Recent Developments in Stay Cable Systems

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1 Recent Developments in Stay Cable Systems PTI Technical Conference, Reno Khaled Shawwaf, Technical Director (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 1 of 45

2 * Cable Stayed Bridges are efficient and attractive * Over 350 have been built in the last 25 years * Spans are getting longer and cables larger * Also used for medium spans and non-highway bridges * Evolution: lock-coil to wires to PT bars and strands * Continuous enhancements and innovations * Recent developments (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 2 of 45

3 Dyna-Grip Wedge-Only Anchorages (Dyna Grip) Standard Cable System: All loads (static and dynamic) are resisted by the wedges No structural socket- All strand types Anchorage cavity is filled with grease/wax compound and sealed with compressed rubber disks Individual strands may be removed for inspection and replaced Special Feature of DSI DYNA-GRIP anchors: Strand sheathing continues to the wedge (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 3 of 45

4 Rosario-Victoria Bridge, Argentina strand DYNA GRIP cable (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 4 of 45

5 Dyna-Bond Bond Socket Anchorages (Dyna Bond) Standard Cable System: Structural grout filler injected into steel socket at the end of construction All loads applied before grouting resisted by the strand wedges Loads applied after grouting transmitted by bond to the socket and directly to the structure Fraction of dynamic loads (live load, vibrations and seismic) reach the wedges Corrosion Protection: All anchorage voids are filled with a solid and robust filler Enhanced fire resistance and protection against vandalism, impact and blast effects All strand types. Greased strands must be cleaned in bond zone (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 5 of 45

6 Alamillo Bridge- Spain strand DYNA-BOND cable (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 6 of 45

7 Provencher Bridge, Canada Dyna Grip and Clevis Anchors (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 7 of 45

8 Clevis Cable Anchorage: Attach to outer surfaces of Tower or Deck Real pin connection- No bending moment High friction damping Hand-hole for inspection & exchange Corrosion Compound (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 8 of 45

9 * The clevis anchorage is fixed to the tower plates with 120 mm pins * Easy to install * Accommodates large sag during installation * Self Aligning * Non-stressing anchorage (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 9 of 45

10 Clevis type cable anchorage: fatigue and static strength test Heavy wall pipe and welded pin plates Wedge plate threaded into clevis pipe 2 million cycles 160 Mpa stress range (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 10 of 45

11 CONTEN- single strand stressing: Cable stayed bridges are getting longer Cable sizes larger: strands is the current world record Stressing equipment- bulky and heavy- need for lightweight equipment! Strand by Strand stressing Reduction of crane & manpower needs Accurate & Reliable TENSA 8600 Multi-Strand Jack Nearly 5 feet long Close to 2 tons (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 11 of 45

12 156 STRAND ANCHOR WEIGHT ABOUT 1.1 METRIC TONS ELECTRO-GALVANIZED FOR TEMPORARY CORROSION PROTECTION ALLOWS UP TO 270 MM THREAD FOR CABLE ADJUSTMENT (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 12 of 45

13 There got to be an easier way to stress! Cables are becoming longer and larger- up to strands Stressing equipment- Kap Shui Mun Bridge, Hong Kong ( strands) (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 13 of 45

14 CONTEN single strand stressing: To obtain the required strand force in the last strand, the force in the first strand has to be stressed higher Using the required cable force and the corresponding end point movements, DSI will compute the forces in the individual strands Strands are installed and stressed one by one. Two interconnected jacks are used: Pilot and Stressing jacks. When Stressing jack reaches same pressure as Pilot jack it will stop. Forces in strands are equal. (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 14 of 45

15 (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 15 of 45

16 Winch Line Glider Strand Standard Cable Strand Installation- I Window at deck and tower not shown. Winch line is inside cable pipe. (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 16 of 45

17 Glider Winch Line Strand Standard Cable Strand Installation- II Glider and strand are inside cable pipe. Pull-through winch at top of tower not shown. (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 17 of 45

18 ConTen Stressing: Two inter-connected jacks- One acts as pilot Initial cable stressing and positive force adjustment New force equal to current force- not sensitive to construction activity (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 18 of 45

19 Provencher Pedestrian Cable Stayed Bridge Cable Designation: CW18 1st stage 2nd stage Stressing Force (kn) Number of Strands (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 19 of 45

20 Cable Adjustment Jacks are required to turn the Ring Nut: small stroke Modular Design: more jacks for larger cables Lightweight Easy assembly Low Profile (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 20 of 45

21 Strand Force Sensors- Dyna-Force system: Uniformity of strand forces within the cable- verification is required Lift-offs during construction stages are routinely performed Cable force verification during service- very important to bridge owners Lift-offs time consuming and impractical during service Load cells bulky and need calibration Dyna-Force is Plug and Read! Dyna-Force: Non-contact compact sensor placed on the strand and measures the stress in the steel by measuring its permeability to electro-magnetic field (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 21 of 45

22 DYNA FORCE Measurement Principles Magnetization forces are introduced into the primary coil by a current, which in turn produces an output voltage across the second coil due to mutual inductance. As the permeability of the core changes, the output voltage changes. The output voltage can then be calibrated to measure the applied stress in the core. (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 22 of 45

