Stay Cables

S t a y C a b l e s
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 Stay Cables

Contents Page

1. An Introduction to Stahlton AG

1.1 In Short . . . 3

1.2 Stahlton and Quality 4

1.3 Cooperation 4

2. Stahlton Stay Cables

2.1 Introduction 5

2.2 Scope of Services offered by Stahlton AG 5

2.3 Description of Stahlton Stay Cables 6

2.3.1 General 6

2.3.2 Anchorages with High Fatigue Strength 6

2.3.3 Cable Composition 7

2.3.4 Indicative Cable and Anchorage Dimensions 10

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2.4 Sta y Cable Works 12

2.4.1 Fabrication and Delivery 12

2.4.2 Site Works 13

2.5 Technical Information 16

2.5.1 Material Specifications 16

2.5.2 Dimensioning Principles 17

2.5.3 Full-Scale Testing 18

Stahlton AG markets the products “HiAm“ and “DINA“ under licence from BBR Holding Ltd,
Zug, Switzerland.

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 Stay Cables

Stahlton Construction Stahlton Building

Technology Products
Post-Tensioning Building Products for externally
Wire and strand cables for longitudinal and insulated masonry, cavity masonry
transverse pre-stressing of bridges, foun- and solid masonry
dation slabs and floors of industrial and
commercial buildings, schools, sports and High quality cavity lintels for buildings, to
recreational centres. accomodate built-in shutters and sunshades.

Prestressed solid lintels, in clay or concrete,

with brick facings to match the external wall
Stay Cables finish, if required.
Parallel-wire stay cables, featuring anchor-
ages with high fatigue strength, for bridges, Thermally insulating, load-bearing masonry
masts, stadia and buildings. starter elements, which solve the problem
of thermal bridging at the foot of external
walls.
Geotechnology
Decorative or accentuated window-sills, made
Pre-stressed, temporary and permanent with GRC, either with or without integrated
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ground and rock anchors for the securing thermal insulation.

of excavation walls and slopes and the
anchoring of foundations etc.
Architectural Elements
Removable MSP bar anchor system for
pre-stressed, temporary anchoring of Window cases, made from GRC, with contin-
excavation walls. uous, integrated thermal insulation.

MSS500 threaded reinforcement system for Plinth elements for the transition zone
non-stressed, temporary and permanent between ground and externally insulated
rock nails and micropiles. facades, made from a combination of GRC
and polystyrene.

Strengthening and Rehabilation

Hollow-core slabs
An extensive range of services for the
strengthening and rehabilitation of struc- Composite ceiling and floor slabs, composed
tures: glued reinforcement (utilizing steel of prestressed lintels, baked cla y hollow-core
and CFRP strips) and post-tensioning transverse bricks, and a top layer of concrete
cables; expansion joints; crack injection. with distribution reinforcement.

Custom Products
Stahlton regularly cooperates with customers
to capitalize on synergies in the development
of efficient and innovative solutions in the
field of GRC.

Stahlton stay cables and associated services are presented in this documentation.

Information on other Stahlton products and services is available upon request.

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 Stay Cables

1. An Introduction to Stahlton AG
1.1 In Short . . .
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S t a h l t o n A G i s a s p e c i a l i s t c o n t ra c t o r w h i c h s u p p l i e s i n n o v a t i ve , e f f i c i e n t p r o d u c t s f o r a l l b ra n c h e s
of construction. In addition to the manufacture, supply and installation of these products,
Stahlton AG provides a comprehensive support service for engineers, architects, contractors
and material traders.

S t a h l t o n w a s f o u n d e d i n 1 9 4 5 b y t h e t h r e e e n g i n e e r s M a x B i r k e n m e i e r, A n t o n i o B ra n d e s t i n i a n d
Mirko Robin Ros. The development of the Stahlton pre-stressed lintel and the BBRV post-tension-
ing system paved the way for a series of subsequent products and systems, which contribute to
t h e s t re n g t h o f t h e c o m p a n y :

· A w i d e r a n g e o f m a s o n r y e l e m e n t s o f f e r s h i g h q u a l i t y, e c o n o m i c a l a n d v i s u a l l y a t t r a c t i v e s o l u -
tions for buildings. The use of GRC, highly-insulating material and newly-developed production
processes helps Stahlton to maintain its leading position in this field.

The post-tensioning systems BBRV and CONA offer a range of options, to satisfy the demands
o f s p e c i f i c s i t u a t i o n s , s u c h a s e x t e r n a l t e n d o n s a n d e l e c t r i c a l l y i s o l a t e d t e n d o n s . Th e C O N A
system is also the basis for CONA-Sol ground anchors, which can be electrically isolated for
permanent applications.

