STAY CABLE SPECIFICATIONS

SUMMARY

1 SCOPE 2

2 FREE LENGTH 2
2. General 2
1 Strand 2
2. Internal Corrosion Barrier Enhancement by Galvanic 3
2 3
Coating. Internal Corrosion Barrier
2. 5
Outer Stay Pipe
3

3. General 8
1 Requirements for Cable Stay 8
3.2 Anchorages Requirements for Cable 10
3.
3 Stay Saddles

1 QUALIFICATION AND TESTING 11

4. Strand 11
1 HOPE Coating and Stay Pipe 12
4 Fully Assembled Stay Cable 13

5 INSTALLATION 16
5.1 Handling 16
5.2 Stay Pipe Assembly 16
16
5.3 Strand-by-Strand Erection 17
5.4 Stressing 17
5.5 Corrosion Protection During Erection 17
5.6 Finishing

Q MAINTENANCE AND REPLACEMENT 18

6.1 Inspections 18
6.2 Monitoring 18
6.3 Maintenance Procedures 18

7 AERODYNAMIC REQUIREMENTS 18
Cross-ties
7.1 Outer Casing Profile
7.2 Stay Cable Damping
7.3
 8 19
1

8 REFERENCES
1 SCOPE
This part of the Specification shall apply to the supply, fabrication, delivery, testing, installation, stressing
and permanent protection of the stay cables.

It includes the stay components which are part of the structure, such as the formwork tubes/pipes, the
anchorage bearing plates, erection devices and incidental materials and labour necessary to form a
complete stay cable system to support the bridge structure in accordance with the design, the applicable
standards, specifications and/or special provisions.

2 FREE LENGTH
The stay cables shall consist of the Parallel Strand System (PSS) made up of parallel, individually
polyethylene coated seven-wire strands, placed inside an external polyethylene stay pipe.

2.1 General
The stay cable free length shall provide redundant protection against corrosion of the strands, by
means of two complementary, nested barriers:
1. The first or internal barrier consists of an internal envelope and an intermediate medium between
the internal envelope and the Main Tensile Element (MTE) protecting each strand individually. The
internal envelope must be completely airtight, watertight and qualified as a corrosion barrier and
shall remain intact between the end anchorages, or throughout the free length, transition areas and
through the pylon saddle. The intermediate medium must prevent any water or moisture that might
get inside a damaged internal envelope from migrating along the length of the individual MTE's.
2. The second or external barrier shall be a continuous external stay pipe protecting the internal
barrier over the free length of the cable.
3. Additional corrosion protection must be provided by hot dip galvanic coating applied directly to the
wires of the strand over their entire length without interruption. The galvanized strand shall comply
with the French Norm NF A 35-035.

The aerodynamic stability of the stay cable, in case of rainy wind, shall be assured by stay pipe surfacing
with as per section 7.1.

The resistance of the stay pipe to environmental aggression (thermal variation, mechanical attack, UV
radiation and stress cracking) shall be ensured by a stay pipe with a thermal expansion range and an
adequate formulation, as well as a transition and/or anti-vandalism tube in the bottom anchorage zone.

The above protection system should demonstrate with proper calculation already approved. on previous
bridges that the stay cable will have a service lifetime of more than 75 years before replacement of the
strands may be considered.

2.2 Strand
The strand shall be galvanized 7-wire prestressing steel strand, filled with grease or wax, and coated with
HDPE sheathing, with the following properties:
 Nominal diameter: 15.7 mm
• nominal resisting section: 150 mm2
• unit weight of completed strand: 1.3 kg/m;

• Nominal tensile strength (GUTS) 1860 mPa (maximum load Fm = 279 kN, 0.1% proof load Fp01= 240
kN);
• strain under maximum load A gt at least 3.5%;
• modulus of elasticity of the bundle of parallel strands of 195 GPa ± 5%;
• very low relaxation not more than 2.5% at 1000 hours at 0.7 Fm (at 20°);

The strands shall comply with category B of [2], i.e. MTEs with special capacities meeting the following test
conditions:
• fatigue strength: 2 million cycles with maximum stress of 0.45 fGUTS and stress variation of 300MPa.
Material test certificates must be submitted to prove the characteristic subject to the approval of The
Engineer.
• deflected tensile strength coefficient of no more than 20% or a "One Pin Test" with a minimum tensile
force of 80% of the actual ultimate tensile strength. Material test certificates must be submitted to prove
the characteristic subject to the approval of The Engineer.

The curvature of strand shall be as follows: when a length of strand is lying free on a flat surface, the
maximum bow height from a base line of 1-meter length, measured inside the curve, shall not exceed 25
mm.

The strand lengths may have welds made on individual rods before drawing but may not be welded
during or after drawing.

2.3 Internal Corrosion Barrier Enhancement by Galvanic Coating

The internal barrier of the stay cable shall be enhanced with a hot-dip coating of the seven-wire
strands. The coated strand shall be in accordance with [2].

