V S L S S I 2 0 0 0 S TAY CA B L E SY S T E M

DESIGN
ENGINEERING
SUPPLY
INSTALLATION
MONITORING
 VSL MAINTAINS THE LEAD
IN STAY CABLE
TECHNOLOGY
Industrial Ring Road Bangkok, 2006 Stay cables installed strand-by-strand.
VSL: a worldwide network
VSLs organisation as a network of closely-
cooperating regional units allows it to provide
a full range of solutions and services worldwide.
Customers have access to a local presence, while
benefiting from global resources, know-how and
expertise as well as VSLs continuing development
of specialist construction techniques. The VSL
networks valueadded services are combined
to provide fully-customised solutions, from concept
to site works, using highly-trained and experienced
staff working in close partnership with clients.
VSL: a commitment to Quality,
Safety and the Environment
VSL pursues a strong QSE policy in keeping
with its position as a technical leader in the
industry. Local teams aim continuously to
establish, maintain and improve their pro-
V S L
active management systems and high
performance standards.
VSL recognizes that employees are the key to
competitiveness and effective working prac-
tices. The company is committed to safety
first and strives for zero accident, with
employees motivated to take the necessary
responsibilities to achieve this goal.
Clearly-defined measures are in place to
promote sustainable development as part of
VSLs contribution to environmental protection.
VSL: a specialist
stay cable contractor
As leader in stay cable technology, VSL paves
the way with new developments. The last
10 years in particular have seen a boom in
stay cables, with a considerable increase in
the span lengths that can now be achieved as
S S I 2 0 0 0 2 S T AY C A B L E S Y S T E M
well as faster installation and erection cycles
thanks to VSLs construction techniques.
VSL has experience of more than
130 cable-stayed bridges, including 40 in the
last eight years, and its close participation
with clients and builders has resulted in a
next-generation technical solution.
The VSL SSI 2000 System described here
combines the latest developments with VSLs
best solutions, and has already been used for
dozens of bridges. The system offers high
fatigue resistance, excellent corrosion
protection and cable-force monitoring, as well
as allowing adjustment, inspection and
replacement of the strands. It maintains
stringent durability standards, whilst
incorporating new features for greater
flexibility and simpler, more slender cables
and anchorages.
 Recent VSL developments
in stay cable technology
VSL Saddle, a patented solution allowing much
simpler pylon design resulting in enhanced bridge
aesthetics;
Compact anchorage, leading to simplified design
and construction of the pylon and superstructure;
Compact stay cable system, resulting in a tighter
arrangement of the strands and hence a reduced
cable diameter and a lower cable wind load;
Cable protected by dehumidification
techniques, a patented solution offering
the lowest wind load on strand cables,
with a permanent monitoring;
Uddevalla Bridge Sweden, 1998
A choice of cable-vibration damping systems, Stay cables installed strand-by-strand and equipped with anti-vibration
which permits optimum load adaptation for each friction dampers.
structure.

Modern engineering:
stringent standards
Designers and regulators throughout the world
are demanding:
increased durability of stay cables, including
corrosion protection of both cable and
anchorage, leak-proofing of the anchorage
assembly, good anchorage conditions, easy
inspection and maintenance, cable
replacement with minimal traffic interruption,
cable vibration control and a compact stay La Unidad Bridge Mexico, 2003
bundle with a reduced wind drag-coefficient; Full scope of bridge construction.
outstanding fatigue and static load
performance levels (200MPa and 300MPa
stress range fatigue test for the SSI 2000
anchorage assembly and components);
improved aesthetics arising from the
availability of saddles, compact anchorages
and coloured cables;
incorporation of damping systems into the
anchorage.

Main contractors also look for optimal

construction schedules such as:
a design that takes into account the close
Liebrueti Bridge Switzerland, 1978
relationship between deck erection and stay First VSL Stay cable bridge
cable installation;
lightweight installation equipment to enable
easier operations and a more flexible erection
programme.

Clients benefit from:

enhanced durability that is built in;
easier long-term maintenance, providing
substantial savings.

The VSL SSI 2000 stay cable system is designed

to meet all of these demanding requirements.

Las Glorias Footbridge - Spain, 1991

Cable installation with
Supply of the stay cables and supervision at installation.
VSL lightweight equipment

V S L S S I 2 0 0 0 3 S T AY C A B L E S Y S T E M
SSI 2000: VSL STAY CABLE TECHNOLOGY
Compact anchorage Several High fatigue performance
Length of a fixed end anchorage complementary VSL strands
for 127 strands is only 440mm. barriers High fatigue performance over 300 MPa
For anchorage water stress range at 2 millions cycles.
tightness system Compatible with VSL SSI Saddle
d) anchorage
Adjustable (or fixed en

Individual strand deviation device

High fatigue resistance
VSL anchorage
Demonstrated by fib and PTI fatigue tests
with combined tension and bending action.
Filtering cable bending stress at the anchorage device
Increased corrosion
protection Individual encapsulation
Each strand separately protected
Factory applied individual protection
inside the anchorage
treatments, for a design life of 100 years
in the most aggressive environments,
without maintenance

The SSI 2000 Stay Cable System is based on proven stay cable wedge/strand
anchorage technology, which has been in use for more than 30 years. It meets
the most stringent requirements and has been used on more than 120 stay
cable projects. The system has successfully passed extensive full-scale fatigue
testing, including the new leak-tightness tests required by the PTI and fib.

High fatigue performance
Anchorages include design features to filter
out vibrations and bending stresses in the
cable before they can reach the anchorage
wedges. Sample stay cables have been
subjected to fatigue testing with cable angular
deviations as defined in the latest PTI and fib
recommendations. Anchorages can be
equipped with additional cable protection
systems where unusual cable deviations need
to be taken into account (see page 6).
High durability and a new
standard of protection
a) For the corrosion protection of the steel
anchorage components, VSL has developed
a new system that provides the best protection
in the most aggressive environments. It enables
100 years of maintenance-free operation for
non-accessible components.
b) Individual encapsulation of each strand
within the anchorage avoids the risk of
corrosion migration between strands. Full
encapsulation is achieved by providing each
strand with its own protection system.
c) Complementary barriers provide a degree of
redundancy to ensure the leak-tightness of the
anchorage. The sealing system has passed the
various tests as defined by fib and PTI.
Cable replacement
without traffic interruption
The very compact nature of the anchorages
allows installation in confined spaces within
box girders and pylons. The single strand
installation method and stressing operations
have been optimised to facilitate cable
installation using very lightweight equipment
for greater flexibility in construction.
Easy incorporation
of a VSL internal damping system
The stay cable system can be designed with
provision for later installation of a VSL
vibration damping system, should it prove
necessary (see page 14).

