Golden Horn Cable Stay Bridge, Special Technical Provisions

Volume I
Istanbul Metropolitan Municipality Chapter 1 – Stay Cables

CHAPTER 1
STAY CABLE SYSTEM

SECTION 1.1 INTRODUCTION

1.1.1 GENERAL

This section of the Special Technical Provisions covers the requirements for the materials,
fabrication, testing, transportation, installation, stressing and corrosion protection syste m
for the stay cable system and stay cable dampers.

The scope of work shall include testing, fabrication, testing, transportation, installation,
and stressing of the stay cable system as specified in the Contract together with the
associated documentation and preparation of a maintenance manual.

All materials and workmanship shall comply with the requirements in the codes and
standards, including amendments to these, stated in these Special Technical Provisions
and in other codes and standards referred to by 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 Special Technical Provi sions and the following general
requirements:

(a) Structural design shall comply with the AASHTO Standard Specification for Highway
Bridges.

(b) Fabrication of steel components shall be in accordance with the requirements of

Chapter 2 of the Special Technical Provisions.

(c) Protective treatment to steel components shall be in accordance with the requirements
of Chapter 4 of the Special Technical Provisions

(d) Acceptable criteria for the stay cable system shall conform to either one of the
following recommendations:

(i) Fédération Internationale du Béton Bulletin No. 30: Acceptance of Stay Cable Systems
using Prestressing Steel (2005)

(ii)Post-Tensioning Institute’s Recommendations for Stay Cable Design, Testing and

Installation (2001)

The stay cable system shall be supplied by a specialist Supplier with previous experience
in the design, supply and installation of the specified system whereas the steelwork
components relating to stay -cable system such as the bearing plates, guide pipes and
anti-vandalism pipes, clevis and pin connections as shown on design drawings at pylon
anchorages may be supplied by other suppliers related to steelwork manufactur ing at the
choice of the Contractor . The appointment of the stay cable Supplier shall be subject to
the approval of the Construction Supervision Officer Engineer Engineer .

The stay cable system shall be consisting of the stay anchorage components which are
part of the structure, such as anchorage system (including clevis and pin connections) ,
guide pipes, anti-vandalism pipes, wedges, bearing plates, tensi oning rings, high density
polyethylene pipe including painting, sealing, damping devices, neoprene boots, bolts,
clamps, bands, and all materials required connecting the stays to the pylons and the steel
superstructure. The stay cables shall form a complete system capable of supporting the
bridge structure.

1.1.2 DESCRIPTION AND GENERAL DESIGN PERFORMANCE

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The stay cable system as shown on the Drawings consists of parallel individually
protected seven wire, galvanized, greased or waxed and HDPE sheathed mono strand s
with wedge anchorages and an additional corrosion protection system consisting of an
outer High Density Polyethylene (HDPE) sheath. The stay cable system shall be designed
such that the replacem ent of any individual cable strands can be carried out. 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 constructi on and in service. During initial stay installation this may be
done strand-by-strand, subject to the Construction Supervision Officer Engineer
Engineer's consent to the methods adopted. After structural completion of the bridge, the
assessment of the stay forces and their final adjustment shall be done 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 deck. The required over length of strands should therefore be
provided at the deck anchorages. The over length of strands shall be completely protected
against corrosion and soiling.

The anchorage details on the Drawings illustrate the principles of the detail design. The
Contractor shall determine the exact dim ensions of the structural steel anchorages
provided in the pylon and deck to suit the cable stay system finally incorporated into the
Works.

SECTION 1.2 MATERIALS

1.2.1 STRAND

The strand for stay cables shall be 15.7 mm nominal diameter, relaxati on class 2, seven
2 2
wire super strand (Area = 150 mm , nominal tensile strength = 1770 N/mm ) for
prestressing of concrete conforming with the requirements of prEN 10337:2003. The
Specified Characteristic Breaking Load shall be 265kN and the Elastic Modulus
2
195kN/mm . In addition, the strand shall be of type; factory galvanized and coated (tightly
extruded) with high-density polyethylene (HDPE) stay cable strand and be provided with a
protective filler inside the interstices between the king wire and the out er wires, and
around the outer wires.

In addition to the standard requirements of prEN 10337:2003 the strand shall comply with
the following particular requirements:

(a) Zinc coating: the zinc coating of wires shall be in accordance with NFA35 -035 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
2 2
the finished product shall not be less than 190 g/m nor more than 350 g/m .
2
(b) Fatigue resistance: 2 million cycles with a stress range= 280 N/mm , and an upper
test stress at 0.45 of the strand’s minimum ultimate tensile stress. The fatigue test
procedure shall be carried out according to the relevant FIB or PTI recommendations.

