Bay Bridge Documents/Reports
The 1989 Loma Prieta earthquake made clear the need to improve the safety of the highway system overpasses and bridges. In the 10 years following that tragic event, Caltrans retrofitted or replaced more than 2,000 bridges and performed work on all 7 state-owned toll bridges in the Bay Area. Over the course of several years, the TBPOC has endeavored to address and resolve an array of critical issues concerning the State’s toll bridge projects and, in particular, several relating to the construction of the new East Span of the San Francisco-Oakland Bay Bridge. With public safety clearly established as priority one, public access to job-level information is also very important. This web page is dedicated to sharing information with the public to help them understand the magnitude of information and complex issues surrounding this iconic project.
SFOBB Old Spans Piers E3-E5 Implosions Project Report January 2017
SFOBB SAS T1 Tower Anchor Rods System Evaluation and Repair – Expert Team Technical Report
February 13, 2014 BATA BAMC Test Progress Review Meeting Agenda
Review of the Failed E2 Embedded Anchor Rod Boroscope Investigation Draft Report (April 17, 2014)
Rod_Test_Briefing_Book_Jan_7_2014%5B1%5D.pdf Rod Test Briefing Book (January 7, 2014)
San Francisco Oakland Bay Bridge-East Span Seismic Safety Project: Monitoring Fabrication Quality of Tower and Othrotropic Deck Sections in China (December 2010)
CalSTA and Caltrans Responses to the California State Senate Transportation and Housing Committee
August 5, 2014 Informational Hearing
9-22-14 CalSTA Response to Senate Transportation Housing Committee
9-22-14 Caltrans Response to Senate Transportation Housing Committee
Response Attachment A
Attachment B Punch List Part 1 as of 9-9-14
Attachment B Punch List Part 2 as of 9-9-14
Response Attachment C
California State Senate Transportation and Housing Committee
August 5, 2014 Informational Hearing
Bay Bridge Lessons Learned: Receipt of Final Reports
Mega-Project Management Lessons Learned Report Cover Letter (Caltrans)
Lessons Learned Report
LAO Report: Technical Review of Design and Construction of New Bay Bridge East Span
Caltrans Response to LAO Panel
De Wolk Report: The San Francisco-Oakland Bay Bridge: Basic Reforms for the Future
Caltrans Response to De Wolk Report
Studies and Documents for De Wolk Report
To view a video recording of hearing, click here
Bay Bridge Punch List
The bridge that was opened on Labor Day 2013 meets all structural and seismic requirements. There are, however, a few outstanding items that the contractor, American Bridge Fluor, is contractually required to resolve prior to conclusion of the contract. Caltrans engineers created this list, which reflects a level of meticulous detail, by inspecting the work of contractors through the state's inspection program. This list, known informally as “the punch list,” is shared with members of the Toll Bridge Program Oversight Committee--the entity created by law to have oversight over the toll bridge program--so it's members, Caltrans, Metropolitan Transportation Commission, and the California Transportation Commission, can monitor progress over time.
Examples of outstanding things we asked the contractor to fix include cosmetic repainting or retightening bolts. As of September 9, 2014, there are approximately 100 open punch list items. Of course, the number of items is an approximation of outstanding work as some items are more labor intensive than others. The list is updated routinely and we expect all items to be completed this year.
Punch List Documents
Photos of Punch List Activities
A worker readies the tower surface for any necessary painting.
A section of the crossbeam is prepped for paint touch ups.
High above the motorists below, almost at the top of the tower, a worker more than 500 feet in the air cleans and prepares the tower's surface for any necessary painting.
Electrical work to a pullbox at the tower of the new eastern span of the Bay Bridge.
Peer Review Panel SAS Tower Foundation Report
FHWA Review of the A 354 Grade BD Bolts Used in the Self-Anchored Suspension Bridge – August 2013
Independent Review of Analysis and Strategy to Shim Bearings at Pier E2 to Achieve Seismic Design Requirements, submitted by Modjeski and Masters, Inc. – August 9, 2013 (PDF)
FHWA review Letter to TBPOC – August 9, 2013
Seismic Safety and Opening of the new Bay Bridge by Freider Seible to TBPOC – August 8, 2013
Seismic Evaluation of SAS at E2 Bent Prior to Completion of Shear Keys S1 & S2 - July 15, 2013
Partial external report; DOT and external participants
Report on the SAS OBG weld issues and solutions
Skyway Tendon Corrosion Reports
TBPOC Report on the A 354 Grade BD High-Strength Steel Rods on the New East Span – July 8, 2013
Metallurgical Testing and Fracture Analysis of 2008 Rods
Presentations from external experts and critics
Technical Workshop on A354BD Components
Blue Tag Logs
The Blue Tag logs listing Blue Tags issued for work on the Self-Anchored Suspension Span of the San Francisco-Oakland Bay Bridge can be found at this link: www.dot.ca.gov/METS-BlueTag
The Blue Tag material release procedure is a mechanism to document material suitability decisions. The Department tracks material issues that, although different from what the contract identified in the original specifications, have been determined through engineering analysis to meet the intended purpose of the original contract.
Note that some entries on the logs are listed as “pending.” Generally speaking, in those cases, the resolution has been identified, the suitable material has been shipped to the jobsite and incorporated into the work. However there may be some minor additional work still pending at the jobsite or there may be adjustments in contract language still pending to complete the documentation. Both issues may be a low priority but will be completed before the project is accepted as complete and outstanding entry items are closed.
