ROAD DEVELOPMENT AUTHORITY

MINISTRY OF HIGHWAYS, HIGHER EDUCATION AND INVESTIGATION PROMOTION

THE DEMOCRATIC SOCIALISTREPUBLIC OF SRI LANKA

CONSULTANCY SERVICES
FOR
DETAILED DESIGN
OF
NEW BRIDGE CONSTRUCTION PROJECT OVER
THE KELANIRIVER

MAIN BRIDGE
CABLE STAYS

REVISION 2
JANUARY 2017

ORIENTAL CONSULTANTS CO., LTD.

KATAHIRA & ENGINEERS INTERNATIONAL
List of Revisions

Revision Reason to Issue Date

0 First issue 16.04.2015
1 Revise fatigue design 29.07.2015
2 Final cable tension calculation method included
 Oriental Consultants Co Ltd.
Katahira& Engineers International Main Bridge – Cable Stays

TABLE OF CONTENTS

Page

1. GENERAL 1
1.1 Basic documents and references 1
1.2 Geometry 1
1.3 Material properties 1
2. CABLE STAYS 2
2.1 Stay data 2
2.2 Sudden loss of stay 5
2.3 Stay exchange 7
2.4 Fatigue 9
2.5 Angular change due to cable sag 14

3. CABLE TENSION 17

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 Oriental Consultants Co Ltd.
Katahira& Engineers International Main Bridge –Cable Stays

1 GENERAL
1.1 Basic documents and references
/1/ Consultancy Services for Detailed Design of New Bridge Construction Project
over the Kelani River, “Design Criteria”.
/2/ Consultancy Services for Detailed Design of New Bridge Construction Project
over the Kelani River, “Global Analysis”.

1.2 Geometry

Figure1 Layout 2nd Bridge across the Nile at Jinja

1.3 Material properties

The following load limit for cable is used according to the Design Criteria report /1/:
Item Load (kN) Stress (MPa)
Guaranteed ultimate (GUTS) Fpu = 256.6 fpu = f’s =1850
SLS general: 0.60GUTS Fu = 154.0 fu =1110
SLS stay exchange: 0.65GUTS Fu = 166.8 fu = 1202
Loss of stay : 0.65GUTS Fu = 166.8 fu = 1202
Table 1 Load limit for cable stays

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 Oriental Consultants Co Ltd.
Katahira& Engineers International Main Bridge –Cable Stays

2 CABLE STAYS
2.1 Staydata
Figure 1 is the key diagram for stay no. The stay no. is from 301-624 according to the
element no. in the finite element model in global analysis /2/. It is noted that in detailed
design drawing, the stay no. ischanged to 101-424 as shown in Table 2.

Figure2 Key diagram for stay no.

Stay no.
Design reports Design drawings
301-324 101-124
401-424 201-224
501-524 301-324
601-624 401-424
Table 2 Stay no.

Tables 3 and 4 show the stay data including number of strands, stay area, permanent
load in stay etc. The number of strands and stay area is determined from maximum
design load in SLS with stress limit of 0.60fpu, where fpu = 1850 MPa.
- Nominal area = 138.7 x No. of strands [mm2]
- Nominal stay steel weight = Area/1000 x 7.85 [kg/m]
- Stay forces at finished bridge is the stay force after stressing of main span bottom slab
tendons, i.e. construction stage 22.3.
- Permanent load in stay at T = 0 is the stay force due to self weight, superimposed dead
load, prestressing, cable tension forces and creep and shrinkage during construction.
- Permanent load in stay at T = ∞ includes the effects of long term creep and shrinkage.
- Max design load SLS is the maximum load in stay at SLS load combinations
according to the design criteria /1/.

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Katahira& Engineers International Main Bridge –Cable Stays

Nominal Stay
Permanent Permanent Max
No. of Nominal stay steel force at Max cable
load in load in Live load Live load design
Stay No. strands area weight finished force
stay T=0 stay T=inf max [kN] min [kN] load SLS
N [mm2] per m bridge SLS/Fpu
[kN] [kN] [kN]
[kg/m] [kN]
301 27 3744.9 29.40 3400 3392 3142 179 -144 3658 0.528
302 27 3744.9 29.40 3400 3428 3205 158 -105 3675 0.530
303 27 3744.9 29.40 3400 3456 3255 139 -70 3684 0.532
304 27 3744.9 29.40 3450 3530 3349 121 -42 3740 0.540
305 27 3744.9 29.40 3450 3550 3388 105 -24 3744 0.540
306 27 3744.9 29.40 3450 3561 3416 93 -15 3743 0.540
307 37 5131.9 40.29 4830 5009 4828 121 -19 5253 0.553
308 37 5131.9 40.29 4830 5025 4859 121 -25 5270 0.555
309 37 5131.9 40.29 4830 5037 4884 134 -30 5296 0.558
310 37 5131.9 40.29 4830 5047 4908 155 -35 5329 0.561
311 37 5131.9 40.29 4830 5045 4919 180 -43 5355 0.564
312 37 5131.9 40.29 4830 5060 4946 204 -60 5396 0.568
313 27 3744.9 29.40 3400 3392 3142 179 -144 3658 0.528
314 27 3744.9 29.40 3400 3428 3205 158 -105 3675 0.530
315 27 3744.9 29.40 3400 3456 3255 139 -70 3684 0.532
316 27 3744.9 29.40 3450 3530 3349 121 -42 3740 0.540
317 27 3744.9 29.40 3450 3550 3388 105 -24 3744 0.540
318 27 3744.9 29.40 3450 3561 3416 93 -15 3743 0.540
319 37 5131.9 40.29 4830 5009 4828 121 -19 5253 0.553
320 37 5131.9 40.29 4830 5025 4859 121 -25 5270 0.555
321 37 5131.9 40.29 4830 5037 4884 134 -30 5296 0.558
322 37 5131.9 40.29 4830 5047 4908 155 -35 5329 0.561
Pylon MB-P20

