New Bay Bridge East Span Skyway & SAS Foundation (E2/T1)

ISI provided quality control inspection and testing services for Kiewet/FCI/Manson (KFM)Joint Venture team project from April, 2003 to March, 2008. The first phase of the replacement of the San Francisco Oakland Bay Bridge is construction of the East Span Super Structure, a $1.04 Billion dollar project, which at the time was the largest single construction contract ever awarded by the State of California. The E2/T1 SAS Foundation project was similar in scope to the Skyway work, but only two very large foundations. ISI performed quality control visual welding inspection and magnetic particle testing of the Pile Sleeve Footing Assembly. There are 160 piles, 4-6 piles per pier. Pile Caps are 40’ x 40’ x 20’ high. Each 8’ diameter pile and corresponding pile sleeve assembly were slotted and tied together with eight 6’ tall x 3’ thick connection plates that were welded the entire length of each plate on both the inside of the pile, and the outside of the pile sleeve assembly. This welding operation typically took from 4 – 8 weeks, depending on the size of the pile and the amount of cracks discovered as the entire footing box welded assembly cooled to ambient temperature. Heating elements were wrapped around the circumference of each slotted plate assembly and kept at a high temperature during the entire welding process (24 hrs/day).