Environmental Groups

1
San Francisco-Oakland Bay Bridge East Span
Seismic Safety Project
STEEL FABRICATORS OUTREACH July 17, 2001
2
Program Project Overview
Amer Bata Senior Bridge Construction Engineer
3
Program

• Project Overview
• Steel Design
• Steel Specifications
• Welding and Testing
• DBE Partner Participation/SBE
• DBE Certification Process
• Break
• Question/Comment Answer
• Open Discussion
• Lunch
• Open Discussion Continues

4
Project Limits
5
SFOBB East Span - Existing/ Proposed
Existing
Proposed
6
Cross Section
Shoulder
Shoulder
Five Traffic Lanes
Bike / Ped
7
SFOBB Contract Segments
Segment
YBI
Skyway
Oakland
SAS
Hinge A
Hinge E
Frame 1
Frame 2
Frame 3
Frame 4
8
Segment 1 - YBI Structures

• Viaduct Modification
• Temporary Detours
• Transition Structures
• EB On-Ramp

9
Detour Structures

• Structural Steel 5,700,000 Kg

10

Segment 2 - Self-Anchored Suspension

• Structural Steel 60,000,000 Kg
• 2.5 m Steel Piles 2,100 m

11
Bridge Elevation
657 m
385 m
80 m
180 m
12 m
Elev. 160m
Pier W2
Aprox. OG along PG Line
Pier 1 Tower
Pier E2
12
Temporary Towers
13
Segment 3 - Skyway

• Structural Steel 33,000,000 Kg
• 2.5 m Steel Piles 15,000 M

14
Transition Span
15
Pile Cap
16
Segment 4 - Oakland Touchdown

• Steel Piling 7,500 M

17
Construction Schedule
Tentative schedule, subject to change
18
Steel Design
Rafael Manzanarez Bridge Design Manager
19
Project Limits
20
Single Tower - SAS
21
Elevation and Plan View
22
Dual Box Girder
23
SAN FRANCISCO-OAKLAND BAY BRIDGE - FINAL TYPE
SELECTION
24
Erection - Temporary Towers
25
Transverse Elevation Looking East
26
Tower Foundation
27
Steel Framing Plan
28
Tower Foundation
29
Elevations
30
Steel Framing Plan
31

Pile
32
Tower Anchorage Layout
33
Tower Anchorage Details
34
Transverse Elevation Looking East
35
Tower Section and Shear Links
36
Tower Diaphragms
37
Tower Shear Link
38
Bridge Plan ( Cable and Saddles)
39
Cable
40
S-Wire Wrapping
41
Tower Saddle
42
Deviation Saddle DetailPlan View
43
W Line Section Type 1A
44
E Line Section Type 1A
45
Floorbeam Section and Detail
46
Typical Crossbeam Details
47
East Cable Anchorage Layout
48
Bushing and Bearing
49
Skyway Structure
50
Plan for Piers E3E14
51
Pile Head Connection
52
Sections
53
Bike Path
54
CISS Concrete Piling
55
Sections and Dimension Table
56
Typical Section
57
Pipe Beam Elevation
58
Section F-F
59
Bent WB1
60
Section A-A
61
Typical Section
62
Section B-B
63
Railing Details
64
Bike/Pedestrian Path
65
Modified Type 732 Steel Barrier - 65 Design
(August 1999)
66
Swiveling Joint Seal Assembly
67
Skyway StructuresFooting Layout No. 2
68
Skyway Precast (1) Hinge A
69
Section A-A YB4E1
70
Section B-B YB4E1
71
Section C-C YB4E1
72
Section D-D YB4E1
73
Section E-E YB4E1
74
Single Tower - SAS
75
Dual Box Girder
76
Structure Specifications
Sharon Naramore Senior Bridge Engineer
77
Steel Items

• Girders, Shapes, Plates
• Piling
• Hinge Joints, Bearings and Pipe Beams
• Anchorages and Saddles
• Tiedowns and Tiebacks
• Barrier, Railing, Lights
• Travelers and Elevator
• Service Platforms and Substation
• Miscellaneous Metal

