An Ultra-Cor highway overpass can span more than six lanes.
One of AIL’s latest innovations, Ultra-Cor Structural Steel Plate is taking engineered buried arch bridges to new dimensions in capability and performance.
Buried arch bridge spans of over 35 m (115′)
With an impressive 500 mm (19.6″) pitch and 237 mm (9.5″) depth, Ultra-Cor’s ultra-deep corrugations allow it to reach greater spans and withstand the heaviest of loads.
Ultra-deep corrugations handle extreme loads
Ultra-Cor galvanized steel plate combines all the advantages of lightweight construction with previously unheard-of strength and durability to create the largest buried arch bridges, tunnels, box culverts and many other types of structures.
And, just like all AIL-engineered arch bridge solutions, Ultra-Cor ships and installs easily with minimal equipment and labour requirements.
Recommended bridge construction applications and more
Ultra-Cor is recommended for large bridges, tunnels, grade separations, road or rail overpasses, stream crossings, heavy haul road crossings, stockpile tunnels, portals and canopies.
Discover the many benefits of buried arch bridges
Structural plate bridges offer many advantages over concrete equivalents and traditional site-built beam bridges, truss bridges or concrete drainage pipes.
Visit our Buried Bridge Benefits page to learn more >>
Bring enhanced aesthetics to your buried arch bridges
From interior finishes and lighting to exterior end treatments and even urban greenways on top, take a look at the full range of possibilities for buried arch bridges in our Design Ideas Gallery.
Visit our Design Ideas Gallery to learn more >>
BROCHURES & VIDEOS
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Ultra-Cor Brochure
See how deep-corrugated Ultra-Cor Structural Steel Plate is taking Buried Metal Bridges to new dimensions in capability and performance with six-lane spans of over 35 m (115'). Product specifications, features, applications, projects. (8 pages).
Download(6.06 MB)
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AIL Buried Metal Bridges & Tunnels Planning & Resource Guide
Discover how AIL's Buried Metal Bridges offer many advantages over concrete structures and bridges in this comprehensive guide with: benefits section; design ideas and sector/application galleries; complete product information and comparisons; and installation details.
Download(12.22 MB)
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Ultra-Cor: the world's strongest structural steel plate
Able to span more than six lanes of traffic, AIL's deep-corrugated Ultra-Cor Structural Steel Plate is taking Buried Metal Bridges to new dimensions in capability and performance.
Play(1:42)
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Two-Flange Tunnel Liner Plate Brochure
Get all the details on AIL’s Two-Flange Liner Plate Solutions in steel or aluminum that provide optimum stability and protection when constructing new tunnels and relining structures under highways and railroads or relining vertical shafts.
Download(3.47 MB)
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PROJECT UPDATE: Bow Valley Gap Wildlife Overpass near Canmore, AB
In this July 2024 video, the concrete collars on the twin 24 m Ultra-Cor arches are nearing completion and the natural wildscaping is underway on the cover. The new crossing is expected to dramatically reduce animal-vehicle collisions along this section of the Trans-Canada Highway.
Play(1:37)
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Ultra-Cor Underpass, TCH Exit 41, St. John's, NL
Take a drone-video tour of this 25.4 m span Ultra-Cor grade separation with MSE Precast Panel Walls that will provide improved access from the Trans-Canada Highway to the Galway development near St. John’s, NL.
Play(1:30)
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PROJECT UPDATE: Ultra-Cor wildlife overpass near Canmore, AB
In this August 2023 video, the twin 24 m Ultra-Cor arch assembly has been completed and engineered backfill is well underway on the Stoney Nakoda Wildlife Overpass over the Trans-Canada Highway at Exshaw. The new crossing is expected to dramatically reduce animal-vehicle collisions.
Play(1:31)
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Ultra-Cor Arch, Swan Creek, CFB Gagetown, NB
This 19.6 m span Ultra-Cor crossing will support CFB Gagetown’s new Leopard 2 Tank and Transporter live loads. We value engineered the structure with Best-Kote protective coating on the leg sections only to deliver a design service life of over 75 years.
Play(1:57)
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Ultra-Cor Arch, Holland Creek, Ladysmith, BC
Our first Ultra-Cor installation in Western Canada was a 19.4 m stream crossing for a private residential development in Ladysmith, BC, near Nanaimo. The multi-use Holland Creek crossing also incorporates two Bolt-A-Plate Round tunnels to connect a recreational trail loop in the area.
Play(1:46)
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UPDATE: Ultra-Cor Arch, Holland Creek, Ladysmith, BC
This summer 2024 video shows how well the vegetated MSE Wire Walls have “greened in” in just one year. The walls are designed with topsoil and fabric at the face to promote vegetation and help the crossing blend in with its natural environment.
Play(1:58)
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Ultra-Cor Arch Grade Separation, Corner Brook, NL
Check out this drone video of the completed Massey Drive Interchange with added construction scenes and Ultra-Cor's capabilities.
Play(1:11)
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Project Profile: AIL’s innovative Ultra•Cor used in record-breaking Dubai project
The Shamal Bridge earned a Guinness World Record for having the world’s largest metal buried bridge with a span of 32.39 m.
Download(3.47 MB)
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AIL's Ultra•Cor used in record-breaking Dubai project
View 3D animation and time-lapse construction on this Guinness World Record project (longest buried metal bridge span) featuring AIL’s Ultra•Cor Structural Steel Plate.
Play(2:59)
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Official opening of record-breaking Ultra•Cor bridge in Dubai
Capsule of the official opening and Guinness World Record presentation for the Shamal Bridge near Dubai, UAE.
Play(1:02)
RELATED PRODUCTS
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Two-Flange Tunnel Liner Plate
Two-Flange Tunnel Liner Plate from AIL provides optimum stability and protection when constructing new tunnels and relining structures under highways and railroads and relining vertical shafts.
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Super-Cor Structural Steel Plate
Choose deep-corrugated Super-Cor for applications like box structures and highway overpasses.
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Best-Kote Buried Bridge Coating
Optional coating extends the service life of structural steel plate to over 75 years.
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MSE Precast Panel Walls
An easy-to-install architectural concrete retaining wall system with a true sense of style.
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MSE Wire Walls
Economical MSE wire mesh retaining walls use heavy-duty galvanized steel components.
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Steel Sheet Piling
Stronger and easier-to-drive sheet pile wall solutions.
