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6.10.7 The scope includes cost of all materials, labour, equipment & operations
required to do this test.

6.11 SPECIFICATIONS & STANDARDS FOR CABLE STAY BRIDGE

6.11.1 STAY CABLE SPECIFICATIONS

This section of the specifications covers the requirements for the materials,
fabrication, testing, transportation, installation, and corrosion protection system
for the stay cables and the dampers.

It includes the stay components which are part of the structure, such as the guide
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.

The scope of work shall include testing, fabrication, transportation, installation,

and stressing of the cable system complete with anchorage components including
steel protection cap, Guide pipes, bearing plates, Anti-Vandalism Pipe, Guide
Deviator, tension rings, saddle (if applicable), Double helical ribs stay pipes,
painting sealing and erection devices and all incidental materials and skilled
labours.

In addition, the scope of work shall include the necessary preparations and design
of all anti-vibration measures that will be necessary if dampers need to be
installed.

All materials and workmanship shall comply with the requirements in the codes
and standards, including amendments to these, stated in these Specifications and
in other codes and standards referred to from these codes and standards.

The stay cable system shall comply with the requirements of Post Tensioning
Institute and in addition, the system shall comply with excerpts listed below, taken
from FIB Bulletin No.30 if Post Tensioning Institute is not up-to-date for a state-
of-the-art technology.

The stay cables shall be supplied, fabricated, delivered, tested, installed, stressed
and permanently protected by the Contractor in accordance with the requirements
of this Chapter of the Specifications and the following general requirements:

(a) PTI Recommendations for Stay Cable Design, Testing, Installation 7th
Edition published in Nov. 2018.

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(b) Fib Bulletin 30 : Acceptance of stay cable system using prestressing steels.
(c) Structural design of steel components shall comply with EN 1993, IRC 22,
IRC 24, IRC 112
(d) Fabrication of steel components shall be in accordance with the
requirements of the structural steel specifications.

The stay cable system shall be supplied by a specialist Supplier with previous
experience in the design, supply and installation of the specified system. The
appointment of the stay cable Supplier shall be subject to the approval of MRIDC.
The stay cables include the stay anchorage components, which are part of the
structure, such as the Guide pipe and the anchorage bearing plates connecting the
stays to the pylons and superstructure.

6.11.2 DESCRIPTION AND GENERAL DESIGN PERFORMANCE

The stay cable system as shown on the Drawings consists of parallel individually
PE-sheathed seven wire galvanized mono-strands with wedge anchorages and an
outer High-Density Polyethylene (HDPE) pipe. The stay cable system shall be
designed such that the replacement of any cable can be carried out, if required,
strand by strand, in order to minimize any traffic disruption during the replacement.
Similarly, the filling of the anchorages with a cement grout or other such hardening
material which would prevent strand by strand replacement is not permitted.
The space between the strands and the outer HDPE sheath shall not be filled.

The system design shall also provide for the assessment and adjustment of the
tension of the stays both during construction and in service. During initial stay
installation this may be done strand-by- strand, subject to the Engineer-In-
consent to the methods adopted. After structural completion of the bridge the
assessment of the stay forces and their final adjustment shall be by hydraulic jack,
The use of shims to provide for the final stay tension adjustments is not permitted.
It is envisaged that, in service, any future monitoring or re-stressing of stays shall
be carried out from the pylon. The required over length of strands should therefore
be provided at the pylon anchorages. The over length of strands shall be completely
protected against corrosion and soiling.

The system design shall allow destressing and removal of the stay cables by the
reversal, at any time during construction or in service, of the erection operations.

6.11.3 MATERIALS

i) STRAND
The cable shall be made of hot galvanised strands in HDPE sheathing. The stay
cable shall be Galvanised, waxed, HDPE sheathed stay strands.

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The main tensile elements of PSS (Parallel Strand System) stays are coated strands
to the requirements of NF A35-035 (Edition 2001) shall be Grade 1860 MPa,
Galvanized, Wax filled, PE-coated, seven wire low relaxation class 2 with following
properties.

a) Nominal dia.: 15.7 mm (T 15.7 strands).

b) nominal resisting section area: 150 mm2
c) nominal linear mass of the bare strand: 1.172 kg/m;
d) strength class fGUTS = 1860 MPa (maximal load Fm = 279 kN, 0.1% proof
load Fp0.1 = 248 kN)
e) strain under maximum load at least 3.5%;
f) modulus of elasticity of the bundle of parallel strands of 195 GPa± 5%;
g) very low relaxation: not more than 2.5% at 1000 hours at 0.7 Fm (at 20 0
C) measured on bare strand.
h) 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 m
length, measured inside the curve, shall not exceed 25 mm.
i) The strand lengths may have welds made on individual rods before drawing
but may not be welded during or after drawing.
j) Fatigue resistance: as per following tables
k) Ductility: The Deflected Tensile test for Ductility shall be carried out in
accordance with ISO 15630-3. The maximum permitted value of the
average coefficient of reduction of the maximum force in the De flected
Tensile test shall not be more than 20%.

Recommended Characteristic
Type of Diameter Tensile Cross Section
Tolerance on Ultimate Force
Steel mm Strength MPa mm2
mass % kN
Strands 15.7 1860 150 ±2 279

Table 6.16: Classification of prestressing steels for stay cables.

