THE FREYSSINET STAY-CABLE

EUGNE FREYSSINET

1879 - 1962

GROUP ORGANIZATION
34 Billion euros or INR 210,000 crores and 164,500 people

1. Recent history of stay-cables Spiral strand or locked coil cables (1950 - 1970)
Prefabricated cables Installation drawbacks
heavy cable large anchorage big jacks

Poor durability
rust in the cable high maintenance cost (paint) flexion at the anchorage low fatigue resistance (100 MPa)

1. Recent history of stay-cables HiAm parallel wire cables (1970 - 1985)

Good fatigue resistance (High Amplitude) Prefabricated cables Installation drawbacks
heavy cable big jacks

Poor replaceability
cement grout / epoxy resin

1. Recent history of stay-cables First parallel strand cables (mid 1970's)

Derived from post-tensioning technology
cement grout / epoxy resin filter zone against bending

Strand by strand installation PT technology limitations

low fatigue limit : 100 MPa unreversible anchorage impossible to remove strands cracks in the grout all strands subject to corrosion

1. Recent history of stay-cables Grouted cables

Cement grout is not a corrosion protection Cement grout is detrimental to fatigue resistance

1. Recent history of stay-cables Grouted cables

Risk of gangrene for cables with general outer barrier
E.g. PWS cables in Zarate bridge (1981, Argentina) or Lanaye brige (1978, Belgium)

1. Recent history of stay-cables Evolution parallel strand cables (1984 - 1988)

Cement grout replaced by wax injection High fatigue resistance anchorage
fatigue jaws developed against fretting corrosion bending stress filters (deviator)

Reversible anchorage
Strands replaceable one by one

Limitations of collective protection

dangerous operations : hot wax injection gangrene : corrosion can spread throughout strands

1. Recent history of stay-cables Evolution parallel strand cables (1984 - 1988)

1. Recent history of stay-cables Freyssinet introduces the Mono-strand (1988 - 1994)

Individual corrosion protection
galvanization wax HDPE sheath

Factory made corrosion protection

industrial process

Eliminates risk of gangrene Strand by strand replacement

1. Recent history of stay-cables Standardization and improvement (1994-2001)

Standardization of stay
erection equipment (winches, Isotension) high level of trained human resources

New developments
internal dampers UV resistant and coloured HDPE stay pipe bending filtration in the anchorage compact stay cable

2. The Freyssinet Monostrand Corrosion protection

Hot dip galvanisation
190 to 350 g/m of zinc applied before final drawing of wires Wax filling around and within strand adhesion properties anti-corrosion layer lubrication against fretting fatigue prevents expense of zinc (redundancy)

Semi-bonded HDPE coating

shape designed for semi-bond (only 12 g/m wax) UV stabilized, shock resistant

2. The Freyssinet Monostrand Why choosing HDPE vs EPOXY ?

Epoxy coated strands do not resist to rotative bending
epoxy cracks after only 190 000 cycles red colour characteristic of fretting corrosion

2. The Freyssinet Monostrand Quality control

Provided only by approved suppliers working under strict partnership agreements Freyssinet has developed a series of tests and equipment
more than 10 production tests HDPE thickness and centering coating continuity impact resistance bond and water-tightness qualification tests before each job fatigue resistance UV resistance

3. The Freyssinet stay cable anchorage

individual wedge only anchorage active stuffing box

12

nds stra 300 to

ess str ing n end atio b tr fil

adjustment nut

Multi-function compact anchorage

3. The Freyssinet stay cable anchorage Bending-stress filtration (patented)

Each strand is guided individually by a trumpet with controlled curvature

3. The Freyssinet stay cable anchorage Bending-stress filtration (patented)

Usually, design of stay cable under SLS load case: fSLS < 0.45 fGUTS CIP recommendations and prEN 1993-1-11: fSLS < 0.50 fGUTS if
Provisions to reduce bending below 50 MPa in anchorage) Mitigation measures against vibrations

3. The Freyssinet stay cable anchorage CIP waterproofing test (2002)

Total test duration = 6 weeks
1. Jack for axial loading [0.20 - 0.50 GUTS ]
dyed water
steel tube

3. Transversal jack for bending [+/- 25 mrad]

Stay anchorage

h 3m

anchor block on sliding plate

2. Heater [20 - 70C]

3. The Freyssinet stay cable anchorage CIP waterproofing test (2002)

3. The Freyssinet stay cable anchorage Corrosion protection

Corrosion protection
patented active stuffing box local wax injection fully reversible

Anchorage parts fully treated against corrosion Passed successfully the CIP waterproofing test

3. The Freyssinet stay cable anchorage Fatigue wedge

Permanent grip on strand
no fretting

Prestressing wedge

Fatigue performance :

Fatigue wedge

3. The Freyssinet stay cable anchorage Mechanical performance of full cable

More than 100 multistrand fatigue and ultimate tests according to PTI and CIP recommendations
8 6 4 2 0
12 31 55 75 9 10

Force

PTI test

0.95 GUTS 0.45 GUTS 200 MPa

2 millions cycles

Time

Anchorage zone lay-out

Pylon

Deck

4. Freyssinet coextruded stay pipe

External layer
colour and UV protection

Internal layer
mechanical resistance

Two helical fillets

rain & wind induced instability

Thickness / diameter ratio (SDR)

adjusted for ungrouted solutions : ex 200mm x 6.2mm

4. Freyssinet coextruded stay pipe

Thermal effects plastic thermal expansion = 20 times steel or concrete
Sheath expansion Anchorage seals

Durability of HDPE
Photo-oxidation (UV) Stress cracking (strains)