· Stahlton is a leader in the strengthening of existing structures: glued reinforcement, utilising

either steel or CFRP laminates, combined with external post-tensioning, can in many cases be
a technically and economically attractive option.

· HiAm and DINA stay cables have been tried and tested all over the world. The durability and
fatigue strength of these systems continue to set the standard, against which other systems
are measured.

Stahlton AG is a privately-owned, independent company, with the majority of the shares in the
possession of two of the founder families.

The head office is situated in Zurich, with branch offices in Mezzovico, Chavannes-près-Renens and
St. Gallen. Manufacturing and fabrication facilities are located in Frick.

The activities of Stahlton AG are handled by two operating divisions – Building Products and
Construction Technology.

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1.2 Stahlton and Quality

Stahlton has been renowned for many years for innovative, trend-setting products in civil engineering
and building. In striving to continue this tradition, we have set ourselv es the following goals:
– modern, economical products and services
– durable, low-maintenance solutions
– safety and flexibility on site
– emphasis on customer satisfaction

In order to achieve these goals, we concentrate on:

– ongoing development of our products and manufacturing processes
– stringent checking of all the important raw materials, upon arrival at our works
– systematic Quality Control at key manufacturing stages
– constant monitoring of the quality of site works

All aspects of the activities of the Construction Technologies division of Stahlton are governed by a
Quality Management system, which has been certified to ISO 9001, and which is regularly independently
verified. In the case of delivery of fully fabricated Stahlton stay cables, this gives owners, engineers
and contractors the reassurance that the critical cable fabrication work has been performed by expe-
rienced personnel under strictly controlled, weather-proof factory conditions – before the cables arriv e
on site. Bottlenecks on the critical construction path can thereby be minimized, and the threat to pro-
duction due to adverse weather conditions is reduced.
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1.3 Cooperation
Stahlton constantly strives to improve the quality of the service offered to its customers. One of the
means by which this can be achieved is by cooperating with other companies whose expertise, expe-
rience and geographical location complement our own strengths. Two examples of this are worthy of
particular mention:
– BBR Holding Ltd, Zug, Switzerland
BBR is the licensor of the HiAm and DINA anchorage systems, which have been successfully
employed on major cable-stayed structures worldwide
– depending on the location of a project, Stahlton may form a joint v enture with a local company,
often a BBR licensee, whose resources and knowledge of the market increase the efficiency and
competitiveness of the services offered

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2. Stahlton Stay Cables

2.1 Introduction
The ever-increasing use of stay cables to
support bridge decks and other structures
has greatly increased the range of possibi-
lities for innovative engineers and archi-
tects. Exciting and demanding structures,
which some years ago would never have
made it past the drawing board, are now
made possible.

The tried and tested BBRV post-tensioning

system was the basis of and inspiration
for the Stahlton HiAm and DINA stay cable
systems, first employed in 1972 to support
the roof of the impressive Olympic Stadium
in Munich.

Years of experience and a constant striving

towards further improvement, combined
with factory fabrication strictly governed
by a certified Quality Management system,
result in quality which meets and exceeds
the rigourous standards demanded of
modern sta y cables with regard to fatigue
resistance, durability and corrosion pro-
tection.

Stahlton’s input does not end, however,

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with the delivery of the cables to site.

Motivated Stahlton engineers and special-
ists have planned and executed the instal-
lation and stressing of HiAm and DINA stay
cables on bridge sites deep inside the Arc-
tic, in South America, and in many places
between.

Sunniberg Bridge, Klosters, Switzerland

2.2 Scope of Services offered by Stahlton

Stahlton can provide the following stay cable services:

– Technical support during the planning and detailing of a project.

After so many years in the sta y cable business, we at Stahlton have a wealth of experience and
ideas, which we are glad to share with engineers and architects planning and detailing new
projects.

– Delivery of factory fabricated stay cables.

Stahlton sta y cables are manufactured by experienced personnel, under weather-proof conditions,
in our factory in Frick, Switzerland. Each step of the manufacturing process is closely monitored
and documented. The cables are delivered to our customers on steel reels, ready for installation.

– Preparation of method statements.

Drawing on the impressive experienced gained from many projects of various sizes, employing
a range of construction methods, Stahlton has the know-how to optimally integrate the cable
installation method into the ove rall construction method chosen.

