San Francisco-Oakland Bay Bridge East Span Seismic Safety Project Contractor Information Meeting Construction Contract 04-0120F4 November 30, 2005

San Francisco-Oakland Bay BridgeSan Francisco-Oakland Bay BridgeEast Span Seismic Safety ProjectEast Span Seismic Safety Project

Contractor Information MeetingContractor Information MeetingConstruction Contract 04-0120F4 Construction Contract 04-0120F4

November 30, 2005November 30, 2005

SFOBB East Span Seismic Safety ProjectSFOBB East Span Seismic Safety Project2

Jon TappingJon TappingInterim SFOBB East Span Interim SFOBB East Span

Project Manager, CaltransProject Manager, Caltrans


Dan McElhinney,Dan McElhinney,District 4 Director, CaltransDistrict 4 Director, Caltrans


DVBE - Civil RightsDVBE - Civil Rights

Robert PadillaRobert Padilla

Statewide Small Business Liaison for Statewide Small Business Liaison for Caltrans, Office of Civil RightsCaltrans, Office of Civil Rights

Disabled Veteran Business Enterprise Disabled Veteran Business Enterprise (DVBE) goal(DVBE) goal

Prime Contractor’s commitmentPrime Contractor’s commitment


Technical IssuesTechnical Issues

Brian MaroneyBrian MaroneySFOBB East Span Technical SFOBB East Span Technical

Manager, Caltrans Manager, Caltrans


Guidelines for Q&AGuidelines for Q&A

Please submit questions in writing on cards Please submit questions in writing on cards providedprovided

Any answers provided today are preliminary and Any answers provided today are preliminary and not considered final until posted on the bidder not considered final until posted on the bidder inquiry web siteinquiry web site

Bidder Inquiry website: http://www.dot.ca.gov/dist4/construction/Inquiries/04-0120F4_inquiry.html

Future inquiries may be addressed to the Duty Senioremail: [email protected]: [email protected] address: P.O. Box 23660, Oakland, CA 94623-0660Mailing address: P.O. Box 23660, Oakland, CA 94623-0660Fax number: (510) 622-1805Fax number: (510) 622-1805All inquiries must include the contract number (04-0120f4)All inquiries must include the contract number (04-0120f4)


Mike WhitesideMike WhitesideUpcomingUpcoming Addenda Addenda


Upcoming Addendum ItemsUpcoming Addendum Items

Addendum 4, early DecemberAddendum 4, early December CJP to PJPCJP to PJP Remove “Unsatisfactory Progress” Remove “Unsatisfactory Progress”

SpecificationSpecification Add Temp. Tower AE & AW final DesignsAdd Temp. Tower AE & AW final Designs Use of Electorslag WeldingUse of Electorslag Welding Pre-Assembly Requirements ReducedPre-Assembly Requirements Reduced Constructability Refinements/Improvements Constructability Refinements/Improvements

& Conflict Resolution& Conflict Resolution



Addendum 5, late DecemberAddendum 5, late December

Performance specifications for castingsPerformance specifications for castings E2 Shear Key/Bearing AlternativeE2 Shear Key/Bearing Alternative Hinge K Pipe Beam FabricationHinge K Pipe Beam Fabrication Hinge K ClosureHinge K Closure Availability of North Side of Oakland Availability of North Side of Oakland

ApproachApproach



Addendum 6, early JanuaryAddendum 6, early January

Miscellaneous clean-up issuesMiscellaneous clean-up issues Constructability Refinements/Improvements Constructability Refinements/Improvements

& Conflict Resolution& Conflict Resolution


Michael StoneMichael StoneScheduleSchedule


SAS ScheduleSAS ScheduleMonths

Previous AdvertisementFirst Working Day DP 1 - 829 Cdays DP 2 DP 3W2 Cap Beam 1950 Cdays 2130 Cdays DP 2Tower Shop Drawings/Fabrication 2310 CdaysE2/T1 Available 34 months

Construct TowerDeck Shop Drawings/FabricationConstruct DeckConstruct Cable System Load TransferComplete SAS for Westbound TrafficComplete SAS

Current AdvertisementFirst Working Day DP 1 - 650 Cdays DP 2 DP 3 DP 4W2 Cap Beam 1770 Cdays 1950 Cdays 2130 CdaysTower Shop Drawings/FabricationE2/T1 Available 36 months

Construct TowerDeck Shop Drawings/FabricationConstruct DeckConstruct Cable System Load TransferComplete SAS for Westbound TrafficComplete SAS

51 5439 42 45 4827 30 33 36

8472 75 78 8166 6948 51 54 57 6039 42 45 6327 30 33 3615 18 21 243 6 9 12

60 63 66 69 723 6 9 12 15 18 21 24 57


SAS Schedule – SAS Schedule – Working DrawingsWorking DrawingsMonths 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Working Drawing Schedule