(c) Ductility: The “One-Pin Test” for ductility shall be carried out in accordance with the
relevant FIB or PIT recommendations. The total elongation, under load, shall not be
less than 3.5% measured in a gauge length of not less than 610mm.

(d) Curvature of strand: w hen a length of strand, on unreeling, is lying free on a flat
surface, the maximum bow height from a base line 1 m in length, measured inside of
the curve, shall not be greater than 15 mm.

(e) HDPE coating: the HDPE coating shall be extruded around the st rand 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 shal l not exceed 19.5 mm.

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The coating material shall be virgin HDPE complying with the minimum requirements
of Clause 1.2.4, Table 1.1. The coating shall be black color.

(f) The base HDPE material shall meet the specific requirements of ASTM D4976
“Standard Specification for Polyethylene Plastics Molding and Extrusion Materials.”
The material shall be UV stabilized and suffer no property degradation for a minimum
of 6 months. The primary properties for this HDPE material shall conform to the
following table:

Property Test Method Acceptable Value

2
Density, (g/cm ) ASTM D1505 0.941~0.965
Melt Index, (g/10 min) ASTM D1238 0.2~1.0
Flexural Modulus, (Mpa) ASTM D790 550~1100
Tensile Strength at Yield, ASTM D638 21~28
(Mpa)
Elongation at Rupture ASTM D638 500%~700%
Hardness ASTM D2240 64~65
Low Temperature Brittleness ASTM D746 -40C at 50% flexibility (min)

The origin and the composition of the sheathing material shall be declared by the supplier.
Recycled product shall be rejected.

The manufactured shea thing shall have the characteristics as described in section
1.2.4.

(g) Protective filler: The protective filler shall be either a corrosion inhibitor grease type
VISCONORUST 2889 or approved equivalent, or petroleum wax type Injectelf CP -
HPF, or approved equivalent. It shall fill the interstices of the wire, and the void
between the outer wire and the outer sheathing. The quantity of wax or grease shall
not be less than 10 g/m. This criteria 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.

1.2.2 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 Engineer Engineer . The test plan shall
include all tests as specified below, their timing in the manufacturing process and all
manufacturing hold points.

The Construction Supervision Officer Engineer shall be afforded the opportunity to select
all test samples and witness all tests.

(a) Unit production for sampling: the unit of production from which test pieces are to be
selected is each continuous manufacture d length of strand.

(b) Load-Strain Tests: test pieces shall be representative specimens cut from each unit of
production at the rate of one sample for each six tonnes or part thereof. At least two
test pieces, one at each end of the unit of production, s hall be taken. Test procedures
shall comply with the requirements of EN 15630 -3.

The Specified Characteristic Breaking Load shall be 265kN the Modulus of Elasticity
shall be 195 kN/mm2 + 5% and -5%

(c) Zinc coating: test pieces shall be representative s pecimens cut at the rate of one
sample for each twelve tonnes or part thereof. At least two test pieces, one at each

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alternate end of the unit of production shall be taken. Measurement and tests for zinc
coasting weight, coating adhesion, and coating unifo rmity shall be carried out in
accordance with the requirements of EN 10244 -1 and EN 10244-2.

(d) Fatigue: one specimen 5 metres in length shall be sampled for each unit of production
or fraction thereof. For each test, 3 samples of minimum length one metre sh all be
taken from this specimen. If the first test piece fails the fatigue test, two more tests
shall be carried out. If either one of the two additional tests fails the fatigue test the
quantity of strand represented by the 3 samples shall be rejected. Fa tigue test shall
be carried out in accordance with the requirement of EN 15630 -3. The Contractor
should note the additional test requirement in Clause 1.4.3.

(e) Ductility: one specimen of sufficient length for three tests shall be sampled from each
unit of production and `One Pin Tests' carried out. The test sampling and procedure
shall be as recommended by PTI or FIB. If the first test piece fails the `One Pin Test'
test, two more tests shall be carried out. If either one of the two additional tests fails
the `Deflected Tensile Tests' the quantity of strand represented by the 3 samples
shall be rejected.

(f) Curvature of strand: this criteria is a guaranteed property the verification of which
shall be included as part of the strand manufacturer's test plan. A st raightness check
shall, as a minimum, be made for every unit of production.

