This document is the property of L&T CONSTRCUTION, EDRC and must not be passed on to any third person or firm

not authorised by us, nor be copied/made use of in full or part by such person or firm

7-Mar-19 A For Approval I. Chen J. Huang B. Wiessler

DATE REV. NO. DESCRIPTION DSGN CHKD APPD
REVISIONS

L&T CONSTRUCTION
HEAVY CIVIL INFRASTRUCTURE - EDRC
CLIENT: AUTHORITY ENGINEER/PMC: 3rd PARTY DESIGN CHECK CONSULTANT:

AMARAVATI DEVELOPMENT
TBD
CORPORATION LIMITED

DESIGN CONSULTANTS:

L&T CONSTRUCTION, HCI WEICON - BRIDGECON L&T INFRASTRUCTURE

EDRC - SPECIAL BRIDGES JV ENGINEERING LTD.
PROOF CONSULTANTS: SAFETY CONSULTANT:

INDIAN INSTITUTE OF McELHANNEY CONSULTING CRAPHTS CONSULTANTS

TECHNOLOGY, MADRAS SERVICES LIMITED PRIVATE LIMITED
PROJECT :
without our prior permission writing

Design and Construction of 6-Lane Iconic Bridge Across River Krishna in Amaravati, Andhra Pradesh
CONTRACTOR:
L&T CONSTRUCTION - HEAVY CIVIL INFRASTRUCTURE
JOB No. O18029-C-BR

TOTAL NO. OF PAGES 10 TITLE :

NAME SIGN DATE
DSGN I. Chen IC 7-Mar-19
STAY CABLE SPECIFICATIONS - CABLE STAYED BRIDGE
CHKD J. Huang JH 7-Mar-19
APPD B. Wiessler BW 7-Mar-19
] CODE REV.
DOC. No. O 18 0 2 9 - C - B R - 0 1 - M B - D C - 2 0 0 5
PTI A

RELEASED FOR PRELIMINARY TENDER INFORMATION  APPROVAL CONSTRUCTION

 Sensitivity: LNT Construction Internal Use
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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

STAY CABLES SPECIFICATIONS

SECTION 5.1 INTRODUCTION

5.1.1 GENERAL

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.

The scope of work shall include testing, fabrication, transportation and installation of the stay cable
system as specified in the Contract together with the associated documentation and preparation of a
maintenance manual. In addition, the scope of work shall include the necessary preparations and
design of all anti-vibration measures that will be necessary in the event that 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 cables shall be designed, 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.

(b) Structural design of steel components shall comply with EN 1993, IRC 22, IRC 24, IRC 112

(c) 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 the Construction supervision officer.

The stay cables include the stay anchorage components, which are part of the structure, such as the
forming tubes and the anchorage bearing plates connecting the stays to the pylons and
superstructure.

5.1.2 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

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

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 Construction supervision officer's 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, or approved equivalent device, which is able to pull a complete stay anchorage. The
fine adjustment to the cable extension shall be made by means of a threaded anchor tube and nut
assembly. 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.

SECTION 5.2 MATERIALS

5.2.1 STRAND
The strand for stay cables shall be Grade 1860 Mpa, Galvanized, Wax filled, PE-coated, seven wire
with low relaxation class 2 with following properties.
 Diameter – 15.7mm
 Area – 150 mm2
 Grade – 1860 Mpa
 Elastic Modulus - 195000 MPa
 Specified Characteristic Breaking Load - 279kN
 Elongation ≥ 3.5%

In addition to above, the strand shall be factory galvanized, coated with high-density polyethylene
(HDPE) and provided with a protective filler inside the interstices between the king wire and the outer
wires, and around the outer wires.
The strand shall comply with the following particular requirements:
(a) Zinc coating: the zinc coating of wire shall be in accordance with pr EN 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.
(b) Fatigue resistance: 2 million cycles with a stress range of 228 Mpa and upper test stress of 0.45
of strand’s minimum tensile stress as specified above.

(c) 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 Deflected Tensile test shall not be more than 20%.

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

(d) Curvature of strand: when a length of strand, on unreeling, is lying free on a flat surface, the
maximum bow height from a base line 1m in length, measured inside of the curve, shall not be
greater than 25 mm.

