Working towards an engineering competition, we made one model of the entire span of the bridge showing one proposed design.  We then made three separate tower models showing alternative tower designs.  This way, our clients were able to present three different bridge concepts using just one large model.

For a brief nano-second, a universe (black holes and all) is created when an atom is smashed in one of several underground accelerators at the Stanford Linear Accelerator Center.  The scientists at SLAC have the capability and technology to measure and record these events in real time.  Buildings are constructed, remodeled, and removed as the equipment required in an experiment changes.  This model was made to assist in the future planning of experiments conducted at SLAC.  It was a true honor to make a model of a place at which the world’s most brilliant minds converge for the purpose of understanding the origins of the universe.

Tower Model (14″ x 16″; 27″ over water line)
Road Section (24″ x 12″)

This model was built to demonstrate the addition of pathways to the new Bay Bridge, enabling pedestrians and cyclists to cross the bay between Oakland and San Francisco.  The engineers needed to find a way to retrofit the West Span with these pathways.  Two different sections of the bridge (one pictured here) were modeled, in order to study the options.  Both included removable pathway structures, allowing the designers to show north side, south side, or both north and south side placement.

As the Bay Bridge engineers worked through the resolution of technical issues, we stood by ready to produce physical mockups or technical check-fit devices for them. These models addressed instances where a physical representation of a design was the best way to know if it would actually work.  The Bay Bridge Light Pole Pedestal was made for that very purpose.  When it was time to order tubing, we asked if they could spare a small section from the actual construction site.  As you can see in the image, it was slightly heavy, but a perfect fit!

When crossing the Bay Bridge (after the initial shock of the toll cost subsides) one rarely thinks about how painstaking it must have been to position each individual strand into a saddle in preparation for the mid-way turn.  With the help of color coding and numbering of every strand, this model was used as a visual aid during practice runs to ensure they got it done right and efficiently.

The lead engineer at Caltrans, in charge of the construction of the new San Francisco–Oakland Bay Bridge, was convinced that the best way to save costs was to find and resolve all of the potential design constructability issues that would normally get resolved in the field ahead of time.  Having us construct the model, document our assembly process, resolve issues as we encountered them, and ultimately send a design package out to bid was an integral part of their plan.  The W-2 Footing was the first contract of the entire bridge construction.  As you can see, the rebar was packed so tightly that lopping off a piece of that doesn’t fit was not an option; the engineers would have had to recalculate.  These adjustments are common in the construction of an overpass or bridge and vary depending on the sequence of assembly, but the sheer magnitude and cost of this project had the person in charge thinking outside the box.  There was initial skepticism among the engineers on the project as to the efficacy of such an exercise, but our first meeting in the early days of construction revealed a series of hidden conflicts and dispelled all doubt.  Over the last several years, the engineering team has thought of dozens of ways to utilize this ‘build it first’ approach to thoroughly test design buildability or accessibility issues that might significantly impact cost.  The modeling process was deemed a great success, saving both time and money in the field and with California taxpayers.

As you might have noticed, both the footing and the pier cap were made at an odd scale. The goal was to make the models as big as possible while still accommodating transport through standard doorways.  The engineering solutions that worked on the footing contract had to be shown to work at the pier cap—where the roadway meets the top of the pier.  The purpose of this was to minimize conflict and added costs on those contracts, as well.

These models were made of colored PVC rod, ground to precise and varying diameters with each color representing a different diameter.  We were excited that our technical and assembly solutions for the design and construction of the models worked out!

As you might have noticed, both the footing and the pier cap were made at an odd scale. The goal was to make the models as big as possible while still accommodating transport through standard doorways.  The engineering solutions that worked on the footing contract had to be shown to work at the pier cap—where the roadway meets the top of the pier.  The purpose of this was to minimize conflict and added costs on those contracts, as well.

These models were made of colored PVC rod, ground to precise and varying diameters with each color representing a different diameter.  We were excited that our technical and assembly solutions for the design and construction of the models worked out!

We CNC machined these odd-looking devices that were designed to be purely functional and dimensionally critical.  The actual sockets were made by different vendors abroad, and had to constrain to tight tolerances to fit just right.  The Bay Bridge engineers had the idea to build these check-fit devices to send to the manufacturer to ensure that every single suspender socket would conform correctly.  Their strategy worked and Caltrans engineers were spared the added cost of having to remake suspender sockets.

This assembly-sequence bridge model section was produced for an engineering competition. Something seemingly so simple was actually a bit tricky as the model was required to maintain a higher tolerance in the construction of the parts for demonstration of the assembly of every part – a precision puzzle, if you will. Bright colors were used to identify and distinguish the different elements that would be discussed in the presentation. The engineers were not so sure of the value of this model, but in the end, the clients in Scotland apparently liked it so much that they asked if they could keep it.

Tower Anchorage Mockup (11’-4” x 13’-0” x 10’-0”)
Tower Splice Mockup at elev. 114.0m (13’-5” x 10’-1” x 14’-9”)
Tower Section Mockup at elev. 89.0m (13’-5” x 10’-1” x 13’-1”)

These full-scale mockups were made for the purpose of design accessibility.  While a small scale model can clearly communicate components and their corresponding relationships, the only way to have absolute confidence that a person with an oversized wrench can get into narrow internal spots during assembly of the tower, was to actually build it to scale.  We constructed full-sized mockups of the most rigorous segments so that the engineers and contractors, themselves, could climb in, move panels, and tighten bolts.  This addressed their concerns, answered their questions, and boosted their confidence in the structural plans.  These models also helped save time and money by streamlining the bidding process for the contractors.