(g) HDPE coating:

(i) Mechanical resistance test: one mechanical resistance test shall be carried out
for each unit of production in accordance with the requirements of Clause 1.2.1 (f).

(ii) Resistance to environment: weather -o-meter test and salt mist exposure. This
test shall be carried out in accordance with Section 4.1.5 of PTI’s Recommendations for
Stay Cable Design, Testing and Installation (2001) .This is a guaranteed proper ty of the
strand and its verification shall be included as part of the strand manufacturer's test plan.

(h) Protective Filler: one test of void filling in accordance with the requirements of 1.2.1(g)
shall be carried out for each unit of production or fractio n thereof.

(i) Performance Test for Individually Sheathed Strand: The Contractor shall furnish to
the Construction Supervision Officer Engineer , a test report 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 (1) to (5) below:

1. Chemical Resistance Test

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

Prior to the delivery of strand to Site the Contractor shall provide strand manufacturer's
certificates, in duplicate, 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 c ast and
the results of all other testing.

1.2.3 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: two types of packing may be used:

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- Reeless coils which are protected such that they can be handled without damage to
the strand;

- Wooden reels.

The Contractor shall check the reliability of the type of packing proposed by the strand
manufacturer with regard to the mechanical protection of the strand, so as to ensure the
strand is not damaged in transit or when delivered to the Site.

1.2.4 STAY CABLE SHEATHING

Stay cable outer sheathing shall consist of high -density polyethylene (HDPE) pipe
conforming to the following requirements. The pipe dimensions shall be as shown in the
Drawings.

The HDPE pipe sheathing shall be coloured as to be confirmed by the Construction

Supervision Officer Engineer , and this shall be achieved by the bi extrusion method (by
which a thin coating of light colour HDPE or equivalent m aterial is extruded over a black
HDPE pipe). The Contractor shall document that the material has a UV resistance at least
equivalent to a black HDPE pipe. The HDPE pipe sheathing shall incorporate a double
helical fillet on the outer surface, extruded duri ng manufacture, so as to mitigate the effect
of rain and wind induced vibration of the stay cables.

The required length of the HDPE pipe shall be obtained by continuous extrusion or by
fusion welding. Fusion welding of the HDPE pipe shall be performed in accordance with
ASTM D2657. The Contractor shall undertake fusion welding procedure trials and submit
the results of these trials to the Construction Supervision Officer Engineer in order to pre-
qualify the fusion welding procedure. At least three trials u tilising 6- foot lengths of HDPE
pipe shall be undertaken in respect of each different pipe size and wall thickness.
Following acceptance by the Construction Supervision Officer Engineer of any of the trial
results, he will give approval to the appropriate procedure. No departure from this
approved procedure shall be made without the prior approval of the Construction
Supervision Officer Engineer .

The Contractor shall check the reliability of the procedures for the packaging, handling
and shipping of the pipe by the manufacturer so as to ensure the pipe will not be damaged
when delivered to the Site. Prior to the delivery of pipe sheathing to 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.

The HDPE pipe sheathing material shall be virgin and shall meet the specific cell category
requirements for PE 324433C and class PE335534C material as defined by Table 1 of
ASTM D3350. The re sultant acceptable values of primary properties for the HDPE
material are as follows:

Table 1.1 - Properties of HDPE Material

ASTM TEST
PROPERTY VALUE
METHOD
Density, g/cc D1505 0.941 - 0.955
Melt Index D1238 max. of 1.0
Flexural modulus, MPa , D790 550 - 1100
Tensile Strength at Yield, MPa D638 21 - 28
Environmental Stress Crack D1639 192
Resistance, F 20, hrs., min. (Condition C)
Hydrostatic Design Basis, MPa D2837 0.86 – 1.10

The material shall meet the requirements of a Class C material: it sha ll be weather
resistant, and contain not less than 2 percent of carbon black and 1000 ppm of
antioxidant. The core material of this bi -extrusion sheathing shall be black.

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1.2.5 ANCHORAGES AND TRANSITION ZONES

Stay cable anchorages shall be designed t o individually anchor each strand by means of
conical steel wedges. The anchorages shall meet the acceptance criteria as specified by
the Post-Tensioning Institute (PTI) in Section 6.1 of Recommendations for Stay Cable
Design, Testing and Installation, 200 1 Edition and in accordance with the further
requirements of this Specification.

