Directorate General of Regional Infrastructure Consortium of Chinese Contractors Ministry of Settlement and Regional infrastructure Republle of Indonesia SURAMADU BRIDGE CONTRACT DOCUMENT _———— SS. 02 - CABLE STAYED SS. 02.1 GENERAL (1) Description This Section specifies the design, fabrication, testing, transportation, installation and anti-corrosive protection for the cables that will be used for the Cable-stayed Bridge of Suramadu Bridge in Indonesia. (2) Types of Cables ‘The main tension elements or cables is : parallel wire cables. (3) Parallel Wire Cables (@) Scope This standard specifies the production methods, specifications, requirements, test methods, inspection methods, packing, storage and transportation for PE shelled large pitch twisted stay cables (PESC), (b) Technology () Cable Body : high strength steel wires, which are twisted in a large pitch, wrapped with filament tape, and extruded with single or multiple sheath. (i) Anchor Set: Itis the parts connected stay cable firmly, made by chill-casting and forging techniques, and can deliver load. (iii) Stay Cable: It is a cable connected with anchor set on both ends of the cable body firmly. SK, 02.2 MATERIALS ‘The diameters of the steel wires that make up the cables is b7.00mm. The sheath consists of black PE inside and Color PE outside. For the double sheath, different color options are available. (1) Technical Requirements {a) The high strength galvanized steel wire in the diameter of 7.00mm shall be in accordance with the specifications of ‘Table 1 (Specification Data) of Chinese GB5223-85 Standard. Volume 1 Specifications Page 258 of 319Directorate General of Regional infrastructure erasure Consortium of Chinese Contractors i rastructure SURAMADU BRIDGE CONTRACT DOCUMENT Volume I (b) The high-density polyethylene in black color shall be in accordance with the specifications of Table 2 (Specification Data) (c) The color high-density polyethylene shall be in accordance with the specifications of Table 3 (Specification Data). (2) Twisting of steel Wires (a) The bundle of internal steel wires shall be twisted in the clockwise direction to form a core whose angle of the outer layer of the steel wires is about 3°+ 5°. (3) Wrapping filament (a) The bundle of steel wires shall be wrapped by filament tape after being twisted in certain angle. The overlapping width of the single tape must not be less than one third of the width of the tape. The wrapping layer shall be uniform and compact without any damage, such as tears or scratches, on the surface of the tape. (b) The number of wrapping layers be defined by the product specification, but must not be more than 4. (4) Sheath extrusion (a) The steel bundle shall be extruded with black PE sheath or PE + Color PE double sheaths after wrapping. The manufacturer and Glient can negotiate the color of the sheath. The extruded sheath shall tidily cover the bundle of stee! wire, and shall not lose shape during production, transportation and hoisting. The appearance of the sheath shall be smooth. The tolerance of thickness of PE sheath shall be less than # 1.00mm. (5) Connection between anchorage and cable {a) The anchorage shall be connected to the cable body firmly. After assembling the cable and anchorage, the assembly shall withstand at least 95% of normal rupture load. (6) Pretension process (a) Each stay cable shall be pretenioned and the pretension load ( Tp ) shall be about 45% to 65% times of the normal rupture load ( P,*).P (b) Parties involved, the manufacturer and the clients, can negotiate a specific value of the Pretension Load. ‘Specifications Page 267 of 19Directorate Genera! of Regional infrastructure Consortium of Chinese Contractors Ministry of Settlement ang Regional Infrastructure Republic of Indonesia SURAMADU BRIDGE CONTRACT DOCUMENT Volume tt ————— Note : * The value Pb is calculated by multiplying the steel wire yielding strength (O,) with the total transverse section area of the steel wires. () After pretension, the shrinkage of the distance between anchor plate and bottom of the anchor set shall be less than 6mm. (7) Tolerance of the cable length (a) The final length of Stay Cable if the designing length. The Tolerance (AL) shall be in accordance with the following definition = (i) If the length of the stay cable is less than 100m, the tolerance of the length shall be less than 20mm. (ii) If the length of the stay cable is tonger than 100m, the tolerance of the length shall be less than 2% of the length. (8) Rupture Load (a) The rupture load (P) of the Stay Cable in static condition shall be more than 95% of design specification (P,). (9) Elongation (2) The elongation (6) of the Stay Cable during the tension test shall not be less than 2%. (10) Modulus of Elasticity The modulus of elasticity (E) of the Stay