ARS GUIDE SPECIFICATION PR CL Gy For Stay Cable Se SUC pti POST-TENSIONING ME iNstITUTE» RECOMMENDATIONS for STAY CABLE DESIGN, TESTING AND INSTALLATION 1 ati POST-TENSIONING ORE institute 1717 W. Northern Avenue, Suite 114 « Phoenix, AZ 85021 ‘Telephona: (602) 870-7540 + FAX: (602) 870-7641 ‘www past-tensioning org @This publication Is Intended for the use of professionals competent to evaluate and implement the significance and limitations of ts contents and who will accapt responsiblity for the application of the Contents. The mcerporation by referenics or quotation of any content In this publication in any contract ocument, design, specifications, drawings, product detafe, purchase orders, and job applications shall be undertaken at the sole risk of these persons, companies, or agencies using any content from this Publicalion, making reference to IL or quoting ftom Rand shell not subject to any liablily the Poot: Tensioning Insitute, its Board of Directors, Its members, and members of PT"'s Committos on Cable Stayed Bridges, Persone, Companies; of agencies making references to or use any content of this publication waive any claims against the Post-Tensioning Insitute, iis Boatd of Directors, iis mombers, and members of PTIs Committee on Cable-Stayed Bridges. Neither the Post-Tonaioning Inatitute, tte Board of Directors, ite members, and members of PTI's Commiltse on Cable-Stayed Bridges in creating ‘his publication make any representation or warranty, express of implied, rogarding, the statements contained herein, inckuding warranties of quailty, accuraoy, workmanship or safety, turther including, but ‘et limited fo, implied warranties of merchantabilty and ‘itness for a particular purpose. THE POST- TENSIONING INSTITUTE, ITS BOARD OF DIRECTORS, ITS MEMBERS, AND MEMBERS OF PTIS COMMITTEE ON CABLE-STAYED BRIDGES SHALL NOT BE LIABLE FOR ANY DAMAGES, INCLUDING CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM USE OF ANY INFORMATION ‘OR RECOMMENDATION PROVIDED IN THIS PUBLICATION, BEYOND REFUND OF THE PURCHASE PRICE OF THIS PUBLICATION. Copyright © 2000 By Post-Tensioning Insitute First Edtion, First Printing, January, 1986 Second Edition, First Printing, February, 1990 ‘Third Edition, Fist Printing, Auguet, 1969 Fourth dion, Ftst Printing, February, 2001 ISBN 1-031086-03-x ‘Al Rights Reserved, This publication or any pert thereof may not be reproduced in any form without the ‘alton permiseion of the Post-Teneloning institute, Printed in USA. Cover Photo: Charles River Bridge, Boston, Massachusetts, USA Photo provided by Peter VanderwarkorForeword “Thig Ath edition containe a complote revision of format and contont from the 3rd dion, The expansion ff content through the 2nd and rd Editions has been re-crgenizéd with the goat of locating all requirements for materials in one section for each olomient of supply. The context of the document has also changed, refiectng a more mature catle-stay market in tho US, with leas ned for introductory or background information on materiale and processes. ‘The 4th Eulion Is published in Si unis, and has been re-oryanized into a Load and Resistance Factor Design (LRFD) format, designed to be used with the AASHTO LRFD Bridge Design Cove. The transformation to LRFD was bonchmrarked against Working Stress Design (WSO) criteria ofthe ord Edition {or the basic dead load + Ive lead ease, The format of fatioue-brovisions also follows that of LRFD, but is othenviso referenced to tho extensive tosting database irom WSD critetia. As a result of the change 10 LAFD, the fatigue design case Is the primary limit stato conditon that relates directly to prior designs. “Thorofor®, Engineers shoud be dellbarate in reviewing the serviceability limit states for unusual-designs ‘that have historically been controlled by tho service eoncitions in WSD. “There are several major adstions to the material and design sections in the ath Edition. The esterla for fatigue testing have been updated to reflect the mest recent resuits from project testing programs, There are new cftetia and performance standards for corrosion protection and rain-wind induced vibration. “There is also a new section for design and testing criteria for saddles, and adctional reccmmendations. {or monitoring and inspection of stay cabies in service. ‘As a result of the changes in both content and organization, the 4th Ediion should be used in its entirety, ‘and not blonded with provisions from earlier editions. The current eniteia for fetique testing and stay design have been revised for internal consistency, and no longar relate cirecly to earlier provisions on fn ed hoc nals. “The recammendations were approved for pubication by ballot ofthe 88 member commtee, and by the Post-Tensioning Instfute's Board of Directors.