All anchorages and fixings shall be capable of developing at least the Guaranteed
Minimum Breaking Load of the stay cables. All anchorage components shall be supplied
with a minimum Charpy V-Notch Toughness of 27 Joules at O°C.

The steel wires of the strands shall not be in contact with any other steel elements, other
than in the jaws, to ensure that fretting corrosion, which may be detrimental to the fatigue
endurance of the stays, cannot occur.

The angular deviation between the steel guide pipe and the centreline of each stay shall
not exceed ±0.25 degrees and the bearing plates shall be installed perpendicular to the
axis of the guide pipe within a tolerance of ±0.15 degre es. Neoprene boots, dampers or
similar devices shall be installed at each anchorage and/or transition zone as means of
reducing the flexural stress variations in the strand at the jaw due to any stay oscillations.
The Supplier of the stay shall document th e efficiency of such means to the satisfaction of
the Construction Supervision Officer Engineer .

Neoprene boots and dampers shall be manufactured from 100% virgin chloroprene. The
sole polymer shall be 100% virgin chloroprene which shall comprise not less than 60% by
volume of the total compound.

Table 1.2 - Requirements for Neoprene Material

PROPERTY METHOD OF TEST REQUIREMENTS

Hardness AS 1683.15 60 ± 5

Ultimate Tensile AS 1683.11 4.75 minimum

Strain

Tensile Strength AS 1683.11 17.0 MPa minimum

Tear Resistance AS 1683.12 Die B 40.0 kN/m minimum
Compression Set AS 1683.13B 30% maximum
(22 hours 70 degree
C)
Ozone Resistance AS 1180.7F No visible cracking after 100
20% strain at 40°C hours
±1° C 1 ppm
Accelerated Ageing AS 1180.3 Maximum permissible change in
(168 hours a properties
70 degree C) Hardness ± 4 Durometer
Tensile Strength ± 10%
Tensile Strain - 15%

The testing of neoprene shall be based on three samples collected from every 250 kg of
mixed neoprene material. Any batch of material r epresented by a sample which fails to
comply with the requirements herein shall not be incorporated in the Works.

Stainless steel for banding shall comply with the requirement of ASTM A240 and shall be
of Grade 316.

The Contractor shall furnish all mater ial specifications, including those not specified herein
or on the Drawings, to the Construction Supervision Officer Engineer for review and
approval. The components of the assembly shall have, whenever possible, an AASTHO or
ASTM (or Euro norm) material and test designation number.

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The Contractor shall prepare Working Drawings detailing the assembly of the range of
sizes and types of anchorages used in the Project, showing all dimensions, tolerances
and materials of the various components, and shall submi t four copies of each to the
Construction Supervision Officer Engineer , in accordance with the requirements of the
Contract, for his approval. Subsequent to any comment by the Construction Supervision
Officer Engineer he shall submit such further amended c opies as required, until approval
is obtained. No manufacture of any part of the cable stays shall be executed until the
relevant Working Drawings have been approved.

The anchorage dimensions shown on the Drawings are for illustrative purposes only. The
Contractor shall be responsible for the design of all anchorages including such
components as clevis plates, pins, bearing plates, recess tubes, steel flanges, deviates
and guides which shall be of suitable type and of sufficient strength for their intended use.
The Contractor shall submit to the Construction Supervision Officer Engineer , at least two
weeks prior to manufacturing commencing, design calculations, or other documentation
based on testing, to justify the adequacy of these components.

1.2.6 STAY CABLE DAMPERS

Stay cables shall be equipped with dampers where necessary to avoid cable vibrations.
Dampers shall be designed and fabricated by the Stay cable supplier and shall only be of
friction or rubber type. Dampers to be placed inside the anti-vandalism pipes of the deck
anchorage shall be used and damper systems that can be installed externally to the
outside of steel pipes and as well as h ydraulic or viscous damper s shall not be permitted.
The damper shall be connected to the steel guide pipe of the a nchorage deck structure or
to an additional extension pipe bolted to the end of the guide pipe. Additional attachment
to the steel deck shall not be permitted. The damping value shall be verified by
measurements by the Stay cable supplier on the completed bridge. The dampers shall be
robust with a lifetime of at least 20 years, interchangeable and easy to inspect.

