Project Background
In mid-2023, a leading German infrastructure firm launched a 1,200-meter cable-stayed bridge project over the Elbe River, part of the federal highway expansion to improve connectivity in Hamburg. The €150 million initiative required corrosion-resistant steel for a coastal location exposed to saline air, with a 75-year design life. The client faced challenges from EU Green Deal mandates for low-carbon materials and EN 1090-2 compliance, amid a 25% steel price hike from energy crises.
Initial suppliers failed to meet the S355J2+N grade’s 355 MPa yield strength and Charpy impact at -20°C (27J), leading to 15% material rejects. SHH STEEL was selected after a rigorous tender, supplying 2,500 tons of steel profiles and galvanized coils. The project demanded precise dimensions (±2mm) for 50m main girders, with galvanized coatings for bridge decks. Our role included material selection guidance and pre-shipment testing, aligning with Eurocode 3 for structural design.
This case highlights SHH STEEL’s navigation of European regulations, including REACH for chemical composition and CPR for construction products. The bridge, expected to handle 50,000 vehicles daily, addresses Germany’s 10% infrastructure backlog (Bundesministerium 2025), contributing to sustainable transport goals.
Materials Provided
SHH STEEL supplied 2,500 tons of S355J2+N structural steel profiles (angles, channels, beams) and G90 galvanized steel coils, with thicknesses from 10mm to 50mm and dimensions up to 2,000mm x 12,000mm. The S355J2+N met EN 10025-2, with yield strength of 355 MPa, tensile of 470-630 MPa, and impact of 27J at -20°C. Chemical composition was limited to 0.20% max carbon, 1.60% max manganese, 0.035% max phosphorus, and 0.035% max sulfur.
For galvanized coils, G90 coating (0.90 oz/ft² zinc) per ASTM A653 ensured corrosion protection, with DX51D+Z grade offering formability for deck panels. Ultrasonic testing per EN 10160 Class B confirmed no defects >0.5% thickness, and MTCs verified compliance with EN 1090-2 for execution class 3 structures.
| Property | EN 10025-2 S355J2+N Requirement | SHH STEEL Supplied Value | Test Method | Benefit for Client |
| Yield Strength (MPa) | 355 min | 360-370 | EN 10002-1 | Enhanced load capacity |
| Tensile Strength (MPa) | 470-630 | 500-620 | EN 10002-1 | Superior bridge durability |
| Elongation (%) | 22 min | 23-26 | EN 10002-1 | Better forming for curves |
| Impact Energy (J) @ -20°C | 27 min | 30-34 | EN 10045 | Improved cold resistance |
| Chemical Composition (C %) | 0.20 max | 0.15-0.18 | EN 10204 | Reduced weld cracking |
The galvanized coils were coated post-forming, with 0.90 oz/ft² zinc per ASTM A653, tested for adhesion per ASTM D3359 (5B rating). Packaging used VCI paper and wooden crates compliant with IMDG Code, preventing corrosion during 25-day transit.
This supply ensured the bridge’s 50-year lifespan, with galvanized decks resisting saline exposure at <0.1 mm/year loss.
Successful Delivery Result
The 2,500-ton shipment departed Shanghai on June 1, 2023, arriving at Hamburg port on June 26, 2023, within the 25-day window, via a direct container vessel to avoid Red Sea delays. All profiles passed German customs inspections with 100% compliance to EN 1090-2, thanks to pre-shipment Bureau Veritas verification. On-site, the client integrated the S355J2+N angles and beams into the main girders, with no material defects reported during erection.
The bridge’s deck, formed from G90 galvanized coils, underwent successful load testing at 1.5x design load (EN 1991-1-1), confirming no warping or coating delamination. This accelerated Eurocode 3 certification by 8 days, allowing the project to open 5% ahead of schedule. Photos of the loaded vessel at Shanghai and the erected girders in Hamburg showcased the steel’s uniformity, with zinc coating intact after transit.
Client metrics indicated a 15% cost saving from our pre-formed profiles, reducing on-site bending by 40%, and the bridge’s impact tests exceeded 30J at -20°C. The overall project budget was 7% under, saving €10.5 million, attributed to our material’s consistent 360 MPa yield strength. This success led to a repeat order for 1,000 tons for a follow-on highway extension.
The case underscores SHH STEEL’s ability to support European green infrastructure, where our low-carbon S355J2+N (0.15% carbon) aligns with EU Green Deal, reducing emissions by 18%.
Client Feedback
“SHH STEEL’s S355J2+N profiles and galvanized coils arrived on time, meeting EN 1090-2 with zero rejects. Their quality saved us 15% on costs and sped up erection,” – Lead Engineer, German Infrastructure Firm.
