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Estadio de Madrid - Roof Structure
Outline Specifications
Remodelling of the Madrid Stadium to a soccer and athletics stadium
(« Ampliación del Estadio de Madrid para su adecuacion a

estadio de fútbol y atletismo »)
Roof Structure – Projecto de Ejecución
Part IV : Outline Specifications
Revision 1.2
March 21 2014
2722 / Sto IV
21.03.2014
Estadio de Madrid – Roof Structure
II
CONTENT
1 General ................................................... 1
1.1 Introduction ................................................ 1
1.2 Scope of work ............................................... 4
1.3 Geometry .................................................... 8
1.3.1 Final geometry of the structure ................................ 8
1.3.2 Deflections under environmental loading ........................ 9
1.3.3 Measurements / Surveys / Accuracy .............................. 9
1.4 Delimitation of the activities ............................. 16
1.5 Workshop drawings .......................................... 18
1.6 Measurements for Payments .................................. 18
1.7 Erection ................................................... 19
1.7.1 General ....................................................... 19
1.7.2 Accuracy assuring trial assembly .............................. 20
1.7.3 Erection of steelworks ........................................ 22
1.7.4 Erection of cable structure ................................... 22
1.7.5 Erection of membrane structure ................................ 23
1.7.6 Erection of the canopy ........................................ 23
1.8 Execution Class ............................................ 25
1.8.1 Failure Consequences Class [CC] as per EN 1990:2010 Table B.1 . 25
1.8.2 Category of operational demands (System Class) [SC] as per 1090-
2 Table B.1........................................................... 25
1.8.3 Category of Production [PC] as per 1090-2 Table B.2 ........... 25
1.8.4 Execution Class [EXC] as per EN 1090-2 Table B.3 .............. 25
2 Quality Control System ................................... 26
2.1 General .................................................... 26
2.2 Requirements for steelworks ................................ 26
2.3 Requirements for cable structure ........................... 26
2.4 Requirements for membrane structure ........................ 27
3 Metal materials .......................................... 28
3.1 General fabrication remarks ................................ 28
3.2 General structural steel remarks ........................... 28
3.3 Mild Steel/ Fine grain steel ............................... 29
3.4 Stainless Steel Plates ..................................... 30
3.5 Aluminium for Clamping Plates .............................. 30
3.6 Bolts and Rods ............................................. 30
3.7 Stainless Steel Bolts ...................................... 32
3.8 Friction Grip connections .................................. 33
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3.9 Material for pins - quenched and tempered steel ............ 34

3.10 Tension rod systems ........................................ 35
3.11 Single bar tendons ......................................... 35
3.12 Cast steel ................................................. 36
4 Corrosion protection ..................................... 44
4.1 General .................................................... 44
4.2 Hot dip galvanizing / galvanizing .......................... 44
4.3 Inside closed sections ..................................... 44
4.4 Miscellaneous .............................................. 45
4.5 Coatings ................................................... 45
4.5.1 CPS 01 – All steelwork and plates ............................. 46
4.5.2 CPS 02 - Hot dip galvanized steelwork, plates, elements and
castings with limited dimensions:..................................... 49
4.5.3 CPS 03 Cable sockets .......................................... 50
4.5.4 CPS 04 – Aluminium clamping plates and corner plates, clamping
edges and membrane details............................................ 51
4.5.5 CPS 05 - Pins, bolts, screws, flat washers and spring washers . 52
4.5.6 CPS 06 - Connections between steel and reinforced concrete (cast
in parts)............................................................. 53
4.5.7 CPS 7 - Duplex, thermal spray zinc + top coat ................. 54
4.5.8 CPS 8 - Friction Grip connection surfaces (head plates) ....... 55
4.6 Painting Inspection and Test ............................... 56
5 Grout .................................................... 58
6 Cable structure .......................................... 59
6.1 General .................................................... 59
6.2 Wires for fully locked cables .............................. 59
6.2.1 General requirements .......................................... 59
6.2.2 Storage of wire coils until the time of stranding ............. 59
6.2.3 Quality controls for the wires ................................ 60
6.3 Fully locked cables ........................................ 61
6.3.1 Structural and mechanical properties of cables ................ 61
6.3.2 Quality control for the cables ................................ 62
6.3.3 Cutting of the cables ......................................... 64
6.3.4 Delivery of the cables ........................................ 65
6.4 Spiral strands ............................................. 65
6.5 Cable sockets / clamps / ring connectors ................... 65
6.5.1 Material ...................................................... 65
6.5.2 Fabrication ................................................... 65
6.5.3 Pre-tensioning of clamping bolts .............................. 66
6.5.4 Slippage test ................................................. 66
6.5.5 Corrosion protection .......................................... 67
6.5.6 Stainless steel cables ........................................ 67
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7 Membrane structure ....................................... 68

7.1 Quality control and guaranty of the membrane material ...... 68
7.2 Quality control of manufacturing ........................... 68
7.3 Technical specifications for membrane Glass / PTFE ......... 69
7.3.1 Quality of materials .......................................... 69
7.3.2 Design of seams ............................................... 72
7.3.3 Mechanical properties and quality control of the seams ........ 72
7.3.4 Mechanical properties and quality control of the Details ...... 74
7.4 Technical specifications for membrane mesh Glass / PTFE .... 79
7.4.1 Quality of material ........................................... 79
7.4.2 Quality control of the membrane mesh material ................. 80
7.4.3 Design of seams (mesh membrane) ............................... 80
7.4.4 Mechanical properties and quality control of the seams ........ 81
7.4.5 Membrane clamping edges – Material 70 ......................... 81
7.5 Damage Test on all structural Fabrics ...................... 82
7.6 Work samples ............................................... 85
7.7 Strengthening the cut outs area ............................ 85
7.8 Closure flap ............................................... 85
7.9 Drainage ................................................... 86
7.10 Manhole .................................................... 86
7.11 Clamp bar system and tangential forces ..................... 86
7.12 Cutting pattern ............................................ 87
7.13 Patterning model ........................................... 88
7.14 Tolerances ................................................. 89
7.15 Folding plan ............................................... 89
7.16 Packaging and Transportation ............................... 90
7.17 Test bed with material samples ............................. 90
8 Bearings ................................................. 91
8.1 Cast in plate tolerances ................................... 91
8.2 Technical Description of sliding bearings .................. 91
9 Stainless steel .......................................... 92
10 Aluminium ................................................ 93
10.1 General .................................................... 93
10.2 Materials .................................................. 94
10.3 Corrosion protection ....................................... 95
10.4 Fabrication and workshop design ............................ 97
11 Drainage ................................................. 98
III
11.1 General .................................................... 98

11.2 Syphonic drainage system ................................... 98
11.3 Gravitiy Drainage system .................................. 101
IV
1 General
1.1 Introduction
While utmost care is taken in the preparation of this document it is

understood that the applicant will seek clarification of the client for a
mismatch of information or missing information.
If not further specified in detail the following glossary is applicable:
• Client = City of Madrid / (Club Atlético Madrid)

• Main Contractor = principle building contractor for the stadium
• Contractor = roof subcontractor (if applicable)
Due to the sophisticated nature of the roof structure, the execution should
be undertaken by an experienced Contractor, which fulfils the following
criteria:
For the steel structure

• execution of minimum 2 steel projects of relevance to the project,
with exposed details and weldings (within the last 5 years)
• execution of minimum 2 steel projects of weight over 3000 t each
(within the last 5 years),
• minimum 25.000t yearly output for the last 2 years - fully covered
facilities for the trial assembly of the compression ring (minimum
length 60m)
Requirements refer to projects of similar nature, such as projects of high
technical level, exposed steel structures and not standard industrial plants.
For the cable structures

• execution of minimum 2 cable projects (prestressed cable structure,
exposed cable structure, cable bridge) of relevance to the project
(within the last 5 years)
• execution of 2 cable projects of min. 200t each, using Galfan (or
equivalent) coated fully locked cables (locked coil ropes with z-
wires within the last 5 years),
• execution of structure with use of locked coil ropes with diameter
100mm and above for architectural application (within the last 5
years),
• fully tested cable socket system,
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technical level, exposed steel structures and not standard industrial plants.
For the membrane structure
• execution minimum 1 membrane sport stadia projects (within the last
5 years),
• execution of minimum 2 membrane projects of min. 10.000m² size,
using PTFE/Glass membrane(within the last 5 years)
• execution membrane projects of min. 500m² panel size, using
PTFE/Glass membrane(within the last 5 years),
• execution of minimum 2 significant membrane projects with free air
installation/erection (no ground supported scaffolding used), using
PTFE/Glass membrane(within the last 5 years)
technical level, exposed membrane structures, sport stadia.
2
Some key points of the design and execution of manufacture in the workshop
are:
• Machine-operated processing of the end plates of all compression
ring elements (i.e. upper chord/ lower chords) to secure the angles,
the length, the fit of the hole shapes, and the precision of the
cable connection boreholes is mandatory. The end plate thickness’
marked on the drawings are data applicable after milling. Respective
provisions to achieve that is in the responsibility of the
contractor.
• Trial assembly of five compression ring elements (over 10 axes) in
each case, together with the associated engineer's measurements and
CAD monitoring of the results. One segment can leave the factory
after the trial assembly. Two segments are to remain in position as
a reference for the next trial assembly. (see also erection drawing)
• Monitoring of manufacture in workshop:
The consultant may conduct, if necessary, extensive monitoring of
the manufacturing work. For this purpose, the contractor is grant
access to the manufacturing processes at any time. A suitable
workplace in the factory is to be made available. Quality assurance
and its documentation require the approval of the consultant.
• Possibilities of 3D-CAD in planning the workshop activities.
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1.2 Scope of work
The scope of the works and services for the contractors comprises the supply
and erection of the complete roof structure, including:
 Steel structure incl. catwalks and all mechanical & electrical
provisions including bearings and supports
 cable structure
 membrane structure
 cladding for canopy, compression ring and tension ring
 roof drainage system
 all temporary works for the roof including temporary support systems
for the trial assembly and the final erection of the compression ring
and catwalks
Included in the roof contract will be the following planning responsibilities:

 design of scaffolding, temporary works and erection analysis
 executive layout of membrane connections to cables as basis for workshop
design of the same
 workshop drawings (steel, cables, membrane)
 complete erection analysis and planning
 for coordination between work packages see architects specification
 executive design and detailing of the louver system at the tension ring
 Complete workshop design including all workshop drawings, including
detailed 3d steel model and fabrication geometry model based on original
shape and layout of steel members as per architectural and engineering
input of roof structure, roof claddings and installations.
 Complete workshop design including all workshop drawings of connections
including supporting calculations according to architectural layout and
only with approval by client.
 Workshop planning of the installation taking into consideration the
results of any as-built survey of connection joints (r/c structure).
 Workshop 3D development of steel work (main structure and secondary
structure.
 Workshop planning of all welds and welding technique
 Workshop planning of all strands/cables, including cutting length,
marking of clamp positioning.
 Workshop planning of all castings, based on the geometry and the layout
provided by the client.
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 The contractor has to adjust all details related to cables and cable
sockets considering the final diameter and socket geometry. The
stiffness of the cables considered in the structural analysis must be
maintained at any time
 Workshop development of geometry of membrane panels including all
eccentricities and cutouts
 Workshop design of membrane attachment details (i.e. clamp bar system,
clamp plates, link plates and edge cables and belts).
 Workshop drawings of all membrane details, based on the structural
design and drawings provided by the client
 Workshop 3D development of gutter details to ensure drainage as
designed.
 Biaxial-testing of all membrane materials, to derive the stiffness
parameters and compensation values for the contractors design. The
contractor has to seek the approval of the client for the testing regime
and procedure.
 Cutting pattern analysis and workshop drawings for all membrane panels,
based on the overall 3D-cable-steel-member-geometry supplied by the
client and finalized in he structural design. It is the task of the
roof contractor, to derive the final membrane geometry, including all
off sets and details. The contractor has to seek the approval of the
client for the final patterning prior to commencement of fabrication.
 Planning for transportation and packing of membrane panels (i.e.
rolling fabric or fold plan).
 Corrosion protection planning and design of all details. Including
corrosion tests by a third party institution
 Workshop design of all fixations of installations (welded on, cast in
or bolted to primary steel structure)
 Executive workshopdesign of dewatering layout and equipment
 Executive workshopdesign of aluminium or coated steel plate cladding
 As-built drawings, whereby the quality and quantity requirements of the
additional technical contract conditions are valid for all contracted
services
 Maintenance proposal (intervals, important elements, service proposals,
specifications of cleaning detergents etc.)
 Further works as described in the following chapters including
adjustment of all details to the finally chosen materials and details.
 Final workshop design of catwalks and catwalk suspension based on the
assumptions made in the structural analysis document, limiting the dead
load to the there specified values.
 All handrails and safety stainless steel cables within catwalk
including workshop design and drawing with approval by client.
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Included in the roof contract are all tests and surveys as defined in these
specifications.
The general architectural and structural design as well as layout of all
elements, members, materials and details shall not be changed. If required,
the contractor has to seek the approval of the client.
Changes and amendments are possible at any time through the client. Additional
planning of the other trades (for instance the reinforced concrete
construction) are to be obtained in due time from the contractor in
conjunction with its design requirements. This is to be taken into
consideration for construction approach and work shop design.
Should changes in weight or stiffness or other circumstances (for which the
contractor bears responsibility) make it necessary to reanalyse the roof
structure, bowl structure or foundations or as well details of the global
system, the contractor owes the client this calculation, including the fees
for review and, if necessary, expenses for reinforcement and reconstruction
measures.
The erection calculations for the steel, cable and membrane structure, the
analysis for all additional erection equipment (jacks, tie-down cables,
additional fixation in concrete structure, scaffolding, etc.), and all shop
drawings have to be done by the contractors. All calculations and drawings
have to be approved by the client and his consultants.
The contractor has to submit the following method statements; further
documents might be required at a later stage:
• Fabrication of compression ring including machining of head plates
• Trial assemblies for compression ring segments, maintaining required
accuracy
• Trial assembly of special details of support structure
• Survey of connection points at RC structure prior installation
• Erection sequences bearings, compression ring, canopy
• Erection sequence cables
• Manufacture, packing and transportation, installation sequence for
membrane including time stepped prestress procedure and connection
• Damage assessment of fabric
• Survey during erection, during cable lifting and as built (as
described later)
• Monthly surveys of foundation settlements from begin of installation
of CR to end of contract of roof contractor and liaison and hand
over to client’s surveyor for a further period of one year.
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• Corrosion protection planning and design of all details and

corrosion protection strategies
• The permissible tolerances are to be considered in the workshop
planning, taking into consideration the various trades. Production
tolerances are to be indicated in the construction drawings at the
interfaces to all relevant trades.
• All engineering tasks and method statements prepared by the
contractor are to be presented to the client for approval in due
time prior to execution
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1.3 Geometry
1.3.1 Final geometry of the structure
The final geometry of the structure is to be established in such a manner,

that the planned geometry as per the clients design is maintained under
constant loads. This is valid for the location of all system joints as well
as for the location of the member centre-lines of all structural members.
Necessary calculations and potentially required adjustments such as

cambering, lengthening of members to compensate shortening through
compression (compression ring, ties and struts and eq.) are within the scope
of the contractor’s work - resulting cost is to be included in the bid.
The maximum permissible manufacturing tolerances of the prefabricated

construction elements and the mounted frame are given in the technical
specifications. Limiting dimensions for the cast pieces are to be taken from
the specific material specifications also within this technical
specification. Respective measures to counter balance such deviations have
to be taken into consideration by the contractor in its workshop planning
and fabrication.
Before commencing the workshop planning / fabrication the connecting elements

(base points) for the distribution of the roof-loads have to be measured
(anchor plates in the concrete grandstands). The protocols for this have to
be submitted to the client. The contractor has to point out the deviations
in dimension determined. Respective measures to counter balance such
deviations have to be taken into consideration by the contractor in its
workshop planning and fabrication. The maximum final tolerances have to
contain both the measurement tolerances as well as the construction
tolerances.
Necessary construction measures for compensating exceeding tolerances are to

be planned. In this regard the contractor is obligated to arrange this with
all trades. Prior to production start, the contractors’ concepts for assuring
the manufacturing precision and the compensation of exceeded tolerances have
to be presented to the client for approval.
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1.3.2 Deflections under environmental loading
The structure of the roof is subject to deflections under environmental

imposed loads. Typical deflections result from wind loading and snow loading.
These deflections are to be considered during construction and layout of
installations and connections.
Some governing values are given in service limit state (SLS), other values
can be taken from the structural analysis report. Downward deflections are
indicated (+), upward deflections are indicated (–). Detailed results can be
found in the structural analysis.
• +/-0.25 m movement of the compression ring in plan

• +2.00 m for membrane and cable structure
• -1.50 m for membrane and cable structure
• +1.50 m for the tension ring
• -1.00 m for the tension ring
1.3.3 Measurements / Surveys / Accuracy
General
Prior to construction and until the final acceptance, the contractor has to
perform settling and deformation measurements which are required for the
precise spatial location of the construction and to verify their planned and
redundant implementation.
During the construction each and every sub contractor within the roof contract
has to handover the actual built geometry to the succeeding sub contractor.
The successor may verify on its own costs the hand over geometry. This
procedure shall happen at least:
• After finalization of concrete structure

• After erection of steel work
• After prestessing the cable structure
• After installation of membrane
• After installation of the canopy
The measurements are to be made especially before and after significant change
in load and internal forces. The progress of the installation and the
equipment is to be taken into account. Scaffolds and other temporary
structures have to be included in the measurements.
Measurement concept
The contractor has to present a measurement program for approval in good time
prior to beginning construction. The measurement program has to consider all
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the essential construction conditions and provide explanations for movements

in the vertical and horizontal direction and tilting and twisting.
The contractor has to present the methods and procedures of the measurement
work accompanying the construction, the control of the individual
construction states and status control as the basis for the status plan. The
contracted party for all survey works must be approved by the client.
In general laser tracker survey is requested.
Submission of the measurement documents
The contractor owes the client the documentation of the measurements including
the comparison of the planned and actual measures in tabular and graphic form
for all stages described above.
The comparison is to contain influences from deviations of temperatures during
the measurement of the calculated deployment temperature.
The documentation is to be presented to the contracting party upon request
or upon completion of the individual building phase at the latest.
After conclusion of the construction measures the contractor has to hand over
to the client all the original documents developed for measurement in
connection with the erection and acceptance of the construction
(calculations, plans, coordinates and height indices, graphic analyses), in
binders and with the corresponding comments, without a claim for additional
remuneration.
Within the scope of the measurement of the roof structure especially the
location of the system joints of all radial cables (pin points), the canopy
anchorage (pin points) and the compression ring sections (centre point) are
in particular to be noted.
During trial assembly and erection the contractor is to maintain an updated