323 37 5131.9 40.29 4830 5045 4919 180 -43 5355 0.564
324 37 5131.9 40.29 4830 5060 4946 204 -60 5396 0.568
401 27 3744.9 29.40 3400 3679 3659 304 -134 4129 0.596
402 27 3744.9 29.40 3400 3674 3641 283 -113 4091 0.591
403 27 3744.9 29.40 3400 3670 3626 266 -96 4059 0.586
404 27 3744.9 29.40 3450 3716 3662 250 -82 4081 0.589
405 27 3744.9 29.40 3450 3712 3647 236 -69 4058 0.586
406 27 3744.9 29.40 3450 3706 3629 222 -58 4037 0.583
407 37 5131.9 40.29 4830 5172 5047 288 -68 5607 0.591
408 37 5131.9 40.29 4830 5161 5015 270 -59 5577 0.587
409 37 5131.9 40.29 4830 5146 4979 252 -55 5544 0.584
410 37 5131.9 40.29 4830 5130 4941 234 -55 5508 0.580
411 37 5131.9 40.29 4830 5112 4902 215 -54 5470 0.576
412 37 5131.9 40.29 4830 5091 4861 198 -54 5432 0.572
413 27 3744.9 29.40 3400 3679 3659 304 -134 4129 0.596
414 27 3744.9 29.40 3400 3674 3641 283 -113 4091 0.591
415 27 3744.9 29.40 3400 3670 3626 266 -96 4059 0.586
416 27 3744.9 29.40 3450 3716 3662 250 -82 4081 0.589
417 27 3744.9 29.40 3450 3712 3647 236 -69 4058 0.586
418 27 3744.9 29.40 3450 3706 3629 222 -58 4037 0.583
419 37 5131.9 40.29 4830 5172 5047 288 -68 5607 0.591
420 37 5131.9 40.29 4830 5161 5015 270 -59 5577 0.587
421 37 5131.9 40.29 4830 5146 4979 252 -55 5544 0.584
422 37 5131.9 40.29 4830 5130 4941 234 -55 5508 0.580
423 37 5131.9 40.29 4830 5112 4902 215 -54 5470 0.576
424 37 5131.9 40.29 4830 5091 4861 198 -54 5432 0.572

Table 3 Stay data – Pylon P20

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Katahira& Engineers International Main Bridge –Cable Stays

Stay
Nominal Max Max
Nominal force at Permanent Permanent
No. of stay steel Live load Live load design cable
Stay No. area finished load in stay load in stay
strands N weight per max [kN] min [kN] load SLS force
[mm2] bridge T=0 [kN] T=inf [kN]
m [kg/m] [kN] SLS/Fpu
[kN]
501 27 3744.9 29.40 3400 3576 3768 143 -61 4026 0.581
502 27 3744.9 29.40 3400 3593 3723 153 -53 3979 0.574
503 27 3744.9 29.40 3400 3606 3687 162 -46 3942 0.569
504 27 3744.9 29.40 3450 3665 3707 168 -39 3966 0.572
505 27 3744.9 29.40 3450 3672 3680 171 -34 3962 0.572
506 27 3744.9 29.40 3450 3675 3653 171 -30 3951 0.570
507 37 5131.9 40.29 4920 5228 5159 231 -38 5586 0.588
508 37 5131.9 40.29 4920 5224 5119 226 -36 5578 0.588
509 37 5131.9 40.29 4920 5216 5077 218 -36 5563 0.586
510 37 5131.9 40.29 4920 5205 5035 208 -39 5543 0.584
511 37 5131.9 40.29 4920 5191 4992 199 -42 5520 0.581
512 37 5131.9 40.29 4920 5174 4947 188 -44 5494 0.579
513 27 3744.9 29.40 3400 3576 3768 143 -61 4026 0.581
514 27 3744.9 29.40 3400 3593 3723 153 -53 3979 0.574
515 27 3744.9 29.40 3400 3606 3687 162 -46 3942 0.569
516 27 3744.9 29.40 3450 3665 3707 168 -39 3966 0.572
517 27 3744.9 29.40 3450 3672 3680 171 -34 3962 0.572
518 27 3744.9 29.40 3450 3675 3653 171 -30 3951 0.570
519 37 5131.9 40.29 4920 5228 5159 231 -38 5586 0.588
520 37 5131.9 40.29 4920 5224 5119 226 -36 5578 0.588
521 37 5131.9 40.29 4920 5216 5077 218 -36 5563 0.586
522 37 5131.9 40.29 4920 5205 5035 208 -39 5543 0.584
Pylon MB-P21