To prevent the galvanization process from resulting in the reduction of the elastic limit, and to ensure a
smooth outer surface of the wires, the coating shall be applied on the wires before the final drawing
operation. The coating of the constituent wires of the strand shall be done before stranding.

The coating shall consist of pure zinc (galvanization) grade Z2 with a minimum of 99.95% purity, as defined
in BS EN 1179. The mass of zinc coating per area shall be between 190 and 350 g/m 2 (average thickness
between 26 µm and 49 µm). The coating thickness shall be uniform (without drops or local thickenings).

2.4 Internal Corrosion Barrier

The internal barrier shall consist of a high- density polyethylene (HDPE) sheath extruded directly on to the
strand, previously coated and filled with petroleum wax.
2.4.1 Individual HDPE sheath

The individual HDPE sheaths shall be made of high-density black polyethylene classified PE 80. The
material used shall be free of recycled materials. The extruded sheath shall comply with the following
physical and mechanical specifications:

Character specified Value specified Test method

Density at 23˙C > 950 kg/m3 NF EN ISO 1183
Melt flow Index of 5 kg at 190˙C < 1 gram per 10 minutes NF EN ISO 1183
Tensile stress at yield point at 23˙C 18 MPa NF EN ISO 527
Carbon-black content 2.3 ± 0.3% by weight ISO 6964
Carbon-black dispersion index <3 ISO 11420
Carbon-black distribution level < C2 ISO 11420

Anti-oxidant content in the final

> 1000 ppm
composition of HDPE

Oxidative induction time at 200 ˙C > 20 minutes ISO/TR 10837 or ASTM D 3350
Elongation at fracture at 23˙C 500% NF EN ISO 527
Elongation at fracture at -20 ˙C 100% NF EN ISO 527
Stress cracking resistance at stress F 50 > 1000 h ASTM 1693, condition B

Table 1: specifications for individual HDPE sheath

The thickness of the individual HDPE sheaths shall be greater than 1.5 mm, and the outer diameter of
sheathed seven-wire strands shall be less than 19.5 mm. The use of thinner HDPE (not lower than
1.1mm) is permitted solely if resistance is proven equivalent to the above.

2.4.2 Petroleum Wax Filler

For normal PSS monostrand stay strand, the intermediate space among the wires and between the
wires and the individual sheath of each strands, shall be filled with microcrystalline wax, i.e. a malleable
crystallized solid consisting of saturated hydrocarbons which are injected in a liquid -state.

In any case, the void filler shall not comprise grease, to prevent problems of thermal stability and
bleed. Due to the cracking hazard, cement grout shall not be used as a void filler material.

The void filler material shall be injected in the workshop of the strand extrusion facility. The manufacturing
process must completely fill the internal voids between the constituent wires of the strand and the
voids between the wires and the individual sheath. Moreover, this process shall ensure that no voids
will appear in the intermediate medium, due to thermal shrinkage, creep, setting or ageing of the void filler.

The filling material shall be continuous and durably stable. The weight of filler per unit length shall be
between 5 and 12 g/m. For individually sheathed strands, the weighting procedure consists of comparing
weights of a factory-made strand length before and after cleaning and de-waxing the wires and the HPDE
sheath which has been cut longitudinally to allow the operations.

Wax filling material shall comply with the following specifications

Character specified Value specified Test method
Pour point > 77°C NF T 60-128
Penetration at 25° C 60/95 (1/10 mm) NF T 60-119
Viscosity at 100 ˙C > 18-22 mm2/s ASTM D 445
Copper strip corrosion 100 hours at 100˙C Level 1 a (no corrosion) NF EN ISO 2160
Rust protection NF X 41-002
• Salt fog: 5% NaCI, 168 hours at 35˙C ± 1° Pass
C NF X 41-002
No corrosion modified by
• Fog: distilled water, 168 hours at 35˙C ± replacing the NaCI
1°C solution by
distilled water

Table 2: petroleum wax characteristics

2.5 Outer Stay Pipe

The outer casing shall consist of one-piece stay pipe through which the strands are threaded, the void
within this outer casing shall not be filled.
The characteristics of the outer casing, especially its thickness and chemical composition, must ensure
good ageing performance against environmental degradation including satisfactory resistance to
ultraviolet radiation.

The outer casing must withstand the mechanical actions that might be exerted on it, and notably:
• the bending and axial force caused by the installation;
• the buckling force that could be caused by compression of the pipe under its self-weight, when it
rests on the bottom anchorage of the stay cable.

The surface of the outer casing shall be patterned or carry other relief according to the provisions of
section 7.1.

The color of the outer casing shall be as per the Engineer requirements provided the impact on
durability is proven satisfactory.