– Cable Installation and Stressing

Depending on the complexity of the project, the resources and experience of the main contractor,
and the stipulations of the project specifications, Stahlton can either install and stress its sta y
cables on a full sub-contract basis, or can assist the main contractor with the cable works,
providing equipment and technical assistance on site.

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2.3 Description of Stahlton Stay Cables

2.3.1 General

A stay cable system is a combination of several individual components, working efficiently as a unit.
The anchorages at either end play a decisiv e role in achieving an optimal exploitation of the steel stay
cable.

Stahlton factory-fabricated stay cables are supplied with either HiAm or DINA anchorages. The cable
system meets the highest standards in terms of fatigue resistance and corrosion protection.

Due to the specialized, sometimes unique, nature of cable-stayed structures, Stahlton stay cable
components are not stocked as standard material, but are instead manufactured to suit the project.
This allows a high degree of flexibility in fulfilling the requirements of our customers and facilitates
solutions which are custom-fitted to a particular situation.

Engineers and architects are encouraged to contact the specialized staff of Stahlton AG at an early
stage, when timely support can help to avoid costly alterations later in the project.

2.3.2 Anchorages with High Fatigue Strength

HiAm and DINA anchorages both exhibit the high fatigue strength required of stay cables. This im-
portant characteristic has been confirmed many times by full-scale testing, as described more fully
in section 2.5.3.

HiAm Anchorage
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Neoprene Boot
Neoprene Ring

HPDE Stay Pipe

Corrosion Protection Compound
Guide Pipe
Bundle of Pa rallel Wire s
Collar Pipe
HiAm Socket

HiAm Compound

Protection Cap Lock Nut Bearing Plate

In the HiAm anchorage, the bundle of wires is anchored in a HiAm socket, which has a conical
form internally. The socket normally features an external thread, enabling the cable forces to be
transmitted into the structure, by means of lock nut and bearing plate. The considerable threaded
length afforded by the HiAm socket permits a simple adjustment of cable forces over a wide range.

Within the cone of the HiAm socket, the wires of the cable are spread out and anchored, by means
of mechanically formed buttonheads, at the perforated plate. The spaces between the wires in the
anchorage cone are filled with a proprietary HiAm compound, composed of epoxy, spherical steel
pellets and zinc dust. The end of the stay pipe is tightly embedded in epoxy at the collar pipe.

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DINA Anchorage

Neoprene Boot
Neoprene Ring
HPDE Stay Pipe

Devi a t o r

Guide Pipe

Corrosion Protection Compound

Bundle of Wires
Collar Pipe

Stressing Sleeve
Anchor Head
Protection Cap Lock Nut Bearing Plate

In the DINA anchorage, the wires are restrained, by means of buttonheads, in the anchor head. The
anchorage zone is injected with proprietary DINA epoxy compound, which prevents fretting and the
ingress of air or moisture, and improves the fatigue resistance of the anchorage. The stressing sleeve
facilitates the stressing of the anchorage, with the cable force being transferred by means of a lock
nut to the bearing plate. Within the telescope pipe, which is tightly embedded in the epoxy of the
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anchorage, the wires of the cable are brought together to form a compact bundle.

HiAm or DINA? The Criteria for Selection

The choice of anchorage is governed mainly by economic and manufacturing considerations. Generally,
however, we prefer to use just one anchorage type in a particular construction. The following is an
indication of the typical ranges of sizes:
– DINA anchorages for smaller cables (between 13 and 199 No. Æ 7 mm wires)
– HiAm anchorages for larger cables (between 56 and 421 No. Æ 7 mm wires)

The selection of anchorage sizes is made anew for each project, taking project-specific conditions into
account. An optimal choice of anchorage sizes leads to a reduction of the manufacturing costs, which
in turn means better value for the customer.

2.3.3 Cable Composition

Each cable is composed of a specified number of bright or galvanized Æ 7 mm wires, arranged in a

compact parallel bundle. Typically, the wire bundle is pulled into a thick-walled HDPE pipe, and the
voids in the pipe are filled with a flexible corrosion protection compound.

C ross-section

HDPE Stay Pipe

Corrosion Protection Compound

Bundle of Parallel Wires Æ 7 mm

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Make-up of the Cable

In the Stahlton stay cable, the load carrying element – the bundle of steel wires – is completely
contained within a closed system. The outer HDPE stay pipe is tightly embedded in the anchorage
epoxy at either end, and is fully welded over the free length. The ends of the wires at the anchorages
are cove red by epoxy, which precludes any ingress of moisture or air into this critical zone.