V S L S S I 2 0 0 0 4 S T AY C A B L E S Y S T E M
Y FOR BRIDGES
Versatility
Designed to accommodate a VSLs vibration damping Low drag coefficient
system which can be installed retro-actively
Measured in wind tunnel

Versatile tension ring Replaceable stay cable system

May be used as a guide deviator
Each strand can be individually checked
for increased cable angular
and at any time, replaced and re-installed.
deviations
Complete cable is replaced with closure
of only one traffic lane.

Reduced cable wind loads
The VSL stay pipes installed on the bridges are
generally equipped with external helical ribs to
suppress vibrations induced by rain and wind.
Wind tunnel testing has demonstrated the
efficiency of the VSL-designed helical ribs in
reducing drag at wind speeds up to 70m/s.
The VSL compact system:
SSI 2000-C for long cables
Wind load on the cables can be an important
parameter for the structural design of bridges with
very long cables. For these cables, VSL has
developed SSI 2000-C, an adaptation of the
standard SSI 2000. It uses the same anchorages
and connections but features a 20% reduction in
cable diameter. Reduced wind loads result from its
use in combination with the lower wind drag
coefficient of the VSL stay pipe.
The VSL SSI 2000-D:
dry air system for lower wind loads
VSL SSI 2000-D is an adaptation of the
standard system, using the same
wedge/strand anchorage technology. Its main
feature is a greatly-reduced cable diameter of
about 30% less than standard, which results
in significantly lower wind loading. SSI 2000-D
cables are protected by dry air using the same
technology as found in the protection of many
steel bridge decks and suspended cables
(see page 10).
The VSL SSI 2000 Saddle allowing
replacement of strand
VSL has developed a patented new pylon saddle
for its SSI 2000 Stay Cable System, designed for
use with the standard sheathed strand used on
extradosed and cable-stayed bridges.
The compact saddle allows strand by strand
installation and replacement of each strand.
Tests have demonstrated that the saddles
fatigue performance is the same as for
anchorages. High friction of the cable on the
saddle allows its use in pylons subjected to
significant unbalanced cable loads (see page 12).

V S L S S I 2 0 0 0 5 S T AY C A B L E S Y S T E M
 VSL SSI 2000 MAIN DIMENSIONS
DECK CONNECTION
Designed with a tension ring or a guide deviator,
and a VSL damping system if required.

Cable equipped with a tension ring

Designed to accommodate a cable
angular deviation of 25mrd
(1.4 degrees) on entry to the
anchorage, as per the PTI
and fib recommendations.

ADJUSTABLE ANCHORAGE
i
min

F1 L1 mini
L1

C1
B1
A1

E1
Guide pipe

D1
Cable equipped with a guide deviator
This provides the anchorage with a greater level of H1 mini
G1
protection in case the cable is subjected to higher
angular deviations such as seismic events. For
long guide pipes the guide deviator protects
the cable from contact, whatever the DECK ANCHORAGE
amplitude. It also allows for the guide with adjustable or fixed end anchorages
pipe assembly to be installed with
increased tolerances.
i
min
L1

Connection detail for subsequent installation of

a VSL damping system
The flange welded to the end of the guide pipe
and the increased diameter of the anti-
vandalism pipe are designed to allow for
later installation of a VSL damping
system, should cable vibrations need
to be rectified. The cable can be
equipped with a guide deviator Cable equipped with the VSL friction damper
(see figure) or, more In the event of unexpected cable vibrations,
generally, with a tension a choice of VSL damping systems - friction
ring. damper or Gensui damper - can be
installed without modification to the
cable assembly.

PYLON ARRANGEMENT
i
min

Distance between facing fixed end

L1

anchorages is 1.4m. Distance of

approx. 3.5m is recommended when
i
min

stressing jacks are used.

L1
L*

1.4m

V S L S S I 2 0 0 0 6 S T AY C A B L E S Y S T E M
 Stay cable equipped
with a tension ring

PYLON CONNECTION

L1
The pylon connection is similar to the deck
connection and can be designed with either
a tension ring or, in some cases, with a

L1
guide deviator.

Stay cable equipped

with a guide deviator

FIXED END ANCHORAGE

L1 mini F2
Cable diameter

C2
A2
E2
Guide pipe

D2
H2 mini
G2

STAY PIPE PYLON ANCHORAGE

DECK CONNECTION PYLON CONNECTION with adjustable or fixed end
FREE LENGHT
anchorages

TENSION
CABLE DIAMETER (mm) ADJUSTABLE ANCHORAGE (at deck or pylon) FIXED END ANCHORAGE (at deck or pylon) RING

ANCHORAGE SSI 2000 SSI 2000-C* SSI 2000-D Anchorage Number A1 B1 C1 D1 E1 F1 G1 H1 mini A2 C2 D2 E2 F2 G2 H2 mini L1 mini
UNIT unit of strands mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