First Working Day

MFSQA / Shop Audit

Material Order

Material Lead Time (to start fabrication)

Mock-ups

Wood Mock-up

Steel Mock-up

Preliminary Erection Plan

Submittal

CT Review

Re-submittal

CT Re-review

Weight Control

Submittal

CT Review

Re-submittal

CT Re-review

Working Drawings

Submittal

CT Review

Re-submittal

CT Re-review

Fabrication

First Shipment

Last Shipment


SAS ScheduleSAS ScheduleChanges since last advertisement

• Increased bidder compensation• Revised CRIP specifications to provide non-compensable

time for CRIP submittal• Reduction in time required for Caltrans to review and

approve weld repairs• Allowing repairs to be made after erection• E2/T1 availability earlier in the contract, more time between

E2/T1 availability and Milestones 2, 3 and 4


Marwan NaderMarwan Nader

Temporary Tower Design ExampleTemporary Tower Design Example


TEMPORARY TOWER TEMPORARY TOWER DESIGN EXAMPLEDESIGN EXAMPLE

November 18, 2005November 18, 2005



Tower ConfigurationsTower Configurations

Tower CTower C

Tower GTower G




DESIGN CRITERIADESIGN CRITERIACodes, Standards, SpecificationsCodes, Standards, SpecificationsApplicable Codes/Specifications:Applicable Codes/Specifications: CalTrans Standard Specifications, 1999CalTrans Standard Specifications, 1999 CalTrans Special Provisions, Contract 040120F4CalTrans Special Provisions, Contract 040120F4 CalTrans Falsework Manual, Rev. 32, November 2001CalTrans Falsework Manual, Rev. 32, November 2001

AISC-LRFD, 1999 for rolled sectionsAISC-LRFD, 1999 for rolled sections API RP2A-LRFD, July 1993 for tubular sections and API RP2A-LRFD, July 1993 for tubular sections and

connections (and pipe piles)connections (and pipe piles) AASHTO-LRFD Bridge Construction Specification, AASHTO-LRFD Bridge Construction Specification,

2nd Ed. (Concrete only)2nd Ed. (Concrete only) ANSI/ASCE 795 (Wind loads only)ANSI/ASCE 795 (Wind loads only)


Independent Loads CasesIndependent Loads Cases

Dead LoadDead Load Live LoadLive Load Vessel ImpactVessel Impact EarthquakeEarthquake

1.0X-direction + 0.3 Y direction0.3 X-direction + 1.0 Y direction

-1.0 X-direction + 0.3 Y direction 0.3 X-direction - 1.0 Y direction

Wind LoadWind Load Wind, Wave and CurrentWind, Wave and Current





Wind, Wave and CurrentWind, Wave and Current

WindWind ASCE 7-95 specifies an 85MPH Wind Gust @ +10m Section 10-1.59 of the Special Provisions specifies a 100 MPH 3-sec gust @ El. +50m. The 100MPH Wind Gust velocity stated in the Special Provisions govern.

The importance factor is 1.15 per revised Special Provisions The exposure coefficients are for exposure D (open water) The gust factor is 0.85 in accordance with ASCE Section 6.6 The shape factor on projected flat surface of the box girder was 1.5 (ASCE Table 6-8),

and 0.8 for the tubular tower structures (ASCE Table 6-9). WaveWave

2m high, 6sec wave per revised Special Provisions Drag and inertia coefficients are 0.65 and 1.6 (ref API RP2A), respectively

CurrentCurrent 3-knot surface current was conservatively assumed

(Note: Vessel Collision Report indicates a uniform 2 knot design current for Impact design).

The surface current velocity profile with depth was developed utilizing a 1/7th power distribution.



Construction Loads/StagesConstruction Loads/Stages

1. Individual deck lifts 1 thru 9 on the appropriate towers

2. In- fill / heavy lifts 1, 2, 3 & 4 on the appropriate towers

3. Connecting the deck sections together in the longitudinal direction

4. Connecting the cross beams in the transverse direction

5. Connecting the deck sections to W2 and E2 cap beams

Tower CTower C Temporary Tower (TT) TT plus Deck Lift #1 (830 Tonnes) on 4 bearing pads TT plus Deck Lift #4 (459 Tonnes) on 4 bearing pads TT plus Deck Lift #4 plus half of Heavy Lift #1 (830/2 = 415 Tonnes) = total 875 T Envelope of Vertical Forces (see Table 1 on Sheet Construction Load No. 1)

