Design &
Engineering

The Experience to Support Your Biggest Projects

Basalt International’s Design and Engineering team is one of the most experienced in the world when it comes to the innovative use of composites for infrastructure components.  Our team has completed 40+ projects across the country – and around the world – over the last decade.

Learn more about our services and how we might assist you

Project Feasibility & Concept Development

  • Site and Needs Assessment:
    Evaluate project requirements, environmental conditions, and logistical constraints

  • Preliminary Design Concepts:
    Develop initial design options tailored to project goals

  • Cost-Benefit Analysis:
    Compare composite solutions with traditional materials to determine economic viability

Regulatory Compliance & Permitting Support

  • Documentation Preparation:
    Provide necessary technical documents for permitting processes.

  • Agency Coordination:
    Assist in communications with regulatory bodies to facilitate approvals

Structural Design & Engineering

  • Custom Bridge Design:
    Design composite bridge systems (e.g., arches, girders, decks) in accordance with AASHTO LRFD specifications

  • Load and Performance Analysis:
    Conduct structural analyses to ensure safety and performance standards are met

  • Integration of Composite Materials:
    Incorporate FRP composites to enhance durability and reduce maintenance.

Manufacturing & Fabrication

  • Component Production:
    Manufacture composite bridge components at their facilities, ensuring quality control.

  • Modular Construction:
    Produce components designed for ease of transport and assembly, reducing on-site construction time.

Construction Support & Installation

  • Training Services:
    Offer training for construction teams on handling and installing composite materials

  • On-Site Technical Assistance:
    Provide guidance during installation to ensure proper assembly and integration

Post-Construction Services

  • Inspection and Maintenance Planning:
    Develop maintenance schedules and inspection protocols to ensure long-term performance

  • Performance Monitoring:
    Implement monitoring systems to track structural health over time

Enlist our Expert Team Today

We’re here to provide solutions to your complex projects.

Contact an Expert

OUR PRODUCTS IN ACTION

Case Study

Grist Mill Bridge – Hampden, Maine (2020)

Replacement of an aging steel bridge with a 75-foot single-span structure

  • Achieved a load test inventory rating factor of 1.66, surpassing the design target of 1.04.
  • Demonstrated excellent deflection and fatigue resistance, meeting AASHTO standards.
  • Instrumented by the University of Maine and UMass Lowell for performance validation.
See Case Study

A Sustainable Composite Bridge Story

See how innovative composite bridge components are lighter, stronger, longer-lasting and easier and less expensive to install.  Hear how Basalt International has the experience to take on projects across the country.

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Trust the Testimonials

Stronger and Lighter, Naturally

"Composite materials like fiber-reinforced polymer (FRP) rebars offer higher tensile strength than Grade 60 steel at just a quarter of the weight—and unlike steel, they don’t corrode. This leads to longer service life for concrete structures. Among the various fibers used in FRP bars, basalt fiber stands out as a naturally sourced and sustainable alternative."​

Alvaro Ruiz Emparanza

Ph.D., P.E.; Founder & CEO, Ecotori, LLC

Streamlined Our Process

"Using basalt rebar streamlined our tilt-up wall construction process, offering exceptional ease of use compared to steel rebar. Its lighter weight, easy handling, and resistance to corrosion have translated into substantial labor savings, allowing us to achieve efficiency without compromising on structural strength."​

Brian Pratt

COO, McGarvey Development Company

Stronger And More Durable

"BFRP rebar is stronger and more durable than the minimum criteria set for GFRP bars and appears to be a viable alternative as a non-corrosive rebar option."​

Steven Nolan

Office of Materials, Florida Department of Transportation

Faster, Stronger, and Longer Life

"The benefits of this bridge-building method are threefold. First, the arches are an instant framework. Second, you don’t need any steel reinforcing bars or rebar, because the arches are twice as strong as steel. And third, the tubes protect the concrete from water and elements, extending the life of the concrete."​

Dr. Habib Dagher

Advanced Structures and Composites Center, U. of Maine

Same Building Method

"Whenever you introduce a new technology like this, contractors don’t always jump on it because there’s a fear that it’s going to be difficult to build. One of the beauties of [our composite bridge system] is that it’s built exactly the same way as you would build a steel girder or a concrete girder bridge."​

Bill Davids

Chair of Civil and Environmental Department, University of Maine

Lighter Means Faster

"A lot of our time-saving activities once we got to the superstructure were absolutely governed by the weight of the girders themselves and the ability to do more things at once"​

Brian Emmons

Project Manager, T Buck Construction

Expertise and Experience Drive Innovation

"It’s a combination of people who know how to build things, how to design things in the real world, plus our knowledge at the University in composite materials. Putting all that together really helped us develop the very unique secret sauce that I think will change how composites will be built in the future."​

Dr. Habib Dagher

Advanced Structures and Composites Center, U. of Maine

Faster Than Expected and No Issues

"Even though we knew this would be erected really quickly out in the field, the speed surprised us. It didn’t take very long for them to get their tubes in place, to get all the decking in place and start the backfill process. When you walk into a brand-new product like this, there is a certain level of risk. But there were just no issues at all with the construction."​

Mark Gaines

Washington State DOT Bridge & Structures Engineer

Read Our Case Studies