The stay pipe arrangement of Stahlton cables is dependent on the type of anchorage chosen, HiAm
or DINA, as the following sketches indicate. A telescopic joint in the stay pipe is required at each
anchorage, to facilitate the fitting of the anchorages to the cable in the factory. The lengths shown
on the sketches are standard values. Deviations from these standard values, to suit project-specific
conditions, are possible, subject to confirmation by Stahlton.

Stay Pipe Arrangement with HiAm Anchorages

St re ssi n g Fixed
A n c h o ra g e A n c h o ra g e

Collar Pipe Telescope Pipe Telescope Pipe Collar Pipe

Lock Lock
Nut HPDE Pipe (HPDE) HPDE Pipe (HPDE) HPDE Pipe Nut

em 0.45 m 4.50 m 4.50 m 0.45 m ef

LHM Cable Length „L“ LHF
(Unstressed Cable at 2 0 °C)

Stay Pipe Arrangement with DINA Anchorages

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St re ssi n g Fixed
A n c h o ra g e Anchorage

Telescope Pipe Telescope Pipe

Lock Lock
Nut Collar Pipe (HPDE) HPDE Pipe (HPDE) Collar Pipe Nut

em 2.50 m 2.50 m
LHM Cable Length „L“ LHF
(Unstressed Cable at 20 °C)

DINA cables are particular-

ly suitable for applications
requiring smaller cables.

The Bridge over the Ljublj-

anica in Ljubljana, Slovenia
features DINA cables with
maximum working loads be-
tween 1’590 kN and 5’060 kN.

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Corrosion Protection
The precise composition of the cable can be chosen to take project-specific factors, such as the loca-
tion, the design life and the demands placed on the structure, into consideration. The following factors
are of particular importance:
– humidity
– influence of salts (marine location, de-icing salts)
– type of environment (aggressive industrial? Indoor use?)
– mechanical demands (danger of rockfalls, vandalism)
– permanent or temporary structure

Possible Combinations Remarks

1 2 3 4
Wire Bundle
bright wire s
galvanized wire s not with cement grout
Corrosion Protection
flexible, petroleum-based
cement grout
Stay Pipe
HDPE
steel not for factory fabrication

Possible Stay Cable Compositions

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The use of a flexible, petroleum-based, corrosion protection compound facilitates the application of
the permanent corrosion protection system in the factory. A temporary protection of the steel wires,
as well as the cable injection works on site, can consequently be dispensed with.

Before being pulled into the stay pipe, the wires of a Stahlton stay cable pass through a bath of corro-
sion protection compound, ensuring that spaces between the individual wires are completely filled.

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2.3.4 Indicative Cable and Anchorage Dimensions

The following tables contain indicative values, which are intended to assist designers at an early
planning stage. Based on project-specific considerations, the cables for a particular structure are
divided into economical groupings, and the optimal dimensions are then determined.

HiAm Cable and Anchorages

Stressing Anchorage Fixed Anchorage

Æ PE
ÆM

ÆM
ÆS
ÆA

ÆA
ÆS

ÆT
B
t t
LSm HM em ef HM LSf
LHM LHF

Cable size (wires per cable) nÆ7 No. 56 91 121 163 196 223 262 301 334 367 394 421
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Cable
Breaking Load Funom kN 3’600 5’850 7’775 10’475 12’595 14’330 16’840 19’345 21’465 23’585 25’320 27’055
max. Working Load Fmax kN 1’620 2’635 3’500 4’715 5’670 6’450 7’580 8’705 9’660 10’615 11’395 12’175
Steel Weight kg/m 16.9 27.5 36.6 49.2 59.2 67.4 79.2 90.9 100.9 110.9 119.0 127.2
Cable Weight kg/m 23.8 33.2 43.8 58.0 71.2 78.4 93.8 104.2 118.7 127.5 138.3 145.5

HPDE Stay Pipe Æ PE mm 110 110 125 140 160 160 180 180 200 200 210 210
Wall Thickness mm 10.0 10.0 11.4 12.8 14.6 14.6 16.4 16.4 18.2 18.2 19.1 19.1

HDPE Telescope Pipe Æ PEt mm 140 140 160 180 200 200 225 225 250 250 250 250
Wall Thickness mm 12.8 12.8 14.6 16.4 18.2 18.2 20.5 20.5 22.8 22.8 18.0 18.0

Steel Guide Pipe ÆT mm 229.0/ 267.0/ 298.5/ 343.0/ 355.6/ 368.0/ 406.4/ 445.0/ 445.0/ 470.0/ 495.0/ 495.0/
(outer/inner diameter) 211.4 251.0 282.5 311.0 330.6 352.0 378.0 405.0 416.6 435.0 455.0 470.0

