Hamburg Port Authority, smartBRIDGE digital twin of the Köhlbrand Bridge
The Köhlbrand Bridge is a key road link in the Port of Hamburg. It opened in 1974, and traffic has nearly doubled since then. In 2023, about 32,000 vehicles crossed it on an average weekday (Hamburg Port Authority, 2026). The Hamburg Port Authority (HPA) inspects, monitors and maintains the bridge closely because of its importance to the port. Recent inspections show an alarming increase in the rate of damage to the longitudinal ribs of the river bridge (Hamburg Port Authority, 2026). To manage this aging asset, HPA commissioned smartBRIDGE Hamburg, a digital twin of the bridge built by a consortium of technology and civil engineering firms (homePORT Hamburg, n.d.).
Approach
Real-time sensor monitoring. More than 500 sensors provide real-time structural health monitoring based on condition data (homePORT Hamburg, n.d.).
One digital twin for all condition data. The digital twin brings analog and digital condition data together. Findings from cyclic structural inspections under the German standard DIN 1076, detailed diagnostic investigations and continuous sensor monitoring are turned into condition indicators (homePORT Hamburg, n.d.).
Predictive maintenance. The aim is more precise damage forecasts and predictive, sustainable maintenance management (homePORT Hamburg, n.d.).
Monitoring triggers inspections. Besides the main inspections, HPA carries out component-specific and special inspections when the ongoing monitoring of the structure indicates a need (Hamburg Port Authority, 2026).
Partners and testing. The consortium includes HPA, MKP GmbH, WTM Engineers, CustomQuake and CON+SCANTECH. A test account shows the digital twin with simulated data, including wire breaks in the stay cables, sustained high traffic loads and hurricane conditions (homePORT Hamburg, n.d.).
Results
smartBRIDGE Hamburg won the buildingSMART International Award 2021 (Asset Management), the NextReality Contest 2021 (Best Innovation) and the Deutscher Digitalpreis 2021 (Digital Transformation) (homePORT Hamburg, n.d.). HPA's goal is to keep the bridge in service for freight traffic until a replacement structure opens. Based on current inspection results, heavy transports over 44 tons that need a permit will be rerouted from 1 May 2026 (Hamburg Port Authority, 2026).
Transferability
DMC ports with aging bridges, quays or jetties can combine regular inspections with continuous sensor monitoring in one data platform. Condition indicators can show when extra inspections are needed, help plan maintenance before damage becomes critical, and support early decisions on load limits and replacement. Ports can start with a small number of sensors on the most critical asset and link them to existing inspection records.
Sources
All information used for this case study was based on publicly available resources.