Cable shall not be than 4.9 x 105 MPa, (11) Mechanical Property-Fatigue (a) The number of broken steel wires shall not be more than 5% of total stee! wires in the stay cable after 2.0 x 10° cycles of dynamic load. (b) The sheath and the anchorage must not suffer any visual damage after 2.0 x 10° cycles of dynamic load. The nut used for the anchorage shall be screwed to the anchor cups under normal conditions. (12) Mechanical property Winding ‘Specifications Page 268 of 319Directorate General of Regional infrastructure cenaeeeiivcd biiniin aneeeaiss? Ministry of Setlement and Regional infrastructure Republic of Indonesia. ‘SURAMADU BRIDGE CONTRACT DOCUMENT (a) The stay cable shall be twistable, and shall not deform after winding on the minimum diameter 17 times the cable diameter. (13) Marking, Packing, Transportation and Storage (a) Marking = () The product number and specification shall be marked in red paint at the connecting pot of the anchor set on each cable. (ii) A certificate of compliance with the name of producer, the name of project, the data of production, the product number, the specification, length and weight of the finished stay cable shall be submitted, The certificate of compliance shall be fastened outside the packing at both ends of the anchor sets. (b) Packing (i) Packing on drums ‘The stay cable with long length and heavy weight shall be packed on drums. The diameter of the barrel shall be larger that 18 x D. The stay cable shall be wound on the drum evenly, and both ends of the anchor sets shall be fixed on the drum, but, it must be ensured that the unloading process be easy. The dimension of the drums shall meet the requirement of transportation. (i) Packing in coilers The stay cable with short length and lightweight shall be packed in coilers. The coilers shall meet the requirement of hoisting. The intemal diameter of the coiler must be larger than 17 x D, and external diameter shall meet the requirements of the transportation. (ii) The anchor sets on both ends shall be coated with grease and packed by two layers of plastic bags, and then, with sackcloth in order to prevent moisture and water from entering. (iv) Both parties, manufacturer and client, can better any specific packing requirements in order to achieve the best protection for the stay cable. ()_ Transportation ‘Speeifications Page 269 of 319Directorate General of Regional Infrastructure Consortium of Chinese Contractors Minsctry of Settiement and Regional Infrastructure Republic of indonesia SURAMADU BRIDGE CONTRACT DOCUMENT eee reece eee eee eee eee (i) The stay cable can be transported by road, railway, and shipping. (i) Loading and unloading processes must satisfy the requirement for specific conditions in order to keep the sheaths and anchor sets from damaging. (d) Storage ()) The stay cable shall be stored inside a warehouse in normal dry conditions. If the stay cable are stored outdoors, a shelter should be used. (ii) the products packed in coilers can be stacked together, but, any damage of sheath and anchor sets shall be avoided. (14) Structure, type and sizes of anchor set Each anchor set consists of six main parts : an anchor cup which has two types of modules ( tensile end and fixed end ), back cover, anchor plate, nut, connecting pot, and sealing cover. The layout of the anchor set is shown on the Anchor Layout Figure. (15) Technical Requirements (a) Materials In general, the materials used to make the anchor cups and nuts shall be of high quality carbon steel. “The materials used for other parts may be selected according to the design and shall conform to the corresponding specifications. (b) Processing The surface of each part of the anchor set shall undergo corrosion protection treatment. The method of corrosion protection can be denied by both parties, such as galvanizing or blackening. When the surface is galvanized , the thickness of zinc layer is ‘about 10 — 30 um. The anchor cups and nuts shall undergo dehydrogenation treatment. When the surface is blackened, the process shall be in accordance with the corresponding specifications. Volume ‘Specifications Page 270 of 319Directorate General of Regional Infrastructure Consortium of Chinese Contractors Ministry of Settlement and Regional Infrastructure Republic of indonesia ‘SURAMADU BRIDGE detecting. CONTRACT DOCUMENT Each anchor cup and nut shall undergo to the ultrasonic Each part of anchor set shall be inspected after the stay cable has been assembled. Table 4: Specifications for High Tensile-strength Wires [Sera items Specifications “| 7 | Nominal Diameter 67.0 (40.08, -0.02) mm 2__ | Roundness << 0.04mm 3__ | Sectional Area 38.48mm* r 4 | Tensile Strength 2 1670MPa 5 _ | Yield Strength 2 1410MPa 6 _| Elongation 2 4.0% (L = 250mm) 7 | Elastic Modulus (1.95012.15) » 10°MPa 8 | Bending in Repetitions _| > 4 repetitions (R= 20mm) 9 | Wrapping 3d * 8 circles 40 _ | Relaxing Ratio 5 2.5% (0.7 G.U.TS, 1000h, 20°C ) 11 _ | Fatigue Stress 360MPa (Upper Stress 0.4505, N= 2 x 10°times) 42 | Amountof Zinc Coating | = 300g/m* 43 _| Adhesive Capacity ‘Sdx2 circles, without exfoliation/stripping 14 _ | Copper Sulphate Dip > Sdips, each lasting for 1 minute 4g _| Linear Feature (Max < 15mm (Chord Length: 1000mm) Natural Chord Bilge ) 46 Rise Difference at the Ee <0.15m Ends of a Free Wire Ring ‘Specifications Page 271 of 319Diroctorate General of Regional Infrastructure Cedthucr cheaae Conmacicrs Ministry of Settlement anc Regional infrastructure Republic of indonesia ‘SURAMADU BRIDGE CONTRACT DOCUMENT Table 2 Specification of black high density polyethylene cer Items Specifications 4 Density 0.942~0.978 g/cm* 2__| Index Number of Melting <0.2 g/min 3 _| Tensile Strength > 20 MPa 4 __| Rupture Elongation > 600% 5 | Hardness, Shore D > 60 6 Vicker Softening > 115°C 7 Brittleness Temperature <-70°C 8 Impact Strength > 25KJ/ m? 9 | Thermal Stress ~Crack > 96h Resistance 70 | Environment Stress —Crack | > 1500h Resistance UV % Exploration 11__| Carbon Content 2.3:40.3% 12 _ | Particle Size of Carbon <20 um 13 | Carbon Dispersion Character Chromatogram Method > 4000 Microscope Method Eligible 14 | Oven Ageing 100 °C, 168 h Environment Remained Tensile Strength | > 85% Remained Elongation at Break >85% uu _ Volume i Specifications, Page 272 0f319Directorate Ge Ministry of Settlament and Regional infrastructure Republic of indonesia Consortium of Chinese Contractors ‘SURAMADU BRIDGE CONTRACT DOCUMENT Table 3 Specification of color high density polyethylene Serial Noe | Items 1 Density 2 | Index Number of Melting < 0.45 g/10min 3 _| Tensile Strength > 20 MPa L 4 Rupture Elongation > 600% 5 | Hardness, Shore D > 60 6 _| Vicker Softening > 110°C 7 | Brittieness Temperature <-70°C 8 _| Impact Strength > 25KJ/ m? g _ | Thermal Stress —Crack >96h | Resistance Environment Stress Crack > 1500h 10 | Resistance UV % Exploration ‘Oven Ageing 100 °C, 168 h Environment 14 | Remained Tensile Strength > 85% Remained Elongation at Break > 85% 12 | Color Stability >7 Degree Testing The Contractor shall do the necessary tests of all elements of the cable stayed and submit the original test result to the Engineer as ‘soon as possible. Volume Specifications Page 273 0f 318Directorate General of Regional Infrastructure Consortium of Chinese Contractors Ministry of Settlement and Regional Infrastructure Republic of indonesia SURAMADU BRIDGE SS 02.3 CONTRACT DOCUMENT ne INSTALLATION The Cable stay system Supplier shall assist the installation of cable stay. 34 32 Production a. Cable stay is produced at the Workshop with accurate length or produced in-situ. b. Cable stay shall be installed pertaining to the procedure described by the cable stay system expert. The expert's cable stay shall be submitted to the Engineer for review and approval. ‘The statement of any method describes the installation activities, including description of major items from any kind of required equipment, such as cable stay installation program owned by engineer that might describe the cable stay energy and elongation values from each cable stay (values given by the contractor), c. Where the production location of cable stay were installed, the correct dimensions shall be done to ensure the entire element of cable stay were installed parallel to one another. Handling ‘a. The expert engineer of cable stay shall use procedures to ensure that the components of it will not damage during handling. b. Cable stay shall be protected from corrosion, hot weather, abrasion, and any kind effect that might dangerous during installation. c. Ina manner of in-situ production of cable stay, the minimum roll diameter for HDPE cable stay pipe shall be made during fabrication, transportation, lodging, and production of cable stay of 25 times outside its diameter, unless otherwise had approved by the Engineer. d. Ata cold weather, the HDPE pipes shall be warmed with the 24°C minimum temperature especially for with or without wiring. At a lower temperature, the above ratios shall be modified accordingly. e. The damage cable strand or carried out components of load shall be disposed. The damages, which are not carried out by the load, with direction by the Engineer, shall be rectified ‘Specifications Page 274 of 31933 34 ‘of Regional infrastructure. Consortium of Chinese Contractors, CONTRACT DOCUMENT ‘especially to install the cable stay. In order to the Engineer instruction, the related components shall be changed. Installation a. The installation procedure of cable stay shall match with the bridge construction stage. b. In regards to the cable stay expert and the arches on the permanent structure