid hardening materials are usually required to reduce closure times.
Sika offers a wide range of tested and well proven grouts and fixing materials based on all the different technologies available including cement, epoxy, polyurethane and PMMA. For many decades, Sika has also provided special products for high precision applications such as bearing plates, rail tracks and ancillary elements like traffic signs and other road and rail elements.
SikaGrout® cementitious grouting products with shrinkage compensation and high-strength development
Sikadur®/ SikaFlow® high performance precision resin grouts based on various chemistries for high durability and excellent mechanical strengths, used to secure elements for proper alignment and transmission of static and dynamic loads induced by vibrations or traffic impacts
Sika FastFix®/ SikaEmaco® cementitious rapid hardening bedding and fixing mortar for road maintenance works
Sika AnchorFix® chemical anchors based on various chemistries for many kinds of anchoring and fixing applications, secures high durability in different substrates of signals and other ancillary elements
7. Rail Fixing, Sealing & Embedding
Sika offers a complete range of globally trusted solutions, engineered for high-performance, tailor-made direct rail fixation to solid substrates like concrete and steel under the brand Sika® Icosit® KC.
Renowned for durability and precision, the Sika® Icosit® KC systems are used in a wide variety of trackwork applications— including discrete and continuous undersealing, embedded rail systems, green tracks, ballast bonding compounds and dielectric membranes to isolate rail systems.
Ideal for railway, light rail, tram, and depot track installations, Sika delivers proven performance wherever long-lasting, reliable rail infrastructure is required.
Sika® Icosit® KC 340/35
Sika® Icosit® KC 340/45
Sika® Icosit® KC 340/65
two-component flexible polyurethane polymer resin grout used for rail systems
with maximum product service loads varying from up to 1 MPa to up to 4 MPa and
axle loads varying from less than 120 kN with high deflection to less than 250 kN and standard deflection
Sika® Icosit® KC 340/4
Sika® Icosit® KC 340/7
two-component flexible polyurethane polymer resin grout used for discrete fixations in rail systems with maximum product service loads varying from up to 3 MPa to up to 4 MPa and axle loads varying from less than 120 kN with high deflection to less than 250 kN and standard deflection; suitable for different types of baseplates
Sikaflex®-406 KC booster accelerated elastic sealant used for joints between rails, adjacent surfaces and with Sika® Icosit® KC products
Sikadur®-32+ two-component epoxy based pourable compound used primer on concrete (dry and mat damp) and steel (also as a coating it has an electrical surface resistance parameters) substrates, also for setting anchor bolts
Sika® Icosit® KC 330 one-component primer for dry concrete and steel substrates
Sika® Icosit® KC 330 FK two-component, fast-setting thixotropic, adhesive material for fixing filler blocks with high initial adhesion
Sika AnchorFix®-3030 chemical anchor based on epoxy resin used to adhere anchor bolts applied with the application dispenser
Sika® Icosit® KC 100 Trackfix
Sika® Icosit® KC 120 Trackfix
two-component epoxy or polyurethane-based injection resins;
thanks to its high mechanical strength, it can be used to fix rail ballast/gravel efficiently in railway construction
8. Advanced Inspection & Monitoring
The condition of reinforced concrete structures and the full extent of any potential damage is often not visible on the concrete surface. Corrosion damage and structural deterioration can develop internally and progress significantly, before becoming visible on the surface, such as with chloride-induced pitting corrosion.
To ensure effective repair and maintenance, it's crucial to optimize the number of structures requiring attention, along with the extent and cost-effectiveness of the work. Predictive maintenance, through optimized life cycle planning, helps anticipate potential damage. The goal is to identify issues early, preventing larger and more disruptive repairs down the line. Achieving this requires detailed and reliable data and information to accurately predict structural conditions and assess the level of deterioration.
DuraMon sensor set including multi-sensors that can be used in both new and existing structures to monitor the existing concrete condition and performance
Sikagard®-8500 CI one-component, dual-phase surface-applied corrosion inhibitor for long-term protection against both carbonation and chloride induced corrosion
Sikagard®-675 W ElastoColor waterproof acrylic resin-based protective coating for concrete for an excellent carbonation protection
Sikagard®-5500 highly elastic, crack bridging, waterproof protective coating for concrete, excellent carbonation barrier
Ensuring Long-Lasting Bridges with Sika
At Sika, we do more than supply innovative solutions — we partner with bridge owners, architects, engineers, and contractors to ensure every project is a success. From new construction to refurbishment, our team provides expert guidance at every stage, helping you build stronger, longer-lasting bridges.
For refurbishment projects, we offer full support from start to finish. This includes an initial survey and assessment, followed by root cause diagnosis, precise specification writing and detailing, and comprehensive method statements to guide the process. We also provide on-site quality control and practical application assistance, ensuring seamless execution and long-term durability.
When it comes to new bridge construction, our expertise helps design structures that maximize durability, sustainability, and cost efficiency over their entire lifecycle. By optimizing materials and construction methods, we reduce maintenance needs, extend service life, and lower total project costs.
With a global presence and a complete range of cutting-edge solutions, Sika delivers high-performance products tailored to meet the toughest bridge challenges — wherever they are in the world.