4. Freyssinet coextruded stay pipe UV durability

Four years of R&D with exclusive supplier HDPE formulation stabilized against photooxidation Accelerated ageing test
3 to 5 times more durable than black or other colored pipe

Durability calculation based on local UV radiation

4. Freyssinet coextruded stay pipe Colours

Accelerated ageing tests with various colours
UV resistance colour stability

Durability up to 90 years in some climates (for certain colours) :

white, light grey or light green

Shining HDPE duct

brushed stainless steel look

4. Stay-cable vibrations Vibration sources

Aerodynamic phenomena on stay cables are complex Among numerous sources of vibrations, the most frequent are 1. Rain & wind induced instability 2. Parametric excitation 3. Ice galloping 4. Wake galloping 5. Buffeting 6. Vortex shedding

4. Stay-cable vibrations Preventive actions

Profiled stay pipe Additional dampers
Internal dampers External dampers Cable tuned mass dampers

Cross ties (aiguilles) Reduce deck / Pylon vibration

spoilers, bridge tuned mass dampers

4. Stay vibration mitigation Profiled stay pipe

Freyssinet double helical rib
extruded during duct fabrication disorganize water rivulets prevents efficiently rain & wind vibration

Tested in CSTB and DMI laboratories

Amplitude

No fillet Fillet 7m/s 15m/s

Wind velocity

4. Stay vibration mitigation Internal dampers

Freyssinet has developed since 1994 a range of internal dampers

Each system is replaceable and easy to maintain All systems have been fatigue tested

4. Stay vibration mitigation Internal Elastomeric Damper (IED)

Elastomeric diabolo made of high damping rubber

4. Stay vibration mitigation Internal Hydraulic Damper (IHD)

Two-part collar on strand bundle Viscous oil

Fixed HDPE piston Moving steel chamber

4. Stay vibration mitigation Internal Radial Damper (IRD)

Three radial piston dampers Articulated on cable and tube

4. Stay vibration mitigation Friction damper vs. viscous damper

Log. decrement

Viscous damper

Friction damper
Threshold (dry friction)

Vibration amplitude

4. Stay vibration mitigation External hydraulic dampers

When imposed by geometry :
distance d is too small cable length L > 300 m

Fixed external damper (FED): two pistons on fixed frame

Brotonne Elorn Cooper River

4. Stay vibration mitigation Pendular External dampers (PED)

Two piston dampers on articulated lever
Normandy Ting Kau Rion-Antirion
5 k ci ht 9 1 2 ai D e b u T ro 0 1 k ci ht 9 1 2 ai D e b u T

a h pl A E L G N A 37 .730

at T

a t t e l g n A

t a er a u q s s i n o i t c e s s i h T n o ly p d i ov a o t t n i o p s i h t n o it a t o r

1 3 2. 8 9 0 4 m m

5. Erection: duct lifting

With winch or crane

5. Erection: strand by strand threading

The strands are placed one by one, with the following cycle:
connection to the shuttle hauling introduction in the top anchorage bottom of the strand is cut introduction in the bottom anchorage stressing by Isotension
Winch

cutting bench

5. Erection: strand by strand threading

Strands are delivered on special coil dispensers

5. Erection: strand by strand threading

1 or 2 strands are connected to winch line by a shuttle

5. Erection: strand by strand threading

The shuttle inserted in the stay pipe

5. Erection: strand by strand threading

The strands are deviated by a deviation wheel and hauled in the stay pipe

5. Erection: strand by strand threading

Automatic hydraulic winch

5. Erection: external access to pylon

Use of mobile working platform or full scaffolding

5. Erection: strand by strand threading

The strands are secured in the top anchorage

5. Erection: strand by strand threading

The strand bottom end is cut on a cutting bench

5. Erection: strand by strand threading

The strand bottom end is inserted in the formwork tube

5. Erection: strand by strand threading

The strand is secured in the bottom anchorage, ready for stressing

5. Erection: strand tensioning

Isotension chair and monostrand jack for stressing

5. Erection: strand tensioning

During the stressing of a new strand
Structure deflection Stay anchorages get closer Reduction of force in strands already placed, similar for all the strands

5. Erection: the Isotension System

The only monostrand stressing system which automatically equalizes the stress among the strands The main contractor can act freely :
stressing sequence is independent on bridge loading

5. Erection: the Isotension System

5. Erection: finishing
Corrosion protection of the anchorage:
steel cap wax injection

5. Erection methods Load Cells

Stay forces can be monitored easily and continuously with the Freyssinet system
monostrand load cell used for Isotension series of monostrand load cells left on previous stay anchorages for geometry control

Long term load cells have been developed

permanent monitoring required type of output: digital / analogic / electrical / optical

8. Freyssinet stay-cable references

Normandy Bridge (France) Elorn Bridge (France) Second Severn Crossing (U.K.) Glebe Island (Australia) Mescala (Mexico) The Dee Crossing (U.K.) Ting Kau (Hong Kong) Charles River Bridge (USA) Tagus Bridge (Portugal) Oresund (Danemark Sweden) My Thuan Bridge (Vietnam) Seohae Grand Bridge (Korea)

Selected References
Bill Emerson Memorial BridgeUSA Moscou Ice Rink Russia Leonard P. Zakim Bridge USA

Jose Alvalade Stadium - Portugal

Viaduc de Millau France

Bridges : more than 140 bridges in the last 12years 55% of the world market
Rion-Antirion Bridge - Greece

Boyne bridge Ireland

Normandy Bridge (France)

Ting Kau Bridge (Hong Kong)

Vasco da Gama Bridge (Portugal)

Seohae Grand Bridge (Korea)

Rion-Antirion Link (Greece)

Millau Viaduct (France)

Incremental launching with temporary stays Special support devices for stays during launching

Thankyou