Stay Cable Care

Introduction

Marcel Poser
Executive Chairman
www.BBRNetwork.com

10 October 2024

Copyright © 2024 1
Over 25 years of experience by the Author

Over 60 years of experience within the BBR Network

2
 Executive Summary

Care of stay cables is vital for the safety and longevity of cable-stayed structures. Effective assessments, conservation and
upgrades of stay cables are critical, especially in older structures.

1. Challenges

Aging Infrastructure:
• Structural Deterioration: When over 20 to 30 years old, cable stays can suffer from wear, corrosion, and risk of failure.
• Material Degradation: Environmental factors and fatigue loading reduce load capacity and increase risk of failure.

High Stress Concentrations at Anchorage and Transition Regions:

• Prone to damage due to high stress concentrations, leakage, and corrosion.

Surface Degradation:
• Surface Wear on Free Length: Exposed cables degrade from UV radiation, moisture, and pollution, weakening integrity.
• Protective Coating Damage: Damaged coatings accelerate corrosion and wear.

Assessment:
• Visual and Endoscopic Assessments: Effective to the extent that relevant areas can be accessed
• Non-Destructive Testing: Require specialized techniques, making them challenging and sometimes insufficient.
• Access and Safety: Ensuring safe access for inspections can be difficult, especially on older structures. 3
 Executive Summary

2. Assessment Methodologies

Smart Asset Model Technology:

• Creating a Smart Asset Model of the structure allows for continuous record-keeping and proactive conservation.

Visual and Endoscopic Assessments:

• Visual: Limited to surface damages; endoscopes detect internal issues but are sometimes restricted by access.
• Drones: Are preferred for flexibility and accessing the cable free length
• Cable trolleys: Can be effective for the free length and requires extensive setup and are less adaptable.

Non-Destructive Testing:
• Ultrasonic Testing and Magnetic Flux Leakage: Detect steel cracks and wire breaks but are costly and complex.
• Ground Penetrating Radar: Effective to detect grounding voids in the free length of older cables.

Force Measurement with Lift-off Tests:

• Essential for assessing tensile force in cables and detecting loss of tension.

Compliance with Standards:

• Adherence to the latest standards is necessary to benefit from evolving knowledge on key aspects related to stay cables.
4
 Executive Summary

3. Conservation and Upgrade Methodologies

Conservation:
• Re-coating and Corrosion Protection: Apply protective coatings to exposed steel elements to prevent corrosion.
• Injection: Fill voids and ensure proper protection of the cable.

Upgrade:
• Replacement of Components: Replace entire cables or specific parts like centralizers.
• Vibration Dampers Installation: Add dampers to reduce oscillations and improve stability.
• Cable Strengthening: Enhance load capacity by adding or upgrading strands.
• Advanced Monitoring Systems: Integrate sensors and monitoring technologies for continuous tracking.

Verification, Documentation & Reporting:

• Performance Verification: Confirm that the functionality and performance align with intended outcomes.
• Record Keeping: Maintain detailed records of all activities in the Smart Asset Model platform.
• Stakeholder Communication: Keep stakeholders informed about progress and significant developments.

5
Cable Stayed Structures
Basics

6
 Cable Stayed Structures

Pylon

Stay Cables

Main Span (Deck) Back span (Deck)

Typical: 250m to 600m

Possible: 10 m to >1000 m

7
Cable Stayed Structures

Fan - Shaped

Harp - Shaped

Fan/Harp - Shaped

8
Cable Stayed Structures

Fan/Harp - Shaped

Harp - Shaped

9
 Cable Stayed Structures

I - Shaped H - Shaped A - Shaped Diamond - Shaped Y - Shaped

10
First Modern Stay Cable Bridge

Strömsund Bridge by Dischinger

Sweden (1956)

11
 Cable Stayed Structures: Cumulative Number Globally

1500 1’000 nos … < 20 years old

Cumulative Number of Cable Stayed Structures [ nos ]