The state letters issued to the contractor relating to work on the Self-Anchored Suspension structure performed in China are available to view at www.dot.ca.gov/StateLetters
Caltrans documents certain important communications to contractors during the course of construction projects. These letters were written on behalf of the Department to the prime contractor regarding work performed at ZPMC. They generally provide or decline authority to follow through on various types of work, and are numbered and retained for future reference.
Weld Inspection Reports
Caltrans documentation relating to welds performed in China on the Self-Anchored Suspension structure are available at these links:
SFOBB Self-Anchored Suspension Bridge Project Project Team Response to QA / QC Expert Panel Recommendations
Caltrans requires contractors to inspect every weld performed on a project. Caltrans personnel review the contractor’s inspection documentation and independently inspect a portion of the welds a second time. Caltrans utilizes a range of technology to perform the inspections. And the process generates a range of documents- for example, Source Inspection Reports, Welding Inspection Reports, and Welding Witness Reports, all of which are contained at the link above.
Contract requirements are used to determine whether welds are acceptable. When projects that require large quantities of welds, Caltrans and the contractor work together to address issues with the welding process and the resulting welds to resolve issues that may arise. When Caltrans does not accept a weld, the weld is removed and a new weld is made. That replacement weld is then inspected and scrutinized just as the original weld was. That process is repeated until an acceptable weld is in place.
Nonconformance Reports and Resolution Documents
Quality Assurance (QA) is used to ensure that fabrication, and related activities, are being performed correctly by construction contractors, fabricators and suppliers. It often includes examining fabrication facilities before work begins and continues through fabrication and approval of material and components used at the job site. Described generally, QA includes systematic, administrative activities that generally seek to improve production and avoid defects.
Nonconformance Reports (NCRs) are issued by Caltrans QA personnel to communicate to the resident engineer that a contractor’s quality control process or test does not comply with contract requirements. NCRs may relate to a process or to a finished product. Or an NCR may alert engineers to a potential irregularity or problem that needs to be addressed. That irregularity may simply involve documentation, or it could involve a test result that does not meet contract specifications.
The nature of the issue determines the approach Caltrans takes to resolving the NCR. A given resolution may occur informally, particularly if the product fabricated meets or exceeds the contract specification, or a resolution may require significant engineering analysis and consideration. In either event, Caltrans works with the contractor to ensure that materials and components incorporated into the project are structurally sound and will perform as needed. Those solutions are captured in the resolution documents.
Notices of Potential Claims
The Notices of Potential Claim submitted by contractors, and related documentation, relating to San Francisco-Oakland Bay Bridge east span projects can be viewed at this lin:
In general, these documents show how Caltrans responds to claims brought forth by the contractor during the course of construction.
The specifications in every construction contract include a claims resolution procedure. Under this procedure, a NOPC is the first formal notification a contractor must provide to Caltrans when it believes a contractual issue has arisen. That notice triggers discussions with the contractor and allows Caltrans to analyze the circumstances giving rise to the claim.
These documents show a range of issues including relatively minor disputes to more complex claims. As such, the negotiations—and documentations--may be straightforward or may be detailed and involved, depending on the issue.
The contractor and Caltrans work hard to reach a resolution. In the course of this work, Caltrans may deny some NOPCs, the contractor may drop some NOPCs, and some NOPCs may mature into claims. An actual claim may be resolved during the progress of the work or the contractor may present the final claim at the conclusion of the project.
The Department is providing Change Orders for the SFOBB eastern span replacement structure contracts at this link: http://www.dot.ca.gov/ChangeOrders/
It is important to be clear on what a Contract Change Order (CCO) actually is. Construction contracts developed and administered by the Department contain detailed drawings (contract plans and Standard Plans) and specifications (special provisions and Standard Specifications) that describe in specific detail the work to be done and the materials to be used. The specifications also outline the quality to be attained, the timeframe for when the work should be completed and how the contract will be administered. The contracts are advertised for a specific time period, bids are solicited and contracts are awarded to the responsible bidder who submits the lowest bid for the contract work.
Detailed drawings and specifications are designed and developed by civil engineers based on known existing conditions and desired end product with educated assumptions of how a construction contractor would approach the work to be done. Specific items of work to be performed are identified and quantities of each work item are estimated, both for volume (how much item work there is) and for estimated cost (cost per unit of work).
On every contract, the type and/or quantity of work needed on a particular item will vary based on actual conditions in the field that were not known during the development phase. Also, actual conditions may dictate a different method of construction or a different solution than contemplated. As a construction contract progresses, ways to expedite work to meet project goals or ways to improve on the original design may become apparent. Such variations from the original terms of the construction contract are handled by formal changes to the original contract, by CCO.
A CCO is a legally binding document used to make changes to any part of the original contract. Every construction contract has CCOs; they are a normal part of administering a construction contract.
These CCOs constitute the remainder of the outstanding documents specified by this request. Therefore, this is the Department’s final response to your request.
Engineer Daily Diaries
The Resident Engineer’s Daily Report/Assistant Resident Engineer’s Daily Report is used by both the resident engineer and the assistant resident engineer to record project activities on a daily basis. Resident engineers include any information that may be pertinent to the project whether there was contractor work or not. Items to include:
- Important discussions and agreements with the contractor, instructions given and to whom, and objections or comments
- Description of the work done for the day and work progress
- Weather conditions
- Other items that may not be included in other reports/documents