6-12 125 95 85 6-12 12 190 230 290 219.1 / 6.3 196 500 30 325 185 260 177.8 / 4.5 150 300 35 210 800
6-19 140 110 95 6-19 19 235 285 355 267 / 6.3 241 500 35 350 230 335 219.1 / 6.3 190 300 50 225 1100
6-22 160 125 105 6-22 22 255 310 385 298.5 / 7.1 261 500 40 360 250 355 219.1 / 6.3 205 300 50 225 1250
6-31 160 135 115 6-31 31 285 350 440 323.9 / 7.1 291 700 45 410 280 415 244.5 / 6.3 230 300 60 250 1400
6-37 180 150 130 6-37 37 310 380 485 355.6 / 8 316 700 50 440 300 455 273 / 6.3 255 250 70 275 1600
6-43 200 170 145 6-43 43 350 425 540 406.4 / 8.8 356 700 55 455 340 505 323.9 / 7.1 285 250 75 280 1850
6-55 200 175 150 6-55 55 385 470 585 419 / 10 391 700 60 495 380 550 323.9 / 7.1 310 250 75 300 1950
6-61 225 185 160 6-61 61 385 470 600 419 / 10 391 700 65 530 380 585 355.6 / 8 330 200 85 320 2150
6-73 250 200 170 6-73 73 440 530 680 508 / 11 446 700 75 530 430 650 406.4 / 8.8 370 200 95 335 2300
6-85 250 210 180 6-85 85 440 540 710 508 / 11 446 700 80 590 430 685 406.4 / 8.8 370 200 110 365 2450
6-91 280 220 190 6-91 91 490 590 760 559 / 12.5 496 700 80 585 480 730 457 / 10 420 200 110 375 2650
6-109 315 235 200 6-109 109 505 610 795 559 / 12.5 511 700 90 620 495 775 457 / 10 420 200 120 385 2800
6-127 315 265 225 6-127 127 560 670 865 610 / 12.5 566 700 95 650 550 845 508 / 11 475 200 130 435 3200

6-175 355 6-175 175 640 770 1000 711/14.2 646 700 110 730 620 1000 711/14.3 530 200 150 460 3700

*with PTI tightly extruded strand Customized sizing can be provided for large cables on request.
Valid for nominal concrete strength at stressing to 45% of stay capacity: 45 MPa (cube), 36 MPa (cylinder). Dimension must be checked in case of other bearing conditions.
Guide pipe to be checked if use of guide deviator or damping system.
Minimum value allows on adjustability of 40 mm.

V S L S S I 2 0 0 0 7 S T AY C A B L E S Y S T E M
ENHANCED DURABILITY WITH SSI 2000
Durability and fatigue strength are the two most important requirements for
stay cables designed to enable 100 years of maintenance-free operation for
non-accessible components in the most aggressive environments. VSL has
recently developed some new products and services, therefore offering
complementary barriers providing new degrees of redundancy.

VSL colored stay pipe with helical ribs,
tested in a wind tunnel
Accelerated ageing tests
Correct specification and manufacturing is
important to avoid significant variations over
time in the characteristics of the non-steel
components such as the HDPE/PP used for the
stay pipe and strand sheathing.
UV radiation and/or pollution may cause the
colour of the HDPE stay pipe to change over
time. The fading of the colour is controlled
such that it remains invisible to the naked eye.
The evolution of the mechanical and
colourimetric characteristics is verified during
accelerated ageing tests of the VSLs coloured
stay pipes.
The SSI 2000 System is now offering new
developments, all leading to enhance cable
durability :
The VSL SSI 2000-D to reduced cable
wind loads
VSL SSI 2000-D is an adaptation of the
standard system, using the same
wedge/strand anchorage technology. Its main
feature is a greatly-reduced cable diameter of
about 30% less than standard, which results
in significantly lower wind loading. SSI 2000-D
cables are protected by dry air using the same
technology as found in the protection of many
steel bridge decks and suspended cables (see
page 10).

Durability of the VSL stay cable system Anchorage leak-tightness test

VSL stay cables are replaceable and have a
design life of 100 years in the most aggressive
environments, as defined by the C4 and C5
categories of the ISO 12944 standard.
VSL specifications for the corrosion-protection
system of steel components are much more
stringent than the durability recommendations
from PTI and CIP. The components which are non-
accessible are manufactured with a protection
system that has a design life of 100 years
without maintenance. The first maintenance
operation on the accessible and replaceable
components is scheduled after 25 years.
Each component and the entire assembly of VSL
anchorages have all been subjected to analysis,
to determine the best materials, component
geometries, assembly type and protection
system to achieve the highest durability.
The barriers that protect the cable along its free
length are checked by appropriate component
tests. It is important to have efficient measures
in place to prevent ingress of water into the
anchorage interfaces, particularly at the deck.
The VSL anchorages sealing system is designed
with a high degree of redundancy and the
anchorage has passed the leak-tightness tests
as defined by PTI and fib. Adjustable anchorages are Tensile test of a sample HDPE
protected by a sprayed stay pipe which has been
metallic coating. subjected to an ageing test.
Durability at the construction stages
The durability of each component depends on
its design and choice of material. However, the
durability of the complete cable will also
depend on the quality of the installation works
and the provisions made for easy inspection
and replacement. VSL has incorporated
permanent control systems which allow for the
detection during the strand installation of any
defect that would reduce the stay cables
durability. Any component can be easily Checking of a 6-37 anchorage after a PTI leak-tightness
replaced without critical delay to the test. After being submitted to mechanical environmental
constraints, the anchorages were placed in a chamber with
installation schedule. 3m-head of dye solution to check the ingress.

V S L S S I 2 0 0 0 8 S T AY C A B L E S Y S T E M
SYSTEM & DEVELOPMENT

DURABLE BUT ALSO AESTHETIC

The VSL SSI 2000 Saddle allowing

cable replacement
VSL has developed a patented new pylon
saddle for its SSI 2000 Stay Cable System,
designed for use with the standard sheathed
strand used on extradosed and cable-stayed
bridges. The compact saddle allows strand by
strand installation and replacement of
individual strands. Tests have demonstrated
that the saddles fatigue performance is the Red color stay pipes White color stay pipes Gold color stay pipes
same as for anchorages. High friction of the (Sucharskiego Bridge, Poland) (Neva Bridge, Russia) (Industrial Ring Road, Bangkok)
cable on the saddle allows its use in pylons
subjected to significant unbalanced cable
loads (see page 12).

VSL solutions for cable vibration

VSL is providing two types of internal damping
systems: the VSL Damper and the Gensui
Damper.
The SSI Stay Cable System can be designed
with provision for later installation of a VSL
vibration damping system, should it prove
necessary (see page 12).

Required durability
of stay cables VSL loadcell

Various durability requirements have been

developed:
PTI stay cable recommendations are for a
75-year design life.
The CIP document says 50 years and
100 years for replaceable and non-replaceable
cables respectively.
fibs stay cable recommendations are
100 years protection against corrosion
for steel components and a design life
of 50 years for non-metallic components,
with replaceability of components.
VSL structural monitoring services
VSL monitoring package is offered as an
additional service to provide the client with
long term cost savings. It can be applied to
structures and to cables. In-house R&D has
placed emphasis on durability method,
measurement and sensor configurations to
optimise maintenance; to detect damage and
confirm diagnosis of deterioration; to validate
and memorise know-how for future projects; to
optimise life cycle cost of the structure.