Property Requirement Acceptance

test method
Elongation at break Not less than 3.5% ISO 15630-3

Constriction at break Ductile break visible to ISO 15630-3

naked eye constriction
1)

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Relaxation 1000 h at 0.70 GUTS, 200 C Note more than 2.5% ISO 15630-3

Fatigue stress range Strands 300 ISO 15630-3

with an upper stress MPa At least 2 106 cycles
limit of 0.45 GUTS 1)

Fatigue stress Strands 380 ISO 15630-3

range with an MPa At least 5 105 cycles
upper stress limit
of 0.45 GUTS
(alternatively to 2
106 cycles) 1)
Fatigue stress range Strands 500 ISO 15630-3
with an upper stress MPa At least 1 105 cycles
limit of 0.45 GUTS
(alternatively to 5
105 cycles) 1)
Tensile test after the fatigue test
At least 95% of GUTS ISO 15630-3
Or
92% of AUTS
Strands 2h 5h
Wires 2h 5h
100 h 400 h
Deflected tensile test Strands Not more than 20 % ISO 15630-3
1)Values as given for minimum performance requirements in table 3.2 and Fig 3.2 fib

bulletin-30

Table 6.17: Proposed mechanical characteristics of prestressing steel

ii) Corrosion Protection System

The following permanent multi-layer corrosion protection system is, based on

present knowledge and experience, believed to provide a 100 year design life of
prestressing steels used in stay cables with high fatigue loading and in the most
aggressive environment, exposure class C5 of ISO 12944-2. It is called "Reference
lowing
independent layers.

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Layer Protection System

(1)

(2) A filler of wax between the prestressing steel and the sheathing (if any)
or the stay pipe

(3) A PE or PP sheathing on the individual prestressing element, or alternatively a

general stay pipe encapsulating the entire bundle of prestressing steel

Table 6.18: Corrosion reference system

The strand shall comply with the following requirements:

(a) Zinc coating: the zinc coating of wire shall be in accordance with prEN
10337: 2003 and EN ISO 15630 - 3 and shall be applied before the last wire
drawing operation. The coating shall be of uniform thickness (without drops or
local thickenings). The weight of zinc coating on the finished product shall not be
less than 190 g/m2 and not more than 350 g/m2 with an average not less than
250 g/m2
(b) HDPE coating: The HDPE coating shall be extruded around the strand and
the protective filler. It shall tightly follow the outer contour of the strand, and it
shall have a minimum thickness of 1.5 mm (-0, + 0. 25). It shall not necessarily
be circular at the outer periphery. The outer diameter of the coated strand shall
not exceed 19.5 mm. The coating material shall be virgin HDPE in black colour.
The properties of the sheathing material PE shall be as per table 6.18 below:
Property Requirement Test method
Melt index 0.35 g and per 10 ISO 1133
minutes under 5 kg
Specific weight, Density g/cm³ 0.9 g/cm3) ISO 1183
Carbon black 2.3 0.3% ISO 6964
Dispersion of the carbon black Index is max. 3 ISO 18553
Distribution of the carbon black Index is max. C 2 ISO 18553
Tensile strength 22 MPa on raw material ISO 527-2
18 MPa on pipe
Elongation at break at 23° C 600 % on raw material ISO 527-2,
500 % on sheathing 50 mm/minute (speed on test)
Elongation at break at 20° C 150 % on raw material ISO 527-2,
100 % on sheathing

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Property Requirement Test method

50 mm/minute

Thermal stability under O2 20 minutes at 210 °C, without ISO 11357-6

degradation
Thermal coefficient of dilatation Value to be declared by DIN 53752
manufacturer
Bending modulus 0C ISO 178
Table 6.19: Characteristics of individual HDPE sheathing
(c) Protective filler: The protective filler shall be a petroleum wax or equivalent
filler approved by MRIDC. The properties are given in table 6.19 below. It shall fill
the interstices of the wire, and the void between the outer wire and the outer
sheathing. The quantity of wax shall not be less than 5 g/m and not more than
16g/m. This shall be verified by weighing a length of strand (measured to the mm)
and further weighing the cleaned and degreased wires and HDPE sheath which has
been cut longitudinally.

Characteristics Test method/ Standard Acceptance Criteria

Congealing Point NFT 60-128 C0

Penetration (1/10 mm) at -200C NFT 60-119 No Cracking

Bleeding at 400C BS 2000:PT121 (1982)
modified
Resistance to oxidation 100 hours ASTM D942.70
at 100°C
Copper-strip corrosion 100 hours ISO 2160 Class 1a
at 100°C
Corrosion 168 Hrs at 350C NFX 41-002 (Salt spray) 1) Pass
Protection 168 Hrs at 350C NFX 41-002 (Distilled water No Corrosion
spray)1)
[S32] or ISO/DIS 9227 [S46]
- 2- -
Content of Cl , S , NO 3: NFM 07-023 (0.005%)
aggressive SO42-: NFM 07-023 ppm (0.010%)
elements

Table 6.20: specifications for Wax- protective filler

iii) TESTING OF STRAND

The strand supplier shall manufacture under an accredited quality assurance system
and shall provide a full manufacturing test plan for the approval of the Contractor

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and the consent of the Engineer-In-Charge. The test plan shall include all tests as
specified below.

Static Test
One static test of failure shall be conducted after completion of each strand fatigue
test. Specimen shall provide not less than 95 per cent of the Minimum Ultimate
Tensile Strength (MUTS) in the static test without failure.

Ductility Testing:
One specimen of sufficient length for three tests shall be sampled from each unit of
production and "One Pin Test" shall be carried out. The test sampling and procedure
-Tensioning Institute's Recommendations
for Stay Cable Design, Testing and Installation (2001). For acceptance, the tensile
force in the sample during the One Pin Test shall be equal at least 80% of the
ultimate strength of the sample. The sample taken for the One Pin Test shall be long
enough for two ultimate strength tests and three One Pin Tests. If the first specimen
fails the One Pin Test, two additional samples shall be tested. If both samples pass,
the material is acceptable, if either of two additional samples fails, the material from
which the sample was taken shall be rejected.

Completed strand:
The test requirements on individually sheathed polyethylene strand are given in
table 6.21 below. Performance tests in accordance with PTI clause 3.3.9 have to be
conducted under an accredited quality assurance system at factory
or an independent laboratory. Past test results for Chemical resistance, Chloride
permeability and salt spray (fog) test may be accepted.