Tower GTower G Temporary Tower (TT) TT plus Deck Lift #9 (892 Tonnes) on 6 bearing pads TT plus Deck Lift #9 plus half of Heavy Lift #3 (1285/2 = 643 Tonnes) = tot al 1535 T TT plus Deck Lift #9 plus half of Heavy Lifts #3 & #4 = 2177 T Envelope of Vertical Forces (see Table 1 on Sheet Construction Load No. 1)


Load CombinationsLoad Combinations

1.4 DL1.4 DL

1.1 DL + 1.3 LL1.1 DL + 1.3 LL

1.0 DL + 1.0 LL + 0.5 Wind + 1.0 Current + 1.0 Impact (Vessel)1.0 DL + 1.0 LL + 0.5 Wind + 1.0 Current + 1.0 Impact (Vessel)

1.0 DL + 1.0 LL + 1.0 EQ1.0 DL + 1.0 LL + 1.0 EQ

1.0 DL + 1.0 LL +1.3Wind +1.3Wave + 1.3Current1.0 DL + 1.0 LL +1.3Wind +1.3Wave + 1.3Current


Tower CTower C

Tubular steel structure, trucked and assembled on site Tubular steel structure, trucked and assembled on site with the use of a crawler cranewith the use of a crawler crane

All tower and truss joints are to be boltedAll tower and truss joints are to be bolted Leg segments bolted together with splice flanges Leg segments bolted together with splice flanges

located near inflection pointslocated near inflection points Pre-installed gusset plates welded to legs for bracing Pre-installed gusset plates welded to legs for bracing

members to be bolted ontomembers to be bolted onto Gusset plates actually penetrate through the legs to Gusset plates actually penetrate through the legs to

provide load continuity through the jointsprovide load continuity through the joints





Tower GTower G

6- leg tubular steel jacket structure, 65m (213 ft) high6- leg tubular steel jacket structure, 65m (213 ft) high 14m x 30m (46 ft x 98 ft) footprint at the top, to match 14m x 30m (46 ft x 98 ft) footprint at the top, to match

bearing locationsbearing locations Pin piles driven through the jacket legsPin piles driven through the jacket legs The jacket base plan dimensions provide the same The jacket base plan dimensions provide the same

overturning resistance in both orthogonal directionsoverturning resistance in both orthogonal directions Bay height chosen to provide efficient diagonal Bay height chosen to provide efficient diagonal

bracingbracing Cross braced to provide ductility Cross braced to provide ductility






3D View of Towers ABC Model3D View of Towers ABC Model


Mode 1 (T=0.78 sec) Mode 1 (T=0.78 sec)


Y Spectral Displacement (5.62 cm at top Y Spectral Displacement (5.62 cm at top of Tower C) (Transverse)of Tower C) (Transverse)


Wind Displacement Wind Displacement (0.8 cm at top of Tower C)(0.8 cm at top of Tower C)


Transverse Pushover at 115mmTransverse Pushover at 115mm


Transverse Pushover

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

50,000

0.000 0.020 0.040 0.060 0.080 0.100 0.120

Displacement at Top of Tower (m)

Ba

se

Sh

ea

r (k

N)

Shear reductions are due to compression member buckling (tension members take over)

Transverse Pushover to 115mmTransverse Pushover to 115mm


3D View of Tower C Model as a separate 3D View of Tower C Model as a separate structurestructure


Mode 2 (T=1.43 sec)Mode 2 (T=1.43 sec)


Y Spectral Displacement (7.63cm at top Y Spectral Displacement (7.63cm at top of Tower) (Transverse)of Tower) (Transverse)


Wind Displacement Wind Displacement (1.06cm at top of Tower)(1.06cm at top of Tower)


Transverse Pushover at 300mmTransverse Pushover at 300mm


Transverse Pushover

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

0.000 0.050 0.100 0.150 0.200 0.250 0.300 0.350


Bas

e S

hea

r (k

N)


Transverse Pushover to 300mm, Force-Transverse Pushover to 300mm, Force-Displacement Curve (76mm Seismic Demand)Displacement Curve (76mm Seismic Demand)


Tower C ConclusionsTower C Conclusions

Combined structure is stiffer; lower periodCombined structure is stiffer; lower period Produces larger forcesProduces larger forces

Separate structure is more flexible; higher Separate structure is more flexible; higher periodperiod

Produces lower forcesProduces lower forces

Consider Base Isolation SystemConsider Base Isolation System (Slip plane at bearing level with retainers)(Slip plane at bearing level with retainers)


3D View of Tower G Model3D View of Tower G Model


3D View of Tower G alone3D View of Tower G alone



Mode 2 (T=1.36 sec)Mode 2 (T=1.36 sec)


IMPACTY Displacement (Y=4.5 cm IMPACTY Displacement (Y=4.5 cm at top of tower, Y=11.5 cm at point of impact)at top of tower, Y=11.5 cm at point of impact)