‘CABLE-STAYED BRIDGES COMMITTEE Chairman Gerard F. Fox ‘Structural Consulting Engineer ‘Garden City, NY onal J. Benomo sean Mer Dyridag-Systome Intorations, USA, In. ‘Ser Intomationsl Bolingbrook IL “Guyancout Cedex, France John E. Broan Emst H Petzold I University of Texas at Austin Sverdeup Ohi Ine asin, TX Maryan Height, 40 Vay Charro ‘Welkor Podolny se Paraone Brinokerholt Quado Consuiling Svuctural Engineer New York, NY Burke, VA ZalYun Fen 1 Kent Preston ‘Shanghal Electie Cable Reseerch Inet. Wiss, Janney, Elstner & Associates Ino Shenghal, China Moorestown, Ni Jean-Philippe Fuzier Jovo-Luls Quintana, Froyesinatinlomational Mexpresa Voslty, Franco Xeahimioo, OF touco Hans Rudol Ganz Henry G. Russel ‘VSL inemnatonal Lt. Honry G. Ruseel, In. Lyssach, Switzorand Giomvon, I avid Goodyear (Vice Chait) Chuck ©. Ruth TY Un international \Washingion State Dept of Transportation Olympia, WA Olympia. WA, eter irvin Khaled Shawmat Rowan Willams Davies & hv, Ine Dywidaa: Systems Intemational, USA, ie. Guelph, ON Canada Bolingbrook, IL Manatu to Liwe Starossek “oly, Japan Technical University of Hamburg-Harturg ater Junguirh Denikeste Hambutg, Geman Dycherholl & Widmann AGS! Holger 8. Svensson Munchen Germany Leontarat, Andra und Parner nn M. Kulick Stuttgart, Gormany occas! @ Masters, Ine. Habib Tabotabal Harrisburg, PA University of Wisconsin-Minvaukes Roger Laorabe awakes, WI PRG (Froyssin!) Yostito Tanck Chaton-sur Seon, France Shinko Wire Company Lid ‘Reymond MoCabo ‘Amagasaki, Japan HNTB Corporation Man-Chung Tang Fairfield, ND, TV Ln iterations Com sae, San Francisco, CA Pat Tenaiaing instiute Dani Tasoin Phoenix AZ . Intemational Bridge Technologies, Inc. ‘Andow tolus Jt San Diego, CA Freyssiet Intemational sosegh K. Tse L Chany, VA Parsons Brinkorhotf Quade & Douglas, tno ‘Alan J. Moreton New York, NY Figg Brge Engineers, ine Midaus Winker “alahaseos, FL BBR Systems Lic SchwerzenbachZurich, Switzertandire | : Table of Contents 1.0 SCOPE 4.4 Roforonced Standards and Specifications. 4.1.1 American Association of Highway and Transporation Officials (AASHTO). . 1.1.2 American Socity for Testing and Matorals (ASTHMA) 4.1.3 American Welding Society (AWS) ......- te 41:14 Califomia Department of Transportation (CALTRANS) sss... 4.1.5 Federal Highway Administration (FHWA) 1.1.8 Federation internationale de la Precontrainte (FIP) 1.7 Post-Tensioning Institute (PTI)... « 1.1.8 Structural Steel Painting Council (SSPC) 2.0 DEFINITIONS AND NOTATION 2.4. Definitions 2.2 Notation . 2.8 Abbreviations... 3.0 MATERIALS . 3.4 General . 82 Main Tension Elements. 82.1 Wire .... See te 7 8.2.1.4 Quality Control 3.2.2 Suand....... Somes : 3.2.2.1 Quality Control 3.2.8 Epoxy Coated Strand 3.2.3.1 Quality Control... 3.2.8.2 Surface Preparation \ 3.2.3.3 Application of Epoxy Coating. . 8.2.8.4 Inspection of Materials . 3295 Replacement of Reeced Epoxy Strand 3.24 Bar 3.2.4.1 Quality Control 3.2.8 Wir or Strand, not Specifically Nomizod In ASTM A421 or A416 3.2.6 Bars not Spocifcally Itemized in ASTM A722. .....- 2.0. 3.9. cdl Shoatod Sands with Corson Iistng Coating 8.9.1 Surface Preparation... : 3.3.2 Application of Corrosion Inhibiting Coatng j 9.3.8 Application of Sheathing : 2.3.4 inspection 3.8.5 Replacement of Rejected Sheathed Strand : 8.8.6 High Density Polyethylene Material for Sheathed Strand 8.37 High Density Polypropylene Material for Sheathed Strand. 48.8.8 Corrosion inhibiting Coating Materfal : 2.8.9 Performance Tests for Individually Sheathed Polyethylene or Polypropylene Strand... Jo... ee servos40 34 Anchorage Gomponents 38 Stay Pipe... 3.5.1 Cross Sectional Area 352 Steel Pipe 36.2.1 Coating .. 353 High Denely Polyethylene Pipe (HOPE 3.5.3.1 Pipe Specifications a 3.5.3.2 Material Specifications ........ 8.5.3.3 Wall Thicknoss oo 3.5.4 Polyinyl Fluoride Tape 36 Portland Cement Grout. 3.6.1 General 3.82 Composition . 36.3 Portland Cement 3.6.4 Water 365 Admbtures .....- 3.6.6 Physical Properties of Grout 3.6.7 Qualification Tests for Grout 8.7 Contralizers ‘SYSTEMS QUALIFICATION AND TESTING . 4.1 Comosion Protection ..... 44.4 General .. 