Characteristics Test method Acceptance criteria Test frequency

Sheathing thickness Calibrated gauge 1.5 mm; -0/+0,5mm
Outer dia. of strand micrometer 19.5 mm 1 test for every coil
Straightness Ruler 25mm/m
1 test for every 20 tons of
> 5 g/m and < 16 g/m
Wax weight Scale tensile element supplied
for the project

Table 6.21: Characteristics of the sheathed and waxed stay cable strand
Performance Test for Individually Sheathed Strand:
The Contractor shall furnish to the MRIDC Engineer in charge, a report for test
performed in accordance with Section 3.3.9 of PTI's Recommendations for Stay
Cable Design, Testing and Installation (2001), prepared by an independent
laboratory documenting compliance with items (I) to (6) below:

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1. Chemical Resistance Test

2. Chloride Permeability Test
3. Impact Test
4. Abrasion Resistance Test
5. Salt Spray (fog) Test
6. Water tightness Test

All deliveries of strand to site shall accompany the manufacturer's test certificates
for each cast of steel, detailing the chemical analysis and the results of all tests
on samples taken from both wire and strand made from that cast and the results
of all other testing. Any previous test results /report shall be accepted for above
mentioned requirement.
iv) PACKING OF STRAND

(a) Coiling: the coiling diameter shall be not less than the 60 times the diameter of
the outer coating of the strand.
(b) Packing: The packing of the coils shall be either reel less coils which are
protected in such a manner that Strand is not damaged during handling of coils.
Alternatively, the wooden reels can also be used.

The Contractor shall check the reliability of the type of packing proposed by the
strand manufacturer regarding the mechanical protection of the strand, to
ensure the strand is not damaged in transit or when delivered to the Site.
v) STAY CABLE PIPE

Stay cable outer pipe shall consist of high-density polyethylene (HDPE) pipe
conforming to the following requirements.

The maximum standard dimension ratio (SDR) shall be 32 for un-grouted stay
cable system proposed in this project. However, the minimum thickness of HDPE
pipe shall be 5 mm.

The surface of the HDPE pipe shall carry double helical ribs to mitigate the effect
of rain and wind induced vibrations of the stay cables.

The HDPE pipe sheathing shall be either White (RAL 9003) or any other approved
colour such as yellow (RAL 1003). Stay cable pipes shall be co-extruded with
fully bonded black core and coloured exterior HDPE pipe. The outer stay pipe
shall be coloured with the colour specified by MRIDC. The Contractor shall be
permitted to propose a full thickness colour HDPE pipe, provided that these

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requirements are met:

The manufactured HDPE pipe shall be tested for durability under natural light
and UV. The change of tensile strength and elongation and of color shall be
documented as a function of time and exposure conditions at the particular
location of the structure.
The Specialist Contractor shall submit test evidence of the colored HDPE pipe
mechanical resistance against ultraviolet degradation for a minimum of 25 years,
and color change for a minimum of 15 years.
Test on the UV-stability have to be submitted to the owner for endorsement
(Xenon WOM test according to ISO 4892-2, the colorimetric measurement for
colour fading according to ISO 11664-4 and mechanical is assessed according to
ISO 6259-1&3, or similar).
WOM test are preferred as they uses Xenon-arc lamp which has the spectral
energy distribution close to natural sunlight. SEPAP test are not allowed as they
use mercury arc lamp which doesn0t represent natural sunlight accurately.
The HDPE pipe material shall be virgin and shall meet the specific cell category
requirements for CLASS PE 325443 and CLASS PE 345444 materials as defined
by table 1 of ASTM D3350. The resultant acceptable range of primary properties
for these HDPE materials is as shown in table below:

Characteristics Value specified Test method

Density at 230 C > 94 kg/m3 ASTM D 1505
Melt flow Index of 5 kg at 1900C< 0.35 1.4 gram per 10 minutes ASTM D1238
Flexural modulus > 750 MPa on average D790
Tensile stress at yield point at >22 MPa on raw material NF EN ISO 527 ISO
23oC >19 MPa on pipe material 6259
Ultraviolet radiation stability Condition E ASTM D 3350
Carbon black content (inner layer
only in the case of a coextruded 2.3 ± 0.3% by weight ISO 6964
colour stay pipe)
Carbon black dispersion index <3 ISO 4437
Carbon black distribution level <C2 ISO 4437
Antioxidant content in the final >1000 ppm -
composition of the HDPE
Oxidative induction time at ISO/TR 10837 or
> 20 minutes
200oC ASTM D 3350
Elongation at break at 230 C >350% on pipe material NF EN ISO 6259

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Characteristics Value specified Test method

Stress cracking resistance at >1000 h ASTM 1693,
stress F 5O condition B
Shore D hardness >50 points ISO 868
Table 6.22: Characteristics for HDPE stay cable 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 9001:2015
standard. The pipes may be provided with double helical ribs on the surface to
control vibrations due to rain and water. Generally, stay cable straight segments
connected by mirror welding.
In addition to the above requirements, the thickness of stay pipes which are
injected with filler shall be Øext /17 and which are not injected with filler may be
reduced to Øext /32 where Øext is the stay pipe outside diameter, but thickness
shall not be less than 5.0 mm.
The Contractor shall ensure that packaging, handling and shipping of the pipe is
done in such a way by the manufacturer that the pipe is not damaged when
delivered at Site. Prior to the delivery of pipe sheathing at Site, the Contractor
shall provide a certificate of analysis, in duplicate, for each shipment, stating the
material meets this Specification together with the results of all tests.

vi) Quality Management System

The contractor responsible for the installation of the stay cables shall have a
quality management system in compliance with ISO 9001: 2015 standards, or
equivalent, covering all aspects of quality control, supply and installation of the
stay cable system execution documents
The following documents shall be present on site:

Assembly outline drawings of the stay cable system, with connections to the
deck and pylon and with the vibration damping devices (if any)
Certificates of the quality control testing of the stay cable components
(traceability)
Deck construction programme
Tolerances on the structural parts of the deck and pylon (particularly for the stay
cable anchorage orientation)
Definition of the cable forces and elongations (from the Designer).
The following method statements for stay cables shall be present on site:
Site preparation: Definition of the storage areas, access and platforms for the
cable installation, space requirements for the stay cable installation.