523 37 5131.9 40.29 4920 5191 4992 199 -42 5520 0.581
524 37 5131.9 40.29 4920 5174 4947 188 -44 5494 0.579
601 27 3744.9 29.40 3400 3494 3024 130 -52 3847 0.555
602 27 3744.9 29.40 3400 3505 3112 122 -42 3822 0.552
603 27 3744.9 29.40 3400 3516 3185 115 -33 3804 0.549
604 27 3744.9 29.40 3450 3576 3296 110 -26 3841 0.554
605 27 3744.9 29.40 3450 3586 3349 105 -23 3832 0.553
606 27 3744.9 29.40 3450 3594 3392 101 -22 3824 0.552
607 37 5131.9 40.29 4920 5127 4890 139 -30 5432 0.572
608 37 5131.9 40.29 4920 5135 4930 145 -30 5437 0.573
609 37 5131.9 40.29 4920 5141 4963 160 -31 5450 0.574
610 37 5131.9 40.29 4920 5146 4993 177 -38 5467 0.576
611 37 5131.9 40.29 4920 5150 5019 197 -51 5486 0.578
612 37 5131.9 40.29 4920 5152 5042 215 -65 5503 0.580
613 27 3744.9 29.40 3400 3494 3024 130 -52 3847 0.555
614 27 3744.9 29.40 3400 3505 3112 122 -42 3822 0.552
615 27 3744.9 29.40 3400 3516 3185 115 -33 3804 0.549
616 27 3744.9 29.40 3450 3576 3296 110 -26 3841 0.554
617 27 3744.9 29.40 3450 3586 3349 105 -23 3832 0.553
618 27 3744.9 29.40 3450 3594 3392 101 -22 3824 0.552
619 37 5131.9 40.29 4920 5127 4890 139 -30 5432 0.572
620 37 5131.9 40.29 4920 5135 4930 145 -30 5437 0.573
621 37 5131.9 40.29 4920 5141 4963 160 -31 5450 0.574
622 37 5131.9 40.29 4920 5146 4993 177 -38 5467 0.576
623 37 5131.9 40.29 4920 5150 5019 197 -51 5486 0.578
624 37 5131.9 40.29 4920 5152 5042 215 -65 5503 0.580

Table 4 Stay data – Pylon P21

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Katahira& Engineers International Main Bridge –Cable Stays

2.2 Sudden loss of stay

The stays are checked for sudden loss of stay with load limit 0.65Fpu. The results are
shown in Tables 5 and 6.

No. of Nominal Sudden Sudden

Stay No. strands area loss of loss of
N [mm2] stay [kN] stay/Fpu

301 27 3744.9 3592 0.518

302 27 3744.9 3617 0.522
303 27 3744.9 3634 0.525
304 27 3744.9 3696 0.533
305 27 3744.9 3703 0.535
306 27 3744.9 3702 0.534
307 37 5131.9 5201 0.548
308 37 5131.9 5226 0.550
309 37 5131.9 5254 0.553
310 37 5131.9 5287 0.557
311 37 5131.9 5311 0.559
312 37 5131.9 5338 0.562
313 27 3744.9 3592 0.518
314 27 3744.9 3617 0.522
315 27 3744.9 3634 0.525
316 27 3744.9 3696 0.533
317 27 3744.9 3703 0.535
318 27 3744.9 3702 0.534
319 37 5131.9 5201 0.548
320 37 5131.9 5226 0.550
321 37 5131.9 5254 0.553
322 37 5131.9 5287 0.557
Pylon MB-P20

323 37 5131.9 5311 0.559

324 37 5131.9 5338 0.562
401 27 3744.9 4102 0.592
402 27 3744.9 4068 0.587
403 27 3744.9 4040 0.583
404 27 3744.9 4066 0.587
405 27 3744.9 4046 0.584
406 27 3744.9 4027 0.581
407 37 5131.9 5594 0.589
408 37 5131.9 5563 0.586
409 37 5131.9 5528 0.582
410 37 5131.9 5489 0.578
411 37 5131.9 5448 0.574
412 37 5131.9 5401 0.569
413 27 3744.9 4102 0.592
414 27 3744.9 4068 0.587
415 27 3744.9 4040 0.583
416 27 3744.9 4066 0.587
417 27 3744.9 4046 0.584
418 27 3744.9 4027 0.581
419 37 5131.9 5594 0.589
420 37 5131.9 5563 0.586
421 37 5131.9 5528 0.582
422 37 5131.9 5489 0.578
423 37 5131.9 5448 0.574
424 37 5131.9 5401 0.569

Table 5 Sudden loss of stay – Stays at pylon P20

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Katahira& Engineers International Main Bridge –Cable Stays

Nominal Sudden Sudden

No. of
Stay No. area loss of loss of
strands N
[mm2] stay [kN] stay/Fpu

501 27 3744.9 3982 0.575

502 27 3744.9 3952 0.570
503 27 3744.9 3929 0.567
504 27 3744.9 3960 0.572
505 27 3744.9 3955 0.571
506 27 3744.9 3944 0.569
507 37 5131.9 5575 0.587
508 37 5131.9 5564 0.586
509 37 5131.9 5546 0.584
510 37 5131.9 5521 0.582
511 37 5131.9 5493 0.579
512 37 5131.9 5459 0.575
513 27 3744.9 3982 0.575
514 27 3744.9 3952 0.570
515 27 3744.9 3929 0.567
516 27 3744.9 3960 0.572
517 27 3744.9 3955 0.571
518 27 3744.9 3944 0.569
519 37 5131.9 5575 0.587
520 37 5131.9 5564 0.586
521 37 5131.9 5546 0.584
522 37 5131.9 5521 0.582
Pylon MB-P21

523 37 5131.9 5493 0.579

524 37 5131.9 5459 0.575
601 27 3744.9 3673 0.530
602 27 3744.9 3681 0.531
603 27 3744.9 3689 0.532
604 27 3744.9 3746 0.541
605 27 3744.9 3754 0.542
606 27 3744.9 3761 0.543
607 37 5131.9 5360 0.565
608 37 5131.9 5373 0.566
609 37 5131.9 5395 0.568
610 37 5131.9 5418 0.571
611 37 5131.9 5439 0.573
612 37 5131.9 5448 0.574
613 27 3744.9 3673 0.530
614 27 3744.9 3681 0.531
615 27 3744.9 3689 0.532
616 27 3744.9 3746 0.541
617 27 3744.9 3754 0.542
618 27 3744.9 3761 0.543
619 37 5131.9 5360 0.565
620 37 5131.9 5373 0.566
621 37 5131.9 5395 0.568
622 37 5131.9 5418 0.571
623 37 5131.9 5439 0.573
624 37 5131.9 5448 0.574

Table 6 Sudden loss of stay – Stays at pylon P21

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2.3 Stay exchange

The stays are checked for stay exchange in SLS with load limit 0.65Fpu. The results are
shown in Tables 7 and 8.

