Caltrans to check parts on Bay Bridge Hundreds of Ohio firm's parts to be reinspected

The new eastern span of the Bay Bridge (right) contains the giant bolts supplied by a firm in Ohio that failed. The Caltrans director has ordered a "complete forensic analysis" on the bolts. The new eastern span of the Bay Bridge (right) contains the giant bolts supplied by a firm in Ohio that failed. The Caltrans director has ordered a "complete forensic analysis" on the bolts. Photo: Michael Macor, The Chronicle Photo: Michael Macor, The Chronicle Image 1 of / 10 Caption Close Caltrans to check parts on Bay Bridge 1 / 10 Back to Gallery

Caltrans will reinspect hundreds of parts provided for the new Bay Bridge eastern span by the Ohio company whose brittle steel rods failed after being tightened in the final stages of the project, officials said Tuesday.

The company, Dyson Corp., has made or supplied a variety of bolts, fasteners and other parts that have gone into construction of the $6.4 billion bridge, which is scheduled to open to traffic the day after Labor Day. They include 4-foot-long, 3 1/2-inch-diameter rods that secure the cables on the span's single, signature tower.

Concern about the company's quality control arose last week when Caltrans disclosed that more than a third of the 96 Dyson-supplied rods used to seismically strengthen the span near Yerba Buena Island had snapped when workers tightened the nuts used to hold them in place.

Caltrans acknowledged Monday that earlier tests performed on some of those galvanized-steel bolts had raised questions about their ability to stretch during an earthquake, but that agency engineers had approved them anyway.

Didn't test for problem

Caltrans did not test the bolts for the problem that it now believes caused them to fail - the presence of hydrogen in the steel, which can make the bolts brittle. Officials assumed that the potential for contamination had been eliminated during the manufacturing and galvanizing process, Caltrans said.

Dyson did not make the steel, but was in charge of the process and conducted its own testing.

It is still unclear whether the problem was in the manufacturing of the bolts or in a subcontractor's galvanizing process, which involves dipping the steel in molten zinc to ward off corrosion. But Dyson is one of the main suppliers of parts for the eastern span project, and with the scheduled opening day just five months away, Caltrans has decided it can't take any more chances.

Caltrans Director Malcolm Dougherty has ordered a "complete forensic analysis" on the bolt failure as well as an audit and reinspection of all Dyson-supplied parts on the span, according to a memo obtained by The Chronicle.

'Contractor on notice'

Dougherty told toll bridge program manager Tony Anziano to "put the contractor on notice in writing that they need to demonstrate that they are in compliance with contractual requirements and secure their proposed course of action."

He also said Caltrans needed to "identify any other components of the bridge that came from the same manufacturer or supplier and reinspect."

Dyson has been the contractor for various fastener parts that have gone into construction since work began on the new eastern span in 2002. Besides the rods for the tower cables, Dyson supplied 17-inch-long, 1-inch-diameter pins used to secure the seismic-stability structures where the company's larger bolts failed.

Reinspection would typically involve sampling Dyson pieces rather than testing every single part, officials say. Caltrans declined to comment Tuesday on the exact number of parts that Dyson has supplied for the eastern span and would not speculate on whether the reinspection might jeopardize the scheduled Sept. 3 opening date.

Company cooperating

Dyson is headquartered in Painesville, Ohio, and employs about 175 workers to fabricate and supply large bolts, screws, nuts and studs. The company was founded in 1884 and boasts that it provided parts for the existing Bay Bridge, which opened in 1936.

Company Chief Executive Officer Brian Rawson has said Dyson is cooperating with Caltrans' investigation. He has referred questions to the agency and the eastern span's general contractor, a joint venture called American Bridge/Fluor. Representatives of that organization have not returned calls seeking comment.

Anziano has expressed confidence that Caltrans can engineer a solution to the problematic bolts without endangering the span's opening date.

One alternative the agency has discussed is installing a steel collar around the seismic-stability structure where the bolts failed and clamping it down with new bolts. Replacing the brittle bolts is all but impossible because they are covered by the eastern-span roadways.

Anziano said the fix would cost about $1 million.

Dougherty stressed that engineers needed to vouch for the span's safety before the first car rolls across.

"I want to reiterate that safety of the bridge once opened is the paramount and controlling factor in all decision-making on this issue," Dougherty told Anziano in the memo. "We will ascertain any cost and schedule implications once the best solution consistent with the design life of the bridge and performance expectations are met."