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Fabrication of Cable Saddles for Bay Bridge East Span’s Self-Anchored Suspension Span

Japan Steel Works, Muroran, Hokkaido, Japan, October 2008

Photos by Torin Boyd

Workers are preparing the molding for the W-line component of the East Saddle in the foundry shop of Japan Steel Works (JSW). Two days later tons of hot molten steel was poured into this mold to make the cast.

The pouring of hot molten steel into a casting mold at the foundry shop of JSW. This was to make the W-line component of the East Saddle of the bridge.

The “West Jacking Saddle” is being hoisted from the location where it was cast, moved by crane to the opposite end of the foundry shop, and torch-cut and hammered to remove the sand casting mold.

Seen here is the completion of the casting phase in which the 150 ton “West Jacking Saddle” was made in the foundry shop of JSW. It was then moved by rail to an adjacent building to undergo the heat treatment phase.

Welders are working on W2E1 component of the West Deviation Saddle in the fabrication shop of JSW.

Welder Akira Takenami makes repair welds on West Division Saddle W2E2

The rough machining of the W2W3 component of the West Deviation Saddle

Ultrasonic testing on the W2E3 component of the West Deviation Saddle

More Bay Bridge construction photos