2.5.1 Drag Force

The drag force coefficient shall not exceed 0.62 on the stay at 55 m/s. Proper testing made with the
supplier's proposed product and details shall be provided at tender stage to demonstrate this performance.

2.5.2 Outer Duct Diameter

The project specifications shall state the type of duct required for the project out of the three available
duct diameters: Standard, Compact or Super Compact.

Depending on the selected option, the outer duct diameter shall not exceed the value stated here
below.

Standard
Number of Duct OD
strands (mm)
12 125
13 140
19 140
21 160
27 160
31 160
37 180
42 200
48 200
55 200
61 225
69 250
73 250
75 250
85 280
91 280
102 315
109 315
121 315
127 315
167 355
Tolerance shall be +/- 3.5 % on OD. The stay supplier shall demonstrate prior experience of stay
installation and strand removal with proposed cable and corresponding duct diameters.

2.5.3 Outer Casing Made of High-Density Polyethylene (HDPE} Pipe

HDPE stay pipe shall consist of a co-extruded high-density polyethylene, with a colored external layer
and colored or black internal layer based on the approval of The Engineer.
Stay pipe shall be made o f high-density polyethylene classified PE 324433 C (if black), or PE
324434 E (if other than black) as per [4] (equivalent to PE 80 or PE 100}. They shall comply with the
following physical and mechanical specifications:

Character specified Value specified Test method

Density at 23"C > 941 kg/m3 ASTM 01505
Melt flow Index of 5 kg at 190"C < 0.35- 0.6 gram per 10 NF EN ISO 1133
minutes
Flexural modulus > 800 MPa on average ISO 178
Tensile stress at yield point at 23"C 19 MPa NF EN ISO 527
Ultraviolet radiation stability Condition E ASTM D 3350
Carbon black content (inner layer only in 2.3±0.3% by weight ISO 6964
the case of a co -extruded color stay pipe)

Carbon black dispersion index <3 ISO 4437

Carbon black distribution level <C2 ISO 4437
Anti-oxidant content in the final >1000 ppm
composition of the HDPE
Oxidative induction time at 200 ˙ C >20 minutes ISO /TR 10837 OR
ASTM D 3350
Izod impact strength at 23 ˙C > 20 Kj/m2 NF EN ISO 180
Stress cracking resistance at stress F50 > 1000 h ASTM 1693,
condition B
Shore D hardness > 55 points ISO 868

Table 3: Specifications for HDPE stay pipe

The use of recycled polyethylene is prohibited. The stay pipe supplier must have a quality
management organization in accordance with the NF EN ISO 9001 standard.

In addition to the above requirements, the stay pipe thickness must be at least Øext/32 (SDR 32) or
6 mm, whichever is greater, where Øext is the stay pipe outside diameter.

2.5.4 Durability of the High Density Polyethylene Pipe

Resistance to the environment of the outer casing shall be demonstrated scientifically: the outer
casing shall be formulated for a lifetime of 75 years, in a climate equivalent to an ultraviolet
solar intensity of 5G Joule/m 2/year (120kly/year), with an average temperature of 22°C. This
calculation shall be backed by previous results of accelerated ageing tests, in SEPAP 12.24 cells.

The color shall remain stable over 30-year duration (minimum), and this durability shall be
demonstrated scientifically.
3 ANCHORAGE

3.1 General
The two ends of a stay cable are called the anchorage zones. An anchorage zone consists of:
• the anchorage head, i.e. the systems consisting chiefly of an intermediary mechanical part
designed to secure the strands of the cable and transmit their force to the attaching parts of the
structure (deck cross beam, gussets, anchor box, etc.);
• the transition zone, which extends from the anchorage head to the start of the free length of the
stay cable (cable and protective barriers); the transition zone is where the strands fan out, and may
comprise deviators, transverse guide systems, internal/external dampers, and sealing systems.

At tender stage, the stay cable supplier shall submit to the Engineer the assembly drawings for the
sizes and types of anchorages used in the project, showing all dimensions and materials of the main
components.
The stay cable system proposed shall be a proven solution, with a record of successful full-scale
system test program(s) and in use on at least 10 bridges (with spans exceeding 300 meters).

All tests required by this specification whether performed for previous projects or performed for
this project must be carried out or witnessed and approved by third parties.

All stay cable systems shall provide for the future addition of at least 5% of capacity through the
installation of additional strands in the existing cable without requiring cable &/or anchorage
replacement When specifying cable anchorage capacities, any group 3 adjacent cables shall have
the ability to add 5% capacity globally (thereby allowing some individual cables to be initially installed
at or near anchorage capacity)

3.2 Requirements for Cable Stay

Anchorages
3.2.1 Transfer of Stay Force
Stay cable anchorages shall be designed to individually anchor each strand by a reversible means.
Hard material (resin) filling or cement grouting shall not be allowed in the anchorage area.

