Lessons from Poland’s MS-3 Bridge

Challenge

When Environment and Infrastructure Collide

Mazury, located in northeastern Poland, is known for its 2,000 post-glacial lakes and undulating terrain. While visually striking, this landscape presents significant challenges for road and bridge construction, particularly when projects must navigate waterways, wildlife corridors, and existing infrastructure simultaneously.

This was the reality facing GDDKiA Olsztyn, the asset owner, when they commissioned a major bypass and expressway project around the city of Ostróda. In 2015,  Budimex S.A., the general contractor, was awarded the contract, which included construction of the MS-3 bridge. This project spans 677 meters (2,221 feet) and measures 28 meters (92 feet) wide. The bridge crosses a creek, two existing roadways, and two animal passageways, each adding complexity to both design and execution.

For stakeholders, the challenge extended beyond construction and posed a question: how to ensure long-term pavement performance on a structure exposed to high traffic loads, environmental stress, and demanding service conditions?

Solution

Rethinking Bridge Deck Performance

Bridge deck pavements are particularly vulnerable to rutting and permanent deformation due to constant traffic loads, temperature fluctuations, and structural movement. Early degradation can drive costly maintenance and disrupt critical transportation routes.

To address this, the MS-3 bridge required a pavement system capable of:

• Withstanding sustained thermal and mechanical stress
• Delivering long-term resistance to permanent deformation
• Supporting efficient installation under complex construction conditions

Importantly, any solution also needed to align seamlessly with established construction practices, minimizing risk during execution.

Advanced Materials, Practical Application

The project team selected HiMA ™ technology-enabled mastic asphalt, using polymer-modified bitumen produced by Locos Asphalt.

The final bridge deck structure was carefully engineered to balance durability and constructability:

• 25 cm (10 in) reinforced concrete bridge deck
• Methyl methacrylate waterproofing membrane
• Two 4 cm (1.6 in) layers of mastic asphalt, including a high-performance layer modified with 45/55-90 HiMA

Execution conditions further highlight the robustness of the solution:

• Mastic asphalt production temperatures ranged from 190-210°C (374-410°F)
• The material was transported for up to eight hours at approximately 200°C (392°F)
• Compaction occurred at 200-220 °C (392-428°F)

Despite the high polymer content and elevated temperatures, Budimex S.A. reported that the material handled similarly to conventional mastic asphalt, an important factor in ensuring smooth implementation without introducing additional construction complexity.

This ability to combine enhanced performance with familiar application methods is the key enabler of successful innovation in infrastructure projects.

Impact

Performance That Extends Beyond Installation

Since completion in 2017, the MS-3 bridge deck has demonstrated strong resistance to permanent deformation, meeting the project’s core durability objectives.

For GDDKiA, this translates to:

• Reduced maintenance requirements
• Lower lifecycle costs
• Increased long-term reliability for road users

In a region where environmental and structural challenges are unavoidable, these outcomes reinforce the value of investing in materials that are designed for long-term performance, not just at the initial delivery.