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Procedures for transport, storage and handling of the individual components.

Procedures for prefabrication of the stay cables, if applicable
Procedures for site assembly before installation (anchorages, stay pipe,
connections including e.g., butt welding of HDPE stay pipes etc.)
Procedures for the stay cable components installation and stay cable erection.
Procedures for temporary corrosion protection (if any).
Procedures for the temporary installation of vibration damping devices (if any).
Procedures for stressing, including measures to be taken in case of deviations
from
specified force or elongation values.
Procedures for filling of anchorages and Saddle , as applicable.
Procedures for final protection of anchorages, connections, etc.
Procedures for inspection at the end of construction for hand-over.

High quality materials shall be used whose properties are generally regulated by
national or international standards, including the respective test procedures.
Minimum requirements are proposed below. Even higher quality standards may
be specified by the Designer. The main materials for stay cables and their
corrosion protection considered here are:

High-tensile prestressing steels as main tensile elements.

Standardized structural steels used for anchorage and saddle components
Zinc or other corrosion-protective coatings on the prestressing steel or structural
steel components
Stay pipes made of HDPE.
PE/PP sheathing on prestressing strands
Filling materials for the protection of the free length and anchorage.
Rubber or poly-chloroprene rubber (e.g., neoprene) for guide deviators or
damping devices.
The material requirements as well as the requirements for transport, storage
and installation of materials must be complied with and specified in quality
assurance and quality control manuals. The types of test certificates to be
provided by the suppliers must be specified (e.g., EN 10204 or equivalent).

In the approval and suitability tests, the properties of all materials used must be
checked and recorded in the test reports. The test results must comply with the
specifications. In addition, the cable supplier has to perform tests on samples of
all important stay cable components upon delivery of the stay cable materials.
Test results shall be recorded and checked for compliance.

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In addition to these tests on standardised components, QC testing on proprietary

components shall be done and include:

Geometry and surface hardness tests on anchor heads

Geometry and mechanical properties of anchorage components such as
wedges and nuts.

It is necessary to take into consideration that all material properties are

temperature dependent.
Although standard testing is performed at room temperature, the influence of
high (e.g., up to 60° C) and of low temperatures (down to -30° C) particularly
on organic materials has to be checked. This may include such aspects as:

Expansion of corrosion-protective compound at high temperatures or

effectiveness at low temperatures
Reduction of the stiffness and strength of HDPE at high temperatures
including its effect on buckling
Effect of varying thermal expansion behaviour.

vii) ANCHORAGES

Stay cable anchorages shall be designed to individually anchor each strand by

means of conical wedges. The anchorages shall meet the acceptance criteria as
specified by the Post-Tensioning Institute (PTI) "Recommendations for Stay
Cable Design, Testing and Installation, 7th published in Nov 2018 and
in accordance with the further requirements of this Specification.

All anchorages and its components shall be capable of developing at least the
Guaranteed Minimum Breaking Load of the tensile elements i.e., strand.
The steel wires of the strands shall not be in contact with any other steel
elements, other than the gripping wedges to avoid fretting corrosion, which may
be detrimental to the fatigue endurance of the stays.
The anchorages shall allow a negative adjustment of the stay cable force
(increase in cable length) by a minimum of 40mm for all cables.

The angular deviation between the steel guide pipe and the centreline of each
stay shall not exceed±0.30 degrees and the bearing plates together with steel
guide pipes shall follow the cable tangent to consider cable sag.

Requirements for Cable Stay Anchorages

The following diagram illustrates general components of Anchorage system.

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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, guide pipe and
guide deviators/damper shown on the drawings shall be of suitable type and
sufficient strength for the intended use.

The stay cable supplier shall submit to MRIDC upon his request results of full-
scale fatigue, static and water tightness tests.

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:

a) Cable deformations caused by catenary effects and wind oscillations at service

and maximum wind speed;
b) Deck and pylon anchorage rotation under live loads;

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c) Inaccuracy of anchorage placing and shuttering tube misalignment:

d) Permanent angles due to the fanning out of the strands;
e) Bending of strand in the anchorage head due to manufacturing tolerances of
anchorage parts
f) The anchorage shall be capable of handling by itself the following combination of
deviation angles, as a minimum, without damaging the cable:
g) +/-20 milli radians static angle to allow for,
i) compaction of strand bundle.
ii) installation tolerances.
iii) deformation of structure due to live loads +/-10 milli radians dynamic angle for
vibrations.

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:
a) Uncertainty regarding the "neutral" position of the anchorages;
b) Uncertainty of the construction loadings and of the stiffness of the structure (deck
& tower);
c) Uncertainty of the unstressed length tension, and temperature of the stay cable;
d) Extension of the stay cable to attain the required preloading;
e) Provision for future increase in dead load (overlay/ resurfacing. widening). etc.;
f) Provision for future increase in the live load:
g) Deformation of the structure resulting from concrete creep and shrinkage or
constructional Inaccuracies. corresponding to mid span deck deflection of L/ 1000
where L is the length of the relevant stay;
h) A safety factor to the satisfaction of the MRIDC Engineer in charge
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.

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Protection against Corrosion

The two complementary corrosion protection barriers defined in para 6.11.3 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. Hard material (resin) filling or cement grout shall not be
allowed in the anchorage zone. 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 as per PTI Recommendations for Stay Cable Design, Testing,
Installation 7th Edition published in Nov. 2018.

The sealing of the anchorage must be effective as soon as the strand is installed to
prevent ingress of water in the anchorage during installation phase.
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.
Cement grout filling or resin filling of any part of the anchorage is not permitted-

Removability
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.

QUALIFICATION AND TESTING

i. Strand
The conformity of the strand to the specifications defined in para 6.11.3 is submitted
to acceptance testing, carried out:

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1. Before selection of the product:

2. During production, at the factory before delivery:
3. Before the extrusion process
4. Inspection unit for sampling: the unit of production composed of coated products
(seven wire strands) coming from the same factory and of the same grade and
nominal dia., manufactured according to the same process. This unit is defined
either by cast or by batch, the mass 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, The
sample shall be used both for fatigue and ductility testing. All strands and test
samples shall be marked in such a manner to ensure traceability during production,
transit, storage and testing.