The anchorage device shall be capable of transmitting the full ultimate tensile force of the cable. All
other components such as bearing plates, recess tubes, steel flanges and deviators shown on the
drawings shall be of suitable type and sufficient strength for the intended use.

The stay cable supplier shall submit to the Engineer, upon his request, calculations for the justification
of these components as well as results of full-scale fatigue, static and water tightness tests.

3.2.2 Filtering Out Angular

Deviations
The anchorage shall comprise cable guide systems in order to prevent significant bending stresses
due to angular deviations of the strand to extend to the anchorage device or wedges.

The design of the cable guide system must take account of transverse and flexural forces resulting
from:
 Cable deformations caused by catenary effects and wind oscillations at service and maximum wind
speed;
 Deck and pylon anchorage rotation under live loads;
 Inaccuracy of anchorage placing and shuttering tube misalignment;
 Permanent angles due to the fanning out of the strands;
 Bending of strand in the anchorage head due to manufacturing tolerances of anchorage parts.

Guide deviators placed in the transition area, imposing a transverse force on the structure ahead of
the stay anchorage in the above cases, are not allowed. The anchorage shall be capable of handling by
itself the following combination of deviation angles, as a minimum, without damaging the cable:
• +I- 20 milliradians static angle or the installation tolerances of the connecting parts (shuttering tube
misalignment), whichever is greater;
• +I- 10 milliradians dynamic angle.

The stay cable supplier shall document the efficiency of such means to reach the following criteria:

• the angle of deviation of any strand in the anchorage or transition zones shall not exceed 25
milliradians.
• the bending stresses in each strand shall be less than 250 MPa in the transition zone at the
entrance of the anchorage under a deviation of 30Mrad and a load of 45% GUTS.
• the bending stress in each strand at the anchorage shall be less than 50 MPa.

The bending stress calculations shall be carried out with the maximum service tension in the cable.

If the anchorages require a deviator to be placed at the guide tube to reduce the deviation induced
bending stresses at the anchorages, any device placed to dampen the cable shall not be a substitute for
the deviator, which shall be kept providing a fixed point to avoid deviation induced bending stresses
from reaching the anchorage.

3.2.3 Possibility of Tension Adjustment

All stays cables shall have the capability for force adjustments achieved by re-positioning the anchorage
with respect to the structure.

This tension adjustment shall be made by means of a threaded tube and ring nut assembly. The use of
shims to provide for stay tension adjustments is not permitted.

The adjustment amplitude shall be sufficient to account for the following:

• uncertainty regarding the "neutral" position of the anchorages;
• uncertainty of the construction loadings and of the stiffness of the structure (deck & tower);
• uncertainty of the unstressed length, tension, and temperature of the stay cable;
• extension of the stay cable to attain the required preloading;
• provision for future increase in dead load (overlay/ resurfacing, widening), etc.;
• provision for future increase in the live load;
• deformation of the structure resulting from concrete creep and shrinkage or constructional
inaccuracies, corresponding to mid-span deck deflection of U1000 where L is the length of the
relevant stay;
• a safety factor to the satisfaction of the Engineer

In any case the minimum adjustment length provided shall not be less than 100 mm for cables shorter
than 100 m and 200 mm for longer cables.

3.2.4 Possibility of Directional Adjustment

The orientation of connecting parts and anchorage heads must take account of the ideal cable-stay
alignment (catenary) under the service conditions of the unloaded structure.
The anchorages must be capable of accepting static angular deviations in excess of the installation
tolerances of the connecting parts: see section 3.2.2.

3.2.5 Protection Against

Corrosion
The two complementary corrosion-protection barriers defined in sections 2.3 and 2.4 must extend
continuously through the free length and entire transition zones.
If the external anti-corrosion barrier is replaced by a local casing in the anchorage, it must be injected
with an appropriate blocking medium. This blocking medium shall be a flexible material.
At the end of the stay cable, the outer casing shall be closed with a watertight cap attached to the
anchorage head and covering at least the entire area of the strand terminations. This cap shall be
removable for inspection of the strand terminations.

This integrity and continuity of the waterproofing must be consistent with the other functions of
the anchorage and maintained under all service conditions (vibration, movement, ageing,
temperature variations, etc.). This shall be demonstrated by the water-tightness test defined in section
4.3.2.

The anchorage shall include a tightening system enabling adjustment or re-instatement of the
waterproofing of the seals during the service life of the bridge.

The water-tightness at the entrance of the strand into the anchorage is a key factor. If the water-
tightness is provided by an 0-ring seal or neoprene sleeve, the waterproofing test shall be done with
material which has been pre-aged with exposure to relevant ozone, oxygen, stress, IR and UV
simulating the design life of the stay.
The sealing of the anchorage should not rely on the elastic performance of rubber or elastomeric or
plastic sealing which can lose their elasticity over years, but on an active pressure in the sealing
material not lower than 20 bars.