1000
HIGH LOW

500 500 nos ... 20 to 60 years old

200 nos ... 30 to 60 years old

1960 1970 1980 1990 2000 2010 2020

Year
12
13
14
15
16
17
18
Stay Cables
Basics

19
 Straight Line

Catenary

20
 Stay Cables: Terminology

cm
80
8–

Anchorage
Catenary

Straight Line

10
0–
50
0c
m
Cable Free Length

m
0c
–5
10

Guide Pipe

Bearing Plate

21
 Stay Cables: Geometry

W.P.
B.P.

10
–5
00
m

E.P.

W.P. Working Point

B.P. Bearing Point B.P.
E.P. Exit Point E.P.

W.P. 22
Stay Cable
Stay Cables: Deck Anchorage
Catenary

Straight Line

Guide Pipe

Anchorage Transition

Anchorage

Bearing Plate
Anchorage Transition

23
 Stay Cables: Pylon Anchorage

Anchorage

Bearing Plate
Guide Pipe

Anchorage Transition
Straight Line

Catenary

Stay Cable

24
 Stay Cables: Loading
LOAD
1000 Short Term

Short Term

750 Service Limit State (SLS)

Axial Stress [ MPa ]

Live
Fatigue Limit State (FLS)

500
Permanent

Construction

Time / Number of Load Cycles [ - ]

25
Construction Load

26
Live Load

27
 Stay Cable Systems
Cable Free Length / Cable Cross Section

28
Generation 0: Unprotected Cable

Locked Coil
UTS 1’400 - 1’600 MPa
Galvanized and/or Painted

Various configurations from multiple suppliers.

29
Generation 0: Unprotected Cable

Single Bar
d = 10 – 50 mm
UTS 1’050 - 1’200 MPa

Various configurations from multiple suppliers.

30
Generation 0: Unprotected Cable

Wire
7 mm
UTS 1’670 - 1’770 MPa

Various configurations from multiple suppliers.

31
Generation 1: Grouted Cable

Stay Pipe (HDPE or Steel)

Grouted

Single Bar
d = 10 – 50 mm
UTS 1’050 - 1’200 MPa

Various configurations from multiple suppliers.

32
Generation 1: Grouted Cable

Stay Pipe (HDPE or Steel)

Grouted

Wire
7 mm
UTS 1’670 - 1’770 MPa

Various configurations from multiple suppliers.

33
Generation 1: Grouted Cable

Stay Pipe (HDPE or Steel)

Grouted

Strand
0.6 - 0.62’’ (15.2 - 15.7mm) 140 - 150mm2
UTS 1770 - 1’860 MPa

Various configurations from multiple suppliers.

34
Generation 2: Extruded Cable

Stay Pipe tightly extruded

Wire
7 mm
UTS 1’670 - 1’770 MPa

Various configurations from multiple suppliers.

35
Generation 3: Injected Cable

HDPE Stay Pipe

Injected (Wax or Grease)

Wire
7 mm
UTS 1’670 - 1’770 MPa

Various configurations from multiple suppliers.

36
 Generation 4: Multi-layer Cable

HDPE Stay Pipe

Injected (only optional)

Strand
0.6 - 0.62’’ (15.2 - 15.7mm) 140 - 150mm2
UTS 1770 - 1’860 MPa
Corrosion Inhibitor
Galvanized (Wax)

Sheathing (HDPE or Epoxy)

Various configurations from multiple suppliers.