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

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.
Relaxation Test
One test per Production unit , but limited to max 1 test per 200MT.
HDPE Sheath and stay Pipe

The conformity of the HDPE sheathing and stay pipe to the specifications is subject
to acceptance testing carried out:

a) before selection of the product;

b) during production at the factory before delivery

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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.
Standard Properties
On each sample, one series of tests is carried out to determine:

a) density of finished product

b) melt index,
c) flexural modulus;
d) tensile strength at yield;
e) 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.
Particular Properties

Unless otherwise agreed prior to starting the production, one accelerated artificial
ageing test shall confirm the durability calculation made. Test results on similar
HDPE formulations shall be supplied by the stay cable supplier at tender stage.
ii. Fully Assembled Stay Cable system

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 MRIDC Engineer
in charge; as per PTI DC45-2 or fib30 with static anchorage deviation during test
(10mrad)
two fatigue and ultimate strength tests, on medium unit, unless evidence of
previous tests is submitted and accepted by the MRIDC Engineer in charge; as per
CIP with dynamic anchorage deviation during test (5 +/-5mrad)

one water tightness test on a reduced unit. unless evidence of previous test is
submitted and accepted by the MRIDC Engineer in charge.

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The specimen assemblies shall be tested by a recognized independent testing

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

All test data and results shall be submitted to the MRIDC Engineer in charge.

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 MRIDC Engineer in charge.

iii. Fatigue and Ultimate Strength Tests of Anchorages (static angular

deviation as per fib30 or PTI)

Test parameters and acceptance criteria shall be as detailed in 6.2.1 of FIB bulletin
30 for stay cable, except where otherwise stated below.

Unless otherwise accepted by the MRIDC Engineer in charge, three complete fully
assembled stay cable specimens shall be fabricated for testing, one specimen shall
be made representing the smallest stay cable, a midrange 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.

The specimen shall undergo two million cycles of the following loading: the axial
stress varies sinusoidally between 0.45 GUTS and 0.45 GUTS - 200 MPa. At the
same time, the stay cable anchorage shall be supported on wedge-shaped shim
-shaped cable
profile.

Figure 1: Fatigue test setup

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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:
The specimen withstands a force greater than the larger of the following: 95% of
the Guaranteed Ultimate Tensile Strength (GUTS) of the cable defined from the
nominal characteristics of the strands;
92% of the Actual Ultimate Tensile Strength (AUTS) of the cable calculated from
the actual strength of the strands
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.)

iv. Fatigue and Ultimate Strength Tests of Anchorages (dynamic angular

deviation as per CIP)

Test parameters and acceptance criteria shall be as detailed in 11.2.2.2of CIP for
stay cable, except where otherwise stated below.

Unless otherwise accepted by the MRIDC Engineer in charge, two complete fully
assembled stay cable specimens shall be fabricated for testing, the specimen shall
be chosen as the midrange of the stay cable supplier range (typically between 37
and 61 strands). 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.

The specimen shall undergo two million cycles of the following loading: the axial
stress varies sinusoidally between 0.45 GUTS and 0.45 GUTS - 200 MPa. At the
same time, the angular deviation of the stay cable shall vary from 0 to 10mrad (ie
5 +/-5mrad).

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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:
The specimen withstands a force greater than the larger of the following: 95% of
the Guaranteed Ultimate Tensile Strength (GUTS) of the cable defined from the
nominal characteristics of the strands;

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92% of the Actual Ultimate Tensile Strength (AUTS) of the cable calculated from
the actual strength of the strands
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.)

v. Water tightness Test

The sample is set up in a steel tube inclined at a typical stay cable angle. As shown
on the drawing below this tube serves as a tank for water head of 3 Ms 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 out the test.

Figure 2: Water tightness test setup

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 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 is 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.
a) 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

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b) 8 thermal cycles obtained through a central heating device heating the water in
the steel tube from 200 C up to 700 C. Two cycles are applied each week.
c) 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 +/-150 mm (angle
of deviation of 4+/-25 milli radians). 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 colouring 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.

vi. Acceptance of Prior Tests of Stay Cables system

A reference of a fatigue test and a water tightness test passed successfully as per
above specifications shall be submitted to the MRIDC Engineer in charge at the
tender stage.

Any previous test, conducted for a previous project as per the present
specifications: may be proposed to the MRIDC Engineer in charge as the basis for
stay cable approval in lieu of the tests specified elsewhere of this tender document.
At a minimum, the stay cable supplier shall provide the following tests:
- 3 x FIB bulletin 30 or PTI DC45-2 for fatigue and tensile test with static angular
deviation
AND
- 2x CIP for fatigue and tensile test with dynamic angular deviation

The quality control tests 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.

vii. SADDLE SYSTEM AT PYLON

Scope
This chapter deals with design fabrication, installation and testing aspects of saddle
system and the pylons of cable stayed bridge, Fabrication and Installation of saddle
system and pylon shall be based on the design, drawings and cable manufacturer's

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detailed drawings. All design and drawings shall be submitted to the Engineer for
approval before start of fabrication.

Features of Saddle
The saddle system shall be designed to provide continuity of the strands through
the pylon. The load transfer capacity across the saddle provided by friction
developed between strand and non-metallic part of the saddle body shall be
sufficient to prevent strand slipping under any construction or in service.

The saddle system shall allow for strand-by-strand installation, inspection and
replacement.
The saddle system shall have identical performance characteristics, durability,
design life, and fatigue performance to those of the stay cable anchorage.