SECTION 1.3 STAY CABLE SYSTEM ACCEPTANCE TESTING

1.3.1 SCOPE OF THE WORK

In addition to tests on individual strands, a program of stati c, dynamic, and leak tests shall
be conducted on fully assembled specimen of stay cables. The specimen shall be the
largest stay cable anchorage fully assembled. This work shall consist of the provision of all
materials, anchorages components; stay cable s pecimens, strand specimens and all labor
and equipment to perform the tests as follows:

(a) Fatigue and ultimate fatigue strength of fully assembled anchorage system
carried out in accordance with relevant PTI or FIB requirement.

(b) Anchorage leak tes t of fully assembled anchorage system carried out in
accordance with relevant PTI or FIB requirement.

(c) The specimen assemblies shall be tested by a recognized independent testing

laboratory. The test procedures and testing laboratory shall be approve d by the
Construction Supervision Officer Engineer .

(c) All testing data and testing results shall be submitted to the Construction Supervision
Officer Engineer.

(d) Fabrication of stay cable anchorage and strand shall not begin until all the required
test prescribed above are successfully completed and a written approval given by the
Construction Supervision Officer Engineer .

1.3.2 ANCHORAGE SYSTEM ACCEPTANCE CRITERIA

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The Contractor shall be obliged to proof that Supplier’s system meets the following
acceptance criteria or a similar test procedure that will be subject to the prior approval of
the Construction Supervision Officer Engineer .

Two complete fully assembled prototype stay cable specimens shall be fabricated for
testing. The specimen shall be m ade representing the largest stay cable in the bridge.
The specimen shall be fully representative of all the details and fabrication procedures to
be employed for production stays and anchorages. The length of each stay cable
specimen shall be a minimum of 6 meters.

The specimen stay cable components shall be tested with their entire load bearing
appurtenances and assemblies comprising neoprene boots and dampers , protective
sheathing together with spacers and the clevis and pin connection on the pylon side . They
shall include an active anchorage and a passive anchorage. Installation tolerances
permitted by Clause 1.2.5 of this Specification shall be incorporated in the test
configuration.. The grease injection of the test specimen anchorages may be omitted,
subject to the consent of the Construction Supervision Officer Engineer .

Test parameters and acceptance criteria shall be as required by the Post -Tensioning
Institute (PTI) in Section 6.1 "Recommendations for Stay Cable Design, Testing and
Installation, 2001 edition". The stay cables shall be tested through 2 million cycles, to an
upper stress of 0.45 of the minimum ultimate tensile strength of the stay cable with a
2
stress range of 200N/mm .

Upon completion of the fatigue testing of both specimens, one specimen shall be
unloaded and the outer HDPE pipe, individual HDPE sheathing and any protective
medium removed to enable the strands to be thoroughly examined. No more than two (2)
percent of the number of individual wires (rounded to the nearest integer) shall have
failed. No failure shall be permitted within or at the face of the jaws, in the anchorage
material, or in any other component of the cable and anchorage system. The maximum
permissible anchor slip shall be limited to 4 mm.

Following the thorough inspection, the test piece shall be reloaded into the test apparatus
and tested to failure. The test piece shall develop a minimum tensile force equal to 95
percent of the characteristic tensile strength of the test cable (number of strands times the
specified characteristic breaking load of one strand).

The other specimen from the fatigue test shall be subject to a leak test as required by the
Post-Tensioning Institute (PTI) in Section 4.1.6 “Recommendations for Stay Cable Design,
testing and installation, 2001”. 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 added to the cable after
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 leak test.

The specimen shall be placed in a chamber so that the anchorage, transition zone, and all
connections between th e transition zone and free length of cable are subjected to not less
than 3m head of water and dye solution. The solution shall contain 3% by volume of red
dye #2. Head may be applied by static measure or pumping.

The test specimen shall be subject to t he required head of red dye solution for a
continuous period of 96 hours. At the end of this period, the specimen shall be removed
from the test solution and immediately subject to destructive examination. The specimen
will be acceptable if visual inspec tion shows that dye has not reached the main tension
element as defined by PTI.

Should any test cable fail to comply with the specified acceptance criteria, the Contractor
may provide, at his own cost, another cable for testing at the same laboratory. Thi s option
may only be exercised once.

If, after re-testing, the stay cables still do not comply with the acceptance criteria, the
Contractor shall develop remedial measures and modify the stay cable system. New cable

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specimens shall be prepared and further tests carried out in accordance with this
Specification. All such testing shall be at the Contractor's own cost until compliance is
achieved.