37
 Locked Coil + Bar Stay Cable

Locked Coil
Low Medium High

Corrosion Protection

Redundancy

Compactness

Fatigue Strength

Bar
Low Medium High

Corrosion Protection

Redundancy

Compactness

Fatigue Strength

38
 Wire + Strand Stay Cable

Wire - Grouted
Low Medium High

Corrosion Protection

Redundancy

Compactness

Fatigue Strength

Strand - Grouted
Low Medium High

Corrosion Protection

Redundancy

Compactness

Fatigue Strength

39
 Wire + Strand Stay Cable

Wire
Low Medium High

Corrosion Protection

Redundancy

Compactness

Fatigue Strength

Strand
Low Medium High

Corrosion Protection

Redundancy

Compactness

Fatigue Strength

40
Stay Cable Systems
Anchorages

41
 Typical Anchoring

Wedge – Strand Button Head – Wire

42
Generation 0: Bonded Anchorages + Unprotected Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer

Socket (Bonded w. Transition)

Deviator Stay Cable

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

43
Generation 1: Bonded Anchorages + Grouted Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer Joint

Socket (Bonded w. Transition)

Deviator Stay Cable

(Grouted)

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

44
Generation 1: Bonded Anchorages + Grouted Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer Joint

Socket (Bonded)

Stay Cable
Transition (Grouted)
(Grouted)
Deviator

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

45
Generation 1: Bonded Anchorages + Grouted Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer + Deviator Joint

Deviation Stay Cable

(Grouted)
Transition
(Grouted)

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

46
Generation 2: Bonded Anchorages + Injected Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer Joint

Socket (Bonded)

Stay Cable
Transition (Grease or Wax Injected)
(Grease or Wax Injected)
Deviator

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

47
Generation 3: Unbonded Anchorages + Multi Layer Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer + Deviator Joint

Anchorage

Deviation Stay Cable

Transition
(Strands in Individual Tubes)

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

48
Generation 4: Unbonded Anchorages + Multi Layer Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer + Deviator Joint

Socket

Deviation Stay Cable

Transition
(Individually Sheathed Strands)

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

49
Generation 4: Unbonded Anchorages + Multi Layer Stay Cable
Protection Cap
Anchor Head w. Lock Nut Free Deviator Joint

Socket

Deviation Stay Cable

Transition
(Individually Sheathed Strands)

Guide Pipe Reducer

Bearing Plate

Drainage

Various configurations from multiple suppliers.

50
 Stay Cable Care
Assessment, Conservation and Upgrade

51
 Stay Cable Care: Degradation

$$$

damage initiation

damage visible
Condition

Cost
failure

Time
52
 Stay Cable Care: Patchwork

damage initiation
Condition = Asset Value

damage visible

Cost
Patchwork

$$

Time
53
 Stay Cable Care: Patchwork

Patchwork (Repair)

Definition: Patchwork and repair involve addressing specific damages or failures with immediate fixes. These solutions are often
temporary and focus on restoring functionality without a comprehensive assessment of the entire system. Identifying hotspots
and high-stress areas, even if difficult to access, is crucial for implementing proactive conservation and preventing future issues.

Characteristics:

• Temporary Solutions: Provide quick fixes without a thorough examination of the underlying issues.
• Restores Functionality: Aims to bring the system back to some level of operational status but not prevent future problems.
• Higher Risk of Reoccurrence: Issues are likely to reappear as the root causes may not be fully addressed.

Example:

• Sealing Visible Cracks: Temporarily prevents water and debris from entering cracks without addressing underlying issues.
• Wrapping Damaged Sections: Provides quick, temporary protection against environmental factors.
• Re-coating Small Areas: Slows down corrosion in specific spots but lacks uniform protection.

54
 Stay Cable Care
Assessment Conservation Upgrade

damage initiation
Asset Condition = Asset Value

damage visible

Cost
$

Time
55
 Stay Cable Care

Care (Assessment, Conservation and Upgrade)

Definition: Care encompasses a comprehensive approach to maintaining and enhancing the longevity and safety of stay cables.
It involves thorough assessment to understand the root cause of issues, identifying hotspots in safety critical areas, planned
conservation, and necessary upgrades to ensure functionality and structural integrity.