Prefabricated Saddle will consists of the following

Saddle System features separate independent hole for each strand. Bundling of
all strands in one saddle pipe is not allowed.
No steel to steel contact between strands and other metallic components,
reducing the risk of fretting fatigue
There should be no accumulation of deviation or normal force from strand located
at top of bundle to strand located at bottom of bundle in Saddle system
In saddle system every strand should be subjected to similar magnitude of normal
/ transverse deviation force and hence differential force distribution is more
uniformly spread among the strands within the cable group
Two separate corrosion protection barriers protect the strands inside the saddle:
Protective strand coating such as galvanizing
Filler injected around the strand
Minimum radius of curvature of saddle pipes shall meet the requirements of clause
3.4.2 of FIB Bulletin No. 30. Acceptance of Stay Cable Systems using Prestressing
Steel (2005). Smaller radius may be accepted if confirmed by full scale fatigue and
tensile test.
Saddle shall be manufactured according to approved drawings. Contractor shall
choose verified products based on performance verification test results that shall
be provided by manufacturer.

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Layout Details of Saddle System

Saddle Fatigue and Tensile Testing

Saddles of cables shall satisfy the same fatigue and tensile performance as the
cable anchorages. Testing of a particular saddle design shall be done with one
representative stay cable as suggested in clauses 6.2.2.1-6.2.2.4 of FIB Bulletin No.
30: Acceptance of Stay Cable Systems using Pre-stressing Steel (2005).

The saddle shall be adequate for both extradosed bridge and stay cable bridge and
therefore shall be qualified for both loading application un-dependently from project
type to be applied. Therefore, the two sets of tests parameters below shall be
performed.
Stay cable bridge Extradosed post tensioning
bridge
Maximum stress 45% GUTS 60% GUTS
max
Stress variation Ds 200 MPa 140 MPa
Static deviation 10 mrad 10 mrad
angle
Saddle opening 60 deg 60 deg
angle
Number of strandsMedium range unit (31 to 61) Medium range unit (31 to 61)
Table 23: test parameter

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Layout for Saddle Fatigue and Tensile Testing

The objective of the saddle fatigue and tensile test is to confirm the performance
of the saddle in terms of fretting fatigue at the entrance into the saddle.

Saddle Friction test

Friction in the saddle shall be demonstrated by tests. Minimum friction coefficient
during service of 0.5 is required. Minimum friction coefficient during construction
of 0.65 is required.
viii. Vibration Control System
Dampers shall be provided to mitigate excessive vibration of stay cables. It is the
responsibility to specify the project specific minimum damping
requirements. Stay Cable system supplier shall provide vibration control systems to
meet the project specific minimum damping requirements over the required
amplitude and frequency ranges.
The supplier shall analyse, design and supply the dampers to mitigate vibration in
cables to obtain a logarithmic decrement greater than 3% on the 3 first modes of
all cables longer than 80 m measured between the top of the bearing plates.
The vibration control system shall be designed to remain functional after application
of strength and extreme limit state loads. Inspection and replacement procedures
shall be prepared for timely evaluation in such events. The design of the vibration
control system shall account for the effects of parameters including temperature
and considerations of the expected ranges of specified performance parameters.

The Contractor shall submit detailed calculation, principle drawings to the MRIDC
for approval prior to fabricating and installing the cable damper.

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6.11.4 INSTALLATION OF STAY CABLES

GENERAL

Stay cables shall be installed in accordance with the procedures prescribed by the
stay cable system Supplier. The Contractor shall submit, for the consent of the
Engineer-In-Charge, the method of working which describes the installation
procedure, a description of the main items of the equipment required, as well as
the construction supervision program for cable installation including the cable force
and the calculated extension of each stay cable.

The stay cable erection procedure shall be compatible with the methods and
sequence of construction for the main bridges. Consent to the Contractor's method
of working and working drawings shall not relieve the Contractor from his
responsibility for performing the work in accordance with the Contract. Stay cables
may be fabricated into full length cables or erected in-situ strand by strand.

During all stages of construction, restraints such as collar rings or P.E ropes tied
around individual stays and anchored to the deck and/or the previous anchor shall
be employed to control stay cable oscillation.

Temporary corrosion protection shall be provided if the permanent corrosion

protection system is not installed at the time of the stay cable fabrication. Any
partially completed stay assemblies shall be stored such that no damage or
deterioration of the stay cable can occur. During all stages of construction,
temporary protection/encapsulation of the strand ends in the entire anchorage zone
shall be employed. Strand ends shall always be protected in the anchorage zone to
prevent water or dust to be in contact with the ends of the strands where the PE
coating has been removed.

HANDLING

The Contractor's method of working shall include procedures, which ensure that stay
cable components will not be damaged during handling.

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

The minimum bending radius for the HDPE outer sheath shall be, during fabrication,
transport, storage or installation of stay cables, 25 times its outside diameter. This
shall be increased to 60 times its outside diameter for any extended storage period.

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All damage to stay cables or components thereof shall be evaluated by the Contractor
and remedied prior to installation of the stays. Any damaged strand, outer HDPE
sheath or load carrying components shall be replaced. Damage to other non-load
carrying components may be repaired subject to the Engineer-In-Charge's consent
to the repair procedures and a satisfactory repair.

STRESSING

Jacks and gauges for stay cable installation shall be calibrated, using a load cell or
calibrated static load machine, within one month prior to the beginning of cable
installation, and every 6 months thereafter for the duration of cable installation. The
6 monthly re-calibration may be performed using a master gauge, provided that the
master gauge has been calibrated with the field gauges at the time of the initial jack
calibration.

In-situ erected stay cables may be tensioned strand by strand provided that it can
be demonstrated, to the satisfaction of the Engineer-In-Charge, that the tension and
extension of each strand is equalized within a range of ±2.5%GUTS. The calculated
extension of each cable shall be based on the test results corresponding to the coils
from which it was manufactured.