3.2.6 Protection Against

Wear
To prevent fretting corrosion and fatigue, no steel to steel contact between the strand and the parts
of the transition zone shall be allowed.

Steps must be taken to prevent fretting corrosion and fatigue at critical points: at each deviation of the
strand, where the strand enters the anchorage head, etc.

In order to avoid an accumulation of causes of fatigue (axial and flexural action effects) at the
anchorage head, steps must be taken to guide lateral displacement of strands: see Section 3.2.2.

Cement grout filling or resin filling of any part of the anchorage is not permitted.

3.2.7 Removabil
ity
Anchorage design must allow for cable replacement with limited impact on traffic: see Section 6.3.

3.3 Requirements for Cable Stay

Saddles

Saddles shall be designed to provide continuity of the strands through the pylon and individually anchor
each strand by a reversible mean. The strands transfer capacity across the saddle shall be sufficient to
prevent strand slipping under any load cases (SLS, ULS, accidental loads).

The adopted friction coefficient value shall be evidenced through tests performed on the saddle
system, with radiuses and deviations relevant for the project. Any evolution due to fatigue loading shall be
evidenced through documented tests.

Tests results shall justify the use of a friction coefficient at SLS not less than 0.30.
3.3.2 Protection Against Corrosion
The internal corrosion-protection barrier of the strands must extend continuously through the entire
saddle zone to provide protection against corrosion and keep water out of the free length of the stay
cable.
The substitution, in the saddle area, of one of the barriers by another mean applied after the installation
of the stands in the saddle is not allowed.

3.3.3 Protection Against Wear

To prevent fretting corrosion and fretting fatigue, no steel to steel or steel to concrete/mortar contact
between the strand wires and any part of the saddle shall be allowed.

3.3.4 Filtering Out Angular Deviations

The saddle shall incorporate a cable guide system at each end in order to prevent high bending stress
concentrations resulting from angular deviations of the strand at the saddle entrance and exit points.

The design of the cable guide system must take into account deviations resulting from:
• cable deformations caused by catenary effects and wind oscillations at service and maximum wind
speed;
• pylon rotation under live loads;
• inaccuracy of saddle placing;
• permanent angle deviation due to the fanning out of the strand bundle.

The saddle shall be capable of independently handling the following combination of deviation angles, as
a minimum, without damaging the cable:
• +/- 20 milliradians static angle or the installation tolerances, whichever is greater;
• +I- 10 milliradians dynamic angle.

The stay cable supplier shall document the efficiency of such means to reach the following criteria: the
bending stresses in each strand shall be less than 250 MPa1 in the transition zone at the entrance/exit of
the saddle under a deviation of 30mrad and a load of 45% GUTS.
3.3.5 Maintenance/Replacement
The saddle design must allow for maintenance and replacement of strand/cables with limited impact
on traffic. Strand removal and replacement shall be performed using the strand-by-strand method.

4 QUALIFICATION AND TESTING

4.1 Strand
The conformity of the strand to the specifications of sections 2.2, 2.3 and 2.4 is submitted to acceptance
testing, carried out:

1
The 250 MPa limit has been proven to be the one under which the fatigue resistance of the strand apart
the anchorage area is not affected by bending stresses.
 • before selection of the product;
• during production, at the factory before delivery;
• before the extrusion process

Inspection unit for sampling: the unit of production composed of bare products (wires or seven- wire
strands) coming from the same factory and of the same grade and nominal diameter, manufactured
according to the same process. This unit is defined either by cast or by batch, the mass of each inspection
unit being no more than 100 tons. When the number of coils in an inspection unit is lower than 3, three
samples are taken. When the number of coils in an inspection unit is greater than 3, one sample is taken per
coil, and the maximum number of samples is limited to 12.

4.1.1 Standard Properties

On each sample, one series of tests is carried out as follows:
• one tensile test;
• one determination of the mass per unit length;
• one control of the metallic coating (mass of coating per unit area, adhesive strength and continuity),
applicable for galvanized strand only;
• one control of straightness.

4.1.2 Particular Properties

Unless otherwise agreed, the following tests shall be carried out on one sample per inspection unit or fraction
thereof:
• one fatigue test;
• one deflected tensile test.

For each test, 3 samples shall be selected. If the test on the first sample fails, two more tests shall be carried
out. If either of the two additional tests fails, the quantity of strands represented by the three samples
shall be rejected.

4.2 HDPE Coating and Stay Pipe

The conformity of the HDPE sheath and stay pipe to the specifications of sections 2.4 and 2.5 is subject
to acceptance testing, carried out
• before selection of the product;
• during production, at the factory before delivery.

Inspection unit for sampling: the unit of HDPE production by the same batch is one production process,
with a maximum of 30 tons of HDPE.

For each production unit, at least three samples are taken: one sample shall be taken at the beginning of the
production, another one close to the middle and a last one at the end.