V S L S S I 2 0 0 0 9 S T AY C A B L E S Y S T E M
SSI 2000 SYSTEM DEVELOPMENT

THE VSL SSI 2000-D SYSTEM

A stay cable system protected by dry air*

Reduced cost for any

cable replacement
Non-sheathed VSL strands
Permanent visual control
of the cable corrosion at the Bearing plate
anchorages, without dismantling.

Protection cap

No damage
of the cable
protection during
Guide pipe installation

Dry air protection

of the cable, the anchorages and
the vibration damping system

Permanent monitoring
of the corrosion protection
system of the cables:
Temperature The dehumidifier unit
Humidity placed within the pylon
Air pressure supplies dry air to the
pylon anchorages.

The airtight HDPE stay pipe is connected at

Non-sheathed strands
protected by dry air
The complete stay cable system is designed so
that the strands are located within an airtight
enclosure along their free length and along the
two anchorage lengths.
The cable, anchorages and any vibration
damping system are all protected against
corrosion.
Dry air
one end to the pylon and at the other to the supply pipe
deck anchorage. The cable is composed of
non-sheathed strands manufactured with
Stay cable
a protective coating such as galvanising.
A dehumidifier unit, which is generally placed
inside the pylon, is equipped with air-pushing
fans to maintain a low but permanent pressure
of dry air along the cable length. This permanent
pressure prevents any ingress of water from the
outside environment into the cable.

* Patent pending

V S L S S I 2 0 0 0 10 S T AY C A B L E S Y S T E M
 Co-extruded
HDPE stay pipe
with helical rib

Cable with 3 nested

layers of protection
Anti vandal pipe
Reduced cable
diameters
Strand cable with the
lowest outer diameter
allowing reduced cable
wind load

VSL friction
damper

Sealing device
protected inside the
anti vandal pipe
The dehumidifier unit placed within the pylon
supplies the dry air to the pylon anchorages.
The dry air flows from the pylon anchorages to
those at the deck. The space between the
strands inside the HDPE pipe allows circulation
of the dry air around the steel strands, with a
pressure at the deck anchorage that is slightly
above atmospheric pressure.
Dry air: a proven solution
The use of dehumidification or dry air systems
to protect steel decks and suspension cables
was introduced in 1971 and it is now a well-
understood and highly-regarded solution.
The efficiency of dehumidification has also
been demonstrated in the protection of the
cables of several suspension bridges,
including those of the Akashi Kaiko Bridges
1991m-long main span.
Increased layers
of corrosion protection
The main tensile elements of standard stay cable
systems are designed with two levels of protection
whereas the SSI 2000-D offers three levels:
- (continuous) steel coating of the strand
- (continuous) dry air around the strands
- an airtight enclosure provided by the stay pipe.
Permanent monitoring of the cable
corrosion protection system
Permanent monitoring of the cable protection is
provided. A protection cap is installed at the
deck anchorage and is designed for the
connection of sensors to measure the humidity,
air pressure and air temperature, as well as the
dehumidification control system.
Anchorage protection cap allowing visual inspection of cable
The anchorage protection cap can also be
designed to allow permanent visual inspection
of the strands and wedges without any need to
interfere with the system. This significantly
reduces the time and costs involved in the
long-term maintenance of the cables.
Offering protection for the deck
The SSI 2000-D Dehumidification System can
also be used to achieve complete protection of
bridge decks that are designed as steel boxes.
The dry air flowing along the cables can be fed
into the compartments of the deck.

The dehumidification equipment used by VSL

for cable protection in the SSI 2000-D System
is based on proven technology. Long-term
experience on steel decks protection has
confirmed the low maintenance costs of
dehumidification systems and their great
reliability. VSL can provide estimates of
running costs if required. The dry air combined protection

V S L S S I 2 0 0 0 11 S T AY C A B L E S Y S T E M
SSI 2000 SYSTEM DEVELOPMENT
THE VSL SADDLE
VSL has developed a new concept in saddles that achieves the performance
of stay cable anchorages. Moreover, each strand of the cable can also be
replaced if required.
One of the great advantages of the VSL Saddle
is that it allows designers to simplify the pylon
structure and use very slender profiles to
achieve an attractive appearance.
The new VSL Saddle was developed in response
to issues with existing saddle designs, relating
to fatigue, fretting corrosion and replacement of
the cables. CIP had considered these issues so
serious that it had recommended abandoning
saddles and using anchorages instead.
Fatigue testing of the VSL saddle
V S L
Two independent corrosion
protection barriers
The compact saddle is composed of a
rectangular steel box filled with a high-strength
Ductal cement grout. The design ensures high
friction between the cable and the saddle.
Cables can be installed or replaced strand
by strand, and the strands can be tensioned
independently. Two separate corrosion protection
barriers protect the cable inside the saddle:
- a protective strand coating such as
galvanising;
- a special flexible filler injected around the
strands, using the same material that protects
the strands within VSL anchorages.
Independent replaceable strands
Each strand of the cable is free and completely
independent in the VSL Saddle. Instead of the
usual design, the VSL Saddle has no corrosion-
susceptible individual tubes. Each strand of
the cable passes through the saddle in an
independent hole in the cement grout. Special
VSL formwork has been designed for this. The
number of holes in the saddle will generally
correspond to the number of cable strands.
However, additional holes can be provided for
extra strands, such as a reference strand for
later inspection.
V shaped holes for high friction
An important feature of the VSL Saddle is the
shape of its strand holes. The holes are V
shaped, instead of the circular ones used on
saddles with individual tubes. This special
hole geometry is the result of extensive testing
carried out in VSLs laboratories to define the
optimum shape to achieve high friction
between the strand and the saddle while
avoiding fretting and allowing easy strand
installation.
S S I 2 0 0 0 12 S T AY C A B L E S Y S T E M
Saddle section, with the V shaped strand hole
Transfer of high cable differential
forces into the pylon
The cable passing through the saddle can be
subjected to differential forces from opposite
sides of the pylon. These forces could induce a
sliding of the cable within the saddle but this
is prevented by the friction of the individual
strands inside the saddle. The laboratory tests
measured the friction coefficient as varying
from 0.4 to 0.7, depending mainly on the
loading conditions.
Angular deviations of the cable
at the saddle
On some cable-stayed bridges, the cable can
be subjected to non-negligible angular
deviations at the pylon. These deviations may
gradually cause deterioration in the cable
protection and in its mechanical strength.
In order to withstand these angular deviations,
the prefabricated VSL Saddle incorporates a
special elastomeric casting resin where the
cables exit the saddle.
No degradation of the cables fatigue
performance
Fatigue tests were carried out on small cable
units in order to determine any effect of the
saddle on the cables fatigue performance. The
strands were tensioned to the cable-breaking
load after two million fatigue cycles with a
stress range of 200MPa and a maximum load
of 45% of cable capacity. No wire breaks were
observed in the saddle and subsequent
dismantling of the strands showed that they
were in very good condition and confirmed the
feasibility of strand replacement.