The jacking force to be applied to each stay cable shall be confirmed by

measurement of the force (or the equivalent jacking pressure) and verified by
measurement of the corresponding extension of the cable. The Contractor shall
implement all available measures to achieve the required cable forces. The load in
any individual cable shall not vary by more than ±5% from the required cable force.
Similarly, the measured extension for re-stressing operation of any cable shall not
vary by more than ±5% from the calculated extension. Should either the tolerances
on cable forces or calculated extension be exceeded, the Contractor shall investigate
the cause and propose the necessary amendments to his method of working.
Following the Engineer-In-Charge's consent to any such changes to the method of
working these shall be implemented immediately.

Stay cables shall be capable of being further tensioned, dimensioned and re-
tensioned more than once during the construction of the bridge. The stressing to the
`Final Stay Force' at the time of final cable tension adjustment shall be carried out
by full jacking of the live anchorage and adjustment of the threaded tube and nut
setting. It is not permitted to detention or retention strand by strand in such a way
that already "gripped" and newly "gripped" lengths overlap by more than 50%. No
"gripped" lengths of strand shall be left permanently within the stressed portion of
the stay.

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FINISHING
After the final cable tension adjustment of all stay cables has been completed the
stressing records of all stays including the extension records shall be submitted for
the approval of the Engineer-In-Charge. Finishing of the anchorage and transition
zones may commence providing the Engineer-In-Charge's approval of these records
has been given.

A detailed procedure for completing these operations (trimming extra length of

strands; anchorage injection with wax; installation of guides, deviators, and all other
miscellaneous items) shall be submitted to the MRIDC for his consent.

6.11.5 MAINTENANCE MANUAL OF STAY CABLES

GENERAL

A detailed maintenance manual for the stay cables shall be provided for facilitating
future maintenance.

The manual shall cover among others the following aspects:

Description of how to monitor the stay cables for excessive wind induced vibration
regularly during major wind events.
Description of how to maintain the internal and eventual external dampers.
Description of how to inspect and ensure that the dampers are functioning.
Description of how to inspect any relative movements of the components inside
the anchorages.
Description of how to inspect the cable anchorage hidden within the anchorage
tube (inspection using an endoscope).
Description of how to inspect and maintain the HDPE sheathing extruded on
the main tensile element or the HDPE stay pipe.
Principles of how to measure the stay cable forces and the eigen-frequencies of
the stay cables.

The contents of the manual shall include, but not be limited to the following parts:
Scope
How to use the manual
Periodic inspection and maintenance
Exceptional inspection
Component description

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Partial or complete replacement of a stay cable

Re-stressing and de-stressing
Repair of corrosion protection
Appendices

INSPECTION AND MONITORING

General

During the design life of the structure the stay cables shall be inspected at regular
intervals mentioned below (included in general site surveillance) to either confirm
the good performance or to detect any relevant damage early. If any damage is
detected, this may be reason for an exceptional inspection, and the relevant
component(s) should be subjected to maintenance, repair and / or replacement as
applicable.

Five different types of inspection are typically applied.

Initial inspection
Routine inspection
Detailed inspection
Exceptional inspection Monitoring.

Documentation of inspections of a structure may include, but may not be limited to,
the following information:
Date of inspection, name of inspectors
Programme of inspection
Data collected during the inspection and / or monitoring
Observation of defects, photographic documentation etc,

Initial Inspection
The initial inspection shall be performed at the end of construction, at the time of
handover of the structure to the owner- This initial inspection shall establish a proper
reference ("birth certificate") of the structure and the stay cables for future
inspections, and shall include at least the following:

Survey of the superstructure alignment

Record of the actual stay cable forces
Record of temperatures (ambient, structure and stay cable components at the
time of the survey)
Periods of critical modes of vibrations of the stay cables.

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Routine Inspection
Routine inspection is achieved as "walk-through" inspection on the structure typically
performed once a year. Routine inspection may include, but may not be limited to,
the following observations, made usually visually without the use of auxiliary
instruments:
Proper condition and position of stay pipes, welds. wrappings, guide deviators,
clamps, damping devices, etc.
Condition of anti-vandalism protection
Qualitative control of cable sag
Signs Of stains, leaks and deformations in anchorage caps and plates
Checking of installed monitoring system
Unusual cable vibrations.

Detailed Inspection

Detailed inspection is suggested to be performed every three years on about 25%

to 50% of the components. This should assure complete inspection of all components
within 12 years. The amount / frequency of inspection should be such that all
components are inspected at least once within their specified period between
subsequent maintenance operations.

For detailed inspections special measuring tools and adequate access means such as
trolleys, scaffolding, etc, should be used. In addition to the controls for routine
inspection, detailed inspection may include, but may not be limited to, the following
examinations:

Condition of the stay cable anchorages, rust formations

Uniformity of stay pipe surface
Damage in stay pipe
Defects at welded joints
Defects in filling materials
Opening of anchorage caps and check for presence of water, degradation of filling
material, etc.
Corrosion of tensile elements at exposed surfaces after removal of anchorage caps

Leak tightness of sleeves / boots

Conditions of;
elastomeric guide deviators (tight fit, bolts)
damping devices (leakage, tight fit)
clamps, as applicable (e.g.- tight fit)

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Corrosion protection of guide pipes and components of anchorage and transition

zones
Condition of installed drains in the anchorage and transition zones Condition of
load carrying elements:
sag of stay cables
geometrical deviation between cable anchorage and structure
A topographic control of the structure is recommended

Monitoring

The following monitoring methods may be considered for stay cables:

Date, location, and type of repair work
Date of replacement, list and certificates of material used for replacement, list of
contractors, stressing records
Details of structural modifications
Name of the responsible person in charge of the maintenance repair and
replacement.

As an option, The monitoring of the Stay Cable shall be submitted by the Stay Cable
Supplier / Firm / Agency. The 10% of the Stay Cable shall be monitored permanently
for Cable tension.

The Stay Cable force monitoring system operating modes shall be as online remote
monitoring and offline monitoring.

MAINTENANCE AND REPLACEMENT

Stay cables shall be maintained in accordance with the maintenance program

specified by the stay cable supplier to achieve the specified design life.

Damaged stay cables must be repaired as soon as possible in order to prevent further
damage to tensile elements, filling materials, HDPE pipe and anchorage components
(FIP Recommendations [23]).