3d model where all original and built system points are to be incorporated.
Other measurement will be required, if there is doubt about proper execution

of work or measurement and can be asked by the client at any time. All costs
incurred in connection with the measurement and the documentation of the
measurement results are to be borne by the contractor and are to be included
in its tender.
Special requirements for built-in components in the reinforced concrete

structure
All the anchoring elements for the roof structure will be installed at the
time when the spectator stand and the foundations are being constructed
(anchor plates).
The steel contractor is to record the positions of all the connecting points
prior manufacture to modify / adjust the workshop drawings to built geometry,
by carrying out his own dimensional checks and surveys. This includes
compensation due to creep, shrinkage and foundation settlements. The
deviations of theoretical and actual measured system points of the recording
of the positions have to be approved by the client and his consultants.
Minimum requirements for surveying work on site
10
The contractor shall establish 6 geodetically points in the area of the

stadium. By performing the following surveys, the contractor is to demonstrate
that the required accuracy is being maintained:
- During the erection of the compression ring, each and every erected
segment is to be surveyed: Measurement of the cable connecting holes
and the bearing plate of the newly erected segment. During CR erection
on a weekly basis, during lifting and prestessing on a daily basis and
for all other stages on a monthly basis.
- After the completion of steel assembly: Survey of all cable connecting
holes, connecting holes of Canopy structure and bearings in the steel
structure (after removal of temporary structure)
- During prestressing of the roof structure: 4 surveys of the cable
structure shall be done (4 times 2x96 points)
- After the completion of cable assembly: Measurement of all cable
connecting points, connecting holes of Canopy structure (2x96 points
to be measured) and cable structure i.e. tension ring (96 points to be
measured). Additionally:
- After the completion of membrane assembly: Measurement of all system
points in the steel i.e. compression ring (96 points to be measured)
and cable structure i.e. inner tension ring (96 points to be measured).
Additionally: In four, by the project consultant defined axis all system
points of radial cable.
- Prior the erection of the Canopy structure: Measurement of all
connection points for the attachment of the secondary structure i.e.
out compression ring (2x96 points to be measured)
- After completion of the roof structure: Complete survey of the roof in
the points mentioned above and at the tip of the main canopy girders
(96 points to be measured).
After completion the measurement strategy and measurements points have to be

handed over to the client for further ongoing measurements. The contractor
may liaise with the client to establish an automated measurement and data
log system to reduce costs for all parties.
The method of optical 3d survey on site must work within a range of + 2 mm.
Tape measurements must be within a range of +-0.5mm. The tapes have to be
calibrated to the ambient temperature during design (T = 8°C with 50N nominal
pull)
The stated survey must be carried out by a licensed surveyor acting on the
contractor's instructions and at the contractor's expense. The measurements
must not be impaired by uneven temperature distributions (resulting from
solar irradiation). This may make it necessary to carry out measurements at
night. In addition, survey work is required during the whole of the assembly
operations. These measurements are to be agreed upon with the client before
the start of the assembly work.
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The contractor is, on his own responsibility, to design long lasting targets,
determine, and affix in good time, all those targets on the structural
components which are required for measurement purposes. The locations of the
targets shall allow for ongoing measurements after completion thus additional
targets may be necessary for hidden locations behind cladding etc. The targets
require the agreement of the client.
All survey results have to be evaluated by the contractor and to be submitted

to the client and his consultant for approval.
Geometrical survey and accuracy in the workshop and assembly yard
The measurements of the trial assembly of the compression ring and geometrical
checks of all other elements (i.e. columns etc.) must be performed by a
licensed surveyor. The consultant is to be informed immediately of the results
and deviations of each section of the survey. All survey results have to be
evaluated by the contractor and to be submitted to the client and his
consultant for approval. The contractor is to introduce the 3d measurements
into a 3d DWG system to overlay original geometry requirement and existing
measurement and determine deviations immediately. This model is to be
submitted to the client after each modification.
The method of optical 3d survey at the fabrication facility must work within
a range of + 1 mm. The measurement of compression ring element length during
trial assembly must work within a tolerance of 1/20000. Tape measurements
must be within a range of +-0.5mm. The tapes have to be calibrated to the
ambient temperature considered during design (T = 8°C with 50N nominal pull)
By performing the following surveys, the contractor is to demonstrate that

the required accuracy is being maintained:
 During trial assembly of compression ring of each individual element
The measurements must not be impaired by uneven temperature distributions

(resulting from solar irradiation). This may make it necessary and
measurements should preferably be performed under a shelter, in order to
eliminate the influence of solar radiation.
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Requirements regarding accuracy
Achieving the tight tolerances specified is the vital part of the construction
work.
Note:
All described tolerances are to be seen globally and relative to the adjacent
system points. The following summary indicates the most important items:
Accuracy requirements for individual plates and profiles
Tolerances for materials shall comply with EN 1090 Tab. A.3 for Execution
class EXC as specified. This includes
 EN 10029 Class B for plates
 EN 10210 / EN 10219 for profiles
Leading accuracy requirements for individual elements of compression ring
 The accuracy required is 0.5 mm/1000 mm for the angle deviation of

either end plate of the compression ring elements, and + 1 mm for the
length of each element.
 The added axial tolerance for any of the elements within the array of
elements shall not exceed a tolerance of + 10 mm. (This has to be
confirmed by means of the trial assembly!)
 2 mm in horizontal direction for each system point of the compression

ring, for the cable connecting holes, pin points to columns and strut
pin points relative to each other within one segment
 Straightness of lug plates, tubes and box sections: 0.05% of the system
length.
 In the manufacture of the welded components, besides tolerances in

length (see above) DIN 8570 / EN ISO 13920 apply. For angles degree of
accuracy highest degree of accuracy A applies, for shape and
straightness highest degree of accuracy E applies.
Accuracy requirements for the trial assembly of the compression ring
With at least five consecutive segments (10 axis; >60m):
 10 mm in every horizontal direction for each system point of the

compression ring, for the cable connecting holes, pin points to columns
and strut pin points, relative to the adjacent system point or in
global.
 5 mm in vertical direction for each system point of the compression

ring, for the cable connecting holes, pin points to columns and strut
pin points.
 The described is to be considered as the controlling requirement.
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Accuracy requirements for anchor plates / bearings
Deviation from the global specified position of the concrete structure:

 top face elevation of the concrete structure: +10 / -20 mm (+ =
upwards)
 side surfaces of the concrete structure: +20 / -20 mm
 These figures are to be considered analogously for inclined surfaces
like pockets and cavities for shear keys and base plates
Deviation from the global specified position of the tension bars, cast-in
parts or bearings:
 max. deviation in vertical directions: +5 / -5 mm
 max. deviation in horizontal directions: +10 / -10 mm
 max. sum of deviations of two adjacent parts: +5 / -5 mm (all
directions)
 These figures are to be considered for all parts of the bearings (refer
also to the chapter “Bearings”).
Accuracy requirements for cables
It is of decisive importance to the structural behaviour and redundancy of

the structure that the planned condition of prestressing should be attained.
There are no opportunities for correction on site. Increased requirements
regarding dimensional accuracy are therefore to be imposed upon the cable
lengths.
The overall length must of highest precision.
Also great precision is required when marking the connecting points for the
clamps.
On the basis of these requirements, the following length tolerances are to

be ensured and proved by measurements:
 The overall length of a cable must be correct within a tolerance of
1:10,000 (0.01%)
 The individual marking for clamps on the carrying cable is permitted
to deviate from the desired measurement by up to 2 mm. Any adding-up
of these permitted deviations is to be avoided. The deviation from the
desired measurement is, when measured over any 10-metre stretch of the
cable, not permitted to exceed 2 mm (0.02%)
14
Accuracy requirements for the build structure
The accuracies required for the assembled and pre stressed final roof
structure are as follows:
 ± 15 mm in plan for each system point of the compression ring,

 ± 2 mm in height for each system point of the compression ring,
 ± 30 mm in plan for each system point of the tension ring,
 ± 5 mm in plan for each ring connector position relative to the adjacent
connector of tension rings,
 ± 100 mm in height for each system point of the tension ring.
 ± 10 mm in height for each system point of the tension ring of adjacent
system points.
It needs to be noted, that non-respective individual tolerances, the accuracy

of the completed roof needs to be achieved. Any required corrective measures,
resulting from adding tolerances need to be planned and controlled by the
contractor and to be approved by the client.
15
1.4 Delimitation of the activities
The following areas of work:

 Steel structure
 Cable structure
 Membrane structure
 Drainage
are separately specified.
Steel structure
* Manufacture, corrosion protection, delivery and assembly of:
 Support structure such as bearing elements and connecting base
plates
 Compression ring
 Canopy steel structure
 Substructure for cladding elements compression ring and canopy
 Canopy edge cladding (steel and aluminium)
 Catwalks in compression ring
 Provisions for drainage and lighting elements
 Drainage utters for compression ring and canopy
* Manufacture, corrosion protection, and delivery of:
 Crosslink, Catwalks tension ring, Flying struts
 Substructure for tension ring cladding elements and
mechanical/electrical equipment
 Cladding elements of tension ring (steel and aluminium)
Cable structure:
 Primary cable structure
 Castings
* Manufacture, delivery, and corrosion protection of:
 edge cables for fabric
 casting clamps for membrane connections
16
* Assembly of:
 Crosslink, Catwalk tension ring, flying struts
 Substructure for tension ring cladding and
mechanical/electrical equipment
 Cladding elements of the tension ring
Membrane structure:
 Primary membrane structure incl. all clamping and connections
to cables
 Upper and lower membrane of canopy
 Compression ring cover membrane structure incl. all details
 Tension ring cover membrane structure incl. all details
 Closure flaps, manholes, water inlets, water deviators, gutter
boxes connected to the membrane
* Assembly of:
 Edge cables
 casting clamps for membrane connections
Drainage:
* Manufacture, delivery and assembly of:
 Complete pressure drainage system for the tension ring
drainage of the main roof, including all inlets, horizontal
and down pipes, connection details to the steel/cable
structure suitable to the chosen system, flexible connections
at the joints between cable structure / compression ring and
roof / concrete structure. Including the calculation of the
complete system and final testing on site.
 Connecting pipes of membrane outlets with the gutter in the
compression ring.
 Downpipes for compression ring drainage of the main roof
 Additional outlets with pipes and downpipes of the canopy over
the Peineta.
 Mock-up for the outlet/collection pan for the “waterfall” at
the canopy.
 Final outlet/collection pan for the “waterfall” at the canopy.
17
1.5 Workshop drawings
All contractors shall prepare detailed workshop drawings for all structural
elements based on the final structural design drawings under the supervision
of an experienced professional Engineer. All workshop drawings have to be
sent to the client and the consultant for approval before fabrication
commences.
The approval includes the member sizes only, but excludes dimensions, cleats,
bolts, welds and gussets etc. The contractor shall allow 4 weeks for checking
and approval by the client, and shall also allow for any possible changes to
shop drawings.
Drawings for approval shall show the elements in their geometrical
configuration with their connecting elements. Single piece drawing will not
be approved. For complex geometries 3D models are necessary for approval.
Generic detail drawings with complex corrosion protection tasks shall be
verified at an early stage by a corrosion protection expert.
All the workshop drawings are to be drawn up in English and Spanish language
with metric measurements.
1.6 Measurements for Payments
All steel elements are measured on metric tons basis and as described in the
technical drawings. No extra amount will be allowed for milling tolerances,
bolts, weld seams, cutting gloss or clippings. The cutting of the shaped and
sheet-metal butt joints into lengths, and the processing and manufacture of
those butt joints, together with the required connections and fastenings, are
to be included in the unit prices. There will be no special remuneration for
any assembly connections, assembly scaffolding or structural details, which
do not have to remain installed.
All cable elements will be measured by item, metric length from pin to pin
of sockets and metric tons given are as reference only.
Membrane roof cover will be measured on metric real area (m²) basis. Remaining
cuttings from patterning won’t be measured; employed material only will be
measured according to the client approved patterning layout, even if the
patterning layout preferred by the client results in higher cuttings.
18
1.7 Erection
1.7.1 General
The proposed erection sequence should only help the contractor to price. The
total responsibility for the finally chosen erection procedures will remain
with the contractor, and may differ from the described proposal.
The erection procedure shall be in accordance with proposals submitted by
the Contractor and approved by the Consultant Engineer.
The Contractor shall inform the Client and his Consultant Engineer when
fabricated sections are ready for inspection prior to erection.
The Contractors have to prepare detailed erection drawings and erection
descriptions, which have to be issued and submitted to the Client and his
Consultant Engineer for approval.
For all erection steps of the structure, the temporary structural systems
have to be considered and all relevant structural calculations have to be
performed and submitted to the Client and his Consultant Engineer for
approval, but this approval shall in no way relieve the Contractor of his
responsibilities for the work under the contract.
19
1.7.2 Accuracy assuring trial assembly
 The required accuracy for the cable connecting holes at the

compression ring steel structure is given in the “outline
specifications”. These stringent requirements can be achieved only by
an accurate fabrication of the compression ring elements combined
with a trial assembly of compression ring parts confirming the
acceptable geometry of the structure.
Following a fabrication procedure is being proposed which will
produce the geometrically and structurally satisfying shape of the
compression ring. The contractor will have to detail the procedure
further.
 The built-up section of the top chord box will be fabricated with all
the lug plates and the head plates.
The accurate length and the angle at either side of the box will be
achieved by milling the head plates of the top chord in the workshop.
Therefore the thickness of the head plates must have sufficient
milling allowance (minimum 5 mm either side) taking care of
inaccuracies during fabrication of the box.
Additionally the bolt holes and the cable connecting holes within the
head plates will be done CNC guided during the process of milling the
head plates at the workshop.
 Similarly the bottom chords of the compression ring will be

fabricated. In this step the lug with the cable connecting hole can
be positional sufficiently accurate.
Milling of the head plates (head plates will have milling allowance)
and drilling of bolt holes will be done for the bottom chords
analogous to the top chord.
 A trial assembly of 5 consecutive chord segements (top and bottom)
ensure that the desired accuracy in the chords themeself is achieved
before transporting them to the site.
 The top and bottom chords connecting struts and diagonals will be
fabricated separately.
 All fabricated and corrosion protected parts will be transported to

site to where the trial assembly can take place. Supports and
scaffoldings on location will be designed and detailed by the
contractor.
 The two longitudinal members of the bottom chord can be assembled in

a jig along with the diagonals and struts. The two chords need to be
placed accurately in reference to each other before welding in the
posts and diagonals.
 For the first trial assembly 5 compression ring segments or more

should be used. For the consecutive assembly a minimum of 2 segments
should be retained as an overlap to generate the as built geometry of
the compression ring.
Smaller numbers of segments for a trial assembly will create more
20
assemblies. This is not desirable.
 The completed bottom chord frame will be positioned on solid

supports. Levels can be adjusted by jacks. A fixed support should be
established at one location allowing the other supports to slide
under temperature influence. PTFE pads are recommended at the
supports reducing the friction coefficient considerably.
At the head plates drifts and bolts are to be used to connect the
adjacent bottom chords.
 The top chord will be placed accurately in reference to the bottom

chord on rigid supports. The top chord joints will be closed with the
help of drifts and bolts.
The diagonals and struts will be installed and fixed by tack welding
in a property laid down sequence.
After having ensured the acceptable geometry the fillet welds for the
diagonals can be completed according to a welding sequence minimizing
welding deformation.
 If any adjustments are necessary at this stage the packing plates in

between two head plates can be remove and machined to the required
shape (increase or reduction in thickness or wedge shape).
 A final survey establishes the as built geometry of that particular

part of the compression ring.
Reference points will be the cable connecting holes and the bearing
plates.
21
1.7.3 Erection of steelworks
After erection of the concrete columns and after the above-mentioned survey,
the built-in components (bearings etc.) for the compression ring elements can
be installed.
After that the compression ring elements can be installed according the
erection drawings on temporary supports.
Element per element will be installed and connected to the prior installed
element by fixing the front plates with HSFG-bolts and connected to the
bearing. For controlled pre-tensioning of the HSFG-bolts a specified torque
will be required.
1.7.4 Erection of cable structure
The cable structure will be laid out on protective elements on the ground or
on the stand superstructure the whole cable structure is pulled by heavy
lifting units, mounted on the compression ring, until the cable structure
reaches its final position, and can be anchored to the lug plate at the
compression ring.
Note:
The whole cable structure has to be pulled in 48 axes at the same time. A
simultaneous tensioning sequences is required.
Requirements:
 surveying of all erection stages by controlling the system nodes,
 heavy lifting equipment up to approx. 3000 kN capacity,
 protection of all stand surfaces.
22
1.7.5 Erection of membrane structure
The stages of installation of the roof panels will be:

 pull out and secure main membrane between two primary cables
 connecting main membrane to triangle membrane at tension ring and
compression ring
 Prestressing of membrane using time stepped procedure
 closing the gap between two panels using welding procedure.
 Installation of compression ring and tension ring cover membranes
It could be necessary to install the membrane panels in an uniformly
distributed sequence instead of axis after axis to avoid highly non-uniform
loading on the roof. Further temporary installation panels or ties might be
necessary to prevent radial cables from deflecting horizontally. The
calculation of the exact sequence and temporary measures is part of the
erection analysis and has to be defined by the contractor (see 1.1 “Scope of
works”). The cladding panels of the radial catwalk change the stress state
of the adjacent main roof panels. This needs to be considered in the
patterning and stressing sequence.
1.7.6 Erection of the canopy
The canopy is subdivided into 16 individual segments each consisting of 6

