Ambhora Stay Cable Bridge, Maharashtra, India

INSPECTION AND TESTING PLAN

STRAND
DSI - Project No.: 19 12 01

DSI - Document No.: 19 12 01 - 302

Orig. 06.01.2020 Manukant Abdalsamad Schraml

Rev. Date Modification Designed Checked Approved

Copyright as per ISO 16016:

The copying, distribution and utilization of this document as well as the communication of its
contents to others without expressed authorisation by DSI is prohibited. Offenders will be held
liable for the payment of damages.
Inspection and Testing Plan Strand

This inspection and testing plan refers to the Construction of Ambhora Stay Cable
Bridge, Maharashtra, India. It deals with the requirements for material of the strand
(bare and completed), external polyethylene sheathing as well as for wax as void
filler material.
Strands will be low-relaxation seven-wire weld-less strands conforming to
prEN 10337:2003. The 7-wire strand will be tested in accordance to the
requirements in enclosure 1, which are based on the project specification
and fib bulletin 30 “Acceptance of stay cable systems using prestressing
steels”, wax as void filler meets the specifications of fib Bulletin 30 (edition: 2005).
All strand characteristics are specified within the Quality Plan Strand (Document
No.: 19 12 01 - 301).

All quality documents will be gathered by DSI and handed over within the stay cable
method statement document Quality Certificates Strand.

Rev.: 0 Date: 06.01.2020 Doc.-No. 19 12 01 - 302 Page 1 of 1

Inspection and Testing Plan Strand - Ambhora Stay Cable Bridge, India

Product: 7 -wire stay cable strand, hot-dipped galvanized, waxed, PE-sheathed, low-relaxation, weldless

Notation of strand (according to prEN 10337:2003): EN 10337 - Y1860S7+Z-15,7-B

Inspection Characteristic Standard Acceptance Criteria Test Method Test Frequency

Nominal diameter D 15,7 mm ISO 15630-3

Cross section A 150 mm2 ±2%

Mass (steel) 1170 g/m ± 24 g/m ISO 15630-3

Ultimate tensile strength Rm 1860 N/mm² ISO 15630-3

Elastic modulus 195000 MPa ±5% ISO 15630-3

Acc. to project 1 test per coil
Characteristic value of maximum force Fm 279 kN ISO 15630-3
specifications
Specified maximum value of and EN 10337
Fm,max 295 kN ISO 15630-3
maximum force
Characteristic value of 0.1 % proof force Fp0,1 248 kN ISO 15630-3

Elongation ≥ 3,5 % ISO 15630-3

7-wire strand

Reduction of area at break ≥ 25 % ISO 15630-3

2 2
> 190 g/m and < 350 g/m EN 10244-1 and
Zinc mass per unit area (tested on 7 wires) 1 test (7 wires) every 16 tons
average value ≥ 250 g/m2 EN 10244-2
Adherence evaluation by EN 10244-1 and
Adhesive strength of zinc coating
wrapping on a Ø25mm mandrel EN 10244-2
1 test (2 wires) every 16 tons
EN 10244-1 and
Continuity of zinc coating Dip leg 2 x 1 min
EN 10244-2
plane, smooth, no area without zinc, EN 10244-1 and
Apperance of zinc coating EN 10337 1 test (7 wires) every 16 tons
no fouling because of clinker, etc. EN 10244-2
Relaxation after 1000 h at 70% of fma ≤ 2,5 % ISO 15630-3 1 test for the project
stress range 300 MPa
Fatigue test upper limit 0,45 • Fma ISO 15630-3
2 • 106 cycles 2 tests every 100 tons
fib Bulletin 30 ≥ 0,95 • fma
Minimum breaking force after fatigue test ISO 15630-3
table 5.2
Deflected tensile test equals One Pin Test EN 10337 ≤ 20% average ISO 15630-3 1 test every 100 tons

Enclosure 1
Rev.: 0 Date: 06.01.2020 Doc.-No.: 19 12 01 - 302 Page 1 of 4
Inspection and Testing Plan Strand - Ambhora Stay Cable Bridge, India

Product: 7 -wire stay cable strand, hot-dipped galvanized, waxed, PE-sheathed, low-relaxation, weldless

Notation of strand (according to prEN 10337:2003): EN 10337 - Y1860S7+Z-15,7-B

Inspection Characteristic Standard Acceptance Criteria Test Method Test Frequency