Cost saving cable VSL Saddle design with

cable connection
The VSL Saddle uses the same standard
tightly-extruded sheathed strand as for stay
cables. No special treatment of the strand is
required and cable replacement can be carried
out with the same standard strand.

Manufactured saddle
for SSI strand cable
Main dimensions
(using VSL SSI 2000)
Woonam Bridge, Korea (2008) :
Cable unit Saddle section installation of the VSL Saddle

A (mm) B (mm)
6-12 175 195
6-19 230 240
6-22 245 250
6-31 185 285
6-37 315 320
6-43 360 340
6-55 365 360
6-61 395 400
6-73 445 420
6-85 455 430
6-91 475 480
6-109 540 490
6-127 550 535

V S L S S I 2 0 0 0 13 S T AY C A B L E S Y S T E M
SSI 2000 SYSTEM DEVELOPMENT
VSL SOLUTIONS FOR CABLE VIBRATION
VSLs experience in suspended structures and the development of damping
systems enables it to assist the bridge designer in carrying out risk analysis
of the cables vibration and in proposing the most appropriate solution.
As indicated in the PTI stay cable
recommendations, the mechanisms of dynamic
excitation are particularly complex and it is not
easy to produce reliable predictions. The first
difficulty for the designer is to assess the risk
of cable vibrations. Various stability criteria
are available to estimate this risk and to
evaluate any damping that is required. The
main approach used by VSL is the net damping
criterion defined by I. Kovacs*.
The design of the VSL SSI 2000 Stay Cable
System allows implementation of additional
measures (such as dampers or cross-ties) in
case of unforeseen vibrations.
The VSL damping solutions
1. Modifications to the cable surface
Stay pipes can be manufactured with helical
ribs. The rib dimensions have been optimised in
wind tunnel testing for maximum efficiency in
suppressing the risk of excitations from rain
and wind while minimising the effect on drag.
2. Use of dampers to increase the structural
damping of the cable
Two different types of dampers are provided by
VSL: the Friction Damper and the Gensui
Damper. Key advantages of these dampers
include their efficiency, their durability and
their low maintenance costs. The two types
complement each other, allowing
implementation of the most suitable solution
depending on the characteristics of the stay
cables, the critical types of vibrations and the
required performance. The Gensui Damper is
optimised for extradosed bridges and for
medium cable lengths on cable-stayed bridges.
It is well-suited for use as an external damper.
The VSL Friction Damper will be the most
efficient solution for more critical cases
including long cables or where there is a risk of
parametric excitations.
* Dr. Ing. Imre Kovacs / Dynamic Consulting
V S L
VSL Friction Damper
Key benefits of
the VSL Friction Damper
Great durability: This great durability is due to the
fact that the damper is designed to work only when
necessary, only when the level of the cable
vibrations is considered critical. At that stage, the
friction damper immediately achieves its maximum
damping effect to stabilise the cable.
High efficiency: Several comparative tests on stay
cables have demonstrated the efficiency of the VSL
friction damper. For example, a friction damper
installed at 6m from the deck anchorage on a
214m-long 97-strand cable achieved a measured
damping (Log. decrement) of more than 9%.
Aesthetics: Installation of damping systems on a
cable-stayed bridge has to avoid any detrimental
impact to the bridges appearance, as this is often a
key feature. The efficiency and compact nature
of friction dampers generally allows them to be
installed near the deck anchorage, where they can
be fully integrated. Other, less efficient, systems
require installation externally on additional supports.
Other advantages of the VSL friction damper VSL Friction Damper with
include: anti-vandalism component
easy access, simplifying inspection during
maintenance operations;
adjustment of the friction force without any need
for dismantling;
it can be installed on any type of cable on
existing bridges where cables are subjected to
unexpected vibrations;
all components of the damper can be dismantled
and/or replaced on site;
damping characteristics are not affected by the
temperature or vibration frequency.
Cables with
VSL Friction Damper
S S I 2 0 0 0 14 S T AY C A B L E S Y S T E M
 Key benefits of
the Gensui Damper
High-damping rubber:
The Gensui damper is composed of several
rubber pads and the cables vibration energy is
absorbed by shear deformation of the pads. Each
pad is made of a high-damping rubber
manufactured by Sumitomo Rubber Industries.

Great simplicity:
The damper is modular, with the number of pads
used depending on the cable characteristics.
A main feature of this damper is its simplicity.
It can be easily installed and configured on
existing bridges.

Great durability with minimal maintenance:

The high-damping rubber pads provide for a North Arm Bridge, Canada (2008)
long design life. Accelerated ageing tests have
shown a life expectancy of 60 years. The damper
requires only minimal maintenance during its
lifetime. This allows dampers to be installed, if cables (by organisations including Shanghai
necessary, at the pylon, where maintenance
access is difficult and expensive. Tongji University, Hong Kongs Highways
Authorities and the Korean Highways
Performance: Corporation). Friction dampers have been
The performance of the damper depends on the
damping capacity of the rubber pad and can be installed on a number of cable-stayed bridges,
adjusted by varying the number of pads. The and to date no cable vibration has been observed
dampers performance is ideal for short and and no damper has needed to be replaced.
medium cable lengths. Performance can be
increased by moving the damper away from the
deck anchorages and/or installing a second More than 40 cable-stayed bridges were
damper at the pylon. The performance does not equipped with the Gensui Damper in 2007.
depend on the cables mode of vibration and it is
not sensitive to variations in temperature. In 2008, 20 Gensui Dampers have been
installed on the cables of the North Arm Bridge
An aesthetic solution: in Vancouver.
The Gensui Damper is installed around the cable
and has compact dimensions, which ensures
that it integrates well. The damper can be easily
used as external damper, installed on an
additional support. Installation of Gensui Damper

3. Installation of stabilising cables:

This solution can be used where the other two
approaches would not be efficient. The
installation of stabilising cables onto the stay
cables is not an easy operation.