4.2.1 Standard Properties

On each sample, one series of test is carried out to determine

 Density of finished products

 Melt index;
 Flexural modulus;
 Tensile strength at yield;
 Carbon black content

A certificate of analysis shall be given with each shipment, stating that the material meets the specification and
showing the test results.

Additional tests such as the resistance to shock depend on the finished product. They shall be
proposed by the stay cable supplier.
4.2.2 Particular Properties
Unless otherwise agreed prior to starting the production, one accelerated artificial ageing test shall
confirm the durability calculation made (as per section 2.5.2). Test results on similar HDPE formulations
shall be supplied by the stay cable supplier at tender stage.

4.2.3 Drag Force

The drag force coefficient shall not exceed 0.62 on the stay at 55m/s. Proper testing, made with the
supplier details shall be provided at tender stage to demonstrate this performance.

4.3 Fully Assembled Stay Cable

Qualification of the stay cable system is based on the following tests on the fully assembled cable:
• three fatigue and ultimate strength tests, on representative units of the bridge, unless evidence of
previous tests is submitted and accepted by the Engineer;
• one water-tightness test, on a reduced unit, unless evidence of previous test is submitted and
accepted by the Engineer.

The specimen assemblies shall be tested by a recognized independent testing laboratory approved by
the Engineer. The Engineer shall be notified a minimum of 30 days in advance of any fabrication or
testing so that a representative of the Engineer may be present when the respective work is being
performed.

All test data and results shall be submitted to the Engineer. Fabrication of anchors and cables shall not
begin until the required tests (or previous test reports) are successfully completed (submitted) and
written approval is given by the Engineer.

4.3.1 Fatigue and Ultimate Strength Tests

Test parameters and acceptance criteria shall be as detailed in Article 11.2 of [1] for category B cables
stays, except where otherwise stated below.

Unless otherwise accepted by the Engineer, three complete fully assembled stay cable specimens
shall be fabricated for testing, one specimen shall be made representing the smallest stay cable, a
mid-range stay cable and a large (the largest when the laboratory testing machine is of sufficient
capacity) stay cable in the bridge. Each specimen shall be fully representative of all details and
procedures for production anchorages.

Stay cables shall be tested with all load bearing appurtenances. They shall include an active anchorage
and a passive anchorage. Strand deviations shall be representative of the most severe installed stay
cable deviations. At the discretion of the Engineer, the anchorages of the test specimens may not be
injected with wax for the tests.

The specimen shall undergo two millions cycles of the following loading: the axial stress varies sinusoidally
between 0.45 fGUTS and 0.45 fGUTS - 200 MPa. At the same time, the cable deviates sinusoidally from the
anchorage centerline, between 0 and 10 milliradian.
 The test bed shall synchronize the maximum and minimum stresses with the maximum and minimum
angles of deviation. The test shall be carried out with the straight set-up outlined below:

The fatigue test is positive if:

• the specimen goes through two million cycles of fatigue loading without detected breakage of more than
2% of the wires of which the stay cable is made;

The ultimate tensile-strength test, subsequent to the fatigue test, is positive if:
o the specimen withstands a force greater than the larger of the following:
95% of the guaranteed ultimate tensile strength FGUTS of the cable, defined from the nominal
characteristics of the strands;
92% of the actual ultimate tensile strength FAUTS of the cable, calculated from the actual strength of
the strands;
o the strain of the specimen under the maximum load is greater than 1.5%, allowing for deformation
inherent to the operation of the anchorages (working-in of jaws, etc.).

4.3.2 Water-tightness Test

Test parameters and acceptance criteria shall be as detailed in Article 11.3 of [11 except where
otherwise stated below
The water-tightness at the entrance of the strand into the anchorage is a key factor. If the water-
tightness is provided' by an 0 ring seal or by a neoprene sleeve, the waterproofing test shall be done
with material which has been pre-aged with a relevant ozone, oxygen, stress, IR and UV exposition
simulating the design life of the stay.
The sample is set up in a steel tube, inclined at a typical stay cable angle. This tube serves as a tank
for water head of 2 metre on the sample, as well as a structural member to stress the stay cable
and bend it. The sample shall not be injected with void filler to carry the test.

After installation of the sample, the cable is stressed up to 0.20 FGUTS, and the tube is filled with dyed
water. The top anchorage shall allow the cable to be stressed. In case of stay cable with a void filler
over the full length or when the stay pipe is attached at both end of the cable the connection of the
stay pipe shall reproduce the reality of the connection and shall also be stressed. If thermal variations
create stresses in stay pipes connected at both ends, the sample shall be set in a manner that this
phenomenon shall be tested.