23 Test results on EM Sensors made by DSI on 0.6 Bare strand Load (kips) Load Cell EM-M (kips) EM-E (kips) Steps (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 23 of 45

24 Penobscot River- Waldo Bridge, Maine: Both Conten and Dyna-Force systems are used in this bridge (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 24 of 45

25 Con-Ten Stressing System- Individual Strand Stressing Pilot Jack Working Jack Bare, galvanized & epoxy coated strands may be stressed with Conten (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 25 of 45

26 Dyna-Force system Capacitor and data storage unit (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 26 of 45

27 DYWIDAG-SYSTEMS INTERNATIONAL WALDO CABLE STAY BRIDGE-STAY 11B STRAND FORCE (KIPS) STRESSING SEQUENCE NO OF STRANDS =67 LENGTH OF STAY = 373 FT COMPUTED-80% FIELD-80% DYNAFORCE-80% COMPUTED-100% FIELD-100% DYNAFORCE-100% NOTE: 1 ST & 2 ND STRANDS STRESSED TO 2 ND CONTEN FORCE AT 80% OPERATION (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 27 of 45

28 Nitrogen Gas Corrosion Protection System: Waldo bridge: First application of inert gas to cable stays Multi-level corrosion protection & monitoring system Sealed positive pressure gas system- about 2 psi Pressure maintained with special valve system Breach to the seal will be immediately identified- early remediation HDPE cable sheathing system must be leak proof- difficult! PE pipe and joints to withstand thermal stresses No need for grease in the anchor zone or sealing cap See-through sealing cap- clear polycarbonate Tests to validate the gas tight system (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 28 of 45

29 Corrosion Protection Levels: PE external pipe, Epoxy coating & Nitrogen (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 29 of 45

30 (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 30 of 45

31 (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 31 of 45

32 (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 32 of 45

33 Maumee Bridge: Sealing cap: very thin stainless steel shell (0.10 and 0.13 inch) with closely spaced bolts Filled with corrosion preventive grease Anchorage components not readily inspect able Standard solution for current cable systems (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 33 of 45

34 See-through cap surrounds all anchor components, is bolted against the bearing plate to seal against leaks of Nitrogen gas and maintain pressure (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 34 of 45

35 Linear Elastic Behavior: Below the yield stress, metals behave in a linear elastic manner Stress S2 = strain x elastic modulus Visco-Elastic behavior: HDPE behaves in an entirely different way, where relaxation would reduce the resulting stress depending on the strain rate! Stress S3 depends on strain rate and time under load- Boltzmann Equation (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 35 of 45

36 Boltzmann Equation for Constant Strain Rate: s3 := ts 0 η ξη SR du + ξ ts ξ u s3= stress at end of time period ts ts= time period ξ= elastic constant η= viscous constant Material properties obtained from tests u= time integration variable SR= strain rate (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 36 of 45

37 Visco-elastic Behavior of HDPE pipe: 160 mm OD, SDR meters To determine the material properties of the HDPE pipe for use in the Boltzmann equations tests were conducted to determine the force resulting from imposing a deformation at two different strain rates These tests were performed at two different temperatures Results from these tests were used to to solve two independent equations for the required visco-elastic material constants. With these constants the behavior of the PE under any strain rate and temperature may be obtained. (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 37 of 45

38 2.00 Load vs. Time 1.50 Specimen in./hr for 6 hours Temperature = ambient Load, kips Time, hrs PE pipe axial load test- Specimen 1: Strain rate= in/hr for 6 hours (Equivalent to 40F in 6 hrs.) Ambient temperature 68 F Specimen 2 was tested for 3 hours at double the strain rate of specimen 1 (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 38 of 45

39 s1 t1 K1 0 η ξη + t1 ξ ξ u du s2 t2 K2 0 η ξη + t2 ξ ξ u du Solving two simultaneous integral equations to obtain the values of ξ and η for each temperature. K and t are test parameters and s is measured at time t. (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 39 of 45

40 Maximum daily temperature change, deg. F: Time period for temperature change, hours: Material elastic constant: Material viscous constant: Time period in seconds: Strain rate per second: ts := th 60 2 ΔT = 80 th := 8 ξ := 669 η := ts = From tests SR := αδt ts SR = Resulting stress at the end of the time period: s3 := ts 0 η ξη SR du + ξ ts ξ u s3 = MPa fp3 := s3 145 fp3 = psi Ratio of relaxed stress to linear elastic stress: fp3 fp2 = About 36% (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 40 of 45

41 41 strand fatigue and leak test (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 41 of 45

42 * strand full scale fatigue and leak test * After PE pipe system was fixed and connected, Nitrogen was introduced * Specimen subjected to 73,000 load cycles * Nitrogen pressure maintained at 4.33 psi for 96 hours and monitored for leaks * Tests were successful (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 42 of 45

43 Test specimen instrumentation (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 43 of 45

44 Cables are critical structural elements and vulnerable to corrosion, fatigue, vibration and accidental damage Their safety, performance and durability should receive continuing focus and efforts to improve them (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 44 of 45

45 (C) COPYRIGHT POST-TENSIONING INSTITUTE, ALL RIGHT RESERVED Page 45 of 45

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