1. San Francisco – Oakland Bay Bridge
Self-Anchored Suspension (SAS) Span
San Francisco
Yerba Buena Island
Treasure Island

2. OVERALL PROJECT SCOPE – ABF JV
FOCUS ON EAST END FABRICATION EFFORT

3. ‐Temporary Works
‐Pier E2/W2 Cap Beams
‐Orthotropic Box Girder (OBG)
and Crossbeams
‐Tower
‐Cable Works and Saddles
‐Bike path/Miscellaneous

4. Temporary Works
• 6,500 MT of Piling consisting of 48”
x 1‐1/4 and 42” x 1‐1/2” Steel Shell
• 4,300 MT for Towers
• 5,500 MT of Truss Material
• 2,100 MT of Driving Frames
• Top of Erection Tower is 163M

5. Pier W‐2 Cap Beam
• 2,300 m3 Conventional Concrete
• 4,500 m3 Self‐Consolidating Concrete
• Concrete Placed in 7 Major Pours
• 1,000 MT of Reinforcing Steel
• 5,765 Meters of Post‐Tensioning Tendons
Yerba Buena Island

6. Pier E‐2 Cap Beam
• 1,600 m3 Self‐Consolidating
Concrete
• Concrete Placed in ONEONE Lift
• 1,200 MT of Reinforcing Steel
• 1,500 MT of Post‐Tensioning
Tendons
Yerba Buena Island

7. Cable Works
One continuous cable, anchored in the East End OBG
Bundled Zinc Galvanized Wires
Protective Zinc Paste
“Elastic” Paint
Parallel Wire Strand Cable (PWS) Composition
S-Wire Wrap
• Main Cable is 784mm Diameter
• 137 Individual Strands
• Each Strand Has 127 Wires
(17399 Wires)
• Cable Weight = 4800 MT

8. Cable Saddles
Pier W2
(1) Tower
Saddle
(2) Splay
Saddles
(2) Deviation Saddles
(1) Jacking Saddle
East Cable Saddle and Anchorage
Tower Saddle
Jacking Saddle
Deviation
Saddle

9. Bike path/Miscellaneous
Bike path to YBI
Pier E2 Bearings and
Shear Keys
Maintenance Traveler

10. Bike path/Miscellaneous
Bike Path to YBI
Pier E2 Bearings and
Shear Keys

11. OBG Fabrication
5A
5B
5C
3A
3B
4A
4B
Lift 5E
Lift 6E
Lift 5W
Lift 6W
• 14 Lifts 43 Segments East and West
• 19 Crossbeams
• Full Length Steel Barrier
• 6 Cable Brackets/102 Suspender
Brackets
• 5 Service Platforms
• 615 Meters Long/30,000 MT
Segment Assembly
Trial Assembly

12. OBG Erection
Crossbeam No. 1
OBG Lift 1E Cradle
OBG Pushing Frame
12” Bore / 150T / 126”
Stroke Jacks

13. OBG Erection
OBG Lift 11East Erection
70M Long / 1470MT Weight
Crossbeam Erection

14. Tower Fabrication
• 4 Shafts, 5 Lifts Per Shaft
• Tower Anchorage Connection/Skirt
• Tower Saddle Grillage/Tower Head
• Cross Braces and Struts
• 160 Meters High/15,000 MT
Tower Shaft Milling
Skin Welding In Rotisseries

15. Tower Fabrication
Trial Assembly of Lift 2
(3000 MT)
Tipping Lift 1 in Trial
Assembly

17. Tower Erection
Tower Footing
(Not In Contract)
Tower Footing
(Not In Contract)
Tower Lift 1 Tip UpTower Lift 1 Tip Up

18. Cable Erection
W2 Tramway and Guiding
System
Catwalk Assembly on OBG Deck
Cable Works:
Catwalk installation
Tower tie‐back
Cable hauling system

19. Cable Erection
First Bridge Lighting
Catwalk Erection
Cable Works (upcoming):
Strand installation (Jan. 2012)
Cable compaction (May 2012)
Suspender Rope installation
(Summer 2012)

20. Shipment From Shanghai, China
To Oakland, California

21. Packing For China
• 13 Checked Baggage
• 4 Carryon Baggage
• 1 Carseat (Never Again Used)
• 1 Three Month Old
• 1 Four Year Old
• 1 Wife
• A Lot of Attention

22. Transporting Chairs/Misc.
Reading the Morning Paper

23. OBG East End
‐Nothing Typical
‐Curve
‐Superelevation Transition at Pier E2
‐Bearing and Shear Key Connection
‐Green Joint/Alignment of Pier E2
‐Cable Alignment (Saddle/Brackets)
‐Architectural Housing/Deck Plate Dropin
‐Cable Anchorage in Lift 14
‐Hinge Tie‐In To Skyway
‐Fabrication Studies

24. OBG East End Team Work (ABF, Caltrans, TY Lin, METS, ZPMC, Candraft)
Team China Working Meetings
RFI Process
Submittal Process
Tolerance Studies
Fabrication/Welding Sequence/Access Studies
Clash/Interference Studies

25. OBG East End Model/Shop Drawings/Parts
Used 3‐D CAD Model To Detail and Construct From
6000 Shop Drawings
XXXXXXX Parts

26. OBG East End Mockup Construction – Investigate Fabrication Procedures
Assembly and Welding Sequence
Bolting/Welding Access
Inspection Testing Plan (ITP)
Inspection Hold Points
Dimensional Control
Painting Sequence/Access
Temporary Attachments
Jig Construction
Pier E2 and Saddle – 300 MT
Hinge – 150 MT
Anchorage – 30 MT

27. OBG East End Survey and Jig Construction
Used 3D Model To Lay Out and Construct Jigs
Provided Instant Geometric Control and QA
Jigs For Deck Plates Through Curve
and Transition
Jigs For Segment Assembly

28. OBG East End Layout Trim Lines and Weld Joint Complexities
Plate Thickness and Cross Sectional Changes

29. OBG East End
Mockup Lessons
Milling and Hole Alignment
Weld Distortion Concerns
Bearing Seats
Tolerances
Pier E2 (Lift 13A Bottom Plate)

30. OBG East EndSaddle Grillage Construction
Mockup Lessons
Cable Geometry
Welding Distortion
Milling Procedure
Layout In Seg Assembly
Saddle Support System
Tolerances

31. OBG East EndSaddle Grillage Construction

32. OBG East EndAnchorage Plate
Mockup Lessons
Geometry Concerns
Weld Distortion Concerns
Vertical Shear Plates
Sandwich Plates
Bearing Blocks
Tolerances

33. OBG East EndBearing Blocks/Sandwich Plates
Cast Bearing Blocks
Milling Sandwich Plates
Tolerance Checks on Sandwich
Plates

34. OBG East EndHinge A At Skyway Connection
Parts Fabrication and Mockup Lessons
Rolling Hinge Pipe Sleeve
Welding Distortion Concerns

35. OBG East EndHinge A At Skyway Connection
Segment Assembly
Survey
Laying Out Cut Lines
Hinge Alignment
Tolerances

36. OBG East EndArchitectural Housing Construction
Difficult Geometry
Survey And Jig Construction
Fit Up Before Load Transfer
Erected After Load Transfer
Quantity of Drilling

37. OBG East EndAncillary Items – Traveler, Bike Path, Barrier, Cable Brackets

38. OBG East EndPutting It All Together
Transporting Segments Outside
Pier E2 Alignment
Green Joint Survey

39. Fabrication Status ‐ COMPLETEOBG East End

40. Google Earth Status

41. FUN