The sample is then submitted to the following loading sequence, defined by Figure 46 of
[1]:
• 10 loading cycles between 0.2 and 0.5 FGUTS, using an appropriate jack at the top anchorage. The
force in the cable is then permanently set to 0.3 FGUTS;
• 8 thermal cycles, obtained through a central heating device, heating the water in the steel
tube from 20°C up to 70°C. Two cycles are applied each week;
• Simultaneously, the stay cable specimen will be bent, using a transverse jack and a sliding bearing
plate under the top anchorage, with a stroke of +/-100 mm (angle of deviation of +/-25
milliradians). 250 cycles are applied per week, alternatively cold and hot.

After this loading sequence, the sample is dismantled carefully; then opened to check that no traces
of water are present on the strands. The test is deemed to be positive if no trace of coloring is
found inside the anchorage or anchorage cap.

Only stay cable systems having previously passed such testing witnessed by a third party can
be qualified
4.3.3 Acceptance of Prior Tests of Stay Cables
A reference of a fatigue test and a water-tightness test passed successfully as per above specifications
shall be submitted to the Engineer at the tender stage. Any previous test, conducted for a previous
project on specimens similar to those recommended for this project, may be proposed to the Engineer
as the basis for stay cable approval in lieu of the tests specified in sections 4.3.1 & 4.3.2.

However, the quality control tests outlined in sections 4.1 and 4.2 must establish that the strands
supplied for this project have geometrical, mechanical and fatigue characteristics equal to the ones
used in the fatigue tests for the previous projects. Further, it must be demonstrated with shop drawings
that the stay anchorage hardware proposed is the same as in the previous tests.

5 INSTALLATION

Stay cables shall be installed in accordance with the procedures prescribed by the stay cable supplier. The
stay cable supplier shall submit to the Engineer, for review and approval, a method statement which
describes the installation operations, including a description of the main items of the equipment required,
as well as an engineered cable installation program that prescribes the cable force and elongation of
each stay cable.

The stay cable procedure shall be compatible with the bridge construction sequence and are generally
erected in-situ. When cables are very short (<30m) and/or insufficient deck space is available for in-
situ fabrication (i.e. erection of pier table cables) prefabrication may be considered provided specific
procedures are developed to ensure the strands remain parallel, equally stressed and that no damage to
any elements of the system is permitted.

Unless otherwise agreed, the Main Contractor will be responsible for the determination and monitoring
of forces and deflections in the permanent structure at all erection stages, as caused by the proposed
erection process.

5.1 Handling

The stay cable supplier shall develop procedures to assure that stay cable components will not be
damaged during handling.

Stay cable components shall be protected from corrosion, heat, abrasion and other harmful effects
throughout the fabrication, shipping, delivery, storage and installation.

The minimum bending diameter for the HDPE outer casing shall be, during fabrication, transport,
storage or erection of stay cables, 50 times its outside diameter.

All damage to stay cables or components thereof shall be evaluated by the Engineer and remedied
prior to installation of the stays. Any damaged strand shall be replaced. Damage to non load-carrying
components shall be repaired to the Engineer's satisfaction prior to the installation of the stays.

5.2 Stay Pipe Assembly

When the stay pipe is made up of sections assembled end-to-end, the sections are assembled by butt
fusion welding (hot-plate welding in accordance with ASTM 02657). The cut ends of sections of pipe to
be joined must be perpendicular to the pipe axis. The strength of a joint must be more than 90% of that
of the intact pipe.

The stay cable supplier shall submit samples to qualify the fusion welding procedure. These samples
shall consist of three 2 meter long pipes per pipe size.

5.3 Strand by Strand Erection

The stay cable supplier shall take appropriate measures to prevent the leading end of the strand damaging
using the stay pipe or the sheaths of the strands installed previously.

All the special features of the stay cable (anchorages, guidance systems, etc.) shall be fitted with
protection to avoid damaging the individual protection of strands.

The stay cable supplier shall take appropriate measures to ensure that the strands are parallel
throughout their length and that they pass through matching holes in the two anchorage heads.

5.4 Stressing
Jacks and gauges for stay cable installation shall be calibrated with reference to a standard pressure
gauge or load cell within one month prior to the beginning of the cable installation, and every 6 months
thereafter, or for 500 strands, for the duration of cable installation.

The standard gauge should have a relative accuracy of at least 0.5% and should itself be gauged by an
appropriate laboratory at least once per year.

In-situ erected PSS stay cables may be tensioned one-by-one provided that it can be demonstrated, to
the satisfaction of the Engineer, that the final tension and elongation of each strand is equalized within
a range of +/-1.25% GUTS. An accuracy calculation shall be provided by the stay cable supplier at tender
stage.

It is not permitted to stress the strands one by one by applying strand forces generated from calculations
based on the deformation of the structure. The preferred method is the so-called "lsotension" method.
All stressing must be recorded automatically with a computer system connected to load cells. The use of
pressure gauges is not allowed for stressing.

In case of length measurement of all the strands before erection, they shall be placed in a straight,
confined and covered area, at a controlled temperature and protected from any damage.