No. of Nominal Stay Stay

Stay No. strands area exchange exchange/
N [mm2] [kN] Fpu

301 27 3744.9 3569 0.515

302 27 3744.9 3592 0.519
303 27 3744.9 3607 0.521
304 27 3744.9 3668 0.529
305 27 3744.9 3674 0.530
306 27 3744.9 3672 0.530
307 37 5131.9 5158 0.543
308 37 5131.9 5180 0.546
309 37 5131.9 5206 0.548
310 37 5131.9 5237 0.552
311 37 5131.9 5259 0.554
312 37 5131.9 5290 0.557
313 27 3744.9 3569 0.515
314 27 3744.9 3592 0.519
315 27 3744.9 3607 0.521
316 27 3744.9 3668 0.529
317 27 3744.9 3674 0.530
318 27 3744.9 3672 0.530
319 37 5131.9 5158 0.543
320 37 5131.9 5180 0.546
321 37 5131.9 5206 0.548
322 37 5131.9 5237 0.552
Pylon MB-P20

323 37 5131.9 5259 0.554

324 37 5131.9 5290 0.557
401 27 3744.9 4034 0.582
402 27 3744.9 4001 0.578
403 27 3744.9 3974 0.574
404 27 3744.9 3999 0.577
405 27 3744.9 3981 0.575
406 27 3744.9 3964 0.572
407 37 5131.9 5509 0.580
408 37 5131.9 5481 0.577
409 37 5131.9 5450 0.574
410 37 5131.9 5415 0.570
411 37 5131.9 5378 0.566
412 37 5131.9 5336 0.562
413 27 3744.9 4034 0.582
414 27 3744.9 4001 0.578
415 27 3744.9 3974 0.574
416 27 3744.9 3999 0.577
417 27 3744.9 3981 0.575
418 27 3744.9 3964 0.572
419 37 5131.9 5509 0.580
420 37 5131.9 5481 0.577
421 37 5131.9 5450 0.574
422 37 5131.9 5415 0.570
423 37 5131.9 5378 0.566
424 37 5131.9 5336 0.562

Table 7 Stay exchange in SLS – Stays at pylon P20

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Katahira& Engineers International Main Bridge –Cable Stays

Nominal Stay Stay

No. of
Stay No. area exchange exchange/
strands N
[mm2] [kN] Fpu

501 27 3744.9 3939 0.569

502 27 3744.9 3906 0.564
503 27 3744.9 3880 0.560
504 27 3744.9 3909 0.564
505 27 3744.9 3903 0.563
506 27 3744.9 3892 0.562
507 37 5131.9 5504 0.580
508 37 5131.9 5494 0.579
509 37 5131.9 5478 0.577
510 37 5131.9 5457 0.575
511 37 5131.9 5431 0.572
512 37 5131.9 5401 0.569
513 27 3744.9 3939 0.569
514 27 3744.9 3906 0.564
515 27 3744.9 3880 0.560
516 27 3744.9 3909 0.564
517 27 3744.9 3903 0.563
518 27 3744.9 3892 0.562
519 37 5131.9 5504 0.580
520 37 5131.9 5494 0.579
521 37 5131.9 5478 0.577
522 37 5131.9 5457 0.575
Pylon MB-P21

523 37 5131.9 5431 0.572

524 37 5131.9 5401 0.569
601 27 3744.9 3637 0.525
602 27 3744.9 3644 0.526
603 27 3744.9 3651 0.527
604 27 3744.9 3708 0.535
605 27 3744.9 3715 0.536
606 27 3744.9 3722 0.537
607 37 5131.9 5306 0.559
608 37 5131.9 5319 0.560
609 37 5131.9 5340 0.562
610 37 5131.9 5362 0.565
611 37 5131.9 5382 0.567
612 37 5131.9 5395 0.568
613 27 3744.9 3637 0.525
614 27 3744.9 3644 0.526
615 27 3744.9 3651 0.527
616 27 3744.9 3708 0.535
617 27 3744.9 3715 0.536
618 27 3744.9 3722 0.537
619 37 5131.9 5306 0.559
620 37 5131.9 5319 0.560
621 37 5131.9 5340 0.562
622 37 5131.9 5362 0.565
623 37 5131.9 5382 0.567
624 37 5131.9 5395 0.568

Table 8 Stay exchange in SLS – Stays at pylon P21

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Katahira& Engineers International Main Bridge –Cable Stays

2.4 Fatigue
Fatigue design of stay cables is calculated from HA load. The maximum and minimum
loads in the stay cables with stress range are shown in Tables 9 and 10. It is found that
some cables in Pylon P20 has stress range more less than 70 MPa. Thus, number of
cable strands for the first 5 cables from the pylon, i.e. stay no. 301-305, 313-317, 401-
405 and 413-417, is increased and the updated stress range of Pylon P20 is shown in
Table 11. The updated stay data of Pylon P20 is shown in Table 12.