blocks with an expansion joint in between two segments.
During stressing of the cable structure the compression ring moves from its
erection geometry much closer to the dead load geometry. The compression ring
shortens and moves radially inwards, towards the soccer field. If the canopy
is installed at a different stage during the construction sequence as assumed
in the design project, this movement has to be compensated in the workshop
design of the canopy members.
It is strongly recommended to install the canopy after completion of

compression ring erection and the stressing of the cable structure. Then the
compression ring has its full torsional stiffness and most of the horizontal
movements of the compression ring already occurred: the compression ring is
close to its dead load geometry. A survey of all canopy structure connection
holes (2 x 96) prior to the installation shall verify this. The top bar
connecting the main body of each radial girders with the top chord of the
compression ring shall be cut to length after confirmation of the correct
position of the upper and lower connection hole of the compression ring. If
required length adjustments to this element can control the vertical and
radial alignment of the canopy edge.
The first step is the prefabrication of the main bodies of the radial girders.
Since there are only two different types it is recommended to built two jigs
to achieve maximum accuracy for these elements. Then the ring beams have to
be cut to length and the end details applied.
23
All individual elements need corrosion protection and can then be transported
to the site. The bar connecting the main bodies of the radial girder and the
top chord of the compression ring is the last part which shall be produced
after survey of the as-built geometry of the compression ring.
On the site two adjacent radial girders starting at one expansion joint shall
be welded together with the ring beams between them. The preassembly yard
for the compression ring can be used. This ladder like element should be
temporarily braced and lifted into place.
The same principle should be applied for the next two radial girders leaving
the ring beams between these two “ladder” elements open. Similarly the third
ladder element can be installed before the geometry of all three ladder
elements is controlled and if necessary adjusted with the temporary bracings.
After that the remaining ring beams always in between two ladder elements
can be bolted in the air, the permanent bracing installed and the temporary
bracing removed.
After the installation of five radial blocks of the canopy one should start
with the next segment of the canopy. After verification of the geometry of
the second segment the girder along the joint between the first and second
segment can be installed. This helps to ensure that all joints are of equal
size and that any construction deviation can be distributed over more than
one joint.
Right after completion of one whole segment the top and bottom membrane, as
well as the front edge cladding, drainage, closure flaps, etc. can be
installed.
24
1.8 Execution Class
Execution of steelwork as well as Inspection level and design checking level

shall comply with EN 1090 and related Codes.
1.8.1 Failure Consequences Class [CC] as per EN 1990:2010 Table B.1
CC3 Roof structure of public event facility without direct

correlation between use and decisive load scenario
1.8.2 Category of operational demands (System Class) [SC] as per 1090-2 Table
B.1
SC2 Structures susceptible to vibrations induced by wind
1.8.3 Category of Production [PC] as per 1090-2 Table B.2
PC2 for welded structure with steel grade S355 or higher
1.8.4 Execution Class [EXC] as per EN 1090-2 Table B.3
EXC 4
25
2 Quality Control System
2.1 General
A quality control system according to ISO 9000 - 9004 is mandatory. The full
quality documentation has to be submitted to the client.
The factory expert is to present acceptance test documents as per EN 10204 -
3.1/3.2 in respect of all the checks regarding geometry, weld seam tests,
castings, doubling tests, and corrosion-proofing.
2.2 Requirements for steelworks
- independent quality control staff

- controlling of:
 material
 material flow
 welding, non-destructive testing as specified below (see Section 3)
 geometry
- documents to certify the controlling
2.3 Requirements for cable structure

- controlling of:
 material
 material flow
 breaking load tests
 non-destructive testing of cables and cast steel elements (see
Section 3 and 4)
 geometry (length)
- documents to certify the controlling.
26
2.4 Requirements for membrane structure

- controlling of:
 material
 material flow
 breaking load tests
 geometry of membrane panels
 packing and unpacking of membrane panels
 damage assessment of fabric
- documents to certify the controlling
27
3 Metal materials
3.1 General fabrication remarks
Use no materials, equipment or practices that may adversely affect the

functioning, appearance or durability of the completed structure, the work
and related construction.
Conform strictly to the materials, finishes, shapes, profiles, sizes,
thicknesses, and joint locations required by the contract documents. Match
all materials to produce continuity of line, texture and colour.
All components exposed in the finished work shall be free from warping; oil-
canning effects; the telegraphing of welds, studs, and other fasteners;
streaks; and tool or die marks. All fabrication of components with edges
exposed to view shall be done prior to finishing.
Manufacturer’s Standards: Materials, components, and systems incorporated
in the Work shall be mixed, applied, installed and otherwise used in strict
accordance with the recommended standards and procedures of the respective
manufacturers.
3.2 General structural steel remarks
Provide in accordance with the stipulated codes. Properly mark and match mark
the material where field assembly is required. Sequence the shipments to
expedite erection and minimize the field handling of material.
Milling: Completely assemble and weld members before milling of surfaces. The
milling device is to be of appropriate capacity to obtain the requested
accuracy.
Welding: It is the steel contractor's task to plan suitable measures for
welding (e.g. shape of seam, seam preparation, heat treatment, welding
sequence, checking of seams, assembly). Welding sequence plans are to be
submitted for approval. Only experienced and qualified welders with
applicable certification will be allowed to weld. For special requirements
for welding (i.e. tubular sections, overhead positions, thick plates, high
grade material, welds of castings to mild steel, dynamic loaded welds etc.)
welders will have to be qualified in tests surveyed by an independent agency
in accordance to EN 10204 - 3.2. A suitable procedure is to be used to
demonstrate that the seams are free of cracks. The nature and extent of the
tests are to be agreed.
The following minimum tests are to be done:

 All seams are to be checked visually to an extent of 100%.
 All the on-site seams for full butt joints are to be checked to an
extent of 100% by ultrasonic testing.
 All the workshop seams for full butt joints are to be checked to an
extent of 25% by ultrasonic testing.
 The minimum extent of the tests for all the other weld seams is set at
20%.
28
 The air tightness of all not maintainable or inaccessible internal

volumes shall be inspected using pressure test to an extent of 100%
In general the quality assurance of the welding work is to be as per EN ISO
14731, EN ISO 3834 and EN ISO 5817 Assessment group: B. Some welds require
the highest assessment group. The weld seams are to be checked as per EN
1090.
If any higher quality of steel is required due to the chosen manufacturing
process (e.g. transverse strain due to welding details) this needs to be
chosen by the contractor without additional remuneration.
Built-up Sections: Assemble by welding and make free of waviness with axes
in true alignment.
Inside closed sections: The interior spaces of hollow steel structural
components are not to be given additional corrosion-proofing, but must be
made airtight. See corrosion protection.
All bolts of connecting parts with or without slotted holes shall be secured
against loosening by suitable means.
The factory expert is to present acceptance test documents as per EN 10204 -
3.1 in respect of all the checks regarding geometry, weld seam tests, doubling
tests, and corrosion-proofing.
3.3 Mild Steel/ Fine grain steel
General structural steels as per EN 10025 are to be employed. The chemical

composition in the melting charges and product analyses must accord with the
values stated. All components are to be of grade S355 J2(+N) unless anything
is stated to the contrary. Additionally plates with thickness of more than
60mm shall be of grade S 355 NL to justify to EN 1993-1-10.
All pipes are to be of steel grade S355 J2H as per EN 10210 unless anything
is stated to the contrary. It is not allowed to use spiral welded tubes. If
tubes with a longitudinal seam are used the seams have to be in one line over
the whole length of the tube.
All the plates and steel components subjected to transverse strain are to be
checked for doublings. In particular, this requirement especially applies to
all central plates and end plates of the compression ring.
Plates and rolled members subject to tension vertical to the rolling direction
as well as the requirement for welding of thick plates will require
appropriate through thickness tension properties (“ttt” / “z-quality”) as per
EN 1993-1-10. Through thickness tension properties (“ttt” / “z-quality”) have
to comply with EN 10164 and need to be verified according to EN 1993-1-10.
29
Unless specified otherwise / verified in more detail the requirements as per

the following table must be met:
Plate t ≤ 8 mm 8 mm < t ≤ 20 mm t > 20 mm
thickness
Required Z15 Z25 Z35
quality
table: general requirements for through thickness toughness
As per EN 1090 cl. 5.3.4 the base material in the area of transversal tension
loading or welded stiffener plates must be quality class S1 for inner
inhomogeneity as per EN 10160.
In general the proof of the required Z quality remains with the contractor
due to the chosen manufacturing.
3.4 Stainless Steel Plates
All stainless steel plates and sections are to be grade 1.4401 with S355 (fyk
= 355 N/mm²) unless stated otherwise. If cold drawn materials are not
available to achieve fyk = 355 N/mm² or if elements have to be welded 1.4462
has to be used instead. Stainless steel C Clips are to be made of grade 1.4401
or 1.4404 S355 (fyk = 355 N/mm²).
3.5 Aluminium for Clamping Plates
Minimum requirement for the powder coated aluminium (and not the raw material)
is fyk = 235 N/mm² as the minimum yield strength. This has to be considered
in the workshop design and final layout of the clamping bars.
3.6 Bolts and Rods
Pretensioned bolts are hot-dip-galvanized high-strength friction grip bolts

of grade 10.9 or 8.8, with nuts and washers. For level of pretension see
design analysis or drawings, in some cases pretension might vary from 100%
value. Washers are to be 300HV type washers.
Unless specified otherwise, bolts are to be prestressed as per EN 1090-2 Cl.
8.3 or 8.5. For applications not regulated hereunder (e.g. bolt in threaded
bore) the torque required to achieve the specified prestress is to be
determined and verified by means of tests (with load cells) following the
procedures as per EN 1090-2 Cl. 12.5.2 and EN 1090-2 Annex H. A Method
Statement for the execution of the torque calibration tests and of the
torquing procedure shall be presented to the client before execution.
Non pretensioned connections are made of grade 5.6 sets of bolts unless stated
otherwise and have to be tensioned with a minimal torque as per EN 1090-2
Cl. 8.3.
Execution and supervision of the execution is to be carried out following EN
1090-2 Cl. 12.5.2.
The properties of all the materials used are to be demonstrated by means of
acceptance test certificates 3.1 according to EN 10204.
30
For all sets of screws (i.e. bolt, washers and nuts including lubrication)
the individual elements shall be of one single manufacture. Always two washers
are to be used in each set for grades 8.8 and 10.9, one on each side.
Manufacture, procurement and delivery are to be in an assembled set.
Threaded rods are hot-dip-galvanized bar sets 8.8 as per EN ISO 898-1 / DIN
976-1 galvanized at “normal temperature” as per EN ISO 10684 (avoid hydrogen
induced embrittlement). Rods need to be delivered to site as assembled set
with nuts and washers and with the required lubrication, demonstrating that
nut and thread are matching well (the nut must be rotatable by hand easily).
The sets of screws shall be assembled out of the following elements.
Set Bolts Nuts Washers Categ

genera code cla label code cla labe code cla label ory
l ss ss l ss
standa
rd
DIN 7990 DIN
7990 SB 7989-1
5
DIN DIN
7969 EN ISO 7989-2
4.6
EN ISO 4034
SB
4016 EN ISO
4 100
EN ISO 7091
4018
DIN 7990 DIN
none
7990 SB 7989-1
EN A
DIN 7968 DIN
15048- SB D
7968 SB EN ISO 7989-2
1 5.6 5 AD
EN ISO 4034
4014 EN ISO 200
SB
EN ISO 7089 300
4017
EN ISO EN ISO 200
8.8 8
4014 7090 300
EN ISO EN ISO EN ISO
SB
4017 10. 4032 7091 suppl
10 300
EN ISO 9 DIN ier
10642 34820
Table: bolts for non-prestressed bolted connections (type A,D,AD)
Set Bolts Nuts Washers Categ

gener code cla label code cla labe code cla label ory
al ss ss l ss
stand
ard
EN ISO A
EN
4014 EN ISO DIN suppl B
14399 8.8 H... 8 H... 300
EN ISO 4032 34820 ier C
-1
4017 D
31
EN EN E
14399-3 14399-3 AD
HR HR
EN EN AE
14399-7 14399-7 BE
EN EN CE
HR
14399-3 14399-3
HR H
EN EN
EN +
14399-7 14399-7
14399-6 suppl
EN EN
10. HV HV ier
14399-4 14399-4 10
9
EN EN
HVP
14399-8 14399-8
HR
EN EN
HRD
14399- HRC 14399-
10 10
Table: high strength bolts for prestressed bolted connections (type
A,B,C,D,E,AD,AE,BE,CE)
Set Threaded Bars Nuts Washers Categ

gener code cla label code cla labe code cla label ory
al ss ss l ss
stand
ard
DIN 976-
EN
1/ suppl EN ISO EN ISO
1090 8.8 8 H... 300 none E
EN ISO ier 4032 7089
-2
898-1
Table: threaded bars for prestressed connections (type E)
Torque and securing measures:

All bolts and nuts are to be locked positively using full pretension (if not
stated to the contrary) or partial pretension and high strength loctite® or
equivalent.
Bolts used for pinned connections must not be prestressed but require a
counter locking nut. Threads may not be in the bearing area.
After tightening/locking of connections the fastener shall be marked and
signed with the initial of the worker using durable colored pencil. The
pretension torque of each bolt is to be stated in a protocol.
3.7 Stainless Steel Bolts
All stainless steel bolts, screws and washers are to be grade 1.4401 / 70
(fybk = 450 N/mm² fubk = 700 N/mm²) or of higher corrosion grade or higher
strength unless stated otherwise.
For pretensioned connections and clamps the actual tension forces achieved
while pretension the bolts using torque has to be tested. This applies to
all sets of screws in various arrangements used for pretensioning (screws in
nuts, in tapped holes, in blind taped holes etc.)
32
3.8 Friction Grip connections
All contact surfaces between the head plates of the compression ring are to
be machined, sandblasted and coated in accordance to EN 1090 to achieve a
minimum friction coefficient of class B (0.4). During transport and
installation these surfaces are to be protected properly. The achievement of
the mentioned friction coefficient is vital to the behaviour of the
compression ring as per the structural design, hence the method statement is
to be approved by the client prior to execution.
33
3.9 Material for pins - quenched and tempered steel
34 CrNiMo 6+QT (Mat.-No. 1.6582) is to be used for all hinged connections.

Material properties according to EN 10343:
Thickness 40 -100 mm 100-160 mm 160-250 mm >250 mm
min.yield 800 N/mm² 700 N/mm² 600 N/mm² 600 N/mm²

strength
min. tensile 1000 N/mm² 900 N/mm² 800 N/mm² 800 N/mm²
strength
min. strain at 11 % 12 % 13 % 13 %
fracture
The properties of all the materials used are to be demonstrated by means of

acceptance test certificates 3.2 according to EN 10204.
Unless stated otherwise pins are to be hot dip galvanized at “normal
temperature” per EN ISO 10684.
The contractor can apply for an alternative material providing the same
material characteristics according to availability and delivery period / time
schedule, to be approved by the client and his engineer.
Unless stated otherwise, pins with diameter > 50mm are to be secured using
cap plates. The cap plates need to be held in place using at least two bolts
grade 8.8 or 10.9 with washers 300HV (pre-stressed). Additionally high
strength loctite® or equivalent is to be applied. Bolts and washers shall be
hot dip galvanized and shall be delivered to site without grease application
and prepared for the use with loctite. Threads at pins shall be re-cut after
galvanization and prepared for application of loctite.
Pins with diameter < 50mm shall be secured using
A) unless stated otherwise: retaining rings similar to DIN 472 heavy duty
shape made of bronze CuSn8 material number 2.1030.34 with Re 600 Rm 720 MPa
together with appropriate hot dip galvanized support washers as per DIN 988.
The dimensions of the grooves for the retaining rings are to be met after
galvanization of the pins considering an oversize initial groove for the zinc
layer. Galvanization must follow EN ISO 10684 with centrifugation to remove
any surplus of zinc from the grooves. Pins, retaining rings and washers must
be delivered to site as preassembled units.
B) pin caps with a machined groove that fits to a machined up-stand at the
end of the pin. This is to provide a mechanical lock against any rotation
between pin and pin cap after assembly. The cap plates are held in place
using one bolt grade 8.8 or 10.9 (pre-stressed). Additionally high strength
loctite® or equivalent is to be applied.
34
3.10 Tension rod systems
Tension rods shall be hot dip galvanized and of type 860 Pfeifer or
equivalent. Only approved and accredited systems of tension rods shall be
utilized. Steel grade S460 of specified diameter coated as per corrosion
specification with top coat RAL. The fork ends shall be "Pfeifer” fork ends
or equivalent.
3.11 Single bar tendons
General information and accuracy
All tension columns have to be connected to the concrete structure by means

of single bar tendons, e.g. the Y-columns. The interaction of steel work and
concrete work for proper positioning and protection of the bars is to be
planned thoroughly by the contractor.
All cast-in parts (incl. tendons, bars) have to be assembled with templates
(both at concrete surface and at anchorage level). Templates must not be
fixed to the reinforcement but directly to the formwork, to avoid shifting
of the cast-in parts during dynamic compaction. The location of all cast-in
parts (global coordinates!) must be measured prior to casting/grouting. The
contractor has to hand over the results of the measuring to the client for
approval.
The permissible deviations of the cast-in units or pre-set tension bars and
edges/elevations of the concrete structure are given in the tolerance chapter.
Anchorage system
Single bar tendon system; unbonded tendons without free tendon duct with
permanent corrosion protection system are to be employed.
System according to current permission/ specification ETA-05/0123 type
DYWIDAG or ETA-05/0122 type SAS or equivalent. Only accredited and officially
approved systems can be proposed. Length of single bar tendons according to
structural drawings in accordance with the roof structural requirements.
Additional length for tensioning process to be considered.
Steel grade Tendons
Steel of grade 950/1050 N/mm² is to be employed, all other components

according to current permission/ specification ETA-05/0123 type DYWIDAG or
ETA-05/0122 type SAS or equivalent.
Delivery, stocking and installation by accredited personal from specialist
contractor only with approval by client and in accordance with respective
ETA and manufacturers conditions.
Great care is to be taken during delivery and assembly that damages are
avoided and the temporary corrosion protection measures are according to the
ETA. Any sort of damage to the bar, the corrosion protection and any type of
corrosion has to lead to rejection. Improper storing and handling will also
lead to rejection. Proper methodology is to be submitted to the client for
approval.
35
3.12 Cast steel
Materials
G18 NiMoCr 3 6 +QT based on EN 103401)
Designation G18 NiMoCr 3 6 +QT

Material no. 1.6759
Code EN 103401)
Thickness (mm) > 250 mm ≤ 250 mm ≤ 150 mm ≤ 80 mm
Heat Treatment +QT2 +QT2 +QT2 +QT1
yield point (0.2 %) 5802) 5802) 630 700
N/mm²
tensile strength 730 – 8802) 730 – 8802) 780 - 930 830 – 980
(N/mm²)
Ductile yield (%) 9 12 12 12
Charpy V-notch Min. 27 Joule at -40°C (for all thickness)
energy Min. 40 Joule at +20°C (for all thickness)
Table: Specification G18
G20 Mn5 +QT based on EN 10340 1)
Designation G20 Mn5 +QT

Material no. 1.6220
Code EN 103401)
Thickness (mm) > 250 mm ≤ 250 mm ≤ 100 mm
yield point (0.2 %) 2802) 2802) 300
N/mm²
tensile strength 500 – 6502) 500 – 6502) 500 - 650
(N/mm²)
Ductile yield (%) 16 22 22
Charpy V-notch Min. 27 Joule at -40°C (for all thickness)
energy Min. 60 Joule at +20°C (for all thickness)
Table: Specification G20
1)It is noted explicitly that the demands specified hereunder are exceeding
the requirements given in EN 10340.
2) Values for higher material thicknesses than

150mm as per EN 10340 (G18)
100mm as per EN 10340 (G20)
are to be approved by an expertise of an accredited institute (e.g. for
Germany “Zustimmung im Einzelfall”).
36
General
The criteria of acceptance are the mechanical characteristics specified.