4.1.2 Baniers acne amie 4.12.1 Anchorage / Free Length intedace 41.3 Materials eee 4.14 Qualication of Barriers 4.4.4. Internal Barriers 441.42 Extomal Barriers 441.6. Qualification of Temporary Corrosion Protection System 4.4.6 Qualification of Anchorage Assombly . AA.GA Specimen. oo... ees 7 41.62 Preparation ...... 6 see eee eee 4.1.6. Testing .. 4.1.7 Acceptance Criteria ‘ 41.74 Barriers .. seen 4.1.7.2 Anchorage Assembly AA8 Ddcumemtation .. 0... ceec eevee eee 4.2 Accoptance Testing of Slay Cables... 4.3 Acceptances of Prior Tests of Stay Cables 44 Quality Control of Other Stay Cable Components... 4.5 Summary of Testing Requirements . wi LRFD DESIGN - BA Loads... 5.1.1 Dead Loads .. 5.12 Live Loads . 5.4.3 Fatigue Load as 5.14 Dynamic Load allowance - 5.1.5 Wind Loads on Stay Gable... 5.1.6 Thermal Loads. 5.2. Wind-Induced Vibrations. 5.2.1 Mechenisms of Dynarnic Exctation 5.2.2 Monitoring of Cable Vibrations 5.2.5 Dealgn Provisions. 5.2.3.1 Contingoney Measures. 5.2.32 Rain-Wind Induced Vibrations 5.2.3.3 Cable Galloping « 52.3.4 Aarodynamic Contour of Cable 5235 Damping .. feceeeeees 5.2.36 Stabilizing Cables ee 5.2.3.7 Connections veceeeeee o 5238 Rattling ad coral 53 Design manos 53.1 Design Limit Setas. oe 8.2 Load Factore and Combinations... . 5.3.3 Rosistanco Factors. 5.3.4 Fatigue Limit Siate : 84 Cable Replacament ...-.... aaa 55 Loss of Cable : 5.6 Construction 57 Design of Gable Saciles ct rent 5.7.1 Generel feeeeeeee becceeeee 5.72 Design Criteria 68.724 Cable Radius ....... 5.7.22 Slip and Force Transfer . 57.2.3 Cable Bonding Stresses ..... 5.7.2.4 Components Design Specification 57.3 Delaling .. as 57.8.4 Corosion Protection System 5.7.8.2 Qualification of Saddle Corrosion Protective System Detalis S74 Testing «+++ ees ieee carers 57.4.1 Saddle Design Testing suhennne' 5.7.4.2 Fatigue Testing : 5.7.4.9 Friction Testing 5.8 Alternative Stay Gable Systems vii60 INSTALLATION OF STAY CABLES ie 6.1 Quality Control Program oe... seco 62 Fabrication ......, 62.1 General 6.2.2 Pro-fabrication 6.2.3 Site Fabrication. . 63 Handling of Stay Cable Components . 6.3.1 Procedures .......... 32 Cable Protection and Coiling 6.3.3 Lifting Devices... 6.3.4 Damage and Repair : 635 Equipment and Cable Protection 64 Packing and Shipping 6.41 Stay Cable Metallo Gener cee 6.42 Strands, Wires and Bars... eee 642.1 Bare Stands and Wires 64.22 Bare Bars . 6.4.2.8 Epoxy Coated, Galvanized oF Shoathod Stand... ‘Anchor and Socket Assemblies. dseaseseerniienies Pipe 6.4.4.1 High Denaly Polyethylene Pipe without Tension Element 6.4.4.2 Stool Pipe : 3 6.4.5 Pre-assemblod Cables with HOPE Pipe BAG Admixtures 6... eee 6.5 Material Site Inspection . 6.6 Storage 8.8.1 Requirements and Limitations 6.6.2 Factity .... iis 66.3 Environmental Conte! 6.7 Pre-installation Inepection . ... 6.7.1 Bare, Epoxy Coated, Galvanized or Sheathed Strand and Wire” 6.7.2 Bere Strands and Wires ‘ 6.7. Epoxy Coatod, Galvanized of Sheathed Strands 674 Bar ..... 675 High Density Paatnene Pipe 6.7.6 Steal Pipe emer 8.7.7 Pre-assembled Cable ‘ 6.7.8 Afichors and Socket Assemblios 6.7.9 Portland Cement and Admixtures 6.8 Stay Pipe Assembly Preparation. . 6.8.1 High Density Polyethylene Pipe 6.8.1.1 Pipe Length... 6.8.1.2 Fusion Welds...SSIIBARBR ss 70 80 20 6.9 Installation... ceveteeees 6.8.2 Steel Pipe - : 6.8.2.1 Welding Requirements =... 6.8.2.2 Inspection for Stea! Pipe weting 6.9.1 Installation Program... 6.9.1.1 Minimum Cable Forces . om 69.2 Temporary Vibration Control 6... sees 6.9.3 Jacks and Gauges : 6.9.4 Stessing .... 6.9.5 Detensioning : 6.9.6 Inctallallon Rovords «s+. seseeeveee 6.8.6.1 Monitoring ...... 6.9.6.2 Permanent Records 6.10 Grouting ......-.. 6.10.1 Grouting Procedure 6.10.2 Grouting Equipment STAY CABLE INSPECTION AND MONITORING 74 General ae % 72 Visual inspection 0.0... ee yee ee ede 7.3 Condition Evaluation, 7.4 Nondestructive Inspection . . 7.5 Frequency of Inspection ........ 7.6 Monitoring of Cabie Vibrations & RERBES REFERENCES 000... 00cccccecceseeeeeetseu esse eene asap aeeaeeee PUBLICATION SOURCES APPENDIX A Dotalls of "Ono-Pin Test". : . APPENDIX B Calculations of Stabilizing-Cable Spacing APPENDIX C Corrosion Protection System Details Agp C1 General . op C-2 Temporary Corrosion Protection Asp 0.3. Wrapping with PVF Tape ‘App C4 Coating for Steel Pipe ‘App.C.4.1 Shop Applied Primo Coat +96 App C4.1.1 Surlace Preparation 6 App 0.4.1.2 Prime Coat Preparation ....... 96 App CA.1.3 Pile Coat Application........