(e) 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. 5). 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 color.
The properties of the sheathing material PE shall be as per table 1 below:
Property Requirement PE (PP) Test method
Melt index  0.35 g and ≤ 1.4 g per ISO 1133
10 minutes under 5 kg
Specific weight, Density ≥ 0.94 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 sheathing
Elongation at break at 23° C  600 % on raw material ISO 527-2,
 250 % on sheathing 50 mm/minute (speed on test)
Elongation at break at –20° C  150 % on raw material ISO 527-2,
 100 % on sheathing 50 mm/minute
Thermal stability under O2  20 minutes at 210 °C, without ISO 11357-6
degradation
(f) Protective filler: The protective filler shall be a petroleum wax or equivalent filler approved by
Construction supervision officer. The properties are given in table 2. 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  65°C
Penetration (1/10 mm) at -20°C NFT 60-119 No cracking
Bleeding at 40°C BS 2000:PT121 (1982) modified  0.5 %
Resistance to oxidation 100 hours at 100°C ASTM D942.70  0.03 MPa
Copper-strip corrosion 100 hours at 100°C ISO 2160 Class 1a
168 hours at 35°C NFX 41-002 (Salt spray) 1) Pass
Corrosion
NFX 41-002 (Distilled water spray) No corrosion
1)
protection 168 hours at 35°C
[S32] or ISO/DIS 9227 [S46]
Content of Cl-, S2-, NO-3 : NFM 07-023  50 ppm (0.005%)
aggressive
SO42-: NFM 07-023  100 ppm (0.010%)
elements

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

5.2.2 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 and the consent of the Construction
supervision officer. The test plan shall include all tests as specified below.

The Contractor shall furnish to the Construction supervision officer a test report prepared by the
manufacturer under an accredited quality assurance plan or by an independent laboratory
documenting the compliance with following items

(a) The inspection unit for coated Strand manufactured in the same process shall be of same grade,
same dia and the lot shall be either 40 tons per cast or part thereof. When the no. of coils for
inspection unit is lower than 3 coils, 3 samples shall be taken. When the no. of coils is more than
3, 1 sample per coil shall be taken subject to a maximum no. of samples limited to 12. On each
sample 1 series of test is carried out as follows:

 One Tensile Test: Test procedures shall comply with the requirements of EN 15630-3.

 One determination of Mass/M: Test procedures shall comply with the requirements of EN
15630-3.

 Zinc coating: Test pieces shall be representative specimens cut at the rate of two sample for
each forty tons or part thereof, one at each alternate end of the unit of production shall be
taken. Measurement and tests for zinc coating weight, coating adhesion, and coating uniformity
shall be in accordance with the requirements of EN 10244-1 and EN 10244-2.

 Fatigue: One specimen 5 M in length shall be sampled for each unit of production or fraction
thereof. For each test, 3 samples of minimum 1 M length shall be taken from this specimen.
Fatigue test shall be carried out in accordance with requirement of EN-15630-3. If the first test
specimen passes, other samples need not to be tested. In case first specimen fails the fatigue
test, the other two specimens shall be tested and both the specimens must pass otherwise the
quantity of strand represented by the 3 samples shall be rejected.

 Deflected tensile test: One specimen (comprising of 5 samples) of sufficient length shall be
sampled according to EN 15630-3 from each 40 tons or fraction thereof. The test shall be
carried out in accordance with the requirement of EN 15630-3. If the D value as average of 5
valid tests is ≤ 20 %, the quantity of strand represented by the specimen shall be passed.

 Completed strand: The test requirements on individually sheathed polyethylene strand are
given in table 3 below. Performance tests in accordance with PTI clause 3.3.9 have to be
conducted under an accredited quality assurance system at manufacturer’s factory or an
independent laboratory. Past test results for Chemical resistance, Chloride permeability and salt
spray (fog) test may be accepted.

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

Table 3: Characteristics of the sheathed and waxed stay cable strand

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
Not soften, crack or visually
Chemical resistance ASTM G20 6 samples per project
deteriorated
Chloride permeability test FHWA-RD-74-018 Permeability < 1 x 104 M One sample per project
No shattering, cracking except
Impact resistance ASTM G14 7 sample per project
at the impact area
Net loss ≤ 0.25 per 1,000 L of
Abrasion resistance test ASTM D968 Two samples per project
abrasive
ASTM B117 No visible cracks up to an
Salt spray (fog) test Two samples per project
(ASTM A416) elongation of 1%
No mass variation before/after
One samples per inspection
Water tightness test XP A 35-037-2 the test on sample weight plus
unit
quantity obtained at the beaker

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.

5.2.3 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 reeless 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, so as to ensure the strand is not damaged in transit
or when delivered to the Site.

5.2.4 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 6 mm.

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

The surface of the HDPE pipe shall carry spiral ridges 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 Contractor shall be permitted to propose a full thickness colour HDPE pipe,
provided that these requirements are met:

The exposed surfaces of all pipes shall be of material that has demonstrated an ultraviolet (UV)
resistance (UV + Visible) in a climate equivalent to a UV intensity of 21 x 107 J/m2 per year with an
average temperature of 22°C. Oxidation visible under a microscope with 100 magnifications shall not
occur before 15 years. Demonstration shall be based on previously conducted tests.