Bearing Plate B mm 365 430 480 545 590 625 675 730 755 795 830 850
Thickness t mm 45 55 60 70 75 75 85 95 95 100 110 105
Centre Hole ÆZ mm 211 251 282 311 330 352 378 405 417 435 455 470

Socket
Outer Diameter ÆA mm 195 235 265 295 315 335 360 385 400 420 435 450
Length Stressing Anchorage LHM mm 355 425 480 550 605 635 665 710 755 790 815 845
Length Fixed Anchorage LHF mm 320 370 415 465 505 525 540 575 605 635 650 675

Lock Nut ÆM mm 245 290 330 365 390 420 450 480 500 520 540 560
HM mm 75 90 105 120 125 135 150 160 165 170 180 185

Protection Cap ÆS mm 219 259 289 319 339 359 389 409 429 449 459 479
LSm mm 283 338 378 433 483 503 518 553 593 623 638 663
LSf mm 178 203 213 228 253 253 253 268 283 288 293 303

Weight of Anchorage (excl. stress. kg 93 157 226 314 391 465 567 688 787 898 998 1’110
Anchor Plate and Guide Pipe) fixed kg 86 142 203 281 347 412 495 600 682 779 861 957

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DINA Cable and Anchorages

Stressing Anchorage Fixed Anchorage

Æ Mm

Æ PE
Æ ZH
Æ Sm

Æ Tm

Æ Mf
Æ Bf
Æ Sf
Æ Tf
Bm
tm
L S m HMm em tf HMf LSf
LZH LHF

Cable size (wires per cable) nÆ7 No. 13 22 31 37 55 70 91 103 121 145 157 181 199

Cable
Breaking Load Funom kN 835 1’415 1’990 2’380 3’535 4’500 5’850 6’620 7’775 9’320 10’090 11’635 12’790
max. Working Load Fmax kN 375 635 895 1’070 1’590 2’025 2’635 2’980 3’500 4’195 4’540 5’235 5’755
Steel Weight kg/m 3.9 6.6 9.4 11.2 16.6 21.1 27.5 31.1 36.6 43.8 47.4 54.7 60.1
Cable Weight kg/m 6.4 8.8 12.4 15.8 20.7 27.6 33.2 39.0 43.8 53.1 56.4 67.2 72.0

HPDE Stay Pipe Æ PE mm 63 63 75 90 90 110 110 125 125 140 140 160 160
Wall Thickness mm 5.8 5.8 6.9 8.2 8.2 10.0 10.0 11.4 11.4 12.8 12.8 14.6 14.6
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HDPE Telescope Pipe Æ PE mm 75 75 90 110 110 140 140 160 160 180 180 200 200
Wall Thickness mm 4.3 4.3 5.1 6.3 6.3 12.8 12.8 14.6 14.6 16.4 16.4 18.2 18.2

Steel Guide Pipe

Stressing Anchorage Æ Tm mm 139.7/ 146.0/ 168.3/ 177.8/ 203.0/ 229.0/ 254.0/ 267.0/ 292.0/ 305.0/ 318.0/ 330.0/ 355.6/
(outer/inner diameter) 125.5 136.0 155.7 165.2 190.4 211.4 238.0 245.0 267.0 285.0 298.0 310.0 327.2

Fixed Anchorage Æ Tf mm 139.7/ 139.7/ 152.4/ 177.8/ 177.8/ 203.0/ 203.0/ 229.0/ 229.0/ 244.5/ 244.5/ 267.0/ 267.0/
(outer/inner diameter) 125.5 125.5 141.2 161.8 161.8 190.4 190.4 211.4 211.4 230.3 230.3 251.0 251.0

Bearing Plates
Stressing Plate Bm mm 230 260 285 305 350 380 420 435 470 510 525 560 590
Thickness tm mm 30 35 35 40 45 50 55 60 60 65 65 70 75
Centre Hole Æ Zm mm 125 136 155 165 190 211 238 245 267 285 298 310 327

Fixed Plate Bf mm 180 210 240 270 305 405 430 415 440 480 495 530 555
Thickness tf mm 25 35 35 45 45 70 80 60 65 75 75 80 90
Centre Hole Æ Zf mm 110 110 125 145 145 175 175 195 195 215 215 235 235