Y Spectral Displacement Y Spectral Displacement (9.7 cm at top of Tower)(9.7 cm at top of Tower)


Wind Displacement Wind Displacement (4.4 cm at top of Tower)(4.4 cm at top of Tower)


Transverse Pushover Displaced Shape Transverse Pushover Displaced Shape at X=0.45 mat X=0.45 m


Transverse Pushover

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

0.000 0.100 0.200 0.300 0.400 0.500


Bas

e S

hea

r (k

N)

No member buckling present at this load level – piles govern capacity

Transverse Pushover Curve to 0.45 mTransverse Pushover Curve to 0.45 m


3D View of Tower G Model Pinned at the 3D View of Tower G Model Pinned at the BaseBase


Transverse Pushover Displaced Shape Transverse Pushover Displaced Shape at X=1.0 mat X=1.0 m


Transverse Pushover

0

5,000

10,000

15,000

20,000

0.000 0.200 0.400 0.600 0.800 1.000 1.200


Ba

se

Sh

ea

r (k

N)


Transverse Pushover Curve Transverse Pushover Curve to 1.0 mto 1.0 m


Lateral Pile Response1.067m diam. X 32mm Pile

(10,000.00)

(8,000.00)

(6,000.00)

(4,000.00)

(2,000.00)

-

2,000.00

4,000.00

- 50 100 150 200 250

Displacement (mm)

Mo

men

t (k

N-m

) -

Lat

eral

Lo

ad (

kN)

w / soil sof tening


Axial Pile Response1.067m diam. x 32mm Pile

-

2

4

6

8

10

12

14

16

18

20

0 10 20 30 40 50 60 70 80 90 100

Axial Displacement (mm)

Ax

ial

Lo

ad

(M

N)

API basic soil criteria w/out API limits 38 wall thickness


Tower G ConclusionsTower G Conclusions

Provide Vessel Impact energy absorption Provide Vessel Impact energy absorption systemsystem(reduces overall demand on tower)(reduces overall demand on tower)

Increase pile diameter and/or reduce Increase pile diameter and/or reduce bracing size bracing size (to provide more tower ductility)(to provide more tower ductility)


It should be noted that this Design Example is a It should be noted that this Design Example is a first iteration in the design process and requires first iteration in the design process and requires further refining in order to meet the full intent of further refining in order to meet the full intent of

the specified design requirements.the specified design requirements.

As noted, there are several approaches to As noted, there are several approaches to meet the requirements of the Drawings and meet the requirements of the Drawings and

Special Provisions.Special Provisions.


Chris TrainaChris TrainaCash Flow AnalysisCash Flow Analysis


Early Pay Items AnalysisEarly Pay Items AnalysisEarly Pay Items Analysis

$0

$200,000,000

$400,000,000

$600,000,000

$800,000,000

$1,000,000,000

$1,200,000,000

$1,400,000,000

$1,600,000,000

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47

Time in Months

Dol

lars

CUMULATIVE TOTAL TROCUMULATIVE TOTAL STRUCTURAL STEELTOTAL CONTRACT COSTTOTAL MONTHLY PAYMENTSMOH AND PERFORMANCE BOND AMOUNTCUMULATIVE MOBILIZATIONESTABLISH MARINE ACCESSACCELERATED WORKING DRAWINGS SUBMITTAL


Steel PaymentsSteel Payments

$0

$200,000,000

$400,000,000

$600,000,000

$800,000,000

$1,000,000,000

$1,200,000,000

$1,400,000,000

$1,600,000,000

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47

Time in Months

Dol

lars

CUMULATIVE MATERIALS (STEEL PLATE) CUMULATIVE ERECT STRUCTURAL STEELCUMULATIVE TOTAL STRUCTURAL STEEL TOTAL CONTRACT COSTTOTAL MONTHLY PAYMENTS MOH AND PERFORMANCE BOND AMOUNTCUMULATIVE FURNISH STRUCTURAL STEEL


Cash Flow AnalysisCash Flow Analysis

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

TIME IN MONTHS

DO

LLA

RS

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

PE

RC

EN

TA

GE

CO

MP

LET

E (T

RE

ND

LIN

E

ON

LY)

TOTAL MONTHLY PAYMENTS TOTAL CONTRACT COST PERCENTAGE PAYED VS. TOTAL CONTRACT COST


Rick MorrowRick MorrowOutstanding Bidder InquiriesOutstanding Bidder InquiriesTower Mock-UpTower Mock-Up

Documents

San Francisco-Oakland Bay Bridge East Span Seismic Safety Project Contractor Information Meeting Construction Contract 04-0120F4 November 30, 2005