No. of Nominal Fatigue Fatigue Stress

Stay No. strands area load max load min range
N [mm2] [kN] [kN] [MPa]

301 27 3744.9 161 -129 77

302 27 3744.9 142 -94 63
303 27 3744.9 125 -64 51
304 27 3744.9 109 -39 39
305 27 3744.9 93 -21 30
306 27 3744.9 77 -12 24
307 37 5131.9 101 -17 23
308 37 5131.9 106 -22 25
309 37 5131.9 117 -27 28
310 37 5131.9 137 -31 33
311 37 5131.9 160 -38 39
312 37 5131.9 182 -52 45
313 27 3744.9 161 -129 77
314 27 3744.9 142 -94 63
315 27 3744.9 125 -64 51
316 27 3744.9 109 -39 39
317 27 3744.9 93 -21 30
318 27 3744.9 77 -12 24
319 37 5131.9 101 -17 23
320 37 5131.9 106 -22 25
321 37 5131.9 117 -27 28
322 37 5131.9 137 -31 33
Pylon MB-P20

323 37 5131.9 160 -38 39

324 37 5131.9 182 -52 45
401 27 3744.9 270 -114 102
402 27 3744.9 250 -95 92
403 27 3744.9 234 -81 84
404 27 3744.9 220 -69 77
405 27 3744.9 208 -59 71
406 27 3744.9 197 -50 66
407 37 5131.9 255 -58 61
408 37 5131.9 239 -50 56
409 37 5131.9 224 -49 53
410 37 5131.9 209 -49 50
411 37 5131.9 193 -48 47
412 37 5131.9 176 -48 44
413 27 3744.9 270 -114 102
414 27 3744.9 250 -95 92
415 27 3744.9 234 -81 84
416 27 3744.9 220 -69 77
417 27 3744.9 208 -59 71
418 27 3744.9 197 -50 66
419 37 5131.9 255 -58 61
420 37 5131.9 239 -50 56
421 37 5131.9 224 -49 53
422 37 5131.9 209 -49 50
423 37 5131.9 193 -48 47
424 37 5131.9 176 -48 44

Table 9 Fatigue design – Stays at pylon P20

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Nominal Fatigue Fatigue Stress

No. of
Stay No. area load max load min range
strands N
[mm2] [kN] [kN] [MPa]

501 27 3744.9 129 -53 49

502 27 3744.9 137 -47 49
503 27 3744.9 145 -40 49
504 27 3744.9 150 -33 49
505 27 3744.9 152 -27 48
506 27 3744.9 151 -25 47
507 37 5131.9 204 -32 46
508 37 5131.9 199 -30 45
509 37 5131.9 192 -33 44
510 37 5131.9 184 -35 43
511 37 5131.9 175 -38 41
512 37 5131.9 164 -39 40
513 27 3744.9 129 -53 49
514 27 3744.9 137 -47 49
515 27 3744.9 145 -40 49
516 27 3744.9 150 -33 49
517 27 3744.9 152 -27 48
518 27 3744.9 151 -25 47
519 37 5131.9 204 -32 46
520 37 5131.9 199 -30 45
521 37 5131.9 192 -33 44
522 37 5131.9 184 -35 43
Pylon MB-P21

523 37 5131.9 175 -38 41

524 37 5131.9 164 -39 40
601 27 3744.9 108 -43 40
602 27 3744.9 102 -35 36
603 27 3744.9 96 -27 33
604 27 3744.9 92 -22 31
605 27 3744.9 89 -21 29
606 27 3744.9 87 -20 28
607 37 5131.9 120 -27 29
608 37 5131.9 125 -27 30
609 37 5131.9 139 -28 33
610 37 5131.9 156 -32 37
611 37 5131.9 174 -42 42
612 37 5131.9 190 -54 47
613 27 3744.9 108 -43 40
614 27 3744.9 102 -35 36
615 27 3744.9 96 -27 33
616 27 3744.9 92 -22 31
617 27 3744.9 89 -21 29
618 27 3744.9 87 -20 28
619 37 5131.9 120 -27 29
620 37 5131.9 125 -27 30
621 37 5131.9 139 -28 33
622 37 5131.9 156 -32 37
623 37 5131.9 174 -42 42
624 37 5131.9 190 -54 47

Table 10 Fatigue design – Stays at pylon P21

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Katahira& Engineers International Main Bridge –Cable Stays

It can be seen that stay no. 401, 402 and 413, 414 still have stress range more than 70
MPa. However, the allowable stress in these stay is now much less than 0.6Fpu as
shown in Table 12. According to Fig 3, the stress range can be increased if the
allowable stress reduces. Thus, all stays now satisfy the fatigue design.

No. of Nominal Fatigue Fatigue Stress

Stay No. strands area load max load min range
N [mm2] [kN] [kN] [MPa]

301 37 5131.9 161 -129 56

302 35 4854.5 142 -94 49
303 33 4577.1 125 -64 41
304 30 4161.0 109 -39 36
305 29 4022.3 93 -21 28
306 27 3744.9 77 -12 24
307 37 5131.9 101 -17 23
308 37 5131.9 106 -22 25
309 37 5131.9 117 -27 28
310 37 5131.9 137 -31 33
311 37 5131.9 160 -38 39
312 37 5131.9 182 -52 45
313 37 5131.9 161 -129 56
314 35 4854.5 142 -94 49
315 33 4577.1 125 -64 41
316 30 4161.0 109 -39 36
317 29 4022.3 93 -21 28
318 27 3744.9 77 -12 24
319 37 5131.9 101 -17 23
320 37 5131.9 106 -22 25
321 37 5131.9 117 -27 28
322 37 5131.9 137 -31 33
Pylon MB-P20

323 37 5131.9 160 -38 39

324 37 5131.9 182 -52 45
401 37 5131.9 270 -114 75
402 35 4854.5 250 -95 71
403 33 4577.1 234 -81 69
404 30 4161.0 220 -69 70
405 29 4022.3 208 -59 66
406 27 3744.9 197 -50 66
407 37 5131.9 255 -58 61
408 37 5131.9 239 -50 56
409 37 5131.9 224 -49 53
410 37 5131.9 209 -49 50
411 37 5131.9 193 -48 47
412 37 5131.9 176 -48 44
413 37 5131.9 270 -114 75
414 35 4854.5 250 -95 71
415 33 4577.1 234 -81 69
416 30 4161.0 220 -69 70
417 29 4022.3 208 -59 66
418 27 3744.9 197 -50 66
419 37 5131.9 255 -58 61
420 37 5131.9 239 -50 56
421 37 5131.9 224 -49 53
422 37 5131.9 209 -49 50
423 37 5131.9 193 -48 47
424 37 5131.9 176 -48 44