Characteristics:

• Holistic Approach: Involves detailed assessments to understand the overall condition and root causes of issues.
• Identifying Hotspots: Focus on hotspots even if difficult to access, to implement conservation and prevent future issues.
• Continuous Assessment: Utilizes advanced technologies for ongoing assessment and timely upgrades.

Example:

• Re-coating and Corrosion Protection: Apply protective coatings to exposed steel elements.
• Replacement of Cables or Specific Parts: Replace entire cables or specific components such as centralizers.
• Installation of Vibration Dampers: Add dampers to reduce oscillations and improve stability.

56
Stay Cable Care: Process

57
 Stay Cable Care: Process

Reconnaissance + Setup
• Collect documents and initial data.
• Conduct basic walk-through and basic visual assessments.
• Setup Smart Asset Model platform.

Assessment
Preparation:
• Review compliance and identify hotspots.
• Plan detailed examination steps and allocate resources.
• Prepare access and clean areas for assessment.

Survey:
• Perform detailed visual examinations.
• Conduct geometrical surveys and mapping.
• Use NDT methods and collect samples for testing.

Analytics:
• Analyze samples in labs.
• Integrate data into structural analysis models.
• Use advanced analytics to identify issues. 58
 Stay Cable Care: Process

Conservation and Upgrade

Preparation:
• Develop plans for repairs and upgrades.
• Compile reports and propose actions.
• Plan follow-up checks.

Execution:
• Implement conservation measures.
• Execute necessary upgrades.
• Verify the effectiveness of upgrades.

Verification:
• Perform quality assurance.
• Verify performance is as intended.
• Documentation and report findings.

Goal: Health Record + Continuous Care

• Regularly assess the structure.
• Update documentation continuously for accurate real-time health records.
• Communicate with stakeholders regularly.
59
Stay Cable Care: Smart Asset Model

60
 Stay Cable Care: Asset Digitalization Maturity Spectrum

Basic Documentation: Most asset owners start at this stage, where asset information is fragmented and poorly organized. There
is a mix of analog data, such as physical blueprints and handwritten notes, along with some digital data like scanned documents.
This data is often incomplete, not comprehensive, and lacks proper documentation, leading to inefficiencies and increased risks.

Digitized Documentation: At this stage, asset owners convert analog data into digital records, creating a more accessible and
organized repository of information. This includes digitizing documents into PDFs, 2D drawings, and 3D models. However, this
information remains static and siloed, lacking integration and cross-referencing, which still leads to some inefficiencies.

Smart Asset Model: This stage focuses on making unstructured digital and analog data usable in a structured and digital way. By
integrating geotagged pictures, checklists, and annotations into 2D and 3D models, asset information becomes dynamic,
interactive, and serves as a health record over time. Real-time updates from technicians and enhanced digital assets provide a
comprehensive view of the asset, making this stage highly valuable for most building management needs.

Digital Twin: This level is generally not relevant for most static built environment assets due to its complexity and high costs. It is
more suited for highly dynamic and complex systems such as airplanes or advanced industrial machinery. Digital twins provide a
fully functional digital counterpart that mirrors the physical asset in real-time. They include simulation capabilities to predict
asset behavior, advanced scenario modeling, and predictive analytics. This level of sophistication allows for highly detailed and
accurate management of complex systems.

61
 Stay Cable Care: Asset Digitalization Maturity Spectrum
High

Level 2:
Smart Asset
Model

s e
ilo ledg
Cost Value Benefit

S
ta ow
Da e Kn
m iv
Fro ract
e
Int Level 3:
to
Digital
Twin

Level 1:
Level 0: Digital
Documentation
Basic
Documentation

Low Level of Digitalization High

62
OKAY… let’s assess the stay cables

63
Stay Cable Assessment
Compliance with Standards

64
 Compliance with Latest Standards
Evolution of Certification Testing to Eliminate Hotspots in Cable Systems.

3rd Edition 4th Edition 5th Edition 6th Edition 1st Edition 2nd Edition
1993 2001 2007 2018 2005 2019
65
 Compliance with Latest Standards
Evolution of Certification Testing to Eliminate Hotspots in Cable Systems.