-++ 7 ‘App CAA Quality inspections for Prime Coal. 7 97 ‘App C42 Field Applied Intermediate and Finish Goats ..... 2... 6... -+. 98 aa 101 APPENDIX D Conversion Factors SI to US Units1.0 SCOPE ‘Thase recommendations pertain to the design, testing and installation of stay cables for cable- stayed bridges using prestressing wires, strand or bar as the main tension element. Recommendations are presented only for stay cables used in redundant cable-stayed bridges. These recommendations are intended to be used Jn conjunction with the appropriate provisions of the "LRFD Bridge Design Specifications’ SI alton, from the American Association of Stato Highway and Trangportetion Cificials.* ‘This edition supersedes all previous editions. Standards and specifications shall refer to the latest edition unless a specific date is given. > number In aod peroneal rele o rulers Heted fn ueton 0. 1.4 Referenced Standards and Specifications 1.4.1 American Association of Highway and ‘Transportation Officials (AASHTO) AASHTO "LRFD Bridge Design Specitications’— 1 Units 1.1.2 American Society for Testing and ‘Materials (ASTD) Asst 96M “Standard Specileston for Carbon Srutura Steer” C:4.0 SCOPE These recommendations do not deal with the design of cable-stayed bridges in general, but are limited to considerations of design, inspection, ‘esting and installation of stay cables. Stay cables utilizing helical or locked-ool strands, or wire ropes are not covered by these recommendations. Fedunant cable-stayed bridges are bridges that are designed 50 that loss of an individual stay ‘cablo would not result in significant structural damage oF failure ofthe bridge. These recommiendations have been drafted on the basis of a typical U.S. construction contract in the public sector where. there are three distinct and seperate parties, namely: + Tho Owner (6. Government or Public Agency) «The Designer (1.2. the Engines!) ‘= The Contractor (Le. the Bridge Builder) The procedures herein reflect this organizational and contractual hierarohy. Elsewhore, contractual arrangements may difer. Likewise on Dosign- Build projects, tne contractual arrangements are diferent. Design procedures not covered by this document should be carried out by a Professionel Engineer quailfied in cable-stayed bridge design. Aliernalive .methods should provide a level of ‘safety and performance equivalent to a design conforming to these Recommendations. €.1.1 See page 90 for more information about the sourees of these documentsAB Aa Aig) Aza Ader aac Aaaw Aaa Aor Aersit Ar area A7eM ares ATTM Aan’ AR guM en7 cis case ca30 caw cose cra Dose 746 70 Recommendations "Standard Spécticaton fr Pip, Steal, Black and Hot Dipped, Zinc-Costad, Welded and Seamless” ‘standard Speciicaton tor Steel Wre,Pain, for CCorerete Reinforcement “Standard Spocfcation tor Zinc {HOLD Ip Galvanized) Goatirgs on ion and Steel Products.” ~Stondard Specticaton for Steel Strand, Uncoated Soven Wire for Praszuesed Conerolo" “Standard Saectcation for Uncoated Stress Fev! Stee! Wie for Prastressert Conerele™ “standard Specticaton for Sampling Procedur for Impact Toothg of Sueur St “Standard Practiees for Packaging, Marking and Loading Methods for Steel Products for Domest Shipment “Standard Speciation for Uncoated High Strength ‘Stoel Bat for Prosresshig Concots" ‘Standard Spacifcaton for Epoxy Coated Feinforong Stee! Bars" “standard Speciation for Epoxy-Caated Seven- Wire Prestrossing Steo! Stand “Standard Practoo for Operatig Salt Spray (Fou) Apparatus! "Standard Spscicaton for Poti! Cement” standard Tost Mothod for Timo of Sating of Hyctavlo—Cement Peele by Gilmore Needles" Standard Test Mattod for Flow of Grout for Preplaces-Aggregate Concrete (Flow Cone Moe t hoo @ ) * “Standard Test Method for Expansion and Biseding of Freshly Mixed Groute for Preplaced-Agsreasie Concrete in the. Laborstry" Standard Test Wethod for Compressive. Strength of Grouts for roplaced: Aggregate Corerete in the Leborston” standard Teat etned for Electrial_ineation of Conctete's Ability. o Reelst Chloe lon Penetration” standard Test Method for Tense Propedion of Pianta" "Standard Test Mathod for Britdaness Temperature of Pastics and Elastomers by impact" Standard Tast Methods for Flwurel Properties of Unreinforced anc Reinforced Fastes and CommentaryRecommendations Commentary tocical insulating Materials* D868 "Standard Test Methods for Abrasion Aesistance cf Crgaric Coatings by Fling Abrasive" 1D 1000 “Standard get Method for Pressure: Sonstive Aadheeive-Costed Tapes Used for Elctoal and tectonic Appicatiens! 