VSL has an impressive portfolio of reference

projects. The VSL friction damper has been Gensui Damper Gensui Damper protected
subjected to several comparative tests on stay on PWS cable with neoprene boot

V S L S S I 2 0 0 0 15 S T AY C A B L E S Y S T E M
STRAND BY STRAND METHOD FOR INSTA
OR REPLACEMENT OF CABLES
VSLs first experiences of cable installation were
with fully-prefabricated cables which required
The strand by strand method developed by transport and lifting of heavy components.

VSL is well adapted for efficient use on any
project, whatever the bridges environmental
conditions are.
A 500m prefabricated cable on its reel can
weigh up to 80t.
The strand by strand erection of cables requires
only light equipment. It can be slightly more
time consuming, but gives advantages when
the plant required for installation is taken into
account.

Operating with the strand by strand

installation method
All the cable installation operations are carried
out using VSL equipment, enabling any tower
cranes used for pylon construction to be
dismantled as soon as the pylon is complete.
Strands supplied from strand coils placed on
the deck are prepared on a working bench.
All the stressing operations are carried out
using the AMS monostrand jack. A compact
VSL stay multistrand jack is only used when a
final de-tensioning operation is unavoidable.
The final operation is the power seating for
each strand and anchorage to ensure that
there is no risk of strand slippage at the
wedges anchored at low tension forces.

Replacement of a 298m cable

In May 2002, VSL mobilised a crew and light equipment to
check some cables and replace a 298m cable on the Ching
Chau Min Jiang Bridge. The stays had been damaged when a
barge collided with the bridge during a typhoon. Site conditions
did not allow access for a mobile crane and all the VSL
equipment had to be man-handled into position. Strands were
replaced strand by strand with the same light equipment used
for cable installation. This benchmark operation demonstrated
that long cables can be replaced without interrupting the traffic
only one traffic lane needed to be closed.

V S L S S I 2 0 0 0 16 S T AY C A B L E S Y S T E M
TALLATION
Jack clearance for the
Main advantages cable stressing operations

of the VSL strand by strand ini

Am
installation
There is total flexibility to adjust the cable
length during installation. This length can be
adjusted to cater for variations in the bridge
geometry during construction.
720
The light equipment induces only small 870
construction loads. The maximum component
weight is about 4t.
On a composite deck, just one part of the cable The strands are tensioned one by one with a VSL monostrand
can be installed as a first step to give support to jack connected to a VSL Automatic Monostrand Stressing
part of the steel deck during its assembly. system (AMS). The AMS processor controls and registers
PYLON Dimensions (mm) of monostrand jack. the parameters of the stressing operation to achieve either
The use of light equipment fitted to the pylon
the required tension or the correct elongation of the strands.
allows the installation of the pylon anchorages TENDON 6-12 6-31 6-61 6-91 6-127
UNIT to 6-22 to 6-55 to 6-85 to 6-109
while the pylon is under construction.
A mini 1000 1050 1100 1150 1200
The stressing anchorages can be installed in
confined spaces inside the pylons as the
installation equipment is small.
The maximum weight of the monostrand jack
tensioning equipment is 20kg. Heavier
k
multistrand jacks are used only in special cases. Jac
Only light equipment is required for any future ir
Cha
B

re-tensioning of the stays.

The method is well-suited to pylons equipped
with the VSL Saddle.
The necessary equipment can be moved easily
on site, giving greater flexibility in the
installation schedule.

Optimised solutions ini

Am
with the VSL Saddle PYLON Dimensions (mm)
The use of independent strands permits the of multistrand jack and chair.
strand by strand installation of the cable. After TENDON 6-12 6-22 6-31 6-55 6-85 6-109 6-127 A typical cycle of five to seven days can be achieved for deck segment
UNIT 6-19 6-37 6-61 6-91
installation of the two HDPE stay pipes on each 6-43 6-73
erection on cable-stayed bridges. VSL-trained staff and VSL tailor-made
equipment can execute the simultaneous installation of two cables on the
side of the pylon, each strand of the cable is A mini 1000 1000 1100 1200 1300 1350 1500
main span (or back span) in a single day with one shift on each cable.
raised inside the stay pipe from the deck to the B 490 620 620 780 780 970 970 Demanding challenges can be met thanks to close cooperation between the
pylon. It is then threaded through one hole of partners, as on the Liz Bridge where 18 stays were installed in the record time
of just one week.
the saddle and pulled down inside the other
stay pipe for connection to the opposite deck
anchorage. Installation of the strands is
achieved through the use of three VSL winches.

VSL lifting winch

V S L S S I 2 0 0 0 17 S T AY C A B L E S Y S T E M
Puente de la Unidad Bridge, Mexico (2003)
In a 50/50 JV, VSL provided project
management, complete technical and
method support and part of the production
management. VSL Mexico also supplied
and installed the post-tensioning, and the
SSI 2000 Stay Cable System

Badajoz Bridge, Spain (1994)

Cables equipped with friction dampers

Ponte Europa Bridge, Portugal (2002)

186m main span length - 91 strand cables

V S L S S I 2 0 0 0 18 S T AY C A B L E S Y S T E M
 Batam Tonton Bridge, Indonesia (1997)
Package: design, supply and installation of stay cables, deck form-travellers and pylon
formwork. Construction engineering for the superstructure construction

Sungai Johor Bridge, Malaysia (2008)

85 strand cables with length up to 275m

Papendorpse Bridge, Netherlands (2002)

120 strand cables

V S L S S I 2 0 0 0 19 S T AY C A B L E S Y S T E M
 Centenario Bridge, Spain (1991)
552m bridge length, with 264m for the main span

