Bentley Systems’ AI and Digital Twins Lead the Charge to Save U.S. Bridges

• 30 November 2025
• Construction Focus
• 1272 Views

In the wake of the 2022 Fern Hollow Bridge collapse, which highlighted the critical vulnerability of America’s aging infrastructure, technology is emerging as the only viable path forward.  The crisis, driven by a funding shortfall and a lack of engineers for manual inspections, is forcing transportation agencies to embrace innovative solutions.

Here are two examples of how Bentley Systems’ digital twin and AI-powered software are setting new standards for efficiency, safety, and infrastructure resilience.

1. Bridging Kentucky: 90% Faster Surveys

The Kentucky Transportation Cabinet faced a monumental task: assessing over 1,000 bridges following devastating floods in July 2022, a process initially projected to take a decade and cost over $7 million.

QK4, Inc., the engineering firm leading the effort, utilized Bentley’s software suite, including OpenRoads, ProjectWise, and Bentley LumenRT, to accelerate their digital approach.

By integrating drone context, laser scans, and field data into a detailed 3D existing conditions model (Digital Twin), QK4 cut survey processing time by a remarkable 90% and reduced overall costs by 50%, saving the state over $3 million.

This digital workflow enabled the rapid replacement of flood-damaged bridges, setting a new benchmark for disaster recovery and infrastructure project delivery.

2. AI-Powered Inspections at Robert Street Bridge

In Minnesota, Collins Engineers, Inc. faced the challenge of inspecting the historic Robert Street Bridge ahead of a major rehabilitation.

The firm worked closely with Bentley, leveraging the iTwin Platform and related AI tools like iTwin Capture and iTwin Experience. They created a high-fidelity digital twin of the structure, using Bentley’s AI defect detection capabilities to automatically find and document concrete cracks.

This workflow saved over 30% in inspection hours and significantly improved the quality and precision of data collection. The project demonstrates how Bentley’s AI capabilities provide precise, timely interventions, enhancing both the engineer’s safety and the public’s reliance on the structure.

The shift toward AI-enabled workflows and digital twins is no longer a matter of preference but a necessity for infrastructure builders. As the backlog of structurally deficient bridges continues to grow, and the resources for traditional methods remain constrained, Bentley Systems’ portfolio—including its focus on the iTwin Platform for creating and leveraging digital twins—is proving vital to the industry.

These tools allow engineers to move beyond manual effort, transforming raw data into actionable insights for the design, construction, and long-term maintenance of the nation’s critical links.

• iTwin
• AI
• ProjectWise
• Bentley Systems
• OpenRoads
• LumenRT