on every vertical frame explanations, shall be completed by contractor. . Jacks and dimensions for cable stay installation shall be calibrated by using load cell or Static Load Calibration machine. Calibration shall not exceed from six (6) months. Re-calibration on the next six (6) months could be done by using master gauge, if the master gauge is calibrated with in- situ gauges at the time of first Jack calibration. d. Cable stay produced in-situ could be strengthened wire by wire if it could be demonstrated to ensure the Engineer, so that the final stress and elongation from each wires is established in the range of 21/2%. fe. The cable stay shall capable to be strengthening, de- tensioning or re-tensioning more that once during the structure construction. These activities could be done even with full jacking from anchor mass and the proper ring setting or wire- by-wire. Stress reducing from wire with wedges tied in the strengthened cable is permitted even if it limited to the construction period. ‘Maximum strength of cable during construction shall not more than 56% from its minimum cable strength load. f. Cable stay shall be designed and installed with adequate vibrations or proper tools to allow de-tensioning without stretching of tools of anchor components of cable stay. At the final stage, there is no de-tensioning cable or re-tensioning in the way of that some of wire part that tied in before by anchor wedges, combined into a stressed portion from those wires. g. All permanent protections to corrosion inside the anchor could be made by grease type VISCONORUST 2889 or equal, which had approved in term of facilitating fast checking and monitoring during maintenance period. Cable Vibration Volume i ‘Specifications Page 275 0f 319Consortium of Chinese Contractors ‘SURAMADU BRIDGE CONTRACT DOCUMENT ‘a. During the all construction level, controlling such secondary fies tied in around cable and anchored on the deck could be used in the purpose of controlling the cable stay vibration. In the act of cable stay shaking after the bridge had built, the permanent damping devices in between main cable stay and deck shall be installed. Estimation on risk of vibration of cable stay and decision to use or not the damping system on cable stay is under designer responsibility. Designer determines the important damping characteristic, Damping tools shall be designed and installed by cable stay expert. b. System of cable stay shall have possibility to enclose permanent damping tools on cable stay in the way of clamping ‘or other method without any important modification for the installed cable stay system. The propose solution will be demonstrated to the Engineer before construction. ¢. Damping permanent tool shall meet the criteria as follow: 4, Damping characteristic shall not be influenced by the longitudinal movement results by load variations. 2. Damping characteristic shall not depend on the temperature or sensitive to vibration frequency. 3. Damping characteristic could be adapted during maintenance activities. All components of damper could be obtained and checked, if necessary, during maintenance period. ‘SS 02.4 MEASUREMENT METHOD AND PAYMENT Cable stay steel will be measured in kilogram, in regards to theoretical kilogram number complete with tools (HDPE, cement grout, anchor, etc) at its location and installed as per shown on drawing or placed in proper order. The material quantity that had completed and installed will refer to the calculation result of weights from cable stay location in accordance with these specifications, ‘The used lengths for calculating the weight for payment shall be shown on the drawing or ordered in written by the Engineer. No measurement or payment made for additional splices by the contractor for his own satisfaction or for anything that is not shown on the drawing and waived by the Engineer. Volume Specifications Page 276 of 319Directorate General of Regional Infrastructure ‘Garena Chinuse Coseautors! Ministry of Settlement and Regional Infrastructure Republic of indonesia SURAMADU BRIDGE CONTRACT DOCUMENT {In term of there is no item of bill of quantity completing the cable stay, the cost will be considered referred to the other item of bill of quantity. PAYMENT BASIS ‘The accepted quantity of cable stay, which had determined and completed above mentioned, will be paid refers to the contract amount for pay items list below mentioned and indicated in bill of quantities, completely on its location. Clips, wire, or other material that is used to enforce the cable stay will be considered to be included in the cost/price of steel. Payment will be made as follow: Pay Item No. Description Measurement unit 7.4(4)s | Procurement and Installation of Ton complete cable stayed ‘Volume i Specifications Page 277 of 19