Sucharskiego Bridge, Poland (2001)

Supply and installation of stay cables,
with VSL Friction Dampers

Second Vivekananda Bridge, India (2007)

Extradossed bridge with pylon saddles and grouted stay cables

V S L S S I 2 0 0 0 20 S T AY C A B L E S Y S T E M
Wadi Abdoun Bridge, Jordan (2006)
Curved deck with inclined pylon

Yichong Yiling Bridge, China (2001)

Supply of stay cable system, erection equipment, stay cable
engineering, site management and site supervision

V S L S S I 2 0 0 0 21 S T AY C A B L E S Y S T E M
 Neva 1 Bridge, Russia (2002)
All cables equipped with VSL Friction Dampers

Houston Ship Channel Bridge, USA (1995)

Supply of stay cables and supervision at installation

Koshiki Daimyojin Bridge, Japan (1993)

Technical consultation and supply of the prefabricated stay cables

V S L S S I 2 0 0 0 22 S T AY C A B L E S Y S T E M
 Pakse Bridge, Laos (2000)
Production and erection of the precast segmental
deck, including: design, supply and operation of
casting cells and launching gantry; construction of
cast-in-situ pier tables; geometry control; supply and
installation of post-tensioning and stay cables

Merida Arch Bridge, Spain (1991)

Supply and installation of the stay cables

Sunshine Skyway Bridge, USA (1986)

Supply of post-tensioning and stay cables. Cables anchored to the pylon
by saddles and equipped with hydraulic dampers

Neva 2 Bridge, Russia (2007)

Supply and installation of stay cables with VSL Friction Dampers

V S L S S I 2 0 0 0 23 S T AY C A B L E S Y S T E M
 Jose Cartellone Construct
Pastaza Bridge, Ecuador (2005)
Supply and installation of the stay cables
Zizkova Footbridge, Czech Republic (2007)
Installation of stays and post-tensioning

Rades-la-Goulette Bridge, Tunisia (2007)

Extensive equipment and services

Kien Hai Phong Bridge, Vietnam (2003)

Supply and installation of bearings and stay cables

Unimas-Sarawak Bridge, Malaysia (2007)

Supply and installation of cables

V S L S S I 2 0 0 0 24 S T AY C A B L E S Y S T E M
Woonam Bridge, South Korea (2008)
VSL pylon saddles designed to allow cable replacement

Safti Bridge, Singapore (1995)

An inclined pylon is stabilised by back-stay cables

Peldar Bridge, Columbia (2002)

VSL Saddle and monitoring services

Liz Bridge, Portugal (2004)

18 stay cables installed in one week

V S L S S I 2 0 0 0 25 S T AY C A B L E S Y S T E M
VSL SERVICES FOR BRIDGE CONSTRUC
Wind speed

MONITORING measured in 3 directions

expressed in m/s

Temperature of cables, concrete

Relevant information is sent expressed in C
straight back to the users desk.
The system works with any IT Humidity
and measurement solution. expressed in %

Rain intensity
VSL expressed in mm

Sun intensity
expressed in W/m2
Remote server
Traffic
expressed in km/h, veh./h, t, type...

Air quality
expressed in CO, NOX, O3, SO2...

Cable force
expressed in kN

m
. co
ing Structural vibration
ni tor acceleration expressed in g
.vsl -mo vibration modes expressed in Hz
www

Angular movement
two directions expressed in

OPERATING COST MAINTENANCE COST

Stress and deformation
MY expressed in m/m and in mm
BRIDGE The Consultant

Material ageing
expressed in Cl-, mV

Inspection and investigation

paper and multimedia reports
The Owner laboratory or in situ tests

DeMon system allows wireless connection from clients office to any type
of sensors on site through internet and wireless devices.

LAUNCHING GANTRIES HEAVY LIFTING

Taiwan High Speed Rail - Taiwan Shenzhen Western Corridor - Hong Kong Nanjing Bridge Heavy Lifting - China

V S L S S I 2 0 0 0 26 S T AY C A B L E S Y S T E M
CTION
FORM TRAVELLERS & LIFTING FRAMES

Angara Bridge - Russia West Tsing Yi - Hong Kong Deep Bay Link - Hong Kong

BEARINGS REPAIR
VSL products and services
As a specialist stay cable contractor,
VSL provides comprehensive technical
assistance from the earliest stage of
the preliminary studies right through to
the detailed design and construction
phases:
consulting services to owners,
engineers and contractors;
static analysis of the structure
(in cooperation with the Engineer);
assistance in the dynamic analysis
Figueira Da Foz Bridge repair - Portugal of cable vibrations and the
recommendation of solutions;
construction engineering;
geometry control during
Pot Bearing DUCTAL construction and final adjustment
of cable forces;
Seonyu Footbridge - Korea method statements for the
construction of the structure and
cable installation;
supply and installation of stay
cables, including anti-vibration
systems;
design and supply of specialist
equipment such as formwork,
launching trusses, climbing forms,
etc;
products and services for
monitoring, inspection,
maintenance and repair works.
Preloaded seismic bearing

V S L S S I 2 0 0 0 27 S T AY C A B L E S Y S T E M
VSL LOCATIONS HEADQUARTERS
VSL International Ltd.
www.vsl.com Scheibenstrasse 70 Bern
CH-3014 Switzerland
Phone: +41 58 456 30 30
Fax: +41 58 456 30 35