1 1004 “Standard Tost Mthod or intial Tear Resistance cf Pleste Fin and Gheetng” 1D 1238 "Standard “Test Method tor Flow Rates of “Thermoplestis by Extrusion Plastometer" 1D 1505 “Standard Tast Method for Density of Plastics by ‘ho Deneity-Gradiont Technique" 1 1600 “Stender Test Method for Envioemental Svaas- Cracking of Ethyire Place" (0.2240 "Standard Tost Method for Fubber Property: Dutemtor Hardnees* 10.2667 “Standard Practice for Heat Fusion Joining of Pollan Pipe and Flings" 19 2697 “Standard Tost Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Matera 19-8098 “Standard Spooicaion for Polyetylone (PE) Fastic Pipe (OR-PR) Based on Contrales Outside Diameter? ‘0 5980 “Standard Speciicaicn for Polyethylene Plates Pipe and Fitings Matocals* 1 S989 “Standard Tost Methods fr Measuring Adhosion by Tapa Test” 4101 "Standard Speciicalon for Propylene Plast: Injecton ane Extrusion Neate” 04541 “Standard Test Method for PulLOf Skength of Coatings Using Portable Achesion Testers" } 0.4976 *Stonderd Speetionten for Polyethylene Plates Molding ard Exuusion ators GS “Teste Menod tor Making Fotentesteno ana Poeniodyamic Anod Polarzafon Measurements* . G14 “Standard Tost Method for impact_ Resistance of Pipaine Coatings (Faling Weight Test" 6.20 “Standard Test Method for Chemical Resistance of Prpaine Coatings! F714 "Standard Speccaion for Polyethylene (PE) Plastic Pipe (SOR-PR) Basedon Cutsce Damoter F 1055 "Standard Speciation for Electrohsion Types i Pobetnylons Fitinge ter Outlda Diamoter i Gonkroled Polyetislone Pipe and Tubing” 1.1.3 American Welding Society (AWS) 10.9 "Standard for Cutiiozion of Welding Procedures and Walder fr Piping ard Tubing?Recommendations iat “Recommended Practices for Root Pass Welding of Pipe Without Backing" 1.1.4 California Department of Transportation (CALTRANS) "Standard Spectcaion, July 1995" 441.5 Federal Highway Administration (FHWA) FHWA-FD-74-018 "Non Motalle Coatings for Roinfocing Bars? 446 Federation Internationale. dela Precontrainte (FIP) “Chies to Good Practice—-Grouthg of Vertica! Ducta* 1.1.7 Post-Tensioning Institute (PTI) “PT1 Gude Spocication—Aaceptanoe Stand tor Fost Tunsioning Systems" “PTI Guide Specttcation Grouting of Fost Tonslonod Struct "PT Guide Specttcaon—Spectication foc Unbonded Sing Strand Tenders" 1.1.8 SSPC: Soctety for Protective Coatings ‘SPONACE No 2 Noer Wie Giaat Cieaing’ PAa—"easurerent of Dry Coating Thickness with Magnetic Gages" Commentary €.1.1.6 Merged with CEB in 1998 and renamed "ttRecommendations 2.0 DEFINITIONS AND NOTATION 24 Definitions Anchorage (socket}—device comprising all components and materials requited to retain the forea in a stressed cable-stay and to transmit this force to the bridge superstructure or tower. A disiinction is made between active (stressing) anchorages and fixed end (non-strassing) anchorages. Anchorage length—the length of cable within the hardware that serves to anchor the cable tension elements, including that length of cable where the tensile elements are alrected into the anchor hardware and tho unstressed strand behind wedges or other MTE anchors. Barrier—a covering over the MTE that protects, the MTE from corrosion. A bartier may provide protection by physical or oloctro-chomical means, fr through a combination of the two. Blocking agent—a filler or coating that serves to prevent the passage of water to oF around the MTE. Centralizer—a non-ioad bearing device between the MTE bundle and the inside of the external stay pipe used to fix tho position of the MTE bundle transversely within the stay pipe. Deviator—the component which serves to deviate the path of the MTE at the end{s) of the transition length. External barrior—a barrior that is exposed to the ‘outside environment inthe design condition forth barrier. Free length—the fength of cable beyond the cable anchorage and transition assembly that affects the MTE, such as trumpets, tension rings. or other strand guides. Grout—a mixture of portland cement, water and approved admixtures, ‘Commentary ©.21 Definitions These devices have traditionally bean helical wire or plastic spacer devices, used to provide clearance between stay pipe and MTE bundle for grouting or vibration control.Recommendations. {nternal barrler—a barrier immediately adjacent to the MTE that protects the MTE from corrasion. “Loltipop"—a length of single