Density ≥ 940 kg/m³ EN ISO 1183

≥ 0.35 and ≤ 1.4 g per 10 minutes
Melt index EN ISO 1133
under 5 kg at 190°C
EN ISO 527-2 3 tests for every 10 tons of sheathing
Test rate 50
Tensile strength at yieled at 23°C ≥ 22 Mpa mm/min +/- 10%.
Test piece shape
HDPE-Sheathing

1BA or 1BB.
Acc. to project
Carbon-black content specifications 2,3 +/- 0,3% by weight ISO 6964
and
Carbon-black dispersion index fib Bulletin 30 table 5.4 < 3
ISO 18553
Carbon-black distribution level < C2

Oxidative induction time (OIT) at 210°C and O2 > 20 minutes ISO/TR 10.837 Guaranteed values by the supplier

EN ISO 527-2
Elongation at fracture at 23°C ≥ 600 % Test rate 50
mm/min +/- 10%.
≥ 150 % Test piece shape
Elongation at fracture at -20°C
1BA or 1BB.

Enclosure 1
Rev.: 0 Date: 06.01.2020 Doc.-No.: 19 12 01 - 302 Page 2 of 4
Inspection and Testing Plan Strand - Ambhora Stay Cable Bridge, India

Product: 7 -wire stay cable strand, hot-dipped galvanized, waxed, PE-sheathed, low-relaxation, weldless

Notation of strand (according to prEN 10337:2003): EN 10337 - Y1860S7+Z-15,7-B

Inspection Characteristic Standard Acceptance Criteria Test Method Test Frequency

Congealing point ≥ 65 °C NFT 60-128

Cone penetration (60 Strokes, 1/10 mm) at 25 °C ≤ 125 1/10 mm NFT 60-119 3 tests for every 10 tons of of filler

Cone Penetration (60 Strokes, 1/10 mm) at -20 °C No cracking NFT 60-119

BS 2000: PT121
Bleeding at 40 °C (Oil separation) ≤ 0.5 % (1982) modified,
duration 168 h
Resistance to oxidation
≤ 0.03 MPa ASTM D942.70
100 hours at 100 °C
Copper-strip corrosion 100 hours at 100 °C Class 1a ISO 2160
Wax

fib Bulletin 30
Corrosion protection (Rust prevention table 5.7
charasteristics)
NFX 41-002 Guaranteed values by the supplier
168 hours at 35 °C Pass
(salt spray)
NFX 41-002
168 hours at 35 °C No corrosion (distilled water
spray)

Content of aggressive elements:

Cl- , S2- , NO3- : ≤ 50 ppm (0.005%) NFM 07-023

SO42- : ≤ 100 ppm (0.010%) NFM 07-023

Enclosure 1
Rev.: 0 Date: 06.01.2020 Doc.-No.: 19 12 01 - 302 Page 3 of 4
Inspection and Testing Plan Strand - Ambhora Stay Cable Bridge, India

Product: 7 -wire stay cable strand, hot-dipped galvanized, waxed, PE-sheathed, low-relaxation, weldless

Notation of strand (according to prEN 10337:2003): EN 10337 - Y1860S7+Z-15,7-B

Inspection Characteristic Standard Acceptance Criteria Test Method Test Frequency

-0 caliper or
Sheathing thickness 1,5 mm
+0,5 mm equivalent
micrometer or 1 test per coil
Outer diameter of strand with PE coating ≤ 19,5 mm
Completed Strand

equivalent
Acc. to DSI strand
Wax weigth specification > 5 g/m and < 16 g/m scale

≤ 20 mm/m 1 test per coil

Straightness of completed strand at delivery ruler
(If the first specimen fails the test, two additional
Nominal mass ~ 1,3 kg/m scale samples shall be tested. If both samples pass, the
material is acceptable. If either sample fails, the
fib Bulletin 30 manufactured length represented by that sample shall
Friction resistance ≥ 1000 N XP A 35-037-1
Table 5.5 be rejected.)
Mass variation = nil
Static Waterthightness test PTI DC45.1-18,3.3.9 XP A 35-037-1 1 test per coil
no water in the beaker
Special Note:
Three (3) retain samplesof every single sheathed strand coil have to be forwarded to DSI Königsbrunn within one (1) week after coiling of sheathed strand. Samples have to have length of at least
1m and shall be taken from beginning and end of a coil

Enclosure 1
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