Stay cables shall be capable of being tensioned, de-tensioned and re-tensioned more than once during
the construction of the structure. These operations may be carried out either by full jacking of the live
anchorage and adjusting the ring nut setting, or strand by strand. If de-tensioning PSS cables strand by
strand in such way that the "gripping" zone is incorporated in the stressed portion of the stay, no
"gripped" zone shall permanently be left on the stressed portion of the stay.

5.5 Corrosion Protection During Erection

If the strand corrosion protection system is not put in place at the time the cable is installed on the
structure, the stay cable supplier should have an appropriate temporary corrosion-protection system
applied.

5.6 Finishing
After the final cable tension adjustment has been completed, and subjected to the Engineer's approval,
the finishing of the anchorage and transition zones (permanent corrosion protection, installation of
dampers, etc.) may be carried out.

A detailed procedure for these operations shall be submitted by the stay cable supplier to the approval of the
Engineer.

6. MAINTENANCE AND REPLACEMENT

A maintenance manual, detailing the inspection program, and maintenance procedures of stay cables shall be
submitted by the stay cable supplier at tender stage.

6.1 Inspections
The inspection program shall comprise at least:
• routine inspection operations at a frequency proposed by the stay cable supplier to the Engineer;
• replacement of one representative strand on 2 stay cables (one in the main span and one in a
back span) to check corrosion protection every 10 years

6.2 Maintenance Procedures

The maintenance procedures shall include at least:
• procedures for minor and major maintenance operations foreseen during the 100 year design
lifetime of the stay cables;
• frequencies of minor and major inspection and maintenance operations
• the replacement procedure for a single strand and a full cable.

The water-tightness of the anchorages shall be inspectable during the maintenance program and shall be
easily reinstated without dismantling any major components.

The anchorage design shall enable the de-tensioning of the cable to a force of 0.10 FGUTS or less, without
any auxiliary means, to facilitate replacement.

The stay cable design shall be such that the replacement of any cable can be done in compliance with the
site safety regulations and with minimum traffic disruption. The replacement of a full cable shall be
possible with the closure of only the one traffic lane adjacent to the stay.

7 AERODYNAMIC REQUIREMENTS

7.1 Outer Casing Profile

Due to structural issues, the drag force on stay cables shall be minimized. Moreover, the risk of rain and
wind induced vibration shall be prevented by adequate outer casing surfacing.
The stay cable supplier shall propose an outer casing surface carrying relief, such as spiral ridges for ex. With
a demonstrated efficiency against rain and wind induced vibration. At least two laboratory testing reports
shall be submitted at tender stage to demonstrate the rain and wind stability of the stay pipe against rain
and wind induced vibration.

7.2 Stay Cable Damping

The stay cable supplier shall perform a vibration analysis at tender stage. Stay cable
Vibration amplitudes shall be less than:

• +/- Øext under a service wind speed of 15 m/s, where 0ext is the stay pipe outside diameter;
• +/- L/500 under maximum wind speed, where L is the free length of the cable.
Stay cables > 80 m in length shall be provided damping systems to obtain a logarithmic decrement
greater than 4% on any cable, whatever the cable vibration amplitude. Damping shall be provided
by viscous means, to obtain a damping independent on the stay vibration amplitude. The supplier
shall design the damping system based on actual damping curves, which shall be available for
Engineer's review.
Friction dampers do not damp small and high vibrations and create shocks when the friction force
is reached and so are not permitted

Damper shall work from very low vibrations (less than 10 mm of stay movement) to large vibrations.

The dampers shall have a durability proven by dynamic tests, with a cumulated stroke of 40,000 meters

without major alteration of the damping curve.

The proposed damping system shall be fully integrated in the anchorage zone so as to minimize
aesthetical. impact. It shall be easily accessed for inspection and maintenance during the life of
the bridge.

The proposed damping system and associated calculation software shall be a proven solution with a
record of satisfactory use on major projects. The damping system(s) shall be qualified by:

• more than 1000 viscous dampers installed,

•
references for cables longer than 200m for internal dampers and 400m for external
dampers and
• more than 5 years of in-place operation.

8 REFERENCES

[1] Stay cables Recommendations of French lnterministerial Commission on Prestressing (Edition

November 2001 in French, June 2002 in English)
[2] NF XPA 35-037-1 et 3 (2002): Torons en acier a haute resistance proteges gaines. Partie 1:
Prescriptions generales et Partie 3 Torons proteges gaines adherents (Type SC).

[3] NF A 35-035 (Edition 2001): Hot Dip Zinc or Zinc-Aluminum Coated Prestressing Smooth Wires
and 7-Wire Strands

[4] ASTM D 3350 (Edition 2002): Standard Specification for Polyethylene Plastics Pipes and Fittings
Materials

[5] prEN 1993-1-11: Design of structures with tension components made of steel (Eurocode)

[7] Fib bulletin 30, Recommendation, Acceptance of stay cable systems using prestressing steels.