sirand, bar or wire encapsulated with a single barrier material or compound over its length (See Section 4.1.4.1.) Main tension element (MTE}—the load resisting prestressing material (strand, wire or bar) that Is ‘designed to carry the tensile load in the cable, ‘Manufactured length of strand—one continuous length of strand produced from a stress-relieving co low relaxation treatment line. Nested barrior—a barrier in series with another banter. Prestressing steol—prestrossing wiro, strand or bar as specified in Section 3.0 used as tho MTE of the stay cable, Polyviny! fluoride tape (PVF)—tape with backing made from a glossy PVF film or equal. Saddle—a structural device that allows both deviation of the MTE and transfor of stay foree into the bridge structure without breaking the continuity of the MTE. (These provisions do not cover frictionless saddles.) (See Section 5.7) Stay cable—the complete cable eystem including anchorages, main tension elements, sheathing anda corrosion protection materials and devices, Sheathed strand—prostrassing stes!_strand coated with a corrosion inhibiting coating and covered by an extruded polyethylene or polypropylene material. Stay Pipe—the external covering of the assembled cable, comprised of either high density polyethylene (HOPE) pipe or metal pipe, or other materials and shapes.to provide part of the cottosion protective system, andior to control temperature variation andor rainwind induced vibrations. Transition length—the length of cable where the MTE is doviated from its neutral grouping of Commentary {ts normal practice to coil this fength into ‘separate reels or reeless packs for shioment These Recommendations address the use of pipe ‘material as an external covering of ihe stay cable. ‘Other technologies that are available for covering stay assemblies are not specifically addressed in these Recommendations. | |io pe ing tin | Recommendations Individual prestressing materials within the stay pipe to the grouping of the individual prestressing materials at the anchorage. 22 Notation Notation is in accordance with the AASHTO "LRFD Bridge Design Specifications” S! Edition” vith adaltional terminology as listed below. A = constant (Eq, 6-8) A, = nominal area of stect ADTT = average daily ruck tatic © = constant (Eq. 5:2) = drag coetfcient (Section 6.1.5) D = cable diameter (Eq. 5) E = elastic modulus (Eq. 58) Fy = elfective modulus of elasticity f,=-minkmum utimate tensile stress fig = actual ultimate tensile stress of proctrossing stool (wire, sirand or bar) used as the MTE of a stay cable ™ = mean cable force under ‘conditions (Eq. 5-7) = cable mass per unit length (Eq. 6-1) ‘= fundamental natural frequency (Eq. 5-2) = 985 days x Ny x1 cycle x ADTT (Ed, 56) = design life of the cable in years (ection 5.3.4) number of strands in a bundle (Eq. 5-7) force effect zzz radius of the cross section of elther wire, strand or bundle (Eq, 5-8) the radius of the saddle bend > Commentary ©.2.2 Notation Alt siress fs based on ‘nominal area as detined In the appropriate ASTM Standard. The actual ulimate tensite strength of presiressing steel usually exceeds the minimum Speciid ulate tensile strength esiablished in the apofcable ASTM specifications (see Section 3.0) by 1% to 5% as a manufacturing tolerence. Al stress is based on ‘nominal area’ as detined in tho appropriate ASTM Standard.Recommendations R, = nominal resistance: nominal breaking strength for stength limit states, and nominal yield strength for service limit states $ = length of the influence line under consideration measured in meters (Section 5.1.3) Usy = ctitical wind velocity (Eq, 5-2) n= load factor: a statistically based muttiglier applied to force effects stress range due to the passage of the faligue load muliplied by 1.4 (Eg. 5-4) (4F), = nominal fatigue resistance (Ea. 5-4) (AF)rmy = constant amplitude fatigue threshold Ea. 55) n= a factor relating to ductity, redundancy ‘and operational importance AF § intinsic_structural damping-fatio-to- critical (Ea. 5-1) p= airdonsiy Eq. 5-1) # = resistance factor: a statistically based ‘multiplior applied to nominal resistance 23 Abbreviation AUTS = actual ultimate tensile strength HDPE = high density polyethylene. HDPP = high density polypropylene. Mg = mogagram (= metric “ton’ or "tonne") MTE = main tension element. MUTS = minimum ultimate tensile strength. PVF = poiyviny! fluoride. Commentary ©.2.3 Abbreviation The Slumit of mass is the kilogram (kg). The name ton has been given to several large mass units that are widely used in commerce aid technology. The Jong ton of 2,240 Ib, the short ton of 2,000 Jb,, and the metric ton (tonne) of 1,000 kg, which is almost 2,205 ib are not Si terms. (See IEEE/ASTM SI-10) —— ee |ame nits 000 hich ‘See Recommendations 3.0 Materials 9.1 General ‘These recommendations cover materials for stay cable systems utilizing prestressing steal 3.2 Main Tension Elements ‘The main tension elements (MTE) tor stay cables covered by these recommendations shall conform to the following specifications, 3.24 Wire Wire used in stay cables shal! conform to ASTM ‘Ma2i/A42iM, "Standard Specification for Uncoated ‘Stress-Relleved Steel Wire for Prestrossed Concrete," Type BA. 3.2.1.1 Quality Control Uniess otherwise stated hersin one test for every 2.5 Mg or portion thereof shall be made for the following: ‘A. Minimum specitied ultimate tensile stress: fg = 1055 MPa 8. Minimum yield stress: fy = 0.90 fy for low relaxation wire fy = 0.85 f for stress relieved wire ©. Elastic modulus: E = 200,000 MPa + 8% ‘Commentary €.3.2 Main Tension Elements For bridges built outside the U.S. comparable national speiifcations should be used tf available, 6.3.2.1 Wire Either stress-relleved {normai-relexation) or low- relaxation wire for prestressed concrete may be used for stay cable application since the creep (or relaxation) is negligible under normal working stress. Outoide the U.S. hot dip galvanized wiro has boon usedfor a number of cable stayed bridges without low-telaxation treatment. The hot alp galvanizing process relieves the internal stresses of wire. At the prasant time, there is no ASTM specification {for het dlp galvanized wire that is suitable for stay cable application. Among the requirements for this, type of wire are tensile strength, load at 1% ‘extension, elongation, coating weight, straightness (cast) and fatigue resistance. 3.2.1.1 Quality Control Minimum Utimate Tonsiio Swength (MUTS) is ‘equal tof, x nominal area! of staateri Recommendations Dustity: {) Reduction of area due to necking at rupture: At least 30% (i) After three “to and fro” bends through 490° around a mandrel with a diameter of 5 wire diameters: No failure Fatigue and static strength: One Sm fong wire sample shall be taken from every 10 Ng er portion thereof produced from each haat of stool. All prestrossing wires and derived tos samples shall be marked in such a manner as to ‘oncure traceability during production trans storage and testing. The test specimens ‘shall be a minimum length of 300 mm. They: shall be anchored in such a way as to ovoid failures in the anchorage zone. Should ary ‘sp9cimen fal within tho anchorage zone, the test shall be discarded and another specimen used from the same sample. The wiros shall bo tested at an upper stress of 0.48 7, and a strase range, 28 shown in ‘Table 3-1 for the selected number of test cycles. At least 5% of the wire tests shall be to 2mlion cycles. A static test to failure shal be conducted atfier each wire fatiguo test. Wire specimens shall provide not less than 0.95 MUTS in the static test. Wire tested without failure for the selected number of cycles and the related stress range, as speeiied above, shall be considered acceptable. In case the first valid test sspocimien from each sample fails the fatigue oF static test, tw9- addtional tosts shall be made on test specimens from the same sampl. If further failures occur, the wire quantity represented by the sample shall be rejected 10 Commentary These cuctifty requirements are in addition to the ASTM Ad21/A421M requirement for total ‘elongation under load of net less than 4% when ‘measured in a gauge length of 250 mm. When choosing the tatique stress range tor the quafty contro! tests, the values trom Table 3-1 may be plotted on @ log-log plot and straight fine interpolation between points an such a plot may be used fo select stress range values and the corresponding required number of load cycles for accelerated testing. (Soe Figure 3.1) 7 althe ital en the a4 fine nay the i | Table 3-1 Summary of Stress Ranges for Fatigue Tests: ‘Type of Stay No. of Cycles ‘Stay Test Fatigue | Component Fatigue ‘Stteas Range! Test Stress Range" MPa ‘Strand? or uncoupled bers* 159 ‘Bars' with (epoxy filled) couplers "To eraute fatigue quaaty of cays, recornmendd that slay specimens be tesled at 2x 10" eyes, *tncidua strand, bar, wre, or glued, oxupied