Tower Anchorage Mockup (11’-4” x 13’-0” x 10’-0”)
Tower Splice Mockup at elev. 114.0m (13’-5” x 10’-1” x 14’-9”)
Tower Section Mockup at elev. 89.0m (13’-5” x 10’-1” x 13’-1”)

These full-scale mockups were made for the purpose of design accessibility.  While a small scale model can clearly communicate components and their corresponding relationships, the only way to have absolute confidence that a person with an oversized wrench can get into narrow internal spots during assembly of the tower, was to actually build it to scale.  We constructed full-sized mockups of the most rigorous segments so that the engineers and contractors, themselves, could climb in, move panels, and tighten bolts.  This addressed their concerns, answered their questions, and boosted their confidence in the structural plans.  These models also helped save time and money by streamlining the bidding process for the contractors.

Tower Anchorage Mockup (11’-4” x 13’-0” x 10’-0”)
Tower Splice Mockup at elev. 114.0m (13’-5” x 10’-1” x 14’-9”)
Tower Section Mockup at elev. 89.0m (13’-5” x 10’-1” x 13’-1”)

These full-scale mockups were made for the purpose of design accessibility.  While a small scale model can clearly communicate components and their corresponding relationships, the only way to have absolute confidence that a person with an oversized wrench can get into narrow internal spots during assembly of the tower, was to actually build it to scale.  We constructed full-sized mockups of the most rigorous segments so that the engineers and contractors, themselves, could climb in, move panels, and tighten bolts.  This addressed their concerns, answered their questions, and boosted their confidence in the structural plans.  These models also helped save time and money by streamlining the bidding process for the contractors.

Tower Anchorage Model (17″ x 16″ x 12″)
Tower Splice Model (16″ x 12″ x 18″)
Tower Section Model (16″ x 12″ x 12″)

Can you imagine being asked to build 3 full scale models of the new Oakland Bay Bridge Main Span Tower?  The question made no sense to us either, until we learned that we would focus on 3 specific sections that have possible accessibility issues, thus, potentially driving up the cost of contractor bids.  What better way than a physical model to address these concerns than to mock up those areas and invite the contractors inside to inspect for themselves?  As model makers, the first step in ensuring that these huge mockups were built efficiently was to first build models and use them with our crew to communicate the design of sub-assemblies, determine construction sequences, and discuss details of each component, all with the simple clarity that a physical model provides.  Consider the irony:  a model maker needing a model!

Tower Anchorage Model (17″ x 16″ x 12″)
Tower Splice Model (16″ x 12″ x 18″)
Tower Section Model (16″ x 12″ x 12″)

Can you imagine being asked to build 3 full scale models of the new Oakland Bay Bridge Main Span Tower?  The question made no sense to us either, until we learned that we would focus on 3 specific sections that have possible accessibility issues, thus, potentially driving up the cost of contractor bids.  What better way than a physical model to address these concerns than to mock up those areas and invite the contractors inside to inspect for themselves?  As model makers, the first step in ensuring that these huge mockups were built efficiently was to first build models and use them with our crew to communicate the design of sub-assemblies, determine construction sequences, and discuss details of each component, all with the simple clarity that a physical model provides.  Consider the irony:  a model maker needing a model!

Tower Anchorage Model (17″ x 16″ x 12″)
Tower Splice Model (16″ x 12″ x 18″)
Tower Section Model (16″ x 12″ x 12″)

Can you imagine being asked to build 3 full scale models of the new Oakland Bay Bridge Main Span Tower?  The question made no sense to us either, until we learned that we would focus on 3 specific sections that have possible accessibility issues, thus, potentially driving up the cost of contractor bids.  What better way than a physical model to address these concerns than to mock up those areas and invite the contractors inside to inspect for themselves?  As model makers, the first step in ensuring that these huge mockups were built efficiently was to first build models and use them with our crew to communicate the design of sub-assemblies, determine construction sequences, and discuss details of each component, all with the simple clarity that a physical model provides.  Consider the irony:  a model maker needing a model!

This model was one of the original entries in the most recent Bay Bridge design competition, and it has also been used in public presentations, design review meetings, news reports, and even a groundbreaking ceremony.  While designing this model, we realized that the strength and durability of the suspension cables was critical.  The model would be moved from site to site and the cable system needed to be durable.  Since the cables themselves were delicate and long, we wanted to make sure they didn’t disconnect or bend, so we made them from a cloth-covered elastic band material.  They did eventually need replacing as they lost their elasticity, but only after over 10 years of constant use!  We recently updated the model adding light standards, belvederes (pedestrian turn-outs), and a fresh coat of paint.

This is an actual-size representation of a section of suspension cable as designed for the new San Francisco–Oakland Bay Bridge.  It shows not only the overall size of the cable, but also what happens to the individual cable strands when compressed to make one large cable.  This colorful section model is on exhibition at the Autodesk Design Museum in San Francisco.

This is an actual-size representation of a section of suspension cable as designed for the new San Francisco–Oakland Bay Bridge.  It shows not only the overall size of the cable, but also what happens to the individual cable strands when compressed to make one large cable.  This colorful section model is on exhibition at the Autodesk Design Museum in San Francisco.