San Francisco-Oakland Bay Bridge
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Project Title:
San Francisco / Oakland Bay Bridge Location:
San Francisco, CA Problem:
Uniformly remove asphalt/epoxy surface without damaging rebar using micromill technology, Restore traffic by 5 am Solution Product:
PPC 1121 Polyester Polymer Concrete 
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Rehabilitate the deck surface of the San Francisco-Oakland Bay Bridge on the suspension span from Treasure Island to the San Francisco anchorage. A total of 1.2 MM square feet of surface, 5 lanes on the upper deck and 5 lanes on the lower deck, approximately two miles long, was repaired. 300,000 cars per day travel this major feeder structure to San Francisco.
Work items:
- Remove existing, unsound asphalt/epoxy surface and concrete mortar cap
- Repair unsound light weight concrete structural surface with polyester polymer concrete
- Repair HP Concrete expansion headers with Polyester Polymer Concrete
- Replace riding surface with Polyester Polymer Concrete-approx 1" thickness
- Replace expansion joint seals with 2- component silicone
Surface Preparation Equipment:
Roadtec RX 45 B rotomill with a 6' Schiebeci milling drum
Standard drum had a 10.5 M spacing for bulk removal of aspalt/epoxy surface. Schibeci RM 350 head was used for fine grinding of materials remaining in the irregular surfaces of the deck.
Steel Shot Blast
Disa-Goff Roadabrator 30 was used for final surface preparation to remove residual contaminants and dust
American Civil Constructors (ACC) was contacted by Nolan Tomasik, Owner of Terrago Equipment, supplier of the Schibeci milling drums. Schiebeci customized the milling heads to meet the specification requirements of the contract. According to Dave Wilkerson, “Shiebeci’s expertise, the attention to detail, and pre-job training, and drum head performance provided the surface preparation productivity key for meeting the planned 115 day of work schedule”.
Polyester Polymer Placement Equipment:
ACC custom Volumetric Mixers-4
1-Two Track, Slip form Paver with 30' averaging skis
ACC fabricated its own mixers to provide accurate component mixing and high volume output of polyester polymer concrete components. Combining 4 volumetric mixers with a 12' wide, two track slip form paver, provided the necessary muscle to place 3200 cubic meters of PPC in a 115 day work schedule (roughly 1/4 mile per day per 2.5 hours of actual paving time). The average actual paving time per shift was approximately 2.5 hours per lane closure.
Polyester Polymer Concrete-Kwik Bond’s PPC 1121:
Cal-Trans has over twenty-five years experience with PPC and specified it on 2006 Bay Crossing Bridges - San Francisco Bay Bridge and the San Rafael-Richmond Bridge. Together, these projects required over 6300 cubic meters to restore the riding surfaces. The PPC 1121 system has demonstrated superior adhesion, abrasion resistance, and protection from chlorides over a long period of time. With the Bay Bridge project, the PPC 1121 product demonstrated the capability of returning traffic within 2 hours of placement at temperatures of 50°F and even lower! Although PPC 1121 has been specified predominantly in the western, usa marketplace, DOT’s and consulting engineers are beginning to understand the economic value of accelerated construction product technology.