Stressing Steeve
Outer Diameter Æ ZH mm 100 120 140 150 175 195 220 230 250 270 280 295 310
Length LZH mm 90 105 115 130 160 190 205 225 245 255 270 290 305
Length Fixed Anchorage LHF mm 45 55 60 60 75 75 90 90 100 105 110 115 125

Lock Nut
Stressing Anchorage Æ Mm mm 140 160 180 195 225 250 280 290 315 340 355 370 390
HMm mm 30 35 40 45 55 60 70 70 75 80 85 90 95

Fixed Anchorage Æ Mf mm 130 135 155 175 185 220 230 250 255 280 285 310 315
HMf mm 30 40 45 50 55 65 70 75 80 85 90 95 100

Protection Cap
Stressing Anchorage Æ Sm mm 129 149 169 179 199 219 249 259 279 299 309 319 339
LSm mm 98 108 113 128 153 178 188 203 218 223 238 253 263

Fixed Anchorage Æ Sf mm 125 130 150 170 180 215 225 245 250 275 280 305 310
LSf mm 34 34 34 34 34 34 34 34 34 34 34 34 34

Weight of Anchorage (excl. stress. kg 15 19 26 34 48 69 86 102 125 150 169 199 230
Anchor Plate and Guide Pipe) fixed kg 11 12 16 22 24 35 40 49 52 65 69 85 90

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2.4 Stay Cable Works

2.4.1 Fabrication and Delivery

Stahlton stay cables are fabricated in our factory in Frick, Switzerland. The wires are cut to length in
an automated cutting unit, which is calibrated at a temperature of 20 °C. Before being cut, each wire is
slightly stressed, to assure complete straightness and consequently an equal length for all wires of a
cable.

Cables are fabricated to the following tole-

rance in length: DL max = ± (L/7500 + 20) mm

Following cutting, the individual wires are

combed to form a parallel bundle, which is
then pulled into the previously prepared
HDPE sta y pipe.

Once they have been fitted at either end, the

anchorages are filled with the appropriate
compound (HiAm or DINA), which is cured
under strictly controlled conditions.

The permanent petroleum-based corrosion

protection compound is applied, between
the wires and in the void between the wire
bundle and the stay pipe, during the factory
fabrication.

The joints between the stay pipe and the

telescope pipe are temporarily sealed in the
factory, allowing a degree of rotation at the
anchorages during coiling and uncoiling.
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These joints are permanently sealed by

electro-welding on site, following uncoiling.

The fully fabricated cables are coiled on steel

drums for transport to the construction site.
Additional protection of the coiled cables on
the drum (e.g. styrofoam packing) may be
applied, depending on the type and duration
of the transport (sea, rail, road). Factory fab-
rication of the stay cables, incorporating a
comprehensive supervision of all manufac-
turing processes, together with extensive,
documented materials testing, ensures that
the highest standards of quality can be
a c h i ev e d .
Filling of HiAm Anchorages

Forming a Parallel Wire Bundle

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2.4.2 Site Works

Cable Installation Method

The installation method for the stay cables of a particular project is determined, taking the following
into consideration:
– construction method (balanced-cantileve r, construction on temporary supports, etc.)
– construction programme
– arrangement of the fixed and stressing anchorages
– size, length and weight of cables
– space available on site
– lifting equipment and scaffolding available

The following is a typical, prov en method of installing stay cables on bridges:

Uncoiling of the cable on the

bridge deck, using an uncoiling
unit and a winch
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Installation of the upper, fixed

anchorage, using a crane and a
deviation device (banana)

Pulling the lower end of the cable

close to the anchorage location,
with a winch, and then pulling the
anchorage into position

Cable stressing and cable force

adjustment by means of a
hydraulic jack at the lower end
of the cable

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Installation Equipment, Space Requirements

A wide range of equipment and auxiliary devices is available for cable installation and stressing.

Uncoiling Units

Large Uncoiler (hydraulic)

Dimensions 5.80 x 3.65 x max. 4.75 m
Cable real 4.50 x 2.50 m
(max. Æ out x width)
Capacity 30 to.
Weight 5.3 to.

Standard Uncoiler
Dimensions 3.80 x 2.25 x max. 4.10 m
Cable real 3.80 x 2.25 m
(max. Æ out x width)
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Capacity 12.5 to.

Weight 1.0 to.

Small Uncoiler
Dimensions 2.30 x 2.10 x max. 3.10 m
Cable real 2.30 x 1.08 m
(max. Æ out x width)
Capacity 5.0 to.
Weight 0.8 to.

