One Startup’s Paper-Thin Stainless Steel Could Change How Bridges Are Built
The future of bridge construction might be getting a major upgrade — and it’s all thanks to one startup’s paper-thin stainless steel innovation. One startup’s paper-thin stainless steel could change how bridges are built by making them stronger, longer-lasting, and far more cost-efficient than today’s rust-prone structures.
Image Credits:Grant Faint/ Getty Images
Why Rust Is the Hidden Enemy of Modern Bridges
Concrete alone isn’t strong enough for the massive loads bridges must carry, so engineers rely on steel rebar for reinforcement. But when that steel begins to corrode, the surrounding concrete weakens — sometimes catastrophically. The problem is so widespread that nearly one-third of U.S. bridges need repair or replacement, a crisis that could cost nearly $400 billion in the next decade.
To fight rust, engineers typically coat rebar with epoxy or use extra layers of concrete. Unfortunately, these are short-term fixes. The only long-lasting solution is stainless steel rebar, but it’s often too expensive to use in every project.
The Startup That’s Reinventing Bridge Materials
That’s where Allium Engineering steps in. The company, co-founded by Steven Jepeal (CEO) and Samuel McAlpine (CTO), believes it has found the perfect balance between durability and affordability. Instead of using solid stainless steel, Allium covers traditional rebar with an ultra-thin stainless steel layer — almost as thin as paper.
This innovative approach could extend a bridge’s lifespan from 30 years to over 100 years, drastically reducing long-term maintenance costs.
“As long as we’re getting full coverage of the surface, a thin layer is enough stainless steel to resist corrosion for hundreds or even thousands of years,” McAlpine explained.
Proving It Works — From Massachusetts to California
Allium’s stainless-clad rebar isn’t just a concept — it’s already in the field. The material has been used in bridge deck replacements on Interstate 91 in Massachusetts and U.S. Highway 101 in Mendocino County, California, as well as in a commercial boat yard in Key West, Florida. These early projects are proving the material’s real-world performance under harsh conditions.
Balancing Cost and Performance
For critical bridges that carry heavy traffic, engineers sometimes opt for full stainless steel rebar — even though it costs up to five times more than conventional rebar. Governments justify the price because it prevents costly shutdowns. But for the vast majority of bridges, epoxy-coated rebar remains the norm, costing about 25–50% more than uncoated steel.
Allium aims to disrupt that market. Its stainless-clad rebar could match or even beat the price of epoxy-coated steel while offering significantly greater protection. According to Jepeal, their goal is to deliver stainless steel performance at epoxy-level pricing, making long-lasting infrastructure more accessible than ever.
A Potential Game-Changer for Infrastructure
If Allium’s approach scales successfully, one startup’s paper-thin stainless steel could change how bridges are built worldwide. The technology could redefine how engineers think about durability, sustainability, and long-term costs — especially as climate change accelerates wear on existing infrastructure.
By combining cutting-edge materials science with practical economics, Allium Engineering may have found the bridge between innovation and real-world impact.
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