Table 11 Updated fatigue design – Stays at pylon P21

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Katahira& Engineers International Main Bridge –Cable Stays

Nominal Stay
Permanent Permanent Max
No. of Nominal stay steel force at Max cable
load in load in Live load Live load design
Stay No. strands area weight finished force
stay T=0 stay T=inf max [kN] min [kN] load SLS
N [mm2] per m bridge SLS/Fpu
[kN] [kN] [kN]
[kg/m] [kN]
301 37 5131.9 40.29 3400 3392 3142 179 -144 3658 0.385
302 35 4854.5 38.11 3400 3428 3205 158 -105 3675 0.409
303 33 4577.1 35.93 3400 3456 3255 139 -70 3684 0.435
304 30 4161.0 32.66 3450 3530 3349 121 -42 3740 0.486
305 29 4022.3 31.58 3450 3550 3388 105 -24 3744 0.503
306 27 3744.9 29.40 3450 3561 3416 93 -15 3743 0.540
307 37 5131.9 40.29 4830 5009 4828 121 -19 5253 0.553
308 37 5131.9 40.29 4830 5025 4859 121 -25 5270 0.555
309 37 5131.9 40.29 4830 5037 4884 134 -30 5296 0.558
310 37 5131.9 40.29 4830 5047 4908 155 -35 5329 0.561
311 37 5131.9 40.29 4830 5045 4919 180 -43 5355 0.564
312 37 5131.9 40.29 4830 5060 4946 204 -60 5396 0.568
313 37 5131.9 40.29 3400 3392 3142 179 -144 3658 0.385
314 35 4854.5 38.11 3400 3428 3205 158 -105 3675 0.409
315 33 4577.1 35.93 3400 3456 3255 139 -70 3684 0.435
316 30 4161.0 32.66 3450 3530 3349 121 -42 3740 0.486
317 29 4022.3 31.58 3450 3550 3388 105 -24 3744 0.503
318 27 3744.9 29.40 3450 3561 3416 93 -15 3743 0.540
319 37 5131.9 40.29 4830 5009 4828 121 -19 5253 0.553
320 37 5131.9 40.29 4830 5025 4859 121 -25 5270 0.555
321 37 5131.9 40.29 4830 5037 4884 134 -30 5296 0.558
322 37 5131.9 40.29 4830 5047 4908 155 -35 5329 0.561
Pylon MB-P20

323 37 5131.9 40.29 4830 5045 4919 180 -43 5355 0.564
324 37 5131.9 40.29 4830 5060 4946 204 -60 5396 0.568
401 37 5131.9 40.29 3400 3679 3659 304 -134 4129 0.435
402 35 4854.5 38.11 3400 3674 3641 283 -113 4091 0.456
403 33 4577.1 35.93 3400 3670 3626 266 -96 4059 0.479
404 30 4161.0 32.66 3450 3716 3662 250 -82 4081 0.530
405 29 4022.3 31.58 3450 3712 3647 236 -69 4058 0.545
406 27 3744.9 29.40 3450 3706 3629 222 -58 4037 0.583
407 37 5131.9 40.29 4830 5172 5047 288 -68 5607 0.591
408 37 5131.9 40.29 4830 5161 5015 270 -59 5577 0.587
409 37 5131.9 40.29 4830 5146 4979 252 -55 5544 0.584
410 37 5131.9 40.29 4830 5130 4941 234 -55 5508 0.580
411 37 5131.9 40.29 4830 5112 4902 215 -54 5470 0.576
412 37 5131.9 40.29 4830 5091 4861 198 -54 5432 0.572
413 37 5131.9 40.29 3400 3679 3659 304 -134 4129 0.435
414 35 4854.5 38.11 3400 3674 3641 283 -113 4091 0.456
415 33 4577.1 35.93 3400 3670 3626 266 -96 4059 0.479
416 30 4161.0 32.66 3450 3716 3662 250 -82 4081 0.530
417 29 4022.3 31.58 3450 3712 3647 236 -69 4058 0.545
418 27 3744.9 29.40 3450 3706 3629 222 -58 4037 0.583
419 37 5131.9 40.29 4830 5172 5047 288 -68 5607 0.591
420 37 5131.9 40.29 4830 5161 5015 270 -59 5577 0.587
421 37 5131.9 40.29 4830 5146 4979 252 -55 5544 0.584
422 37 5131.9 40.29 4830 5130 4941 234 -55 5508 0.580
423 37 5131.9 40.29 4830 5112 4902 215 -54 5470 0.576
424 37 5131.9 40.29 4830 5091 4861 198 -54 5432 0.572

Table 12 Updated stay data – Pylon P20

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Katahira& Engineers International Main Bridge –Cable Stays

Figure3 Allowable stress and fatigue stress range of stay cables

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Katahira& Engineers International Main Bridge –Cable Stays

2.5 Angular change due to cable sag

Cables shall be set out to align with cable sag angle due to permanent load. The angular
change due to cable sag ( ∆α ) can be calculated from:

g ′L2
f′=
8S

 4 f ′ −1  g ′L 
∆α = tan −1   or ∆α = tan  
 L   2S 

Figure4 Angular change due to cable sag

Summary of the results is shown in Tables 13 and 14.