Deviating from EN 10340 / EN 10293 the properties must be met and verified
at the final casting piece near the surface and at the core and at the
locations with maximum utilization. Tests at the cast-on parts are not
accepted as sole verification of the properties. Additional castings for
destructive testing have to be considered. The location for the extraction
of the specimen shall be at the location of maximum stresses indicated within
the structural design report unless specified otherwise.
A secondary metallurgy treatment is mandatory.
The following additional restrictions are to be met for G18:
S < 0.005%, N < 0.010%, Al < 0.038%, Ph < 0.012%
Ladle analysis has to correspond to the stipulated standard on delivery. The
content of Al and N is to be analyzed and presented to the client additionally.
Furthermore, in order to achieve the material characteristics specified, for
the chemical composition of 1.6759 stricter restrictions need to be followed
than allowed by EN 10340 especially for the elements C, Mn, Al, Cr, Mo and
Ni. Same can be required for the other materials.
The minimum fP,0.2 strength at the surface (the centre of test body shall be
at 15mm below surface) shall be 700N/mm² (G18) and 300N/mm² (G20) for all
thicknesses.
Workshop Engineering, Method Statements and Schedule of manufacture and

testing
The development of the total casting methodology including optimization of

shape, mould, solidification analysis, location of feeders and vents, cooling
accelerators, heat treatment procedure (QT) is within the full responsibility
of the foundry, including time and test expenses needed to achieve the
specified product.
Prior to fabrication the foundry has to check the construction drawings with
respect to cast-ability and test-ability. In order to achieve the highest
possible quality, the foundry shall suggest concepts for optimization of
founding and testing procedures based on their internal investigations (an
optimized solidification analysis is expected for complicated geometries) if
applicable and seek clarification with the client in case of proposed
modifications. After approval by the client, optimizations shall be
incorporated into the workshop drawings / workshop models.
Before starting to fabricate, the foundry shall present the following
documentation to the client for review and must be approved by the 3rd party:
 Fabrication and testing schedule (FTS) in which the quality assurance
procedure and the dates of the fabrication steps are given
 Heat treatment schedule specifying temperatures, holding times and
cooling speeds
 Testing instructions for the non-destructive testing with detailed
directions on how the testing is performed (what, where, how) that is
done during quality assurance
 Test instructions for destructive testing with detailed information of
location and orientation of the test specimen. Unless sample drawings,
37
defining the location of specimen for destructive testing, are given

by the client, a sample drawing must be provided by the foundry and
presented to the client and its 3rd party for acceptance in due time
prior to execution
Compliance with the fabrication procedure shall be supervised by a 3rd party
inspection and verified by a 3.2 certificate.
Mechanical characteristics
Additional to the requirements specified in EN 1559 / EN 10340 / EN 10293

the mechanical characteristics shall be demonstrated by destructive testing
on specimen taken out from one casting of the first batch (one destructive
test for each typology of castings). The location for the specimen shall
cover zones of high utilization as indicated by the engineer as well as
critical zones related to the solidification process.
Tolerances
For the fabrication of the steel castings the tolerance grades according to
ISO 8062 (1997-08) apply. Required tolerance grade:
 nominal dimensions > 25 mm: CT 11
 nominal dimensions < 25 mm: CT 10
 for cable grooves at least (all diameters): CT 8, unless specified
other
Specific demands may supersede the above mentioned classification and require
a higher accuracy. This will be indicated in the drawings.
Heat treatment
The heat treatment has to be done according to EN 10340 / EN 10293.

Three Brinell hardness tests at 4mm below surface after the heat treatment
shall be carried out at each casting unless specified otherwise as an
additional test. The sampling location and shape (4mm overcast to be removed)
shall be clarified with the client's engineer. The maximum specified strength
may not be exceeded.
38
Quality class
Required grades of quality are based on DIN EN 1993-1-8 Table NA.B.2.:

Quality class conform to EuroCode 1993-1-8 Tabelle NA.B.2
For welding ends Grade 1 is required in general.
Quality class 1
Quality class 2
Quality class 3
The required higher quality class applies in the areas marked and with a
depth of min 30mm from the surface of the casting.
Figure: Areas of the casting and respective requirements for the quality
class (shown at a typical ring cable connector)
39
Testing scope and stipulated grades for defects
Non destructive testing according to EN 1559-2 and scope of testing:

The surfaces have to be at least cleaned and allow for a visual inspection
according to EN 12454. The surfaces for the non-destructive tests have to be
prepared according to the required tests (BNIF-guideline Nr. 359-01 (France).
Also compare EN 1369, EN 1370, Founding - Surface roughness inspection by
visual tactile comparators.)
(a) Visual (b) Surface testing (c) Volume testing -

Inspectio inspection inner defects
n
VT MT 3) PT RT 4) UT
Magnetic Dye Radiographi Ultrasonic
particle penetration c examinatio
inspection test examination n
Code EN 12454 EN 1369 EN 1371-1 EN 12681 EN 12680-1
BNIF-
guideline
Nr. 359-01
Required - 3S1 for SM2 SP2 / CP2 RV1 / RV2 / UV1 / UV2 /
grade raw cast for linear for linear RV3 UV3
surfaces signals and signals and as per as per
- 3S2 for signals in a signals in a DIN EN 1993- DIN EN
ground row LM2 / row LP2 / 1-8 Table 1993-1-8
surfaces AM2 (class b AP2 (class b NA(D).B.2 Table
resp. c, resp. c, and NA(D).B.2
depending on depending on design and
the wall the wall drawings design
thickness) thickness) drawings
Scope 100% 100% 100% 100% 100%
Remarks Cracks are Cracks are Cracks are
unacceptabl unacceptabl unacceptabl
e e e
Table: Non Destructive Testing
3) For surfaces that are inaccessible for the magnetic particle inspection
(MT) a dye penetration test (PT) can be carried out.
4)Alternatively to the radiographic examination (RT) ultrasonic examination
(UT) can be carried out where technically applicable. A minimum of one piece
per geometry is to be tested by RT if the elements contain welding ends and
in case of non acceptable results of the UT. In case of results below the
acceptance criteria RT has to be used for the other pieces as well.
The testing methods chosen by the fabricator due to the specifications above
have to be specified in the testing schedule in advance, showing the entire
fabrication sequence and testing procedure. All fabrication steps, tests,
hold points and 3rd party inspections must be indicated in detail.
Any expenses for testing incurred by the foundry and 3rd party inspection are
to be included in the unit price. The same applies to the expenses for
material verification.
40
Repairs
Necessary repairing welds before delivery have to be coordinated with the

client respectively the client’s testing agent. Welds at castings have to be
executed according EN 10340. Repair welds require upfront acceptance of the
client's engineer.
It has to be investigated whether the defect cannot be eliminated by grinding
of a selected area, provided an acceptable remaining area.
Repairs are to be tested as per (b) surface testing (or (c) volume testing
for deep repairs) to an extent of 100%.
Certification and Delivery documentation
Verification with compliance test certificate EN 10204 3.1 / 3.2 (third

party):
Compliance certificates EN 3.1 3.2
10204
Chemical composition 100% -
Mechanical Properties cast-on 75% 25%5)
parts
Fabrication (heat treatment 100% -
+QT)
NDT 75% minimum 25%5)
Destructive testing on real - 100%
parts
Geometry 100% -
Table: Volume of Testing (3.1 / 3.2) and required certificates
5) The selection of the 25% rests with the client
For acceptance certificate 3.2, the independent testing institute needs to

be invited for the inspection early enough (at least one week prior to the
commissioning date). All required documentation (see above) has to be included
with this invitation.
The approval is based on the results of all performed tests. It does not
relieve the fabricator from the responsibility regarding hidden defects.
Before the agreed commissioning date, the fabricator has to check and confirm
the compliance with the stipulated dimensions in the acceptance certificate.
Unless specified otherwise, the ID-number given in the order and the material
no. have to be stamped at the position denoted in the order drawings. The
steel letters have to be rounded off.
The full documentation has to be handed over to the client who determines
the safe-keeping duration. The documentation has to include but is not limited
to
- ID-number and order number
- Material designation
- Heat number, ladle analysis, and melting process.
41
- Results of all mechanical tests including strength, toughness and

hardness tests (all tested values have to be stated)
- Complete information on all heat conducted treatments, including the
actually measured time-temperature curves.
- Photos or sketches of all positions prepared for welding.
- Confirmation that the welding was performed solely according to the
approved welding plan by welders qualified for the chosen welding
process.
- Confirmation of the ordered quality documented by the protocols of
the non-destructive testing.
- Confirmation of the dimensions
42
Welding of castings to steel / casting to casting
Welds at cast steel have to be performed according to EN 10340 section 6.2.

In general a specific WPS (Welding procedure specification) and PQR (Process
Qualification Record) is required.
The assessment is done according to EN ISO 5817, Welding - Fusion-welded
joints in steel, nickel, titanium and their alloys - Quality levels for
imperfections. The highest quality level is required. The results have to be
documented with an acceptance certificate 3.2 according to EN 10204.
Special attention has to be paid to the execution of the weld at the base
(no cracks, full crack free penetration at the root).
It is suggested to test several random samples from the ongoing fabrication
by destructive tests to check the conformity with the reference sample from
the welding procedure tests in coordination with the engineer of record.
The welds are to be executed as full penetration welds.
The hardness at the welds is to be checked randomly. It must not exceed a
hardness of HB = 260 (GS20) resp. HB = 320 (GS18).
Welds have to be inspected by NDT to an extent of 100% using visual inspection,
surface inspections and volume testing. Cracks are unacceptable.
Inspection (d) Visual inspection (e) Surface testing (f) Volume testing -
of welds inner defects
VT MT 3) UT
Magnetic particle Ultrasonic
inspection examination
Code EN 12454
BNIF-guideline Nr. EN ISO 17638 EN ISO 17640
359-01
Required - 3S1 for raw cast
grade surfaces EN ISO 23278 - level EN ISO 11666 level 1
- 3S2 for ground 1
surfaces
Scope 100% 100% 100%
Remarks Cracks are Cracks are
unacceptable unacceptable
table 3.12-1 Testing of Welds
3) For surfaces that are inaccessible for the magnetic particle inspection
(MT) a dye penetration test (PT) can be carried out.
43
4 Corrosion protection
4.1 General
Great care shall be taken in view of the corrosive environment of the

structure. The guarantee undertakings from both the manufacturer and
applicator must be provided with the tender proposals. The applied Corrosion
Protection System (CPS) shall meet the requirements of the highest corrosive
category stated in EN ISO 12944. The described system shall be a recognized
paint system and shall have a minimum life-time of more than 15 years.
For the coatings the following information is required:
 Product name with detailed product, application and safety data sheets;
 Product manufacturer, ISO rating of manufacturer, place of manufacture
and technical back-up available in Spain;
 Detailed case histories;
 Performance guarantee offered.
 Name, location and ISO rating of proposed coatings applicator.
4.2 Hot dip galvanizing / galvanizing
In general all smaller mild steel elements like membrane plates and built in
parts as well as pins, bolts and cast elements are to be hot-dip galvanized.
The galvanizing agency has to be internationally accredited and well
experienced with high grade steels and avoidance of hydrogen embrittlement.
Detailed description see below under coating.
4.3 Inside closed sections
The interior of inaccessible or hollow sections and boxes of steel structural

components do not require additional anti-corrosion coating, but must be
manufactured airtight. Before the external coating is applied, the air
tightness of the weld seams and the boxes is to be checked (e.g. by means of
air pressure, soapy water, etc.) The pressure testing is to be planned
carefully for all segments to not overload the section by internal pressure.
For this purpose, suitable testing openings having lock screws are to be
located on all the lowest points of the structural components. Certificates
according with EN 10204 3.2 are to be drawn up regarding the tightness
testing.
Stainless steel rainwater pipes inside closed sections, if applicable, shall
be tested for water tightness using a pressure of at least 4 bars, before
and after welding and securing inside the steel columns.
44
4.4 Miscellaneous
The colour shade of the last top coat in each case is described in detail in
the architectural drawings and is to be approved by the client. For this
purpose the contractor is, without receiving any special remuneration, to
produce sample areas which will be used to decide the final colour shade.
4.5 Coatings
Various corrosion protection systems (CPS) are to be utilized for different

elements.
CPS 01 Coating as per technical specification
 All steelwork and plates
 stiffeners
 steel of installations
 secondary elements
CPS 02 Hot dip galvanized steelwork and plates with limited dimensions
 Catwalk - and roof access (stair treads, ladders, suspensions etc.)
 steel gratings and grids
 tension rods
 fixing systems for MEP - equipment and other provisions
CPS 03 Cable sockets
CPS 04 Aluminium clamping details

 clamping plates and corner plates along membrane edges
CPS 05 Connection parts

 Pins, bolts, screws flat washers and spring washers.
CPS 06 Connections between steel and reinforced concrete.

 Cast in parts
 Base points
CPS 07 Thermal spray galvanized and coated (duplex) for castings

 - ring cable connectors
 - hanger clamps
 - clamp covers
45
4.5.1 CPS 01 – All steelwork and plates
Coating system for steel constructions, excellent gloss and colour retention,
corrosion category C4 high durability.
In workshop
Surface preparation blast cleaning to Sa 2 1/2 of DIN EN ISO 12944 part 4
with sharp edged material, roughness acc. to ISO 8503/1 Type G Segment 2-3
Primer coat:
2-C-Epoxy- Zinc dust min 80% zinc in the dry film
Dry film thickness: 60 µm
Product: Interzinc 52 or eqv.
-grey-
Intermediate coat:
2-C- recoatable epoxy micaceous iron oxide intermediate coat
Product : Intergard 475 HS or eqv.
Colour shades acc. to RAL white
Top coat:
2-C- Acrylic -Polysiloxan - long time overcoatable top coat with excellent
color and gloss retention
Product : Interfine 878, or eqv.
Colour shades acc. to RAL, BS, MNS, Munsell or similar
On construction site
Repair of damages caused by transport /installation. Surface preparation to
PMa or PSt 2-3 of DIN EN ISO 12944 part 4
Touch up Primer coat:

2-C-Epoxy-Surface tolerant
Product: Interplus 356 or eqv.
46
-alu-
Touch up Intermediate coat:

2-C-Epoxy-Surface tolerant
Product: Interseal 670 HS or eq.
-grey or acc. to RAL , BS, NCS, Munsell or similar -
Touch up Top coat:

2-C-Acrylic-Polysiloxane- long time overcoatable top coat with excellent
color and gloss retention
Dry film thickness: 50µm
Product : Interfine 878, or eq.
Architectural coat (Optional):