bar, respectively S00 Section 3.2.2 and 323. ‘See Section S24 ‘Soe Seton 82 + Upper bore sess tel shal ba 0.45 f Figure 3.1 Fatigue Safety Philosophy 10° sre arent atone Sarr — abe ett = z j 10° io oF ot Life (Number of Cycles) At = Quality Assurance (17 MPa-coupied bar, 63 MPa strand and uncoupled bar, 108 MPa-wire) 42 = Length effect, anchorage stress riser, salety (84 MPa) 11Recommendations Corrosion: Prior to shipment from the manufacturer, all wiros shall be free from visible corrosion One § m wire samplo shall be taken at Fandom from every 10 Mg or portion thereot, produced from each heat of steel. Tho sample wires steel surfaces shall be thoroughly exposed (when coated) and ingpected for evidence of corrosion. I visible corrosion is found, the wire quantity represented by that sample shall be rejected. 3.2.2 Strand Strand used in stay cables shall conform to ASTM AMI6/A416M "Standard Spectication for Stee! Strand, Uncoated Seven-Wire for Prestressed Concrete," and shall be weldless, low-relaxation grade. 12 Commentary ©.3.2.2 Strand Welaléss in the context of strand used ior slay cables includes removal of ail wire rod welds. Low-olaxation grado ie recommended because the lew-relaxaton strand: (1) has proven to have @ sound tensile strength troughout tho entire lengifvas it nas been subjected to a near Breaking Jad in the low relaxation treatment; (2) has better ‘straightness (oast) for easy cablo fabrication. Hot dip galvanized strand has been used on several major cable-stayed bridges outside the US. Galvanized strand is made trom oither as- ‘galvanized wires (In Japan) or drawn galvanized wires (in Europe). The advantage of as- galvanized wire is heavier coating weight (300 g/t? oF more} for better corrosion protection. The advantage of drawn-gaivantzed wire, on the other hand, is improved fatigue performance and tighter control an tolerance, Low-relaxation grade is often times. recommended for galvanized strand as well because of the above mentioned reasoris. Galvanized strand should meet or exceed the requiremenis of ASTM A416 as well as the requiremenis of soction 32.2.9 Galvanized prestressing strand may be used in contact with cement grout provided the steel has been marutactured in accardance wit the latest ASTM A416, BS 5896 or EN 10138 standard. Experience has shown that strand manutacturee esstay use rave aire king ‘iter fon the aa ized as- (200 other thter | the the odin thas atest dard. ‘urea rT pe Recommendations 9.2241 Quality Controt Uniass otherwise stated herein, one test for each ‘manufactured length or 10 Mg, whichover is loss ‘or portion thereof shall bs made for the ‘ellowing: ‘A. Minimum utimata tansite stress: fy = 1880 MPa B. Minimum yiald stress: Jy = 090 fe ©. Blastic modulus: E = 197,000 MPa + 5% D. Dusty: A*One-Pin Test" as outlined in Appendix A shall be conducted on a sample taken from each manufactured length ot 10 Mg {whichever is less) or portion thereof. For acceptance, the tensile force in the sample during the one-pin test shat equal at least 08 faq. The sample taken for the One-Pin Teal shall be long enough for two ukimate strength tests and thros one-pin tests. Hf the first specimen fails the one-pin test, two addtional samples shall be tested. If both samples pass, the material is acceptabla. If ‘either sample fails, the manufactured tength represented by ‘that sample shall be rejected. E, Fatigue and static strength: (One § m long strand samplo shall be taken from every 10 Mg produced from each manufactured length or 10 Mg, (whichever Ig lass} or portion thoroof. Al prestressing strands and derived test samples shall be ‘marked in such a manner as to ensure traceability during production, - transit, 18 Commentary to these standards is not susceptible to hydrogen ‘embrittlement. ©€.3.22.1 Quality Control The provisions of this section apply to all strands Including uncoated, galvanized, epoxy-coated, ‘and sheathed strands. The One-Pin test for duatilty is in addition to the requirement of ASTM A41E/A416M that the total ‘elongation, under load, shal not be less than 3.8% measured in a gauge length of not less than 810 mm. When choosing the fatiue stress range for the qually contro! tosts, the vaives trom Table $-1 ‘may be plotted on a tog-tog plot and straight line interpolation between points on such a plat may be used’ fo select stress range values and the ‘corresponding required number of load cycles for ‘accolerated testing. (See Figure 3.1)