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Katahira& Engineers International Main Bridge –Cable Stays

Cable no. L [m] α [degree] No of strands A [m2] S [kN] g [kN/m] ∆α [degree]

301 27.52 29.02 37 0.00513 3142 0.44 0.10
302 31.87 26.33 35 0.00485 3205 0.41 0.11
303 36.27 24.30 33 0.00458 3255 0.39 0.11
304 40.71 22.71 30 0.00416 3349 0.35 0.11
305 45.18 21.43 29 0.00402 3388 0.34 0.12
306 49.66 20.38 27 0.00374 3416 0.32 0.12
307 54.16 19.51 37 0.00513 4828 0.44 0.13
308 58.67 18.77 37 0.00513 4859 0.44 0.14
309 63.19 18.14 37 0.00513 4884 0.44 0.15
310 67.71 17.59 37 0.00513 4908 0.44 0.16
311 72.24 17.11 37 0.00513 4919 0.44 0.18
312 76.78 16.68 37 0.00513 4946 0.44 0.19
313 27.52 29.02 37 0.00513 3142 0.44 0.10
314 31.87 26.33 35 0.00485 3205 0.41 0.11
315 36.27 24.30 33 0.00458 3255 0.39 0.11
316 40.71 22.71 30 0.00416 3349 0.35 0.11
317 45.18 21.43 29 0.00402 3388 0.34 0.12
318 49.66 20.38 27 0.00374 3416 0.32 0.12
319 54.16 19.51 37 0.00513 4828 0.44 0.13
320 58.67 18.77 37 0.00513 4859 0.44 0.14
321 63.19 18.14 37 0.00513 4884 0.44 0.15
322 67.71 17.59 37 0.00513 4908 0.44 0.16
323 72.24 17.11 37 0.00513 4919 0.44 0.18
324 76.78 16.68 37 0.00513 4946 0.44 0.19
401 27.29 28.13 37 0.00513 3659 0.44 0.08
402 31.62 25.40 35 0.00485 3641 0.41 0.09
403 36.00 23.33 33 0.00458 3626 0.39 0.10
404 40.43 21.72 30 0.00416 3662 0.35 0.10
405 44.87 20.42 29 0.00402 3647 0.34 0.11
406 49.34 19.36 27 0.00374 3629 0.32 0.12
407 53.83 18.48 37 0.00513 5047 0.44 0.13
408 58.32 17.73 37 0.00513 5015 0.44 0.14
409 62.82 17.09 37 0.00513 4979 0.44 0.15
410 67.33 16.53 37 0.00513 4941 0.44 0.16
411 71.85 16.05 37 0.00513 4902 0.44 0.18
412 76.37 15.62 37 0.00513 4861 0.44 0.19
413 27.29 28.13 37 0.00513 3659 0.44 0.08
414 31.62 25.40 35 0.00485 3641 0.41 0.09
415 36.00 23.33 33 0.00458 3626 0.39 0.10
416 40.43 21.72 30 0.00416 3662 0.35 0.10
417 44.87 20.42 29 0.00402 3647 0.34 0.11
418 49.34 19.36 27 0.00374 3629 0.32 0.12
419 53.83 18.48 37 0.00513 5047 0.44 0.13
420 58.32 17.73 37 0.00513 5015 0.44 0.14
421 62.82 17.09 37 0.00513 4979 0.44 0.15
422 67.33 16.53 37 0.00513 4941 0.44 0.16
423 71.85 16.05 37 0.00513 4902 0.44 0.18
424 76.37 15.62 37 0.00513 4861 0.44 0.19

Table 13 Angular change due to cable sag – Stays at pylon P20

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Cable no. L [m] α [degree] No of strands A [m2] S [kN] g [kN/m] ∆α [degree]

501 27.52 29.02 27 0.00374 3768 0.32 0.06
502 31.87 26.33 27 0.00374 3723 0.32 0.07
503 36.27 24.30 27 0.00374 3687 0.32 0.08
504 40.71 22.71 27 0.00374 3707 0.32 0.09
505 45.18 21.43 27 0.00374 3680 0.32 0.10
506 49.66 20.38 27 0.00374 3653 0.32 0.12
507 54.16 19.51 37 0.00513 5159 0.44 0.12
508 58.67 18.77 37 0.00513 5119 0.44 0.14
509 63.19 18.14 37 0.00513 5077 0.44 0.15
510 67.71 17.59 37 0.00513 5035 0.44 0.16
511 72.24 17.11 37 0.00513 4992 0.44 0.17
512 76.78 16.68 37 0.00513 4947 0.44 0.19
513 27.52 29.02 27 0.00374 3768 0.32 0.06
514 31.87 26.33 27 0.00374 3723 0.32 0.07
515 36.27 24.30 27 0.00374 3687 0.32 0.08
516 40.71 22.71 27 0.00374 3707 0.32 0.09
517 45.18 21.43 27 0.00374 3680 0.32 0.10
518 49.66 20.38 27 0.00374 3653 0.32 0.12
519 54.16 19.51 37 0.00513 5159 0.44 0.12
520 58.67 18.77 37 0.00513 5119 0.44 0.14
521 63.19 18.14 37 0.00513 5077 0.44 0.15
522 67.71 17.59 37 0.00513 5035 0.44 0.16
523 72.24 17.11 37 0.00513 4992 0.44 0.17
524 76.78 16.68 37 0.00513 4947 0.44 0.19
601 27.29 28.13 27 0.00374 3024 0.32 0.07
602 31.62 25.40 27 0.00374 3112 0.32 0.08
603 36.00 23.33 27 0.00374 3185 0.32 0.09
604 40.43 21.72 27 0.00374 3296 0.32 0.10
605 44.87 20.42 27 0.00374 3349 0.32 0.11
606 49.34 19.36 27 0.00374 3392 0.32 0.13
607 53.83 18.48 37 0.00513 4890 0.44 0.13
608 58.32 17.73 37 0.00513 4930 0.44 0.14
609 62.82 17.09 37 0.00513 4963 0.44 0.15
610 67.33 16.53 37 0.00513 4993 0.44 0.16
611 71.85 16.05 37 0.00513 5019 0.44 0.17
612 76.37 15.62 37 0.00513 5042 0.44 0.18
613 27.29 28.13 27 0.00374 3024 0.32 0.07
614 31.62 25.40 27 0.00374 3112 0.32 0.08
615 36.00 23.33 27 0.00374 3185 0.32 0.09
616 40.43 21.72 27 0.00374 3296 0.32 0.10
617 44.87 20.42 27 0.00374 3349 0.32 0.11
618 49.34 19.36 27 0.00374 3392 0.32 0.13
619 53.83 18.48 37 0.00513 4890 0.44 0.13
620 58.32 17.73 37 0.00513 4930 0.44 0.14
621 62.82 17.09 37 0.00513 4963 0.44 0.15
622 67.33 16.53 37 0.00513 4993 0.44 0.16
623 71.85 16.05 37 0.00513 5019 0.44 0.17
624 76.37 15.62 37 0.00513 5042 0.44 0.18