If the acceptance criteria cannot be met by the Contractor's proposed stay cable system,
the Contractor shall ch ange the Supplier. In the event that a new cable stay Supplier is
appointed no additional costs or extension of time for consequent delays will be
considered by the Contracting Entity.

SECTION 1.4 INSTALLATION OF STAY CABLES

1.4.1 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 Engineer , the method of working which describes the installation
procedure, a description of the main items of the equipment required, as well as the
Engineering program for cable installation including the cable force and the calculated
extension of each stay cable.

The stay cable erection procedure shall be compatible wit h 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 cable s may be fabricated into full length
cables or erected in-situ strand by strand.

The Contractor shall be responsible for the determination and monitoring of all forces and
deflections in the permanent structure at all erection stages in accordance with th e
requirements of these Special Technical Provisions .

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 protected such that no damage or deteri oration 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 be
equipped with permanent protection joints to be incorporated for each strands in the
anchorage zone in order to prevent water or dust to be in contact with the ends of the
strands where the PE coating has been removed.

1.4.2 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 compon ents 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 not be installed on the structure. Damage to other non
load-carrying components may b e repaired subject to the Construction Supervision Officer

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Engineer's consent to the repair procedures and a satisfactory repair being completed
prior to the installation of the stays.

1.4.3 STRESSING

Jacks and gauges for stay cable installation shal l 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.

Prefabricated cables shall be jacked as a full unit. When prefabricated on the Site, pre
tensioning of individual strands may be allowed up to 10 percent of the final installation
force called for in the cable. Procedures shall be developed to ensure that the pre -
tensioning is equalised for all strands in a given cable within a range of ±2 1/2 percent.

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 Engineer , that
the tension and extension of each strand is equalised within a range of ±2 1/2 percent.
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) a nd 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 for ce. 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 n ecessary amendments to his method of working.
Following the Construction Supervision Officer Engineer 's consent to any such changes to
the method of working these shall be implimented immediately.

Following stressing to the `Initial Stay Force' the Contra ctor shall check the deck profile
and, if necessary, adjust the cable force, within the permitted tolerance of ±5%, to achieve
the theoretical deck profile at the particular construction stage. The actual jacking loads
shall take due account of any constru ction loading on the span and allow for bridge and
ambient conditions being different at the time of stressing to those assumed in the design.

Stay cables shall capable of being further tensioned, detensioned and re -tensioned more
than once during the con struction of the bridge.

The stressing to the `Final Stay Force' at the time of final cable tension adjustment shall
be carried out by strand by strand jacking . If the de-tensioning procedure requires in such
way that the "gripping" lone is temporarily i ncorporated in the stressed portion of the stay
further strand fatigue testing shall be undertaken. A single strand, as used in the Project,
anchored within the jaws shall withstand, without rupture, 100,000 loading cycles when
tested with a stress range o f 350 Mpa with a maximum stress equal to 56 percent of the
specified characteristic breaking load. It is not permitted to detension or retension strand
by strand in such a 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.
The maximum cable tension at any stage during construction shall not exceed 56 percent
of the guaranteed ultimate tensile strength of the cable stay.

1.4.4 FINISHING WORKS

After the final cable tension adjustment of all stay cables has been completed the
stressing records of all stays, including the extension records and the deck profile survey
shall be submitted for the approval of the Construction Supervision Officer Engineer .
Finishing of the anchorage and transition zones may commence providing the
Construction Supervision Officer Engineer 's approval of these records has been given.

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Golden Horn Cable Stay Bridge, Special Technical Provisions
Volume I
Istanbul Metropolitan Municipality Chapter 1 – Stay Cables

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 Engineer for his consent.

SECTION 1.5 MAINTENANCE MANUAL OF STAY CABLES

1.5.1 GENERAL

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

The manual shall at least cover the following aspects:

• Descriptions of how to monitor the stay cables for excessive wind induced
vibration regularly during major wind events.
• Descriptions of how to maintain the internal and eventual dampers.
• Descriptions of how to inspect and ensure that the dampers are functioning.
• Descriptions of how to inspect any relative movements of the components inside
the anchorages.
• Descriptions of how to inspect the cable anchorage hidden within the anchorage
tube (inspection using an endoscope).
• Descriptions 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 at least the following parts:

• Scope
• How to use the manual
• Periodic inspection and maintenance
• Exceptional inspection
• Component descriptions
• Partial or complete replacement of a stay cable
• Re-stressing and de-stressing
• Repair of corrosion protection
• Appendices

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