2-C-Polysiloxan - long time overcoatable top coat with excellent color and
gloss retention
Product : Interfine 878, or eqv.
Edge Protection
All edges and welds shall be provided with an additional stripe coat of epoxy
MIO. The stripe coat shall cover the edge and weld and run 50 mm onto the
flat surface. The total dry film thickness on the stripe coated areas shall
be 400 microns. All right angle and sharp edges shall be broken and smoothened
with a minimum radius of 2mm.
Notes
Primer and intermediate coats to be applied in the shops with due cognisance
being taken of the over coating time requirements between the various coats.
Coating sequence as described.
Stripe coating to be carried out as described.
All site repairs to handling and erection damage shall be carried out as
described
Architectural coat to be applied on site after erection.
47
All nuts and bolts to be patched with intermediate coat prior to the
application of the finishing coat.
All welds to be coated shall be blast cleaned to grade Sa 2½ to ISO 8501-1.
The surface quality of grade Sa 2½ to ISO 8501-1 shall be present immediately
prior to coating. If the surface has deteriorated between blast cleaning and
the time of coating it shall be re-blasted to Sa 2½ before coating.
The surface roughness after blast cleaning shall be according to ISO 8503/2-
G and as specified by the coating manufacturer for the particular primer to
be used. The coating manufacturer shall confirm in writing the value of
roughness.
Areas of damages and site welds shall be made good according to the defined
specifications.
The Contractor shall apply all coatings under shop conditions, on site and
in the fabrication shop or yard, in strict accordance with the manufacturer’s
instructions and recommendations. These detailed instructions and
recommendations shall be documented and submitted prior to approval of the
Contractor's proposal.
The coating manufacturer shall be present during coating application to ensure
materials are used in accordance with the instructions and recommendations.
Coating system for steelwork according to EN ISO 12944, Corrosive category
C-4, high durability (H)
Ensure by design that no metals, including alloys of the same base metal,
are placed together in a manner, combination, or location likely to give rise
to damage by electrolytic action or other corrosion. In particular, avoid
metal to metal contact between aluminium and metals other than an appropriate
alloy of stainless steel as per the recommendations of the material
manufacturer and to the approval of the Architect. Ensure that dissimilar
aluminium alloys in contact with each other are compatible with each other
or are isolated. Any other dissimilar materials are to be treated or protected
in such a manner as necessary to prevent corrosive action.
Isolation of dissimilar metal surfaces to prevent electrolytic action shall
be accomplished by materials that are impervious to moisture and non-
absorptive.
Aluminium surfaces in contact with mortar, concrete, fireproofing, plaster,
masonry, or absorptive materials of any kind shall be coated with an anti-
galvanic material, impervious to moisture.
48
4.5.2 CPS 02 - Hot dip galvanized steelwork, plates, elements and castings
with limited dimensions:
In workshop
Surface Preparation: Sweep blast
Primer Coat:
hot dip galvanizing to ISO 1461:1999 or equivalent EN. Minimum layer thickness
85 µm or - limited to ring connectors and cast elements - with cable grooves
spraying galvanizing minimum layer thickness 1000 µm.
Intermediate Coat:
Intergard 475 HS or equivalent two component recoatable epoxy micaceous iron
oxide tie coat/intermediate coat dry film thickness 80 micron
Finishing Coat:
2-C Acrylic-Polysiloxane Interfine 878 or equivalent two component
polysiloxane finishing coat dry film thickness 60 micron
Notes
Cable contact surfaces / cable grooves will be zinc sprayed with 1mm thickness
to achieve friction coefficients and soft cable saddle beds.
The galvanized surface shall not be passivated.
Uncoated areas for renovation by the galvanizer shall not exceed 0,5% of the
total surface area of a component. Renovations at the galvanizing works shall
be done by zinc metal spraying. The zinc thickness shall be 30 micron greater
than the specified galvanizing zinc thickness.
The galvanized surface shall be sweep blasted prior to the intermediate coat
application.
The intermediate and finishing coats are to be applied in the shops with due
cognisance being taken of the over coating time requirements between the
intermediate and finishing coats.
Stripe coating to be carried out.
follows:
Galvanizing to be repaired with either zinc metal spraying or epoxy zinc rich
paint. The zinc rich paint shall contain a minimum of 80% zinc in the dry
film and the thickness shall be 30 micron greater than the specified
galvanizing zinc thickness. The damaged area shall be thoroughly cleaned and
the repair coating shall overlap onto the surrounding sound zinc for a
distance of at least 50 mm.
49
4.5.3 CPS 03 Cable sockets
In workshop
Surface Preparation: Sweep blast
Primer Coat:
Hot dip galvanizing to ISO 1461:1999 - minimum layer thickness for castings:
85 µm
Intermediate Coat:
Intergard 475 HS or equivalent two component recoatable epoxy micaceous iron
oxide tie coat/intermediate coat, dry film thickness 80 micron
Finishing Coat:
2-C Acrylic-Polysiloxane Interfine 878 or equivalent two component
polysiloxane finishing coat
dry film thickness 60 micron
Notes
The galvanized surface shall not be passivated.
Uncoated areas for renovation by the galvanizer shall not exceed 0,5% of the
total surface area of a component. Renovations at the galvanizing works shall
be by zinc metal spraying. The zinc thickness shall be 30 micron greater than
the specified galvanizing zinc thickness.
The galvanized surface shall be sweep blasted as described prior to the
intermediate coat application.
The intermediate and finishing coats are to be applied in the shops with due
cognisance being taken of the over coating time requirements between the
intermediate and finishing coats.
Stripe coating to be carried out as described
follows:
Galvanizing to be repaired with either zinc metal spraying or epoxy zinc rich
paint. The zinc rich paint shall contain a minimum of 80% zinc in the dry
film and the thickness shall be 30 micron greater than the specified
galvanizing zinc thickness. The damaged area shall be thoroughly cleaned and
the repair coating shall overlap onto the surrounding sound zinc for a
distance of at least 50 mm.
Intermediate and finishing coats to be repaired as described
All galvanized nuts and bolts to be patched with intermediate coat prior to
the application of the finishing coat.
50
4.5.4 CPS 04 – Aluminium clamping plates and corner plates, clamping edges
and membrane details
Coating System:
Degrease and clean
Apply one coat of epoxy primer - 25 to 35 micron
Apply one coat of polyester powder coating – 60 to 70 micron (HWF-Powder
coating)
Application of primer and powder as per the proprietary powder coating methods
(method statement to be provided by contractor)
Notes:
The powder coating material as well as the applicator must have an GSB
approval; The qualification must be proved before application will take
place
Textured or ‘structured’ powder coatings will not be acceptable due to
variations in film thicknesses
Application methodology must ensure required mechanical properties of base
material after coating
Profiles to be degrease and cleaned
Damage to the coatings during installation and torquing of bolts shall be
carried out using a two component polyurethane acrylic coating as
recommended by the powder manufacturer in accordance with a customized
touch up instruction (to be provided by the contractor)
Temperature control and coating time control for temperature coatings
required to avoid loss of yield strength
Color shades acc. to Clients specification.
51
4.5.5 CPS 05 - Pins, bolts, screws, flat washers and spring washers
All pins, bolts, screws, flat washers and spring washers shall be hot-dip
galvanized.
Hot dip galvanizing to be in accordance with ISO 1461, DIN 267
Minimum zinc thicknesses shall be as follows:
Articles of diameter less than 12 mm 45 micron
Articles of diameter of 12 mm or greater 60 micron
Articles of diameter of 40 mm or greater 85 micron
Painting (after installation and retensioning, if required)
Where the structures are painted (CPS 01) or galvanised and duplex coated
(CPS 02, 03), all nuts and bolts shall be degreased, and shall be fully coated
in accordance with the specification applicable to the structure or component.
52
4.5.6 CPS 06 - Connections between steel and reinforced concrete (cast in

parts)
Surface Preparation - Abrasive blast clean Sa 2½
Primer before installation:

ethyl based inorganic 2-C zinc silicate weldable primer(min 80% zinc in the
dry film
dry film thickness 20 – 25 micron
Interzinc 22 or eq.
- grey –
Finishing System:
DENSO Covercoat System or eq. with polyurethane finishing coats
The above described top coat shall be provided on the concrete exposed surface
for a distance of minimum 80 mm from the flange edge.
The edges shall receive additional protection as described.
53
4.5.7 CPS 7 - Duplex, thermal spray zinc + top coat
Application: cable clamps and ring cable connectors
In workshop
Surface Preparation: blast clean to Sa 3 of DIN EN ISO 12944- 4 with sharp
edged material, roughness acc. to ISO 8503/1 Type G Segment 2-3
Primer Coat:
thermal spray zinc to DIN EN ISO 2063:2005. Minimum layer thickness:
160 m in general,
1000 m in the cable groove in contact to the cable.
Holding primer (Tie Coat):

Intergard 269 or equivalent fast drying two component epoxy holding
primer, dft 40microns
Intermediate Coat:
Intercure 420 or equivalent two component epoxy micaceous iron
intermediate coat, dry film thickness 80 micron
Finishing Coat:
see CPS 01
dry film thickness 60 micron
54
4.5.8 CPS 8 - Friction Grip connection surfaces (head plates)
Qualified friction grip surface as per EN 1090-2 Class B

ensuring a friction coefficient of  = 0.40
In workshop
Surface preparation to Sa 2 1/2 of DIN EN ISO 12944-4 with sharp edged

material, roughness acc. to ISO 8503/1 Type G Segment 2-3
Primer Coat
Interzinc 22 or equivalent ethyl based inorganic zinc silicate weldable
two component primer with qualified friction grip coefficient  > 0.40.
dft 25-30 m.
55
4.6 Painting Inspection and Test
Surface Preparation: The surface shall be visually inspected for dust, oil,
rust spots and other substances. Note: Sand blasted surfaces may show defects
or errors in fabrication (e.g. welds) which otherwise would stay undetected.
In such case, the responsible inspectors should be immediately contacted.
The cleanliness of the surface shall be compared to the cleanliness degree
specified in the painting scheme. This comparison is done with the visual
samples of Standard SIS 05 5900 - 1967.
The rugosity profile shall be measured in 1 sq. meter of the surface, at the
start of the sand blasting, and this will be repeated at each 500 sq. m. or
fraction of equipment, and every time the sand or grit is changed.
In pipes, the rugosity shall be measured in 1 meter at the start of the
operation, and then every time the grit is changed.
The rugosity will be determined by the use of a “profile gauge”, making a
series of measurements, the average of which is the rugosity value.
The results of all these operations must be recorded. The rugosity profile
should vary between 40 and 75 mm. which is probably around 1/3 of the total
thickness of the dry film of the painting scheme.
Paint film should be checked for the following defects:
 Runs
 Blisters
 Wrinkling
 Cracks
 Bubbles
 Craters
 Impregnation of grit
 Flaking
 Poor adherence
Adherence: The adherence test shall be done after the time for drying and
curing of the film, in accordance with ASTM Standard D-3359, with an X cut.
The minimum acceptable level will be 3A.
The test shall be performed in each 30 meters of piping, in each lot of
prefabricates pieces not larger than 30 m, and in each equipment.
For painting systems with primer of inorganic silicate base and thickness of
the dry film in each coat equal to or greater than 75 mm, the same test by
ASTM D-3359 with an X cut will be used, with minimum acceptable level 3A,
that is, removal of small dents up to 1.6 mm in any side along the cuts, to
determine the adherence.
The adhesive tape to be used in these tests shall have an adhesivity degree
of 40±2.8 g/mm2 (3M tape 810 or similar).
56
In no case ordinary masking tape will be accepted.

Since this is a destructive test, the test areas shall be immediately touched
up.
Dry Film Thickness: The test of dry film thickness shall be performed after
each coat, with the use of a micrometer with precision of 5 μm.
Five measurements will be done for each 15 running meters, or five
measurements for each group of prefabricated pieces not reaching 15 m.
Five measurements will also be done for each 10 sq. meters, or five
measurements for each equipment.
Each measurement will be the average of three readings made at the same point.
Both the averages in each point and the general average must be within the
thickness interval established for each painting scheme.
A general average below the minimum thickness specified for the painting
scheme will not be acceptable.
When a decrease in thickness is detected, a further additional coat must be
applied in all the involved area, except in the case of zinc-rich paints,
when all the paint must be removed and the work repeated.
The final thickness will be acceptable up to 20% above the maximum specified,
except for zinc-rich paints, where this value will be 10%.
Both the averages in each point and the general average must be within the
thickness interval established for each painting scheme.
In all tolerances and measurements the error of the instrument must be added
(tolerance of the instrument = ± 5%)
The maximum and minimum thickness for primer paints will be for high spots,
that is, the net thickness, difference between the reading for the primer
and the reading on the bare surface after sand blasting.
57
5 Grout
To level the base points properly the volume between steel base plate and
concrete foundation socket is to be grouted if not directly cast in. The
grout touching surfaces need to be clean. The grouting procedure needs to
ensure that full contact is reached. No air bubbles shall be trapped. Exposed
grout surfaces are to be maintained with sufficient inclination in order to
drain water.
Pagel Grout V1/10, V1/50 or V1/160 or eq.

Required material properties:
Grouting height mm 50 -100
Amount of water % 10–12/ 11
Material needed kg/dm3 2,00/ 2,10
Density of freshly mixed mortar kg/dm3 2,30/ 2,33
w/c-value 0,35
Extension 24 h Vol. % 1,0
Extension 28 d Vol. % 1,0
Compressive strength 24 h N/mm2 49/ 51
Compressive strength 7 d N/mm2 70
Compressive strength 28 d N/mm2 90/ 91
Compressive strength 90 d N/mm2 110/ 98
E-Modul (cylinder) 7 d N/mm2 33000 / 34500
E-Modul (cylinder) 90 d N/mm2 39300 / 40100
58
6 Cable structure
6.1 General
For all cables, fully locked cables made from hot-dip-galvanised and galfan
coated wires are to be used.
The rated tensile strength of all the wires involved in the cable structure
must not exceed fu,k = 1570N/mm2 for the fully locked cables, and 1770 N/mm2
for the spiral strands where applicable.
6.2 Wires for fully locked cables
6.2.1 General requirements
The wires are to be manufactured from unalloyed, solidly cored high-grade

steel as per DIN EN 10016. The chemical composition in the melting charges
and product analyses must accord with the values as per DIN EN 10016. Each
hot-rolled wire coil is to have a plate attached stating the purchase order
designation, melting charge number, and hot-rolled wire grade designation.
The diameters of the round wires, and the heights of the Z-shaped wires, are,
for the cables which are to be turned through an angle, limited to 0.3% of
the radius of the circle along which the cables are to be turned.
Round wires are, in accordance with DIN 2078, to be manufactured within the
diameter tolerances there stated. The wire diameter must not go below
d=0.71mm.
Shaped wires having a Z-shaped cross-section are to be manufactured as per
DIN 779. The cross-section of the shaped wires may deviate from the rated
cross-section by from -2% to +5%. Wedge shapes are not permitted.
The rated tensile strength of hot-dip galvanised and galfan coated wires is
related to the steel cross-section. The surface of the wire must be free of
harmful faults such as soot, cracks, notches, etc., if these impair the
usability of the wire more than inconsiderably.
Each wire coil is to have a plate attached to it indicating: designation of
purchase order, designation of shape, dimensions, melting charge number,
serial number of coil, and stamp of quality controller.
6.2.2 Storage of wire coils until the time of stranding
The coils are to be so stored that they are protected against meteorological
and mechanical influences, and this also applies when they are being
transported. If the wires were not stranded on the premises of the wire
manufacturer, the attached plate must also state the wire manufacturer, the
cross-section, and the rated tensile strength.
59
6.2.3 Quality controls for the wires
The independent quality control test must be acknowledged by a recognised

testing establishment. Tests have been passed if the samples display the
quality features laid down in the standards. If a sample does not meet the
requirements, then, as a substitute, two new samples are to be taken from
the same piece of wire and tested. If these samples also do not meet the
requirements, the entire manufacturing batch is to be tested. The units
failing the test are to be removed from the batch.
After the tests have been completed, the test records, together with the
acceptance certificates, are to be submitted to the S.O. All the expenses of
the quality control tests are to be borne by the contractor; if they are not
recorded as individual items, they are to be included in the unit prices.
The following tests are required on the wires:
A) For the wire rod:
Analysis of the melt of each melting charge as per DIN 17140, section
3.3.2 (EN 10204, 3.1)
B) For the cable wire:
Pieces of wire for tests are to be taken from the wire coils which
have been made ready for stranding. Their length must also be
sufficient for repeat tests. The piece of wire, and the wire coil, are
to be adequately marked.
Tests performed on each wire coil:

 Tension test as per EN 10264, EN 10218, (EN 10204, 3.1)
 Reverse bending test as per EN 10264, EN 10218, (EN 10204, 3.1)
 Torsional test as per EN 10264, EN 10218, (EN 10204, 3.1)
Tests performed on every 5th wire coil:

 Inspection of coating including total weight and adhesive force of
coating as per
EN 10244-2 (EN 10204, 3.1)
 Dimensional accuracy of the round wires and shaped wires (EN 10204,
3.1)
The tension test is to determine not only the tensile strength, but also the
breaking elongation. The latter must attain the following minimum values:
Bare wires:
3.5% min. when Lo = 10 x D or Lo = 11.3 x A0.5 (shaped wires)
Coated wires:
4.2% min. when Lo = 10 x D or Lo = 11.3 x A0.5 (shaped wires)
60
When the dimensional accuracy is tested, the cross-sections are in each case
to be ascertained by two measurements of diameters, with one measurement
being vertically above the other. In shaped wires, the cross-section is
calculated from the measured weight by means of g=7.85kg/dm3.
6.3 Fully locked cables
6.3.1 Structural and mechanical properties of cables
The cables are to be manufactured from round and shaped wires of locked
design. The cross-section and structure are to be determined by the
contractor. They must include at least two layers of shaped wires. The
structure of the cables must allow for the planned angle of 20d through which
the cables are to be bent.
All the wires of the locked cables, with the exception of the two outer layers
of shaped wires, are to be thick-galvanised as per DIN 2078. The shaped wires
are to be given a galfan coat with a minimum weight of at least 300g/m².
The wires are to be given their galvanised coats by the hot-dip process. A
unilateral alloy of zinc and aluminium (5 weight %) is applied in a molten
state as a protective metal. As regards the galvanic coating, the
International Lead Zinc Research Organisation was granted a patent in 1984.
The client is to be informed of the structure of the cables in good time,
and that structure is to be agreed upon with him.
The modulus of elasticity of the cables must be E=160’000+5’000N/mm².
The lengths of twist of the cables are to be adapted to the modulus of
elasticity and to the angle through which the cables are planned to be turned.
The individual wire lengths are to be stranded alternately left-hand and
right-hand.
The cables must be good to bind together, i.e. the cable diameters of layers
located one above another must be so co-ordinated that no arches can form.
The inner corrosion-proofing to be given to the cables used in the cable
structure consists of an inner filling which has an active pigment (inorganic
zinc paint) and remains paste-like. The inner filling must be compatible both
with the zinc coating of the cables and with the galfan coating.
The dosing of the inner filling is to be such that the last two layers will
get no inner filling. The total amount of inner filling is to be established
to provide the full corrosion protection.
The cables are to be marked at the places where it is planned that clamps
and saddles are to be connected, and also at the positions of the cable heads.
They are also to be given a straight surface line.
The anchorage in cable heads by means of hot sweating using redistilled zinc
alloys of the "Zamak" type as per DIN 1743 is to be carried out in accordance
with DIN 3092.
61
Factory records of the serial designations for the manufactured cable batches
and for the individual cable lengths into which they are cut up are to be
kept and submitted to the customer.
6.3.2 Quality control for the cables
General
The section on quality controls on the wires applies analogously here. The
following tests of the cables are required and to be carried out in accordance
to the related codes.
Samples for tension tests and long term tests

The sample items are to be decided by agreement between contractor and quality
controller, the designation of the relevant cable batch is to be given, and
the characteristic data are to be registered in factory records. The sample
items must have a cable head of the planned type on at least one side of
them.
Tension tests (EN 10204, 3.2)

Expansion measurements and tension tests are to be performed for
- All cable types and diameters
The following data are to be ascertained in the test:
- modulus of elasticity, after 5 and 10 load cycles between 5% and 50%
minimum breaking force, being measured as a secant for the rising load;
- cable stretch;
- cone setting in the sockets;
- real breaking strength of the cable.
The testing facility must have been calibrated by a body recognized by the
state.
The Clients is to be informed in due time about the location and schedule of
the cable testing, which shall be undertaken in the presence of the quality
controller. The tests need to be carried out in due time before the cutting
length determination.
62
Long term test (Creep test) (EN 10204, 3.1).