Table 14 Angular change due to cable sag – Stays at pylon P21

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Katahira& Engineers International Main Bridge –Cable Stays

3. Cable tension
In an extradosed bridge, the bridge girder is supported by 1) cables and 2) stiffness of
the girder itself. This is unlike cable stayed bridge where the girder is completely
supported by cables. This is the reason that in extradosed bridge, girder depth is varied
and thicker than cable stayed bridge.

The cables are used to carry part of girder dead load (DL), superimposed dead load
(SDL) and live load (LL). Part of these 3 loads is also carried by stiffness of the girder.
For cables to carry DL, we have to pre-tension (stress) the cables at casting of girder
segment in the construction stage. The pre-tension force in cable is called ‘initial cable
tension force’. When the next segment is cast and the next cable is pre-tensioned, it will
also affect the force in the previous installed cable so the force in the previous cables
will change. Until the bridge is completed the force in each cable will keep changing
due to weight of segment and pre-tension force of cable that comes later. The final force
in cables when the bridge is finished is called ‘final cable tension force’.
In the design, we can obtain the final cable tension force by trial and error to optimize
the cable force and moment in bridge girder. Once the final cable tension force is
obtained, we do backward analysis to obtain the initial cable tension force to pre-tension
each cable at each construction stage.

In actual construction, the final cable tension force is given in the drawing to the
contractor. They will also have to do backward analysis based on their construction
method and schedule to obtain initial cable tension force to pre-tension each cable at
each stage. The initial cable tension force obtained by the contractor may not be the
same as the designer’s. This is because assumption of construction method and schedule
may be different. However, the main point is to achieve the same final cable tension
force.

In some cases, however, the actual final cable tension force when the construction
finishes may not be the same as the desired value. (This can be measured when the
bridge is finished.) This is due to difference in construction and calculation assumption.
In that case, the contractor has to adjust the cable force. It is called cable tension force
adjustment. This is only done in the actual construction not in the design.
As mentioned above, part of the loads is carried by the girder. So the girder is
strengthened by prestressing tendons and prestressing bars. The prestressing tendons
and bars are stressed when the girder is cast.

Figures below present the construction stage of the bridge as explained above. Figure 1
shows bending moment at casting of segment D. Figure 2 shows bending moment after
pre-tension cables at segment D with initial cable tension force 3470 kN. It can be seen
that the moment is significantly reduced. Figure 3 and 4 show the same at segment E.

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Katahira& Engineers International Main Bridge –Cable Stays

At this stage, we can observe the change in cable tension force at cable segment D.
Figure 5 and 6 show the same at segment O.

Figure 7 shows bending moment at bridge finishes. At this stage, force in cable at
segment D becomes 3400 kN. This value is the final cable tension force that we want to
have. Please see also table 2 under section 1.6 Cable tension forces in 2. Load summary.
It shows 3400 kN for cable 301, 313. In actual construction, contractor will check the
force in the cable at this stage. If the forces are different more than the allowable
tolerance, they will have to adjust the force.

Figure 8 shows bending moment at segment O if there were no cables at all (moment = -
1,600,331 kN-m). It can be compared with moment in Figure 6 with cables (moment = -
245,135 kN-m). The difference is the moment carried by cables. Figure 9 shows
bending moment at bridge finishes if there were no cables (moment = -1,976,347 kN-
m). This can also be compared to the value in Figure 7 with cables (moment = -633,206
kN-m)

Figure 1 Bending moment at casting of segment D

(Moment = -243,118 kN-m)

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Figure 2 Bending moment after pre-tension cables at segment D

(Moment = -155,650 kN-m)
Cable is pre-tensioned with initial cable tension force 3470 kN.

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 3 Bending moment at casting of segment E

(Moment = -241,724 kN-m)
At this stage, force in cable at segment D is 3515 kN. The change is due to the weight of
segment E.

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 4 Bending moment after pre-tension cables at segment E

(Moment = -148,513 kN-m)
Cable at segment E is pre-tensioned with initial cable tension force 3441 kN.
At this stage, force in cable at segment D is 3441 kN.

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 5 Bending moment at casting of segment O

(Moment = -346,676 kN-m)
At this stage, force in cable at segment D is 3315 kN.

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 6 Bending moment after pre-tension cables at segment O

(Moment = -245,135 kN-m)
At this stage, force in cable at segment D is 3207 kN.

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 7 Bending moment at bridge finishes

(Moment = -633,206 kN-m)
At this stage, force in cable at segment D is 3400 kN. This is the final cable tension
force we want to have. Please see also table 2 under section 1.6 Cable tension forces in
2. Load summary.

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 8 Bending moment after casting segment O without cables

(Moment = -1,600,331 kN-m)

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Katahira& Engineers International Main Bridge –Cable Stays

Figure 9 Bending moment at bridge finishes without cables (Moment = -1,976,347 kNm)

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