Originally published on: https://www.buildoffsite.com/publicationsguidance/publications/
Major bridge and viaduct projects are under increasing pressure to deliver more — faster construction, lower costs, improved sustainability, reduced disruption and infrastructure that lasts longer. A new industry guide explores how combining Design for Manufacture and Assembly (DfMA) with Offsite Construction can help achieve all of these goals.
Our team was proud to contribute to this guide, which examines how these approaches work together across the entire lifecycle of bridge and viaduct infrastructure — from early design and procurement through to assembly, operation and long-term maintenance.
Traditionally, large infrastructure projects have been heavily dependent on extensive on-site construction. The guide highlights how Offsite Construction changes this model by shifting much of the manufacturing and assembly process into controlled factory environments.
This enables:
By designing components specifically for manufacture and assembly, project teams can also reduce complexity, streamline logistics and minimise waste throughout the delivery process.
One of the key themes explored in the guide is designing infrastructure with longevity and adaptability in mind.
Offsite-manufactured components can incorporate additional built-in functionality, including:
This approach supports smarter asset management and more efficient maintenance strategies over the lifetime of the structure.
The guide also demonstrates how closer collaboration between designers, manufacturers, suppliers and clients encourages innovation from the earliest project stages.
Through modularisation and mass customisation, teams can develop product families that meet strict requirements around:
Importantly, this collaborative approach helps projects apply Lean principles more effectively, reducing waste, improving predictability and supporting better programme outcomes.
For bridge and viaduct projects spanning existing roads, railways or waterways, minimising disruption is critical.
Because many components are manufactured and pre-assembled offsite to precise tolerances, on-site installation becomes significantly faster and more controlled. This reduces:
The guide also highlights how controlled manufacturing environments create better opportunities for continuous improvement, long-term learning and safer working practices.
Ultimately, the guide demonstrates that designing for manufacture and assembly is about much more than construction efficiency. It represents a more integrated, forward-thinking approach to infrastructure delivery, one that delivers benefits for funders, contractors, local communities and end users alike.
By reducing component counts, increasing functionality and simplifying logistics, DfMA and Offsite Construction can help create infrastructure that is more resilient, more efficient and better suited to future demands.