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Stressing Units

W
L

Indicative weights and space requirements

Stressing Fo rce Space Requirement Weight of

L x W Stressing Units
10’000 kN 3’000 x 800 mm 3.5 t
7’500 kN 2’500 x 700 mm 2.5 t
5’000 kN 2’000 x 600 mm 1.5 t
3’000 kN 2’000 x 500 mm 1.1 t
2’500 kN 1’500 x 400 mm 0.5 t

Ideally, access to the lock nut should be possible from 2 opposite sides of the HiAm or DINA
a n c h o ra g e .

Other Equipment
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Auxiliary equipment, such as deviation elements (bananas, saddles), jack handling equipment etc.,
is provided by Stahlton according to the requirements of the project. In some cases, this auxiliary
equipment must be manufatured specially for a project, but, quite often, equipment in stock can be
suitably altered.

Equipment and Services Normally Provided by the Customer

Since each project requiring stay cables is unique, the equipment and services required of the customer
are negotiated and agreed at the beginning of each project. Some typical requirements, however, are
listed below:

Cranes and lifting equipment

– equipment to unload the cable reels and equipment containers on site
– equipment to lift the upper end of the stay cable to the pylon
– mobile lifting equipment on the bridge deck to move equipment and materials, and to assist in
placing the stressing equipment
– light lifting equipment at the pylon, to assist with the handling of the cable pulling equipment

Working platforms
– platforms outside the pylon head, to facilitate the guiding of the anchorages into the guide pipes,
and the fitting of neoprene rings and boots
– platforms at the upper and lower anchor plates, to facilitate the pulling-in and stressing of the
cables

Infrastructure and facilities

– storage space for cable reels, equipment and containers
– electrical power and water
– cov ers and heaters to warm the coiled cables before uncoiling, should cable installation take place
in winter
– office space and facilities for Stahlton’s engineer
– accomodation for Stahlton’s personnel

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2.5 Technical Information

2.5.1 Material Specifications

Post-tensioning wire
Nominal Diameter Æ nom = 7 mm

Ultimate Tensile strength ftk = 1’670 N/mm 2

Yield Strength f y0.2 = 0.85 – 0.95f t k

Elongation at Rupture e10 = min. 5% (L = 10 x Æ nom )

Contraction Z = min. 30%

Modulus of Elasticity Em nom = 201 kN/mm 2

Fatigue Strength 350 N/mm 2 over 2 million load cycles, at an upper limit of 0.45f t k

Ductility (Reverse Bend Test) min. 4 bends

Galvanizing min. = 280 g/m 2

max. = 400 g/m 2

Stay Pipes
Stay pipes are fabricated from High Density Polyethylene (HDPE) pipes, manufactured in accordance
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with DIN 8074 and DIN 8075. In addition to the requirements of these standards, the pipes must comply
with Stahlton’s internal, more stringent, requirements concerning diameter tolerances and tempering.

Due to the exposed nature of stay cables, the UV stability of the HDPE is extremely important. While
the stabilization of black HDPE by means of the addition of carbon black has been prov en and accep-
ted, the effective stabilization of coloured HDPE is a more recent development. Stahlton cooperates
closely with its suppliers to ensure that the stay pipes possess the necessary resistance to UV radiation.

Corrosion Protection Compound

The corrosion protection compounds used by Stahlton must satisfy stringent internal requirements,
such as:
– the dropping point must be in a range which ensures an adequate consistency at the upper ambient
temperature, while accommodating an effective injection of the fluid compound
– regular consistency over the range of expected ambient temperature s
– adequate viscosity at injection temperature
– low oil separation
– low water-soluble ion concentrations
– low oxidation
– excellent corrosion protection characteristics
– high flash point

Anchorages
HiAm anchorage sockets, S 355 J2G3 (SN EN 10025)
lock nuts f tk /f y0.2 = min. 520/320 N/mm 2

DINA stressing sleeves, 42CrMo4 (SN EN 10083)

lock nuts f tk /f y0.2 = min. 900/650 N/mm 2

DINA anchor heads 42CrMo4 (SN EN 10083)

f tk /f y0.2 = min. 1000/750 N/mm 2

Anchor plates S 355 J2G3 (SN EN 10025)

f tk /f y0.2 = min. 490/315 N/mm 2

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2.5.2 Dimensioning Principles

In the absence of requirements to the contrary by the customer, Stahlton sta y cables and anchorages
are dimensionsed according to the following criteria:

Cables
Steel cross-section As = n x Æ nom
² x p /4
(where “n“ is the number of wires and “Æ nom “ is the
nominal wire diameter)