Maintenance, repair, replacement and strengthening comprise;

Maintenance
Special repairs (e.g., repair of stay pipe: Polyvinylidene fluoride tapes in
accordance with ASTM DICOO, may be used in case of damage and for application
of paint coats)
Replacement of cables (e g. after accidental damage)
Strengthening if necessary, e.g., due to increased traffic loads.

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AERODYNAMIC REQUIREMENTS
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 cuter
casing surfacing.

The stay cable supplier shall propose an outer casing surface carrying relief, such as
spiral ridges for example, with a demonstrated efficiency against rain and wind
induced vibration. At least one laboratory testing reports shall be submitted at tender
stage to demonstrate the rain and wind stability of the stay pipe against rain & wind
induced vibration.

Stay Cable Damping

The dampers shall have a stroke able to accommodate vibration amplitude of ±L/500
of the cable.
Stay cables >80m in length shall be provided damping systems to obtain a
logarithmic decrement greater than 3% on any cable, whatever the cable vibration
amplitude
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.

6.12 BRIDGE MONITORING SYSTEM (BMS)

6.12.1 The Bridge Monitoring System covers the use of the devices which enables
the continuous monitoring of static and dynamic parameters of the main
structural elements.

Monitoring system shall be designed within the scope of the application project
in order to collect data in a data collection unit placed in a section of the bridges
which can be easily accessed.

All devices used must have the precision and interval characteristics
appropriate with dimensions so that they can provide the detection of the
appropriate calculation notifications. Also, durability of all the transducers and
data acquisition system must be guaranteed.
The Bridge Monitoring System (BMS) shall include the following elements:
Dynamic stay cable force control system; determination of force in the
monitored cables at every moment shall be provided. Stay cable force control

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system shall provide starting of re-tensioning operations in cases of

deterioration of the balance of the bridge because of straining effects or
earthquakes and provide information relating to the life of the stay cables.
Dynamic wind and earthquake Monitoring system; earthquakes and
storms shall be identified and characterized real time together with their effects
on the bridges. Wind and earthquake monitoring system shall provide the
bridge designers the information which will enable them to decide what should
be done after an earthquake or storm.

BMS (Bridge Monitoring System) will report the actual situation of the Bridges
at any time by warning or Internet messages (e-mail or SMS).

6.12.2 General Requirements

BMS shall meet the following requirements:
a. Overall Performance
At a frequency of 300 Hz per channel for each measure, the acquisition and
storage of dynamic data in real-time data filtering strategies.
Creating the daily, weekly, monthly and annual data files in accordance with
pre-defined data filtering strategies and warning data files in accordance
with pre-defined warning strategies.
Ensuring adequate Monitoring acquisition rate (1 kHz) in order to prevent
overlap.
Ensuring data management in compliance with Universal EVERSENSE
standard.
Synchronization of all measurements with GPS universal time.
Providing an online data pointer with HTML interface compatible with
Internet Explorer.
Automatic warning in the form of message, SMS or voice message in case
of warning.
Providing remote configuration feature for BMS.

b. Data Security and Reliability

-15 °C to +60 °C operating temperature
Automatic detection of power loss, failure of data transmission or software
failure. In this case, BMS shall inform the bridge operator or related person
in real-time messaging or SMS. In case of software failure, BMS shall
automatically reboot itself.
Protection against power failure during a minimum of 60 minutes
(uninterrupted power supply, generator etc.).

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Protection against currents from the lightning in accordance with NF C15-

100, and UTC C15-443 standards.
The storage of audit data in case of the transmission loss due to earthquake.
Provision of backup for data storage.

c. Requirements related to Monitoring:

For this purpose, BMS contractor will submit at least 5 references for remote
monitoring system on the bridge including a main span in real-time.

d. System operation, maintenance and warranty

The system shall be warranted for the duration of 3 years as of the date of
commissioning. Faulty components shall be replaced within 3 months as of the
date of determination of the defect. Contractor of Monitoring system shall
provide training in the use of the system with at least one operator.

6.12.3 Dynamic cable force control system for the stay cable system
Load compartments shall be equipped with at least 8 cables. The final selection
of cables supervised shall be verified with the bridge designer.

Parameter Value
Measurement type Static or dynamic
Global error <0.5 kN
Span 160 kN
Material Stainless steel
Operating temperature -25°C to 75°C
Protection Class IP67
Current conditioning system types Isotension / voltage
Isotension / current
Force control system shall carry out the rain flow analysis of the data in real time.
Table 6.24: Cable parameters
6.12.4 Characteristics of the load compartments shall meet the following
requirements:
i. Earthquake monitoring system shall include the following elements:
1 x 3D accelerometers, at each shore
1 x 3D accelerometers, at each pylon, at deck elevation
1 x 3D accelerometers, at each top of pylon
1 x 3D accelerometers, on decks mid- span, on the upstream side

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1 x 1D accelerometers, on decks mid- span, on the downstream side

8 x 2D accelerometer, at the stay cables to be selected (load cells to be
provided by the cable supplier)
For earthquake characterization Duhamel algorithm shall be included in dynamic
earthquake monitoring system. In order to analyse the dynamic behaviour of the
cables, they shall be equipped with a wind and meteorological monitoring
system.

ii. Accelerometers shall meet the following features:

Parameter Value
Measuring range +/-2g
Use temperature -20°C / +80°C
Shock >1500g
Average life 10 years
Power consumption <1,5 W
Protection index IP65
Wind and meteorological monitoring system shall meet the following requirements:
Parameter Value
Wind speed measuring range 0-100m/s
Wind direction measuring range 0-355°
Air temperature measurement range +/-50°C
Air relative humidity measurement range 0-100%
Luminosity measurement range 0-100W/m2
Sampling frequency 0 ila 20Hz
Use temperature -50°C / +50°C
Average life 10 years
Power consumption <3 W
Protection index IP65

Table 6.25: Accelerometer Parameters

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