78
Steel Structures Special Provisions

• Buy America
• Welding
• Steel Audits
• Steel Pipe Piles
• Steel Structures
• Miscellaneous Metal
• Plus the Information Handout

79
Buy America

• Standard Requirements
• Does not apply to temporary towers
• Does not apply to detour structures

80
Welding Quality Control

• Applies to all steel items
• Welding Meeting
• QCM
• QCP
• Document Submittals

81
Steel Audits

• Applies to all steel items
• Steel Fabrication Meeting
• Self Audit
• Caltrans Audit
• Document Submittals

82
Steel Pipe Piling

• UT Technician Certification (field welds)
• AWS D 1.1 and API combined code
• Field welds vs. shop welds
• NDT requirements
• Documentation Submittals

83
Steel Structures

• AISC Cbr, Major Steel Bridges, endorsement F,
  FCM
  
• AISC, CASE, Certified Advanced Steel Erector,
  endorsement F, FCM
  
• Mostly ASTM A709, with supplementary
  requirements
  
• AWS D 1.5
• Construction Surveying

84
Steel Structures

• Typical Structural Steel
• girders, plates, shapes, connections
• Furnish
• Erect
• Orthotropic box mock assembly
• Barrier, Rails and Light Standards

85
Steel Structures

• Non-typical Structural Steel
• Hinge pipe beams
• Modular joint seal assemblies
• Circular segmented bearings
• Travelers and Elevator
• Substation components
• Service platforms
• Casting allowed for SAS components

86
Miscellaneous Metal

• Welding Quality Control
• Some connection requirements may apply
• May attach to steel structure elements so the
  connection is governed by Steel Structures
  requirements

87
Information Handout

• Caltrans UT Technician Certification Program
• Steel Audit Form
• PIDP Report

88
Welding and Testing
Jim Merrill Senior Welding Engineer
89
Steel Materials Testing - QC/QA

• Welding Quality Control
• Steel Audits
• Project Specific Discussion

90
Welding Quality Control

• Field Vs. Shop
• Quality Control Manager (QCM)
• Pre-weld Meeting
• Quality Control Plan (QCP)

91
Weld Quality

• Shop Vs. Field
• Code Quality is the same
• Same Allowable Stress
• Skill Level of Welders

92
Quality Control Manager (QCM)

• Must be a Direct Employee of Prime
• Primary Contact for Quality Matters
• Review submittals
• Represents contractor and subs
• Certified Welding Inspector (CWI)
• Level II in NDT Methods Utilized

93
Pre-weld Meeting

• Discussion of Sec. 8.3 (Special Provisions)
• Certification of personnel
• Procedure Qualification
• Development of QCP
• Required documents
• Questions from the Contractor

94
Quality Control Plan

• Welding Procedures
• WPS, PQR
• Caltrans Witness
• Welder Qualifications
• Process, 3 year limit
• Caltrans Witness
• NDT
• Level II, III
• Written Practice

95
Steel Audits

• Self Audit
• All audit items are contract requirements
• Caltrans Audit
• Prior to beginning Fabrication
• Formal Audit
• Purpose to Determine Capability
• Re-audit
• If required
• Max 3 times

96
Project Specific

• Caltrans UT Certification
• Deck Mock-up
• Distortion Control Plan
• QC Presence
• Fatigue Details
• Fabrication Survey

97
Caltrans UT Certification

• Caltrans UT Technician
• Certification Program
• Written Portion (Code Knowledge)
• Hands on (code technique acceptance)

98
Deck Mock-up

• Fabricator to Provide Deck Mock-up
• Demonstrate Fabricators Procedures
• Welding Procedures
• Distortion Control
• Assembly Practice

99
Distortion Control Plan

• Orthotropic Deck, Tower
• Holding of required dimensional tolerances
• Jigs and Fixtures
• Prevention of residual stress
• Lamellar tearing
• Pre and Post weld Heat Treatments

100
QC Presence

• QC CWI Presence
• When any work is being performed
• all shifts
• all shops
• Before, During and After Welding
• 30 minute max duration

101
Fatigue Details

• Specific Shape
• Weld Profile
• Depth of Penetration

102
Fabrication Survey

• Must be performed at Fabrication Facility
• Deck Sections per Fit-up
• Match Field Erection