Page 21 - BusinessWest August 4, 2025

Span of Action
UMass Amherst Studies How 3D Printing May Aid Bridge Repair
An innovative 3D printing technique called cold spray was
recently applied to a Western Mass. bridge, in a first-of-its-
kind, proof-of-concept demonstration that could reduce the
repair cost of critical infrastructure and disruptions to passing traffic.
The test repair, led by UMass Amherst in collaboration with
researchers from the Massachusetts Institute of Technology (MIT)
Department of Mechanical Engineering, was made in Great Bar-
rington on the ‘red bridge,’ formerly known as the ‘brown bridge’ and
built in 1949.
“Now that we’ve completed this proof-of-concept repair, we see
a clear path to a solution that is much faster, less costly, easier, and
less invasive,” said Simos Gerasimidis, associate professor of Civil
and Environmental Engineering at UMass Amherst and one of the
principal investigators on the project. “To our knowledge, this is a
first. Of course, there is some R&D that needs to be developed, but
this is a huge milestone.”
Other collaborators on the project include the Massachusetts
Department of Transportation (MassDOT), the Massachusetts Tech-
nology Collaborative (MassTech), the U.S. Department of Transpor-
tation, and the Federal Highway Administration.
“Any time you drive, you go under or over a corroded bridge,”
Gerasimidis said. “They are everywhere. It’s impossible to avoid, and
their condition often shows significant deterioration. We know the
numbers.”
Across the U.S., 49% of the nation’s bridges are only in ‘fair’ con-
dition, and 6.8% are rated ‘poor,’ according to the 2025 Report Card
for America’s Infrastructure. The projected cost to restore them
exceeds $191 billion. Roughly 9% of Massachusetts’s 5,295 bridges
are structurally deficient and require repair — a need that far out-
paces available funding. The former brown bridge, which crosses
the Housatonic River at the intersection of state routes 7, 41, and
23, served as a demonstration site for new technologies aimed at
addressing the broader crisis.
The cold spray technique of additive manufacturing (often called
3D printing) involves spraying high-velocity metal powder particles
to coat sections of the beam. Repeated sprays create multiple layers,
restoring thickness and other structural properties to the treated
area.
This method has proven to be an effective solution for other large
structures like submarines, airplanes, and ships, but this is the first
time it has been applied to a bridge. Bridges present unique chal-
lenges due to their size and because the 3D printer must be brought
on site.
One of the biggest advantages of the technique is that repairs
can be made with minimal disruptions to traffic. “Every time you do
repairs on a bridge, you have to block traffic; you have to make traf-
fic controls for substantial amounts of time,” Gerasimidis explained.
“This will allow us to [apply the technique] on this actual bridge
while cars are going [across].”
Part of this work has been developing 3D LiDAR scanning meth-
ods to replace time-consuming, subjective visual assessments, he
added, which enables researchers to precisely identify corrosion,
develop a digital repair plan, and deposit the material only where
necessary. “By combining scanning with precise material deposition,
we can be very targeted and say,
‘we’re going to print here and here
and here, and we’re going to give
this bridge another 10 years of
Printing
Continued on page 22 >>
“Any time you
drive, you go
under or over
a corroded
bridge. They are
everywhere. It’s
impossible to
avoid, and their
condition often
shows significant
deterioration.
We know the
numbers.”
Your Vision...
QUALITY SERVICE
SUPERIOR TECHNICAL EXPERTISE
QUICK RESOLUTION
Your project is too
important to leave to
chance, let Chicopee
Industrial Contractors
be your solution.
Boldly Brought to Life.
Elevate your designs with custom
graphics and signage that
transform spaces into immersive
brand experiences. From
LEED-certified solutions to striking
architectural enhancements, our
expertise ensures every detail
aligns with your creative vision.
Let's make your next project unforgettable.
Architectural & Window Films • Wall Coverings
Feature Walls • Dimensional Logos
Signs of All Kinds
31 Benton Drive • East Longmeadow, MA • 413.525.2244 • gographix.com
YOUR ONE-STOP SOLUTION FOR RIGGING,
RELOCATION AND STORAGE NEEDS.
413.538.7279
www.chicopeeindustrial.com
Rigging Millwright Transportation Relocation
Industrial Construction Storage WBE
Business W est << CONSTRUCTION >>
AUGUST 4, 2025
21