Long term tests for determination of the cable creep shall be carried out
for:
4 cable diameters to be defined by the project consultant
The procedure shall include 10 cycles to 50% of the minimum breaking force
and determination of the cable modulus upfront (See tension test). Afterwards
the cable shall be kept under constant load of 40% of the minimum breaking
force for at least 200h at a temperature of 20°C (± 3K). The evaluation of
the tests shall be carried out compensating the influence of temperature
deviations for a reference temperature of 20°. The length of measurement
shall be minimum 2m. The evaluation shall be presented as list of readings,
analysis of the extension at 20° (excel format) and in two graphs with linear
scale and logarithmic time scale. For creep compensation the expected total
creep value shall be considered by an extrapolation of the long term test
results for 5 years.
Dimensional accuracy (EN 10204, 3.1)

Volume:
All cable types and diameters
The outer diameters of the cables are - by two measurements, one vertically
above the other - to be ascertained firstly at both ends, in each case about
1m from the point where the cable enters the cable head, and secondly in the
area of the connection with saddles or clamps. Permissible diameter tolerance:
±1%.
Accuracy requirements
Volume:
All cable types and diameters
In order to achieve the expected structural behavior and redundancy of the
structure it is mandatory to achieve the defined condition of prestress and
geometry with high precision and as per design intend. Provisions for
adjustments on site are not foreseen and not in line with the design intend
except for elements stated explicitly. The cable manufacture, marking and
cutting subsequently must provide highest precision.
- Cable Length:
The overall length of a cable must be correct within a tolerance of 1:10'000
(0.01%)
63
- Cable Marks:
Cable Marks on the surface of the cables are required in order to allow
precise assembly of connectors and cable clamps. The individual marking for
clamps on the carrying cables must be carried out with a tolerance of less
than 2 mm. Adding up of deviations along the cable must be avoided.
- Cable Diameter:
Tolerances of the cable diameter of Fully Locked Cables must be less than
±1% and must be considered during workshop design.
6.3.3 Cutting of the cables
When cutting the cables into lengths, the contractor is to ascertain the
overall amount of the extension, taking into account the test results.
Temperature influences are to be included here.
All the cables are to be cut into lengths using, for the cutting into lengths,
a force which has been determined by the Contractor and is to be agreed upon
with the consultants. This force is to correspond approximately to the force
of the cable in the supporting framework under dead load.
The exact cable lengths must be calculated by the assembly planner after
receiving the results of the tests performed on the premises of the cable
supplier or at a testing establishment. The relevant cable forces and
coordinates of the cable system points will be supplied by the Consultants
responsible for the final design.
Using the system points supplied, the extended cable length can be calculated
in its final state. The free length of cable, or the distance between the
bolt axes, results from the geometrical dimensions of the anchoring cables
and is taken into account accordingly in the calculation.
Using the extended cable length and the force resulting from the calculation
of the supporting framework, the non-extended length of the cables can now
be calculated. For this purpose, the modulus of elasticity ascertained in
the test is employed.
The force relating to the cutting into lengths is not equal to the force
arising in the supporting framework. The extension of the cable is therefore,
on the basis of the non-extended length, calculated using the above-mentioned
force relating to the cutting into lengths. In addition to the elastic change
in the shape of the cable, there is also a creeping (plastic) change in the
shape. This permanent change in shape (0.2 - 0.5o/oo) is measured by long
term test or by submitting comparable test results, and is included in the
calculation of the final points which are to be marked; that is, when the
cables are cut into lengths and marked, the length used for this purpose is
reduced by the extent of the expected creeping change in the shape.
64
6.3.4 Delivery of the cables
The cables are to be marked with the designations stated in the contractor's
drawing, and are to be in coils, sufficiently protected.
A plate is to be attached to them giving the following details: information
on the manufacturer's factory, cross-section, and length. The plate is also
to bear the quality controller's acceptance stamp. The quality controller is
to place a lead seal on the wire by which the attached plate is made fast.
Even at the time when the cables are loaded on to the vehicle at the
manufacturer's factory, care is to be taken that they will, during transport,
be supported well enough not to be damaged. The same applies to any
intermediate storage at the manufacturer's factory.
Any such major damage to the coating as results from transport and assembly
is to be avoided, as it would be detrimental to the purpose for which the
cables are to be used. Smaller areas of damage (with any individual area
measuring no more than 1cm²) are - using inorganic zinc paint or sprayed-on
galvanization - to be immediately repaired in such a way that the original
corrosion-proofness factor of the zinc layer is restored.
6.4 Spiral strands
Where applicable, the section on locked cables applies analogously to the

spiral strands of the suspension and membrane border cables.
The cable structure consists of 37 individual wires. All the individual wires
are to be installed with galfan coating at least 300 g/mm² thick.
The spiral strands are anchored in swaged on press fittings. The security of
the anchorage against breaking must be at least 90% of the breaking strength
of the cable. No slippage shall occur.
The modulus of elasticity of the cables must be E = 160’000 + 5’000 N/mm².
6.5 Cable sockets / clamps / ring connectors
6.5.1 Material
For all cable sockets and for the ring connectors cast steel of the quality
GS 18 is to be used. Specifications see section “Cast steel”. The socket
system shall be accredited and approved by a third party institution. For
clamp covers and hanger clamps S460 N/M is preferred.
6.5.2 Fabrication
The tolerances applied to the manufacture of the castings are to be taken

from the described valid technical regulations, unless the construction plans
prescribe any other values. Where measurements and their tolerances are
dependent on the dimensions and tolerances of other structural components
65
(e.g. cables, bolts), they must, by agreement with the customer, be

coordinated with one another and also made to function properly. This applies,
in particular, to the fits of boreholes and to the diameters of grooves and
cables. The design materials are to be adapted to the required accuracy of
measurement and the required surface conditions. In some cases the cable
clamps have to transfer differential forces by contact areas between bracket
and body. These parts are to be machined to tight tolerance as per valid
regulation (max. 10 micron).
6.5.3 Pre-tensioning of clamping bolts
Each bolt of the cable clamps and clamp covers has to be pre-tensioned to
the given, nominal value by means of appropriate and calibrated tools (e.g.
electric or hydraulic torque wrench). In order to compensate the loss of pre-
stress due to material creep, cable contraction, etc., each bolt has to be
re-tightened another three times, means four times in total. Between one and
the next tensioning step a minimum holding time of 4 hours must be maintained.
Unless indicated otherwise, the last tightening sequence must be carried out
after the assembly of the cable structure is completed and the cable is
prestressed to permanent condition.
The stressing method and sequence as well as the calibration of the

appropriate torque shall be documented and presented within a Method Statement
in due time before start of erection.
Each bolt head must be marked individually and distinctively after each
tensioning step. The different steps should be identified by different kinds
of markings. In addition the entire pre-tensioning procedure has to be
recorded in tabled form, indicating the applied torque moment, the used tool,
date and time. For all four steps the pre-tensioning has to be conducted in
crosswise sequence.
The used tools (torque wrenches) must comply with DIN EN 1090-2, 8.5 regarding
calibration, maintenance, etc.
6.5.4 Slippage test
The cable clamps are to be subjected to a slipping test. The following

conditions are to be observed here:
A method statement for the procedure of the slippage test has to be handed
to the clients engineer for review.
Cable clamps are to be subjected to a slippage load test as per EN 1993-1-11
following the procedure hereunder:
- The clamps (all clamps to be tested) are mounted to the unstressed cable
following the identical procedure and with the same equipment intended for
site. The sequence of pre-stressing shall be identical to the intended
sequence on site considering the number of load application cycles and
standing times.
- The cable is loaded to a load of 45% of Fuk.
66
- The slipping resistance of the clamp is measured (force at 0.5mm

displacement). The load-displacement graph is to be recorded up to a
displacement of 5mm.
- If applicable a re-tensioning cycle of the bolts is carried out and the
slippage force is re-measured.
Further the actual tension forces achieved while pre-tensioning the bolts
using torque has to be tested. This applies to all sets of screws in various
arrangements used for pre-tensioning (screws in nuts, in tapped holes, in
blind taped holes etc.) The tests can be performed on the samples used for
the tension test on the cables (test records as per EN 10204 - 3.1).
The test volume and evaluation shall be performed following EN 1990 appendix
D3 d) for determination of the friction force based on a statistical
evaluation as per EN 1990 appendix D.7.2.
6.5.5 Corrosion protection
Refer to chapter corrosion protection for details.
6.5.6 Stainless steel cables
All stainless steel spiral strand cables to be of grade 1.4436 (f uk =

1450 N/mm2) unless stated otherwise.
67
7 Membrane structure
7.1 Quality control and guaranty of the membrane material
The cloth supplier is to subject the Glass PTFE cloth to a seller's

inspection. For this purpose, for each delivery, the cloth supplier must
receive, from the weaving mill and from the coating supplier, a confirmation
- consisting of acceptance test certificates 3.1 as per EN 10204 - that the
material delivered is of the required material quality. The certificates are
to be presented. Design live to be greater than 20 years.
The contractor needs to provide a full unconditioned 10 year guaranty for
the performance of the installed fabric material, including the following
aspects:
- Fungus and mould growth
- Structural properties (material strength, seam strength)
- Colour and translucency
The guaranty must cover the fabrication and installation of the product,
under the condition that the maintenance has always been carried out as per
maintenance manual provided by the contractor.
7.2 Quality control of manufacturing
Additional to the in-house quality assurance tests of the manufacturer the

third party expert shall verify the ongoing manufacture. The tests described
below shall be undertaken for:
every 10000 m2
every new coating batch of material
every change of manufacturing technique
The new set of information is to be compared with the initial tests. The
client shall be notified immediately when variations in quality appear.
The above is seen to be a minimum requirement, in case of insufficient in-
house quality assurance, varying quality or missing information or
documentation the client has the right to expand the involvement of third
party inspections on the contractors’ expense.
68
7.3 Technical specifications for membrane Glass / PTFE
7.3.1 Quality of materials
The colour, appearance and translucency of the material shall be as specified

below and consistent throughout the whole roof. The surface shall be very
smooth with no discontinuities, change in colour and thickness. Material with
visual defects will be refused if the defect would visible of a distance of
more than 5m using backlight.
A PTFE-coated glass cloth having the following set of properties is to be

used for the main membrane:
Support cloth: High-strength glass cloth, EC 3/4,
Weave: Linen or panama weave
Coating: Coated with PTFE on both sides.
Translucency: 12% at 550 nm for Material 20
15% at 550 nm for Material 50
Maximum bias: 1.0°
Maximum bowing: 2%
The coated material must be flame retardant, and be of class BS476 Part 6,
class 0 (or eq. class B1 as per DIN 4102 or eq. ASTM E 108 class A).
A certificate must be enclosed with the tender.
Mechanical properties of coated material Type 20 – Chukoh Skytop FGT 800 or

equivalent
Minimum breaking strength (95% fractal values in accordance to DIN 53354

using 100mm samples)
Warp > 157 kN/m
Weft > 127 kN/m
Tear resistance (DIN 53363)
Warp > 0.5 kN/m
Weft > 0.5 kN/m
Weight 1.15 kg/m² + 10%
Adhesive strength (DIN 53357) > 1.6 kN/m
Fire rating (DIN 4102) class B1
69
Stiffness of material for the working stress range (2kN/m-30kN/m)

Maximal warp stiffness (EA) 1600 kN/m
Minimal warp stiffness (EA) 1200 kN/m
Maximal fill stiffness (EA) 1100 kN/m
Minimal fill stiffness (EA) 850 kN/m
The stiffness values shall be derived using the test method standard MSAJ/M-
02-1995 established by the membrane structure association of Japan.
The upper layer of the Canopy (material type 20) shows only little double
curvature in some areas. For the crucial ponding analysis additional values
for different stress ratios in warp and fill directions were derived from
the material properties of the Chukoh Skytop FGT 800 material (see structural
report for details). The contractor shall proof by a 1:1 load test of one
canopy panel that the chosen membrane material shows sufficient stiffness. A
frame shall be built for the most unfavourable membrane panel geometry of
the canopy with a stiffness that is comparable to the stiffness in the real
canopy structure. The membrane shall be connected to the frame in the same
way as in the actual structure. A snow load shall be simulated and the
deformed geometry is to be surveyed. Three different snow load patterns shall
be tested in accordance with the designer. The test shall verify the proper
drainage of the panel in the loaded condition. Stress/ strain curves or
equivalent shall be provided for the chosen material for different warp:fill
load ratios in addition to the uniaxial stiffness described above.
70
Mechanical properties of coated material Type 50 – Chukoh Skytop FGT 600 or

equivalent
Minimum breaking strength (95% fractal values in accordance to DIN 53354

using 100mm samples)
Warp > 137 kN/m
Weft > 102 kN/m
Tear resistance (DIN 53363) Warp > 0.5 kN
Weft > 0.5 kN/m
Weight 1.0 kg/m² + 10%
Adhesive strength (DIN 53357) > 1.6 kN/m
Fire rating (DIN 4102) class B1
Stiffness of material for the working stress range (2kN/m-30kN/m)

Maximal warp stiffness (EA) 1450 kN/m
Minimal warp stiffness (EA) 600 kN/m
Maximal fill stiffness (EA) 1100 kN/m
Minimal fill stiffness (EA) 600 kN/m
The stiffness values shall be derived using the test method standard MSAJ/M-
02-1995 established by the membrane structure association of Japan.
A list of the following characteristic values of the materials Type 20 and

50 is to be provided to the consultant:
- Picks (DIN 53853)
- Closeness of yarn (DIN 53830)
- Weave (DIN 61101)
- Grey cloth weight (DIN 53854)
- Total weight of coated cloth (DIN 53352)
- Breaking strength (DIN 53354)
- Tear resistance (DIN 53363)
- Biaxial wide panel tear test (European Design Guide for Tensile Surface
Structures A3.1 / A4.2.6)
- Adhesive strength (DIN 53357)
- Character of surface / coating.
- Breaking strength after crease fold ASTM D 4851 (-97)
71
7.3.2 Design of seams
The joint between one membrane and the next consists of a welded seam of 75mm
width. All welds are slightly to be tensioned to line up weld marks during
welding and to prevent weld shrinkage or uneven welds. The edges of the
electrode must be rounded.
During welding the integrity of the coating material shall be maintained to
prevent exposed fibres. Connections of single layer to double layer are to
be made as a three layer weld!
Design of joint line between main membrane and triangle membrane

The joint between the membrane and the cable cuff consists of a welded seam
of 75mm width.
The cuff is fabricated out of bias cut membrane orientated in general 45
degree to the main connecting fabric. All welds are slightly to be tensioned
to line up weld marks during welding and to prevent weld shrinkage or uneven
welds.
At the openings of the membrane cuff an additional membrane is welded onto
the cuff for reinforcement. Uneven welds shall be prevented. In case where
the full tensile capacity and stiffness is required in on main direction both
layers of membrane shall be oriented in the same direction.
7.3.3 Mechanical properties and quality control of the seams
Before manufacture is begun, the contractor is to demonstrate, by means of

tests performed on sample bodies, that the seams manufactured by him meet
the requirements stated below.
The following proofs are to be provided:
Material 20: Test group 1: T = 23°C

A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n23 and the standard deviation s23 are to be ascertained from the
breaking loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater
than the permitted Z23,w = 133 kN/m and Z23,f = 114 kN/m. The tests are to
be carried out in warp and fill direction.
In addition, the variation coefficient
23
v  s23
n
for random samples must be less than 0.12.
72

than the permitted Z23 = 92 kN/m. The tests are to be carried out in fill
direction.
23
v  s23
n

70
vs 70
n
direction.
70
vs 70
n
73
7.3.4 Mechanical properties and quality control of the Details
Membrane clamping edges – Material 20

Before cloth manufacture begins, the contractor is to demonstrate, by means
of tests performed on sample bodies, that this detailed structure fulfils
the requirements stated below. The sample bodies are 100 mm in width. Their
geometry corresponds to that of the membrane clamping which is to be
constructed.
The following tests are to be performed:
Test group 5: T = 23°C

A total of 5 tension tests on test bodies 100 mm in width. The average value
n23 and the standard deviation s23 are to be ascertained from the breaking
loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater than
the permitted Z23,w = 133 kN/m and Z23,f = 114 kN/m. The tests are to be
carried out in warp and fill direction.
23
v  s 23
n

70
vs 70
n
74
Membrane clamping edges – Material 50

the permitted Z23 = 123 kN/m. The tests are to be carried out in warp
direction.
23
vs 23
n

than the permitted Z70 = 116 kN/m. The tests are to be carried out in warp
direction.
70
vs 70
n
75
Cuff edge detail – Material 20

the requirements stated below. The sample bodies are 100 mm in width. Their
geometry corresponds to that of the cuff detail which is to be constructed.
The following tests are to be performed:

direction.
23
vs 23
n
Cuff edge detail – Material 50

direction.
23
vs 23
n
76
Clamping edge at lower gutter detail – Material 20 reinforced

the permitted Z23 = 170 kN/m. The tests are to be carried out in fill direction
the reinforcement is to be welded on 45° bias.
23
v  s 23
n
77
Joint line detail between main and triangle membrane – Material 20 in membrane
cuff and reinforced
the requirements stated below. It is the responsibility of the successful
contractor to set up the geometry corresponding to membrane joint line detail
which is to be constructed. All details of this test need to be defined in
detail in conjunction with the client and his engineer.