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:

PROPERTY ASTM TEST METHOD VALUE

Density,g/cm3 D1505 >0.940
Melt Index, g/10 minutes D1238 0.2 to 1.4
Flexural modulus, Mpa , D790 >750
Elongation at break test (at 23°C, test speed 50 D638 350 %
mm/minute) testing shall be performed once for each
pipe dimension per lot
Tensile Strength at Yield, MPa D638 >21
Environmental Stress Crack D1639 600
Resistance (F20, hours) (Condition C)

5.2.5 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 edition”
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 angular deviation between the steel guide pipe and the centerline of each stay shall not exceed
±0.30 degrees and the bearing plates together with steel guide pipes shall follow the cable tangent in
order to consider cable sag.

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

5.2.6 Vibration Control System

Dampers shall be provided to mitigate excessive vibration of stay cables. It is the design consultant’s
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 analyze, 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, shop and erection drawings to the Construction
Supervision Officer for approval prior to fabricating and installing the cable damper.

SECTION 5.3 STAY CABLE ACCEPTANCE TESTING

5.3.1 SCOPE OF THE WORK

In addition to test on individual strand a program of static and dynamic testing shall be conducted on
fully assembled specimen of stay cable system. These tests shall consist of the provision of all
materials strand specimen and all equipment for fatigue, ultimate strength, ductility and static load
testing as follows:

Fully Assembled Stay Cable

Qualification of the stay cable system is based on the following tests on the fully
assembled cable:

 One Fatigue and ultimate strength tests, on representative unit of the bridge: Test procedure shall be
as required by section 4.2 of PTI 7th Edition published on November 2018. Stay Cable specimen shall
have a minimum length of 3.5 m. The anchorages of the stay cable specimen shall be supported on
wedge-shaped shim plates, creating angular deviations of 0.01 radians, and oriented such as to create
an S-shaped cable profile. Being a Cable Stay Bridge stay cable specimen shall be tested for 2 million
cycles for an upper stress of 0.45 times minimum ultimate tensile stress and a stress range of 159
MPa. During fatigue testing not more than 2% of the number of individual wires may fail (rounded to
nearest whole number). No failure shall occur in the anchorage material, or in any component of the
anchorage during the fatigue test. Any failure of anchorage component or anchorage material during
the fatigue test shall be the cause for rejection of the test.

After fatigue loading the test specimen shall be reloaded, with the wedge-shaped shim plates
remaining in place, and shall develop a minimum tensile force equal to 92% of the actual ultimate

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

tensile strength of the cable or 95 % of the minimum ultimate tensile strength of the cable, whichever is
greater. The actual ultimate tensile strength of the test cable shall be determined from the results of
tensile tests on the individual strands.

 Water-tightness test, on a reduced unit: One fully assembled stay cable anchorage complete with
transition zone, a minimum of 1 m of free length, and all caps and seals, coatings and coverings that
will be installed in the actual application shall be subjected to water tightness test as defined below.

The specimen shall be the smallest stay cable anchorage assembly tested for fatigue test. All
connections, clamps, caps, seals, adhesives, coatings, or other corrosion-protection details that will be
subjected to stress in the loaded cable shall be installed on the specimen before it is subjected to the
fatigue test. Grease caps, strand caps, or other seals at the rear of the anchorage that are not subject
to live load stress or strain may be omitted from the fatigue test, provided that they will be added to the
installed cable after stressing in the field. Special sealers, tapes, clamps or other devices that will not
be part of the installed cable may not be used for the water tightness test. Test parameters and
acceptance criteria shall be as required by section 4.1.6.1 of PTI 7th Edition published on November
2018.

Stay cable tests conducted for previous projects on specimens similar in design and details to those
proposed for this project shall be considered as a basis for stay cable system approval subject to the
satisfaction of Construction Supervision officer. However, even if the previous tests are considered for
approval of the system the routine quality control tests shall establish that the prestressing steel
supplied for this project has fatigue characteristics comparable to the prestressing steel used in the
acceptance tests of the stay cable specimens in the previous project.

SECTION 5.4 INSTALLATION OF STAY CABLES

5.4.1 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 Construction supervision officer, 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

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

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.

5.4.2 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.

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
Construction supervision officer's consent to the repair procedures and a satisfactory repair.

5.4.3 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 Construction supervision officer, that the tension and extension of each strand is
equalised within a range of ±2.5%. 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 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
Construction supervision officer's consent to any such changes to the method of working these shall
be implimented immediately.

Stay cables shall be capable of being further tensioned, detensioned 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 detension or retension strand by strand in such a

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AMARAVATI DEVELOPMENT CORPORATION LIMITED
Design and Construction of 6-Lane Iconic Bridge Across River Krishna, Amaravati, Andhra Pradesh

way that already "gripped" and newly "gripped" lengths overlap. No "gripped" lengths of strand shall be
left permanently within the stressed portion of the stay.

5.4.4 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 Construction
supervision officer. Finishing of the anchorage and transition zones may commence providing the
Construction supervision officer'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 Construction supervision officer for his consent.

SECTION 5.5 MAINTENANCE MANUAL OF STAY CABLES

5.5.1 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
• Partial or complete replacement of a stay cable
• Re-stressing and de-stressing
• Repair of corrosion protection
• Appendices

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