0.6° +/- 1.4° +/- 0.6°

159 MPa 200 MPa Temperature

2‘000‘000 cycles 2‘000‘000 cycles 20°C – 60°C

Axial Fatigue Test Axial Fatigue Test Leak Tightness Bending Fatigue Test
< Year 2000 > Year 2005 > Year 2005 > Year 2019 66
Stay Cable Assessment
Hotspots

67
 Hotspots

Anchorage Region: “Hotspot” very high stress concentrations, high failure risk
damage, leakages. corrosion

Transition Region: “Hotspot” high stress concentrations, high failure risk

damage, leakages. corrosion

Cable Free Length: limited stress = modest failure risk

damage to stay pipe, leakages

68
 Hotspots: Access Dilemma

Anchorage Region: “Hotspot” but typically difficult to access

Transition Region: “Hotspot” but typically difficult to access

Cable Free Length: modest risk, and relatively easy to access

69
 Hotspots: Deck Anchorage

Damage, Leakage, Corrosion à Fracture

Grouting or Injection Void, Corrosion à Fracture

Damage, Leakage, Corrosion + High Stress Concentrations, à Fracture

Damage, Leakage, Corrosion + High Stress Concentrations, à Fracture

70
 Hotspots: Pylon Anchorage

Damage, Leakage, Corrosion + High Stress Concentrations à Fracture

Grouting or Injection Void, Corrosion à Fracture

Damage, Leakage, Corrosion à Fracture

Damage, Leakage, High Stress Concentrations à Fracture

71
Stay Cable Assessment
Hotspot: Anchorage Rotation

72
Deflection

Live Load

73
 Deck Deflection
W.P.

B.P.

B.P.

W.P.
74
 Deck Deflection
W.P.

B.P.

B.P.

W.P.
75
 Deck Deflection = Anchorage Rotation

Ax
is S
tay
Ca
ble
-P
L

Permanent Load (PL)

Deck B.P.

Ax
is
St
ay
Ca
Ax bl
is e-
St PL
ay
Ca Typical anchorage rotation from deck deflection ( a ):
ble
-S
LS
FLS +/- 0.1 to 0.3° (high cycle fatigue)
SLS +/- 0.2 to 1.0° (low cycle fatigue)
Fatigue Load (FLS)
Service Load (SLS)

Deck a

B.P.

76
 Anchorage Rotation

Typical anchorage rotations from cable vibrations ( a ):

Undamped 2.0 x D +/- 0.2 to 1.0° (high cycle fatigue)

Damped LS / 1700 +/- 0.1 to 0.3° (high cycle fatigue)

Example Fred Hartman Bridge in Houston, TX (USA)

Copyright © 2000 Ferguson Structural Engineering Laboratory
Austin (TX) – Texas Department of Transportation

77
Anchorage Rotation

78
 Anchorage Rotation + Construction Tolerances

Hotspot Hotspot
High Stresses Impact

Survey

79
 Anchorage Rotation + Construction Tolerances

Hotspot
High Stresses

Survey

80
 Anchorage Rotation + Construction Tolerances

Hotspot Hotspot
High Stresses High Stresses

Survey

81
Stay Cable Assessment
Endoscopy + Visual Assessment

82
 Endoscopy + Visual Assessment

Tool Priority 1 Tool Priority 1 Tool Priority 2 Tool Priority 3

Visual External Visual Internal Grouting Defects / Leakage Visual External

Effective Expensive but Effective Limited Scope Expensive

Endoscope / Borescope
Minimal Scope Diameter < 4mm
Long Scope Length > 2m
Large Tip Articulation > 100°
Camera High Resolution > HD Thermal Camera Cable Crawler with Camera

83
Endoscopy + Visual Assessment

Anchorage Region

Transition Region

Cable Free Length

84
 Endoscopy + Visual Assessment

Remove Cap Remove Reducer

Remove Grout or Remove Injection Material

Endoscopy Important Remarks

Possible à generally, no limitations

Possible with Limitations à Limitations = too small openings, only surface visible (example HDPE extruded strand) etc.