Americas Europe Asia

ARGENTINA AUSTRIA SPAIN BRUNEI THAILAND
VSL Sistemas Especiales de Grund-Pfahl- und Sonderbau GmbH CTT Stronghold VSL Systems (B) Sdn. Bhd. VSL (Thailand) Co. Ltd.
Construccin Argentina SA HIMBERG BARCELONA BRUNEI DARUSSALAM BANGKOK
BUENOS AIRES Phone: +43 2235 87 777 Phone: +34 93 289 23 30 Phone: +673 2 380 153 / 381 827 Phone: +66 2 679 76 15 - 19
Phone: +54 11 4326 06 09 Fax: +43 2235 86 561 Fax: +34 93 289 23 31 Fax: +673 2 381 954 Fax: +66 2 679 76 45
Fax: +54 11 4326 26 50
CZECH REPUBLIC VSL-SPAM, S.A. CHINA PRC TURKEY
BOLIVIA VSL Systems (CZ) Ltd. BARCELONA VSL (China) Engineering Corp., Ltd. Mega Yapi Construction & Trade Co. Ltd
Postensados de Bolivia PRAGUE Phone: +34 93 846 70 07 HEFEI ANKARA
San Miguel, LA PAZ Phone: +420 2 51 09 16 80 Fax: +34 93 846 51 97 Phone: +86 551 382 29 18 Phone: +90 312 490 90 66
Phone: +591 2 27 70 338 Fax: +420 2 51 09 16 99 Fax: +86 551 382 28 78 Fax: +90 312 490 90 55
Fax: +591 2 27 96 183 SWEDEN
FRANCE Internordisk Spnnarmering AB HONG KONG VIETNAM
CHILE VSL France S.A. VSTERHANINGE VSL Hong Kong Ltd. VSL Vietnam Ltd.
VSL Sistemas Especiales de LABGE Phone: +46 8 5007 3820 CHAI WAN HANOI
Construccin S.A. Phone: +33 05 61 00 96 59 Fax: +46 8 753 49 73 Phone : +852 2590 22 88 Phone: +84 4 976 50 88
SANTIAGO Fax: +33 05 61 00 96 62 Fax : +852 2590 02 90 Fax: +84 4 976 50 89
Phone: +56 2 571 67 00 SWITZERLAND
Fax: +56 2 233 67 39 GERMANY VSL (Switzerland) Ltd. Intrafor Hong Kong Ltd. Ho Chi Minh City
VSL Systems GmbH SUBINGEN CHAI WAN Phone: +84 8 8106 817
COLOMBIA BERLIN Phone: +41 58 456 30 30 Phone : +852 2836 31 12 Fax: +84 8 8106 818
Sistemas Especiales de Construccin Ltda. Phone: +49 30 53 01 35 32 Fax: +41 58 456 30 35 Fax : +852 2591 61 39
BOGOTA Fax: +49 30 53 01 35 34
Phone: +57 1 620 96 34 VSL (Suisse) SA FT Laboratories Ltd.
Fax: +57 1 620 58 16 GREAT BRITAIN SAINT LEGIER PING CHE
VSL Systems (UK) Ltd. Phone: +41 58 456 30 00 Phone: +852 2758 48 61 Australia
MEXICO BEDFORDSHIRE Fax: +41 58 456 30 95 Fax: +852 2758 89 62
VSL Corporation Mexico S.A de C.V Phone: +41 58 456 30 30 VSL Australia Pty. Ltd.
MEXICO Fax: +41 58 456 30 35 INDIA
VSL India PVT Ltd. NEW SOUTH WALES
Phone: +52 5 511 20 36 Phone: +61 2 9 484 59 44
Fax: +52 5 511 40 03 NETHERLANDS CHENNAI
Heijmans Beton en Waterbouw B.V. Phone: +91 44 4225 11 11 Fax: +61 2 9 875 38 94
UNITED STATES ROSMALEN Fax: +91 44 4225 10 10
VStructural LLC Phone: +31 73 543 66 02 Middle East QUEENSLAND
Phone: +61 7 3265 64 00
BALTIMORE, MD Fax: +31 73 543 66 11 INDONESIA
PT VSL Indonesia Fax: +61 7 3265 75 34
Phone: +1 410 850 7000 UNITED ARAB EMIRATES
Fax: +1 410 850 4111 NORWAY VSL Middle East LLC JAKARTA VICTORIA
VSL Norge A/S DUBAI, UAE Phone: +62 21 570 07 86 Phone: +61 3 979 503 66
STAVANGER Phone: +971 4 333 6262 Fax: +62 21 573 12 17 Fax: +61 3 979 505 47
VENEZUELA Phone : +47 51 52 50 20
Gestin de Obras y Construcciones C.A. Fax: +971 4 333 0008 JAPAN
Fax : +47 51 56 27 21
CARACAS VSL Japan Corporation
Phone: +58 212 941 86 75 PORTUGAL TOKYO
Fax: +58 212 941 86 75 VSL Sistemas Portugal Phone: +81 3 3346 8913
Pre-Esforo, Equipamento Fax: +81 3 3345 9153
e Montagens S.A.
S. DOMINGOS DE RANA KOREA
Phone: +351 21 445 83 10 VSL Korea Co. Ltd.
SEOUL
Africa Fax: +351 21 444 63 77
Phone: +82 2 553 8200
VSL GEO Fax: +82 2 553 8255
EGYPT Sistemas de Aplicao em Geotecnia SA
Matrix Engineering Company S. DOMINGOS DE RANA MALAYSIA
CAIRO Phone: + 351 21 445 83 10 VSL Engineers (M) Sdn. Bhd.
Phone: +20 2 344 19 00 Fax: + 351 21 445 83 28 KUALA LUMPUR
Fax: +20 2 346 04 57 Phone: +603 7981 47 42
Fax: +603 7981 84 22
MOROCCO PHILIPPINES
Renfor-Bat VSL Philippines Inc.
TANGIER PASIG CITY
Phone: +212 39 95 80 87 Phone: +632 672 17 03
Fax: +212 39 95 80 85 Fax: +632 672 13 95
SINGAPORE
SOUTH AFRICA VSL Singapore Pte. Ltd.
Tsala-RMS Construction Solutions (Pty) Ltd SINGAPORE
Johannesburg Phone: +65 6559 12 22
Phone: +27 11 878 6820 Fax: +65 6257 77 51
Fax: +27 11 878 6821
TAIWAN
VSL Taiwan Ltd.
TAIPEI
Phone: +886 2 2759 6819
Fax: +886 2 2759 6821
Copyright 2008, VSL International Ltd.
Printed in France patented.

The information set forth in this brochure including technical and engineering data is presented for
general information only. While every effort has been made to insure its accuracy, this information should
not be used or relied upon for any specific application without independent professional examination
and verification of its accuracy, suitability and applicability. Anyone using this material assumes any and
all liability resulting from such use. VSL disclaims any and all express or implied warranties of
merchantability fitness for any general or particular purpose or freedom from infringement of any patent,
trademark, or copyright in regard to the information or products contained or referred to herein. Nothing
herein contained shall be construed as granting a license, express or implied under any patents.