Nominal cable breaking load F tk = A s x f tk nom

Maximum working load F m a x = 0.45 F t k

Maximum stress variation D ft = 200 N/mm 2

(at an upper stress limit of 0.45 f t k )

Moduls of Elasticity Em = 201 kN/mm 2

Anchorages
Maximum load capacity not less than F tk = Nominal cable breaking load

Check in the working state for

– max. working load F m a x = 0.45 F t k
– max. stressing load Fj = 0.56 F t k
(short-term loading – e.g. during cable replacement)
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The design and detailing of the transmission of the cable forces into the structure is the responsibility
of the designer. The anchor plate dimensions proposed by Stahlton in this documentation are minimum
dimensions, taking into consideration the space required for the cable installation and stressing
equipment, and assuming the anchor plate to bear evenly on a concrete with 28-day cube strength of
35 N/mm 2 (SIA 162, SIA 162/1).

Anchor plates and guide pipes are generally not included in the scope of sta y cable supply, as such
materials are normally readily available locally.

Four threaded holes are usually required in the anchor plates, to secure the installation and stressing
equipment. A drainage slot, for any condensation water which might build up in the guide pipe, is also
required on the bearing surface of the lower anchor plate. Precise details should be agreed between
the customer and Stahlton, as part of the overall installation procedure, prior to the procurement of
the parts concerned.

HDPE Stay Pipes:

The stay pipes are normally thick-walled HDPE pipes. This thick sheathing provides a robust outer
protection barrier for the cable, being fully welded from end to end, and is appropriate to the
construction site environment.

The choice of pipe diameter is governed by the diameter of the wire bundle and the tolerance required
for cable fabrication.

Cable Length:
In order to determine the fabrication length of a cable, we require either the unstressed cable length
„L“, or the following information:
– the distance between anchorplates at t o or t ¥ , taking pre-camber, elastic deformations, elastic
shortening and creep into consideration. The presentation of information in the form of three-
dimensional coordinates is preferable
– inclination of the chord, if coordinates are not available
– cable force at t o or t ¥
– the reference temperature

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2.5.3 F u l l - S c a l e Te s t i n g
During the development of the HiAm and DINA anchorage systems, and subsequently to satisfy
project-specific acceptance testing requirements, more than ninety full-scale fatigue tests – in many
cases followed by a static tensile test - have been performed on HiAm and DINA specimens. These
tests have been conducted in internationally recognized test institutes by either BBR, Stahlton or other
BBR licensees. The exceptional fatigue strength of the cable systems has thus been clearly demon-
strated, time and again. The impressive performance of HiAm and DINA test specimens, when tested
for static tensile strength upon successful completion of 2 million cycles in a fatigue test, is worthy
of particular mention. Maximum test loads in excess of the nominal breaking load have often been
re c o rd e d .

The following table of selected test results gives an indication of the HiAm and DINA quality, with
respect to fatigue strength.

Fatigue Test Static Tensile

Test

Anchorage No. of Nominal Upper Stress Range No. of Max. Load as

Ty p e Æ 7 mm Wires Breaking Stress Level Cycles of Nominal
Load (kN) as % of GUTS (N/mm 2 ) Breaking Load

HiAm 127 7’673 45.0% 161 2 x 10 6 107%

HiAm 217 13’100 45.0% 196 2 x 10 6 99%

HiAm 295 17’822 36.7% 200 2 x 10 6 107%

DINA 37 2’305 Not performed 107%

DINA 192 12’340 45.0% 245 2 x 10 6 96%

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DINA 241 15’007 45.0% 245 2 x 10 6 Not performed

A full list of stay cable tests is available upon request.

Full-Scale Fatigue Test at the Technical University, Munich

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Sunniberg Bridge, Klosters, Switzerland

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 Stay Cables

Bridge over the Rhône, Transport of cable drums by rail Bridge over the Rhine,
Chandoline, Switzerland Schaffhausen, Switzerland
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Utsjoki Bridge, Finland – Utsjoki Bridge, Finland – Pulling a deck anchorage into
pylon head fixed deck anchorage position

5’000 kN stressing assemblies Pedestrian bridge, Rumlang, DINA stressing anchorage

Switzerland

Bridge over the Thur, Altikon, A lifting/deviation construction Tähtiniemi Bridge, Finland
Switzerland

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Stahlton AG
Riesbachstrasse 57
Postfach
CH-8034 Zürich 8
Switzerland

Telephone +41-1-384 89 90
Telefax +41-1-422 11 16
E-Mail: info@stahlton.ch
http://www.stahlton.ch

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