Only Possible with Openings à Openings = drilling, wedging etc.

85
Endoscopy + Visual Assessment

Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

86
Endoscopy + Visual Assessment

Wedging Drilling Opening

Void

87
Endoscopy + Visual Assessment
Cable Free Length

88
 Generation 0: Unprotected Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal

Locked Coil
UTS 1’400 - 1’600 MPa
Galvanized and/or Painted
Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
89
 Generation 0: Unprotected Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Single Bar
d = 10 – 50 mm
UTS 1’050 - 1’200 MPa
Tensile

External View: Damage, Corrosion

Visual + Endoscopy Internal View: -

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
90
 Generation 0: Unprotected Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal

Wire
7 mm
UTS 1’670 - 1’770 MPa
Tensile

External View: Damage, Corrosion

Visual + Endoscopy Internal View: -

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
91
 Generation 1: Grouted Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal
Stay Pipe (HDPE or Steel)

Grouted

Single Bar
d = 10 – 50 mm
UTS 1’050 - 1’200 MPa
Tensile

External View: Damage, Corrosion

Visual + Endoscopy Internal View: Damage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
92
 Generation 1: Grouted Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal
Stay Pipe (HDPE or Steel)

Grouted

Wire
7 mm
UTS 1’670 - 1’770 MPa
Tensile

External View: Damage, Corrosion

Visual + Endoscopy Internal View: Damage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
93
 Generation 1: Grouted Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal
Stay Pipe (HDPE or Steel)

Grouted

Strand
0.6 - 0.62’’ (15.2 - 15.7mm) 140 - 150mm2
UTS 1770 - 1’860 MPa
Tensile

External View: Damage, Corrosion

Visual + Endoscopy Internal View: Damage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
94
 Generation 2: Extruded Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal
Stay Pipe tightly extruded

Wire
7 mm
UTS 1’670 - 1’770 MPa
Tensile

External View: Leakage, Damage, Corrosion

Visual + Endoscopy Internal View: Damage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
95
 Generation 3: Injected Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal
HDPE Stay Pipe

Injected (Wax or Grease)

Wire
7 mm
UTS 1’670 - 1’770 MPa
Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
96
 Generation 4: Multi-layer Cable

External Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Internal
HDPE Stay Pipe

Injected (only optional)

Strand
0.6 - 0.62’’ (15.2 - 15.7mm) 140 - 150mm2
UTS 1770 - 1’860 MPa
Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
97
Endoscopy + Visual Assessment
Anchorage

98
 Bearing Plate + Guide Pipe

Endoscopy

Possible

Possible with Limitations

Only Possible with Openings

Guide Pipe Reducer

Bearing Plate

Drainage

Visual + Endoscopy External View: Damage, Leakage, Corrosion

99
 Generation 0: Bonded Anchorages + Unprotected Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer

Socket (Bonded w. Transition) Endoscopy

Deviator Possible

Transition Possible with Limitations

Only Possible with Openings

External Tensile External Tensile

External Internal Tensile

External Internal Tensile

External External Internal Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
100
 Generation 1: Bonded Anchorages + Grouted Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer

Socket (Bonded w. Transition) Endoscopy

Deviator Possible

Transition Possible with Limitations

(Grouted)
Only Possible with Openings

External Internal Tensile External Internal Tensile

External Internal Tensile

External Internal Tensile

External External Internal Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
101
 Generation 2: Bonded Anchorages + Injected Stay Cable
Protection Cap
Anchor Head w. Lock Nut Centralizer

Socket (Bonded) Endoscopy

Possible
Transition (Grease or Wax Injected)
Possible with Limitations
Deviator
Only Possible with Openings

