新奥克兰大桥设计

SanFrancisco–OaklandBayBridgeSELF-ANCHOREDSUSPENSION(SAS)SPAN22•ProjectOverview•ConventionalVsSASBridge•SFOBBSASFeatures•InternationalFabrication•TemporaryBridge•ShearLegCrane•ConcreteWorks•QualityProgram–Audits–QualityPlans–Mock-upsandPre-qualifications–NCRProcessing–In-processTestsandInspections–WeldTrackingSanFrancisco–OaklandBayBridgeSELF-ANCHOREDSUSPENSION(SAS)SPAN33ProjectOverview44October17,198955CurrentEastSpan66ReplacementSpan150YearServiceLife1400YearEarthquake77SanFrancisco-OaklandBayBridge(SFOBB)Self-AnchoredSuspension(SAS)SASYBITransitionBIDAMT$1.41BFirstWorkingDateMay18,2006EstimatedCompletionDateSpring2013WestApproachWestSpan88ExistingViewDrivingWesttoSanFrancisco99Bicycle/PedestrianFacility1010RemovalE2CrossBeamProjectGeneralBridgeDeckTemporaryTowers/TrussesT1TowerCableSystemW2CapBeamMechanical\ElectricalSummaryProjectSchedule1111ConventionalVsSAS1212ConventionalSuspensionBridge•Twotowers•TwoMaincablesanchoredtoland•Decksectionsliftedin-place1313Self-AnchoredSuspension•Needtobuildabridgetobuildthebridge•Bridgedeckactsascompressionmember•Transferofdeckloadstocableislaststructuraloperationperformed1414SASFeatures1515SFOBBSAS•TowerHeight=160m•DeckLength=625m•Superstructure=43,603,000kg1616T-1TowerLayout1717OneTower(4Legs)SeismicShearLinkBeams1818OrthotropicDeckandCrossbeam1919SingleCableConceptCableWrapsAroundRoadwayCableInstallation•Asymmetricalsingletower•Onecontinuousmaincable•Bridgedeckssuper-elevatedandcurved•Loadtransfernotinfreehangingposition•Finalstructuralanalysiswillbe“as-built”analysis20205.4mmZincGalvanizedWire5.4mmZincGalvanizedWire127WirePWSStrandwithGreaseApplicationofIndividualWire127WirePWSStrandwithGreaseApplicationofIndividualWire17,400WireMainSuspensionCable17,400WireMainSuspensionCableElasticNoxidePrimerandPaintElasticNoxidePrimerandPaintS-WireWrappingS-WireWrappingZincOxide/ZincDustPasteZincOxide/ZincDustPasteCableismadeupof137PPWSCompositionofSASCable2121SASSaddleLocation(Total6)SASSaddleLocation(Total6)(1)TowerSaddle(2)SplaySaddles(2)DeviationSaddles(1)JackingSaddle21212222WestDeviationandJackingSaddlesatW2WestDeviationandJackingSaddlesatW2Status¾Developingpatternfor“E”linesegment2¾Moldingsaddlefor“E”linesegment1HingeKDeviationSaddleJackingSaddle2323HingeKHingeK2424E2BearingandShearKey2525TowerBoltedSpliceDetails2626Bolting•ASTMA490MboltswithDacrometcoating–A490boltsrarelyusedonbridges–Coatingsnotallowedbycurrentstandard–Norotationalcapacitycriteriaformetric•Boltinginconfinedspace2727InternationalFabrication2828FabricationProcessJapanSaddles-JapanSteelWorksKoreaSuspenderCables-KiswireBearings-HochangMachineryIndustriesShearKey-HochangMachineryIndustriesPWSCables-ShanghaiPujiangCableCoTowerFabrication-ZPMCOrthotropicBoxGirderSections-ZPMCBikepath-ZPMCShanghaiPipeBeams-OregonIronWorksWashingtonMiscSteel-D.SBrown&WestmontIndustriesMinnesotaSo.CalifSASSAS--InternationalFabricationEffortInternationalFabricationEffort2929NewTowerFabricationShopSuperstructureFabricator-ZPMCChangxingIslandFacilityShanghai,PRChina3030Tower3131OrthotropicBoxGirderU-RibBendingMachineSubmergedArcWeldingGantry3232OrthotropicBoxGirderOBGLiftsLinedUpOBGLiftAssembly3333DeliveryofOBGandTowerLifts3434SaddleFabricationSaddleFabricationJAPANSTEELWORKSCastingWestDeviationSaddle3535SaddleFabricationTypes:SaddleFabricationTypes:MachiningWestDeviationSaddle3636ShanghaiPujiangCableCo.,Ltd.PWSCableTapingPWSCableAssembly3737GoodwinSteelCastingsMock-upCastingPatternShop3838Xitang,PRCPWSCableStoke-on-Trent,UKCableBands3939TemporaryBridge4040TemporaryWorksW2E2CABDFG1234568710912111314HT1Facts•6,500MtonsofPilingconsistingof48”x1-1/4and42”x1-1/2”•4,300MtonsforTowers•5,500MtonsTrussMaterial•2,124MtonsofDrivingFrames4141TemporaryTowerFoundations4242TemporaryBridge4343ShearLegCrane4444ShearLegCraneandBargeLiftingCapacity:1700MtonsBoomLength:100MetersSelfErectingBoom4545ShearLegCrane4646ConcreteWorksE2CrossbeamW2CapBeam4848W2CapBeamDetailsElevation4949CableTie-downDetails5050W-2CapBeamFacts•2,300cubicmetersconventionalconcrete•4,500cubicmetersself-consolidatingconcrete(8,700PSI)•1,000tonsofrebar•Dimensions:55’Wx225’Lx22’D5151PierE2Details5252E-2CrossBeamFacts•2,000cubicmetersself-consolidatingconcrete(8,700PSI)•650tonsofrebar•Dimensions:15’Wx200’Lx20’D5353QualityProgram5454FacilityAudits5555Audits(40performedto-date)•Extensivein-depthfacilityaudits–Auditchecklistfromlessonslearned–Paperworkapproval(Englishonly)beforeaudit–Facilityaudit•Americanstandards•Verifycapabilityandcontrol/traceabilitythoughouttheprocess•Extensiveinternationaltravel•SomedoingworkforCaltransonotherprojectsdonotreceiveapassfortheSAS•Extendstolowertiersubcontractors–CannotstartANYworkuntilpassinganaudit–Financialpenaltiesforfailinganaudit5656QualityPrograms5757QUALITYPLANS(14approvedto-date)•CONTRACTDOESNOTREQUIREONECOMPREHENSIVEABFJVQCPROGRAM/MANUAL•SPECIFICCONTRACTQUALITYPROGRAMREQUIREMENTS–SEVERALQCMANAGERS–SEVERALQCPLANS–OTHERFABRICATIONSPECIFICPLANS(i.e.,THERMALCONTROLPLAN,PRECASTFENDERS,BEARINGLUBRICANT,CABLEBANDSLIP,etc.)58585959Mock-UpsandPreq