A total of 3 biaxial tension tests on the following test bodies shall verify
the pull out force of the clamp and membrane cuff. The minimum pull out force
should exceed Zr = 95 kN or Z23 = 133 kN/m in warp and fill. Prior to testing
the maximum pull out force the friction coefficient between cable and membrane
cuff needs to be verified, varying the ratio warp and fill stresses, measuring
the movement of the cuff against the clamp.
78
7.4 Technical specifications for membrane mesh Glass / PTFE
7.4.1 Quality of material
A PTFE-coated glass mesh having the following set of properties is to be used

for the main membrane:
Support cloth: High-strength glass cloth, EC 3,

Weave: Scheindreher weave
Coating: Coated with PTFE
Open Area 20% + 2%
Maximum bias: 1.0°
Maximum bowing: 2%
The coated material must be flame retardant, and be of class B1 as per DIN
4102. (A certificate must be enclosed with the tender.)
Mechanical properties of mesh material Type 70 – Verseidag B 18656 or

equivalent
Breaking strength (DIN 53354) Warp > 100 kN/m
Weft > 90 kN/m
Tear resistance (DIN 53363) Warp > 0.5 kN
Weft > 0.5 kN/m
Weight 0,5 kg/m² + 10%
Warp stiffness (EA) 2400 kN/m + 20%

Fill stiffness (EA) 1900 kN/m + 20%
A list of the following characteristic values of the material is to be

provided to the consultant:
- Closeness of yarn (DIN 53830)
- Weave (DIN 61101)
- Grey cloth weight (DIN 53854)
- Total weight of coated cloth (DIN 53352)
- Breaking strength (DIN 53354)
- Tear resistance (DIN 53363)
79
- Biaxial wide panel tear test (European Design Guide for Tensile Surface
Structures A3.1 / A4.2.6)
- Adhesive strength (DIN 53357)
- Character of surface / coating.
- Breaking strength after crease fold ASTM D 4851 (-97):
7.4.2 Quality control of the membrane mesh material
The cloth supplier is to subject the PTFE-coated glass fibre mesh to a

seller's inspection. For this purpose, for each delivery, the cloth supplier
must receive, from the weaving mill and from the coating supplier, a
confirmation - consisting of acceptance test certificates 3.2 as per EN 10204
- that the material delivered is of the required material quality. The
certificates are to be presented.
The contractor needs to provide a full unconditioned 10 year guaranty for
the performance of the installed fabric mesh material, including the following
aspects:·
- Fungus and mould growth
- Structural properties (material strength, seam strength)
- Colour and translucency
The guaranty must cover the fabrication and installation of the product.
7.4.3 Design of seams (mesh membrane)
The joint between one membrane mesh and the next consists of a welded seam
of 75mm width. All welds are slightly to be tensioned to line up weld marks
during welding and to prevent weld shrinkage or uneven welds.
80
7.4.4 Mechanical properties and quality control of the seams

tests performed on sample bodies, that the seams manufactured by him meet
the requirements stated below.

direction.
23
v  s23
n
7.4.5 Membrane clamping edges – Material 70
The clamping edge is to be build using the continuous base material through
the whole detail. Weld width 70mm.

the permitted Z23,w = 120 kN/m and Z23,f = 95 kN/m. The tests are to be
carried out in warp and fill direction.
23
vs 23
n
81
7.5 Damage Test on all structural Fabrics

tests performed on sample bodies, that the creases, folds and damages
occurring during manufacture and packing will not lead to an unsafe structure
due to reduced material strength.
The specialist contractor will need to assess the most harmful procedure from
of manufacture to installation on site. Having recognised the most harmful
treatment for the material the samples shall be damaged in the same way. The
damage to the sample shall be done in a defined way using force, fold radius,
temperature (i.e. double force if not preventable) or similar measurable
parameters.
Always ten samples of each harmful treatment type will be made, five of them
(Set A) will be tested as described below. The other five (Set B) of the
group will be send to the client and remain to be compared later with the
actual damages occurred on the installed membrane panel. The client will have
the right of refusal of membrane panels, which are damaged more as those of
Set B.
The contractor is to ensure that the inspection of each installed panel is
shortly done after installation by a third party and signed of temporarily
for this stage, in order to prevent an impact on the overall program of
replacement panels. Depended on the location, visibility, size of the damage
and current prestress level and maximum stress level at the relevant area
repair patches will be allowed. However not more then 2 repair patches per
panel will be accepted. The six groups of tests described here are seen to
be the minimum requirement and it is the responsibility of the contractor to
foresee other damages, which may occur during the time from delivery of the
material to installation.
Material 20:
Test group 13 Set A : T = 23°C
direction.
23
v  s23
n
82
Material 20:
Test group 14 Set A: T = 23°C
direction.
23
v  s23
n
Material 50:
direction.
23
v  s23
n
Material 50:
direction.
23
v  s23
n
83
Membrane mesh Glass / PTFE

Material 70:
direction.
23
v  s23
n
Material 70:
Test group 75 Set A: T = 23°C
direction.
23
v  s23
n
84
7.6 Work samples
The successful contractor is to demonstrate his capability of manufacture on

all structural membrane details prior manufacture incorporating all
reinforcements, attached details like closure flaps and clamp bars etc.
The contractor shall make the inspection of all details available to the
client and his consultant engineer.
The following details will be seen as the minimum requirement for work samples
or mock ups:
4 No. Standard Clamping detail (various angles) incl. closure flaps (Main
roof and Canopy)
2 No. membrane cuffs
2 No. Joint line detail incl. clamp and cables
2 No. Gutter detail incl. steel gutter, cables, drainage, closure flaps and
sealants (Main roof and Canopy)
2 No. Butterfly detail incl. cables, closure flaps and sealants
2 No. Compression Ring Cover membrane lower clamping detail incl. clamps,
turnbuckle, belt and welds etc.
2 No. Lower Canopy Cover membrane clamping detail incl. clamps and closure
flaps
7.7 Strengthening the cut outs area
The cut out areas are strengthened by attaching one additional membrane layer.
Membrane reinforcements joining onto a cable cuff require reinforcing of the
cuff itself too.
7.8 Closure flap
The closure flaps are to be design thoroughly by the contractor. The general
layout is given in the technical drawings. The closure flap has to maintain
watertight at all times. The flaps have to be accessible and withstand all
environmental impacts. Lateral movements are to be taken and buffeting has
to be avoided.
85
7.9 Drainage
The drainage installations are to be considered in the patterning of the

membrane. Fixations and reinforcements if required are to be planned. The
same applies to the emergency overflow installations.
7.10 Manhole
Various roof access provisions (manholes) are to be considered in the fixed

membrane panels as indicated in the architectural drawings. The penetrations
are to be considered in patterning and final form finding. The membrane forces
have o be transferred safely around / through the detail. The layout and
appearance can be seen in the architectural drawings. The hatch is to be
executed as a 1.00m*1.00m aluminium frame system with PTFE cover with a
vertical up stand of 150mm. The element is to be powder coated RAL.
7.11 Clamp bar system and tangential forces
The clamp bar system and all other membrane details shall be of the highest
technical standards and satisfy the highest architectural demands. All
details shall be maintenance free in respect of the corrosion protection for
the life span of the membrane. The proposed system shall be verified by using
a corrosion test by an independent institute. If the test is not satisfactory
to the client, another corrosion protection methodology shall be proposed and
tested until approval. The test shall include all materials of the final
chosen system (cable, plastic inlay sleeve with bitumous layer, stainless
steel, straps, bolt and washer system, coated aluminium clamps. etc.) The
clamp bar system shall not weaken the membrane strength.
The aluminium clamp bar system shall be manufactured in accordance with DIN
4113 / DIN 1725 T1 the required material strength is to be chosen satisfying
the structural requirements or as stated in the specifications and drawings.
All bolts, washers and nuts and fixings are to be made of stainless steel.
The clamping edges touching the membrane need to be rounded of using r = 3
mm or greater. Corner plates shall be made of stainless steel or aluminium.
The radial clamp bar system has to carry tangential forces.
An approximate axial force of 100 kN (SLS) may be used for the design of the
clamp bar system. The final force is to be determined by the contractor during
the final workshop form finding and patterning procedure. Further design
forces are provided in the global analysis.
Further all clamp bar systems are to extend 3.5 mm per metre clamp bar length
using elongated holes at the end connection only. It is the responsibility
of the specialist contractor to carry out the final calculations and design
86
to the forces and membrane stress levels provided. Detailed force printouts
and axial forces will be issued on request. The design calculation have to
be submitted to client and his design engineer prior to fabrication.
The clamp bar system has to be connected by link plates at upper and lower
face of the clamping profile. (stainless steel chain link plates). As many
kilometres of clamps will be necessary for the projects, tests shall prove
the integrity of the final chosen system.
7.12 Cutting pattern
The main surface of the membrane is made up of a total 96 prefabricated

panels. 48 individual shapes are defined using a patterning model. The
geometry of the other 48 panels can be fabricated handed.
There are 48 triangle membrane panels at the tension ring and 48 triangle
membrane panels at the compression ring. The patterning model needs to define
only half of them, the other half needs to be fabricated handed.
The strips within the individual panels are arranged radial. Also the seams
at the triangle membranes and the tension ring cover are to be arranged
radial. The seam lines should run visually continuously from the triangle
membrane into the main membrane (i.e. the triangle membrane will have the
same numbers of cloths between two axis as the main membrane).
There are 2x2 bays were an additional membrane layer is installed to cover
the radial catwalk plus a cover membrane of the underside of the radial
catwalk. This leads to additional 6 panels; 3 individual ones and 3 more
fabricated handed.
The upper surface of the Canopy is made up of 192 prefabricated panels. 96
individual shapes are defined using a patterning model. The other half needs
to be fabricated handed. The strips are arranged radial and have to be aligned
between the outermost ring and the ring adjacent to the compression ring.
There are a couple of cladding membranes (mesh membranes) where some of them
have little or no double curvature in order to simplify the curring pattern.
These are:
- Lower surface of the Canopy
- Lower cladding of compression ring
- Upper, inclined cladding of compression ring
- Triangular cover membrane at tension ring (optional)
The panels size and shape has to be adjusted to the corresponding substructure
for the cladding. The seams shall be oriented radial and always aligned with
the neighbouring panel.
The final seam layout needs to be approved by the clients representatives.
87
The shear angle resulting out of cloth width and length on each cloth has to
be limited to 2 degree. The shear angle can be derived using the European
Design Guide for Tensile Surface structures chapter 8.1 (8/3)
The contractor will determine the correct cut of the membrane. The contractor
is to determine, by means of tests for each cloth production unit, the
characteristic values which relate to the biaxial expansion behaviour of the
membrane and are required in order to ascertain cutting pattern of the
membrane. The load – time curves used for the biaxial tests have to submitted
to the structural engineer for approval. Further proposals for decompensation
need to be submitted to the structural engineer for approval.
7.13 Patterning model
The patterning model should incorporate the exact geometry reflected in the
3D analysis model and all the relevant the detail drawings. Mayor cut out
areas for detailing need to be incorporated. Drawings defining the system
points of the pattering model have to submitted to the structural engineer
for approval.
The mesh size of the form finding model needs to reflect the complexity of
the geometry and curvature. No mesh size shall be bigger than 1m diagonal
length. The joint line area between the main fabric, the triangle membrane
itself and the area of lens shaped double cables joining the two fabrics
shall be meshed much denser to reflect the complex geometry and curvatures.
For patterning the soft support of cables and cable deflections this needs
to be incorporated in detail. The connection onto the tension ring cable need
to be considered pretensioning the respective cable with the set pretensioning
force and set length on elastic basis and the correct stiffness.
The forces introduced by the suspended radial catwalk will affect the membrane
shape and the shape of the tension rings. These effects are subject to the
weight of services and will need to be considered. Therefore the contactor
will determine the weight of services accurately at a very early design stage
in order to proceed with the cable geometry and patterning.
88
7.14 Tolerances
All fabric panels shall be checked for correct geometry prior to packing.
The control measurements need to be done under the same climate conditions
under which the panel was fabricated. The measurements for the main membrane
panels (main roof and canopy) are to be done on at least four location along
the fill direction and two locations in warp direction.
At least four measurements are to be done on each triangle membrane panel.
Each cover membrane needs to be measured at two locations in fill direction
and every 5m in warp direction.
The control measurements need to recorded and made available to the client
and his consultant within three working days on request.
The contractor shall propose a procedure describing how to achieve accurate
control measurements on all panels. Further the achievable tolerances for
manufacture of the panels itself and for the control measurement shall be
enclosed with the tender documents.
7.15 Folding plan
If the panels cannot be rolled up on hanging tubes and transported hanging

suspended only of the tube ends the manufacturer has to develop a folding
plan and a folding procedure.
Before manufacture has begun a folding procedure is to be developed for every
significantly different shape (five) using a patterned real size disposable
model. It is currently assumed that two triangle shapes, one main roof
membrane panel, one canopy membrane panel and at least one cover membrane
panel could be sufficient. Using these models varying folding techniques are
to be developed minimising the number of folds and especially minimising the
number of crosswise folds to an absolute minimum. The fold plan and locations
of crosswise folds are to be sent to the engineer for approval.
The folds of the best folding technique are to be marked (numbered in the
folding sequence) on the panel and surveyed on the flat panel. The so derived
fold lines and crosswise points are then to be digitalised and printed onto
all cloths using a numbering system. It might be necessary to scale this fold
line arrangement to adjust the plan to the slightly varying panel sizes.
Before packing, big foamed tubes are to be fixed securely onto the fabric on
the relevant sides using tapes. During folding it is now to be ensured that
the fold will wrap around the foam tube and not fold at a different location.
On the areas of crosswise folds big foam pads are fixed on both sides to
increase the fold radii.
All folding aids are to be removed on site. The printed on fold lines shall
be removed after the client and his consultant engineer have inspected the
panel using the damaged samples (set b) provided by the contractor.
89
7.16 Packaging and Transportation
The individual membrane elements are to be packed in accordance with the

packaging instructions (folding plan, marking specifications, type of
packaging, planned transportation) in such a way that damage in transit is
excluded.
In order to prevent damage by chafing during transportation, each individual
membrane element has to be wrapped in a protective covering material or other
suitable material. The packaging has to be chosen so as to ensure damage-
free loading and unloading (rolled is preferred). The rolled or folded and
packaged membrane must not be walked on or put under load at any time.
7.17 Test bed with material samples
For each material a test bed with 30 strip samples and 2 biaxial samples is
to be set up for the purpose - as part of the supervision of the building
work - of obtaining information on the particular current state of the
membrane material and the current strength of the seam.
The strip samples used for this purpose are approx. 100 mm wide and 900 mm
long. The strip samples are to be manufactured with parallel threads. They
contain a seam running across their longitudinal direction. The samples are
loaded with a creep-generating permanent load corresponding to the pre-
tension in the building structure. In the test bed, the samples are at an
bed is to be placed in
such a way that the atmospheric load on the samples approximately corresponds
to that on the actual building.
90
8 Bearings
To minimise the bearing and column sizes high strength bearings are to be
used, which require high strength concrete columns.
The height levels for the top of concrete indicated in the drawings depend
on bearing type and manufacturer and type of casting in procedure. If
necessary the steelwork connecting the compression ring chords and the bearing
has to be adjusted during workshop design to accommodate for the chosen
bearing.
8.1 Cast in plate tolerances
Special manufacturing techniques will be required for the cast in plates into
the column heads to achieve the following tolerances. The tolerances for the
cast in plates are + 5mm in height, + 0.5 degree in all elevations. The
maximum dislocation of the bolt holes sideways of + 3mm of horizontal fixed
bearings and + 10mm for horizontally free bearings.
8.2 Technical Description of sliding bearings
For type and forces refer to drawings.
Spherical Bearings with low friction behaviour (µ < 2,5%).