External Internal Tensile External Internal Tensile

External Internal Tensile

External Internal Tensile

External External Internal Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
102
 Generation 3: Unbonded Anchorages + Multi Layer Stay Cable
Protection Cap
Anchor Head w. Lock Nut Free Deviator

Anchorage Endoscopy

Deviation Possible

Transition Possible with Limitations

(Strands in Individual Tubes)
Only Possible with Openings

External Internal Tensile External Tensile

External Internal Tensile

External Internal Tensile

External External Internal Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage, Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
103
 Generation 4: Unbonded Anchorages + Multi Layer Stay Cable
Protection Cap
Anchor Head w. Lock Nut Free Deviator

Socket Endoscopy

Deviation Possible

Transition Possible with Limitations

(Individually Sheathed Strands)
Only Possible with Openings

External Tensile External Tensile

External Internal Tensile

External Internal Tensile

External External Internal Tensile

External View: Damage, Leakage, Corrosion

Visual + Endoscopy Internal View: Damage, Leakage Corrosion

Tensile Element: External Damage, Corrosion, High Stress à Fracture of Tensile Element
104
Endoscopy + Visual Assessment
Examples

105
 Endoscopy + Visual Assessment
Protection Cap
Anchor Head w. Lock Nut Centralizer Joint

Socket (Bonded w. Transition)

Deviator Stay Cable

Transition

106
 Endoscopy + Visual Assessment
Protection Cap
Anchor Head w. Lock Nut Centralizer + Deviator Joint

Bonded Anchorage w. Socket

Deviation Stay Cable

Transition

107
 Endoscopy + Visual Assessment
Protection Cap
Anchor Head w. Lock Nut Centralizer + Deviator Joint

Deviation Stay Cable

Transition

108
Stay Cable Assessments
Non-Destructive Testing

109
 Non-Destructive Testing

GPR Magnetic Flux Leakage Ultrasonic Testing Other

ONLY Grouting Defects Wire Breaks Steel Cracks Specific Applications

Easy but requires Expensive Expensive Specific Knowledge

Cable Crawler or Manlift Complex Method Requires High Skill by Application

Acoustic Emission
Concrete Ultrasound
Radiography
Eddy Current
Impact Echo

… others

Cable Crawler with Sensor

Cable Free Length ONLY Steel Elements Anchorage Many Niche Applications

110
 Non-Destructive Testing

Anchorage Region

Transition Region

Cable Free Length

111
Stay Cable Assessment
Lift-off Test / Force Measurement

112
 Lock Nut

Anchor Head

Mono Jack

Bearing Plate 50
0-
15
00
cm

113
 Lock Nut

Anchor Head

Bearing Plate

Stressing Chair

Multi Jack

114
Stay Cable Assessment
Other Methods

115
 Other Methods

1. Chemical Analysis
• Cementitious Materials: Assess strength, durability, and corrosion potential.
• Polymers: Flexibility, Adhesion, chemical resistance.
• Injected Fillers (wax, grease): Consistency, corrosion resistance.

2. Extracting Single Tensile Elements

• Sampling: Extract wires/strands.
• Tensile Testing: Measure tensile strength, yield strength, elongation.
• Fatigue Testing: Simulate cyclic loading and determine remaining life.
• Fractography: Analyze failure modes, fatigue, corrosion.

3. Additional Assessment Methods

• Plug Test: Estimate cable force.
• Acoustic Emission Monitoring: Detect cracks and defects.
• Radiographic Testing: Detect internal defects.
• Electromagnetic Testing: Eddy current for surface defects.
• Potential Measurement: Assess corrosion susceptibility.
• Structural Analysis: Verify bridge performance under actual loading and geometry.
• Monitoring Sensors: Install sensors for continuous monitoring of structural health.
116
Stay Cable Care
Method Statement

117
Stay Cable Care: Process

118
 Stay Cable Care

Reconnaissance

The reconnaissance phase provides a high-level overview of the asset to understand what you are dealing with before diving into
detailed assessments. This step helps identify the key characteristics and potential challenges of the asset, setting the stage for
informed planning and decision-making.