Bearing according to Eurocode EN, DIN codes or equivalent Spanish codes
The supplier has to certify his third party control according EN 1337-2,
chapter 8.
The constant low friction of the used sliding material has to be confirmed
by long term tests of an independent testing institute with the following
conditions:
- average contact pressure p = 60N/mm²
- Constant sliding velocity 15mm/s
- Accumulated sliding path 50km
The maximum sliding coefficient during the test is µ < 3% with –35°C.
Characteristic pressure of the sliding material fk = 180N/mm²
The bearings are to be protected using expansion bellows covering the complete
contact surface of the bearing.
91
9 Stainless steel
All stainless steel plates and sections to be grade 1.4401 S355 (f yk = 355
N/mm²) unless stated otherwise.
Stainless steel C Clips to be made of grade 1.4401 or 1.4404 S355 (fyk = 355
N/mm²).
All stainless steel bolts, screws and washers to be grade 1.4401 / 70 (fybk =
450 N/mm² fubk = 700 N/mm²) or of higher corrosion grade or higher strength
unless stated otherwise.
For pretensioned connections and clamps the actual tension forces achieved
while pretensioing the bolts using torque has to be tested. This applies to
all sets of screws in various arrangements used for pretensioning (screws in
nuts, in tapped holes, in blind taped holes etc.).
92
10 Aluminium
10.1 General
There will be some Alumnium parts used in the cladding of the Canopy edge,
compression ring and tension ring. No major load bearing elements are made
of Aluminium.
The drawings show general concepts for the cladding parts based on approved
products. The successful contractor is encouraged to modify the cladding
elements to their specific products without altering the general appearance.
The changes and detailing have to be approved by the client prior to
production.
A mock-up for the following elements shall be presented prior to manufacture
of the cladding elements:
- Canopy edge (minimum 2m segment including substructure, drainage gutter
and a typical joint)
- Cladding of upper and lower tension ring (minimum 1 m segment of each)
- Aluminium Lamellas between tension rings (one small segment, approx.
3.5 x 4 m, including lamellas, two support struts and all visible fixing
elements; the inclination of the lamellas needs to be adjustable)
For the outer surface of the cladding solid aluminium sheets are preferred
(e.g. Novelis FF2 or equivalent). The contractor is encouraged to study
economic alternatives like composite aluminium (e.g. Alucobond or
equivalent), honeycomp aluminium (e.g. Alucore or equivalent) or corrugated
aluminium sheets (the outer surface shall be as smooth as possible, upstands
like in standard Kalzip or equivalent systems are not desired). The contractor
has to adjust all the connection details, edge details, etc. to the chosen
system and present it to the client for approval.
The chosen systems need a technical approval issued by an accredited European
agency and comply with codes described below.
All surfaces shall be flat and the individual sheets shall be mounted
constraint free by the means of bolts or rivets with a soft (plastic)
interlayer to allow thermal expansion. The bolts/rivet alignment shall be
uniform and as unobtrusive as possible. Gaps between the sheets shall be
parallel and smooth (free of displacements). Since the outer edge of the
Canopy is a twisted surface small displacements between adjacent sheets are
acceptable (< 5 mm). The surface quality between the different panels
The contact between steel and aluminium is to be avoided by using appropriate
interlayer.
Welding of aluminium, especially on site, shall be avoided. If the contractor
chooses to weld the aluminium, it is his responsibility to chose a proper
alloy, which is weldable, and compensate for the strength reduction in the
heat affected zone in his design.
93
For the substructure standard extruded sections are proposed. The

availability has to be confirmed by the contractor. Due to the amount of
substructure, the contractor is encouraged to propose a weight optimized
custom made extruded section with the same structural properties if this
leads to a more economic solution. Lower alloy strength can be compensated
by a higher moment of intertia. The outer shape of the cladding should not
be affected by any change in the substructure without written approval of
the client and his representatives.
The fire rating of the entire system shall be of the same level as the
membrane structure or higher (class B1 as per DIN 4102 or eq. ASTM E 108
class A or BS476 Part 6, class 0 or eq.).
10.2 Materials
All aluminium componenets used for cladding, substructure, etc. shall comply
at least with all relevant national and international standards, especially
with the following (if nothing else is stated on the drawings or structural
description):
o UNE 38350,
o UNE 38337,
o UNE EN 573-1, -2, -3 and –4,
o UNE EN 515,
o UNE EN 485-1,
o UNE EN 754-1, -2 and –7,
o UNE EN 755-1, -2 and –7,
o UNE EN 485-2, -3 and –4,
o UNE EN 508-2,
o UNE EN 1559-1 and –2,
o UNE EN 1706
o UNE EN 12020-2.
The chosen alloy needs to fulfill the following requirements:

- Sufficient strength to resist all impacts (like loads, climatic
impacts, etc.).
- Sufficient ductility to fabricate (bend or fold) the individual
elements.
- Compliance with the chosen method of connection (bolts, rivets, stut
welds, weld, glue, etc.)
- Compliance with the chosen surface finish treatment
- Adequate to resist corrosion.
For the connection between aluminium elements all relevant international and
national codes need to be fulfilled, in particular:
o UNE EN 439
o UNE EN 14532-3.
Facade elements need to fulfull all relevant national and international codes,
in particular:
94
o UNE EN 10025-1
o UNE EN 1461.
For the connection between aluminium and steel elements all relevant
international and national codes need to be fulfilled, in particular:
o UNE EN ISO 14555,

o UNE EN 288-3 y
o UNE EN ISO 898-1 and -2,
10.3 Corrosion protection
The aluminium must be protected against corrosion with an adequate covering.

Direct contact between other metals is to be avoided in order to prevent
intermetalic corrosion. If it can´t be avoided, for example in load bearing
connections, metals with an adjacent galvanic potential need to be chosen or
other means of electric insulation need to be done. The minimum is to prevent
access by any electrolytic substance between materials with different
potential.
All galvanized elements used for the cladding need to comply with all national
and international standard, in particular with:
o UNE EN 1461,
o DIN 50976 y
o DIN 267-10.
All aluminium surfaces have to anodized or coated according to the architects

specifications.
Anodized surfaces
The surfaces shall be continuous, uniform and without shine on the exterior
face sheet. Different samples of the proposed surface treatment shall be
provided for approval by the client and the architect prior to any surface
treatment works. The samples should also sufficiently represent the texture
variations that can be expected from the anodization process.
The surface shall show sufficient resistance against abrasion.
A temporary protection during transport and installation shall be provided.
If there is a danger of damage after installation this protection needs to
be in place until the construction work in the relevant area are completely
finished. Reparing of damaged pieces is not allowed. All damaged pieces must
be replaced by new elements.
95
Coated surfaces
Coated surfaces (powder termolaqcquered/Aluminio termolacado en polvo) shall

comply with the requirements of the 12th edition of “Specifications for a
quality label for paint, lacquer and powder coatings on aluminium for
architectural applications”.
In particular the thickness of layer will be between 60 and 90 microns. Once
chosen, the same treatment for all the work will be used. If the material
base has drills or openings of nonprecise form (for example, an aluminum
panel perforated in all their surface) the termolacado finish is always
applied after carrying out the perforations, irrespective of whether this is
done by drill, punching or stamping. If the material base is going away to
be folded (for example an aluminum panel forming trays), the application of
the coated finish needs to be done afterwards.
The service life of the coating system has to be at least 25 years.
Different samples of the proposed surface treatment (5 samples with 1200 x
200 mm for each major type of cladding) shall be provided for approval by
the client and the architect prior to any surface treatment works.
A temporary protection during transport and installation shall be provided.
If there is a danger of damage after installation this protection needs to
be in place until the construction work in the relevant area are completely
finished. Reparing is only allowed under the supervision of the architect.
The specifications of the supplier need to be taken into account. The
architect has to approve the repairal works.
Maintenance
The cladding contractor has to provide a maintenance manual containing

detailed information on:
- Cleaning (Frequncy, recommendation for washing-liquids, special
cleaning processes)
- Inspections
- Repair
- Replacement of elements
96
10.4 Fabrication and workshop design
As much as possible of the fabrication work shall be done in the workshop

with appropriate quality control. The assembly work on the site shall be
minimized.Especially welding, glueing, etc. on site shall be avoided.
A detailed fabrication and erection methodology shall be submitted by the

cladding element sub-contractor. This shall include detailes about cutting
tolerances, connection details of elements and corrosion protection. The sub
contractor needs to be certified according to ISO 9000 or equivalent.
All welds, weld certification, etc. shall be in accordance with:
o UNE EN 288-1, -4 and –13.

o UNE EN 1011-4
o UNE EN 287
o UNE EN 895 and 910
The sub-contractor allows for regular inspections by the client or independent

third party quality assurance. On request he has to provide material samples
of the chosen materials.
All cladding elements have to fullfil the following requirements:

- Resistance against all exterior impacts
- Not exceeding the acceptable deformations
- No permantent (plastic) deformation due to exterior loads
- No susceptability to vibrations
- Maintaining all these characteristic during the whole life-span
- Show no visible defects, permanent deformations, distorsions, etc.
- Surface must be flat, smooth and without visible defects
- Edges must be straight and smooth.
The workshop design of the cladding elements must be coordinated with the
workshop design of the steel and cable contractor. The cladding contractor
has to work with the final 3d cable geometry. He also has to consider that
the workshop drawings show the unstressed geometry of the steel/cable
structure, while the cladding elements have to be mounted to the dead load
geometry which might differ. Any change in the connection details between
cladding and main structure needs to be incoprareted in the workshop design
of the steel/cable contractor.
97
11 Drainage
11.1 General
There are three drainage systems in the structure.

1. Tension Ring: Syphonic system
2. Compression Ring: Gravity drainage
3. Canopy edge: Gravity drainage
All three systems have to be designed according to the Spanish regulations.

A maintenance manual has to be provided for the drainage system. Details
about the drainage system can be found on the drawings and drainage report.
11.2 Syphonic drainage system
PERFORMANCE OBJECTIVES
The rainwater from the flat roof outlets located at roof level will be
collected and discharged to the below ground drainage system by a symphonic
rainwater systems (e.g. the Geberit Ltd. Pluvia Syphonic or equivalent) in
full compliance with BBA Certificate No. 92/2729 or an Spanish equivalent.
The installer will design and install all rainwater pipework including all
rainwater outlets and connections to drain. The installer should note that
the specification should be strictly adhered to and the installer must ensure
that all other designers are aware of particular technical requirements such
as syphon breaks etc.
Generally this will comprise of:

1. Syphonic rainwater system complete, including rainwater outlets, pipework,
expansion joints, supports and syphon break with connection to drain.
2. The provision of all design information, including drawings to comply with
Building Regulations
3. Provision of all design information, including drawings to meet the
requirements of the construction team.
Significant relative movements between Roof Strucutre and Concrete need to

be compensated as well as differential movements between Radial Catwalk and
Compression ring. Significant vertical movement of the so called tension ring
should be accounted for.
DESIGN PARAMETERS
The design calculation software should be dedicated to the pipe and fittings,
type of manufacturer used within the system and comply with BBA Certificate
No. 92/2796.
Calculations must be provided by the installer, containing the following
information and within the specified limits:-Pipe Size 40 to 315mm diameters.
Negative Pressure: Not to exceed -800mm/bar on pipe sizes up to 160mm and
not to exceed -450m/bar on pipe sizes 200 and above, unless PN 4 grade pipe
is used when –800mm/bar is acceptable.
Water/Air Mixture: Not below 60% water volume.
Velocity: Not below 1 0.7 metre/sec
Roof outlets will operate at their maximum capacity with a retained head of
40mm or less in accordance with CEN.
98
Outlets in gutters will have a maximum working capacity of:

6 litres/second for Series 5 outlets with 56mm diameter spigots
The minimum working capacity will be 1 litre/second.
Design of syphonic rainwater system = 100mm/hr. rainfall intensity.
Any calculated intensity above this value, which is established using EN
12056-3 should be accommodated via a secondary system.
A design check will be carried out to monitor site changes and adjustments
made where necessary. The revised calculations will be included in the
operating and maintenance manuals.
SYSTEM DESCRIPTION
The syphonic rainwater pipework will comprise:-Pluvia syphonic rainwater

disposal system (or equivalent).
The complete system will be installed using either roof outlet made from
Stainless Steel, or Plastic, Geberit Series 5 or 7 fitted within the roof
construction and HDPE pipe conveying the surface water to drain. The pipework
will collect the rainwater from the roofs and be routed at high level to the
point where it will drop and connect to drain. The connection to the below
ground drainage will be carried out in a manner which will break the syphon
at that point.
MATERIALS
All materials will be manufactured under a ISO 9000 approved scheme.

All component parts of the system will be covered by manufacturers warranty.
Pipe fittings and accessories: HDPE carrying a current BBA Certificate.
All pipes and fittings must be capable of withstanding the negative pressure
produced by the syphonic actions, maximum -800mm/bar up to 160mm pipe. -
450m/bar between 200mm and 315mm pipe unless PN4 grade pipe used when –
800mm/bar is also acceptable.
The rainwater outlets will be capable of being fixed to the concrete slab.
The fastening system materials to be galvanised mild steel and must be capable
of withstanding all stress produced by thermal expansion and vibration. The
carrying rail should be minimum 30mm seamless box section.
INSTALLATIONS
The syphonic rainwater system will be installed only by the designers approved
installers.
All pipe and fitting joints including the joint to the outlet will be fusion
welded either electro sleeve coupling or butt weld.
All bends, unless otherwise specified to be 45o.
Horizontal pipes in excess of 1m in length must be fastened by means of a
purpose made pipe bracket to a square rail immediately above the pipe. Fixed
points will be provided at 5m intervals by a means of a welded sleeve on the
pipe and a purpose made bracket between the sleeve and the square rail.
Intermediate sliding supports to fasten the pipe to the rail will be at the
following intervals:
Pipe 40mm to 75mm diameter 0.8m.
Pipe 90mm diameter and above 10 x overall pipe diameter.
The rail to be fixed to the roof structure at maximum intervals of 2.5m.
The installer should allow for some secondary bracketing as a result of the
height from fixing rail to roof structure. The installer is advised to visit
site to survey the proposed routes.
99
FIRE COMPARTMENT INTEGRITY
Where pipes pass through fire compartment walls, floors and ceilings provide
and install an intumescent firesleeve having an appropriate Agrement
Certificate or third party test report.
The firesleeves shall have a fire rating compatible with the wall, floor and
cavity barrier to which it is fitted. The firesleeves will be fitted in full
compliance with the manufacturers requirements.
PROTECTION
Throughout the installation of the syphonic rainwater system the installer

will be responsible for preventing the entry of debris into the outlets and
pipework.
Roof areas will be kept free from debris and outlet gratings will be fitted
as soon as possible.
HEALTH AND SAFETY
When the horizontal high level pipework is being installed at high level,
the installer will be responsible for providing a suitable working platform
for the installation of the rainwater pipework.
WORKING DRAWINGS
The installer will submit working drawings to the engineer showing sizes,
routing, invert levels, points of access, connection to drain and outlets
prior to commencing installation works. Drawings will be as produced by a
draughtsman using a computer aided draughting or equal.
Two copies of the working drawings will be issued to the Site Engineer.
RECORD DRAWINGS
The installer will keep a set of working drawings on site marked-up to show
"as installed" routes, sizes, access locations, invert levels etc. On
completing the installation the installer will incorporate the alterations
onto their working drawings using computer aided draughting and issue to the
Client via the engineer.
It should be noted that the installation would not be deemed complete until
the record drawings and where necessary revised calculations have been issued
and accepted.
OPERATING AND MAINTENANCE MANUALS
The installer will issue four bound copies of Operating and Maintenance
manuals for the rainwater disposal system to include the following as minimum:
(a) Indicating names and address of client, project manager, architect,

consulting engineers,contractors and installer.
(b) Description of systems installed.
(c) Planned maintenance requirements.
(d) Details of guarantee.
(e) Calculations.
(f) Isometrics (which have been produced using CAD).
100
It should be noted that the installation would not be deemed complete until
the Operating and Maintenance Manuals have been issued and accepted.
TESTING
All completed rainwater systems to be air tested to a minimum of 100mm water

gauge over 3 minutes. There will be no drop in pressure during this period
in time.
11.3 Gravitiy Drainage system
Design of all drainage systems according to CTE and EN 12056.
Gutters to be made of galvanized steel sheets.
Pipes galavanized or PE. Connections between inlets connected to the membrane

strucutres and the drainage system with flexible pipes.
The drainage contract includes all fixation elements to the main steel /
concrete structure. Refer also to the Bill of Quantities for items to be
considered.
At the transition between roof and concrete structure funnels are introduced
into the concrete to catch the water from the roof. A mock-up and test of
this element shall verify the dimensions of the funnel and outlet.
The Canopy is drained via free falling water at three points. A mock-up and
test shall verify the proposed dimension but also allow to judge the visual
appearance of the falling water. It is anticipated to create a rather uniform
wall of water with a defined width in contrast to a very local beam of water.
All requirements for the Syphonic Drainage System apply accordingly to the
Gravitiy drainage.
101

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Estadio de Madrid - Roof Structure

Remodelling of the Madrid Stadium to a soccer and athletics stadium

(« Ampliación del Estadio de Madrid para su adecuacion a

Roof Structure – Projecto de Ejecución

Part IV : Outline Specifications

3.9 Material for pins - quenched and tempered steel ............ 34

7 Membrane structure ....................................... 68

11.1 General .................................................... 98

While utmost care is taken in the preparation of this document it is

• Client = City of Madrid / (Club Atlético Madrid)

For the steel structure

For the cable structures

Requirements refer to projects of similar nature, such as projects of high

1.2 Scope of work

Included in the roof contract will be the following planning responsibilities:

• Corrosion protection planning and design of all details and

1.3.1 Final geometry of the structure

The final geometry of the structure is to be established in such a manner,

Necessary calculations and potentially required adjustments such as

The maximum permissible manufacturing tolerances of the prefabricated

Before commencing the workshop planning / fabrication the connecting elements

Necessary construction measures for compensating exceeding tolerances are to

1.3.2 Deflections under environmental loading

The structure of the roof is subject to deflections under environmental

• +/-0.25 m movement of the compression ring in plan

1.3.3 Measurements / Surveys / Accuracy

• After finalization of concrete structure

the essential construction conditions and provide explanations for movements

Submission of the measurement documents

During trial assembly and erection the contractor is to maintain an updated

Other measurement will be required, if there is doubt about proper execution

Special requirements for built-in components in the reinforced concrete

Minimum requirements for surveying work on site

The contractor shall establish 6 geodetically points in the area of the

After completion the measurement strategy and measurements points have to be

All survey results have to be evaluated by the contractor and to be submitted

Geometrical survey and accuracy in the workshop and assembly yard

By performing the following surveys, the contractor is to demonstrate that

 During trial assembly of compression ring of each individual element

The measurements must not be impaired by uneven temperature distributions

Requirements regarding accuracy

Accuracy requirements for individual plates and profiles

Leading accuracy requirements for individual elements of compression ring

 The accuracy required is 0.5 mm/1000 mm for the angle deviation of

 2 mm in horizontal direction for each system point of the compression

 In the manufacture of the welded components, besides tolerances in

Accuracy requirements for the trial assembly of the compression ring

With at least five consecutive segments (10 axis; >60m):

 10 mm in every horizontal direction for each system point of the

 5 mm in vertical direction for each system point of the compression

 The described is to be considered as the controlling requirement.

Accuracy requirements for anchor plates / bearings

Deviation from the global specified position of the concrete structure:

Accuracy requirements for cables

It is of decisive importance to the structural behaviour and redundancy of

The overall length must of highest precision.

On the basis of these requirements, the following length tolerances are to

Accuracy requirements for the build structure

 ± 15 mm in plan for each system point of the compression ring,

It needs to be noted, that non-respective individual tolerances, the accuracy

1.4 Delimitation of the activities

The following areas of work:

1.5 Workshop drawings

1.6 Measurements for Payments