• Initial Document Review: Reviewing the most relevant documents and records, such as design plans, care records, and
assessment histories.

• Understanding the Layout of the Structure: Conducting a walkthrough and, as required, initial measurements to gain a
preliminary understanding of the structure’s layout.

• Initial Visual Assessment: Performing a preliminary visual assessment to identify obvious issues.

119
 Stay Cable Care

Setup Smart Asset Model

The Setup of the Smart Asset Model * involves creating a digital replica of the asset and establishing a comprehensive and
interactive Digital Environment that integrates existing data and is ready to incorporate new data inputs. This setup allows for
seamless updates and real-time monitoring, consolidating all relevant information to enhance management and decision-
making. By leveraging this digital environment, stakeholders can anticipate maintenance needs and ensure the asset’s optimal
condition and performance over time.

• Detailed Document Review: Collecting and reviewing all relevant documents, such as design plans, care records, and
assessment histories. This helps in understanding the structure’s history and identifying potential areas of concern.

• Geometrical Layout Data: Having accurate geometrical survey data in the form of maps, 2D drawings, or 3D models is an
essential step to set up the Smart Asset Model. This data can be obtained from existing records or through Geometrical
Surveys.

• Smart Asset Model Platform Setup: Establishing an interactive digital environment for data collection, analysis, and
documentation. This platform will integrate all data collected during the care process, providing a holistic health record.

* for example: Eagle Inspect from Screening Eagle Technologies

120
Stay Cable Care: Smart Asset Model

121
 Stay Cable Care

Assessment

Step 1: Preparation
• Standard Compliance: Review project-specific testing and certification evolution to identify hotspots in older cable systems.
• Detailed Step Planning: Plan the examination steps, including “Hotspot” identification and reviews of critical areas.
• Access Preparation: Plan access methods (e.g., gantries, cranes, scaffolding).
• Cleaning Preparation: Plan cleaning procedures for clear visibility and accurate assessments.
• Resource Allocation: Allocate necessary personnel, equipment, and materials.
• Safety Planning: Develop and implement a safety plan to address potential hazards and ensure compliance with regulations.

122
 Stay Cable Care

Assessment

Step 2: Survey
Detailed Geometrical Survey:

• Bearing Points of Anchorage: Verify the alignment and integrity of bearing points.
• Exit Points of Cables: Assess the condition and alignment of cable exit points.
• Angular Alignments: Check angular alignments and any misalignments of anchorages and cables.
• Misalignments: Identify and document any misalignments between anchorages and cables.

Gaining Access to Anchorages:

• Access Methods: Use appropriate access methods such as scaffolding, cranes, or rope access to reach anchorages.
• Cap Removal: Remove anchorage caps to access the internal components.
• Filling Material Removal: Remove grout or other filling materials to expose the anchorages for detailed assessment.
• Post-Assessment Replacement: After assessment, replace or refill the materials and reseal the anchorages.

123
 Stay Cable Care

Assessment

Step 2: Survey
Gaining Access to Anchorage Transition:

• Access Methods: Use appropriate access methods such as scaffolding, cranes, or rope access to reach transitions.
• Reducer and Centralizer Removal: Remove reducer and centralizer to facilitate assessment of the cable transition zones.
• Post-Assessment Replacement: After assessment, reinstall the respective components.

Detailed Visual Examination:

• Endoscopic Assessment: Use endoscopes to assess internal areas that are not easily accessible.
• Drone Assessment: Utilize drones equipped with high-resolution cameras to assess the cable free length
• Photographic Documentation: Capture detailed photographs for record-keeping in the Smart Asset Model and further
analysis.

124
Endoscopy + Visual Assessment

Anchorage Region

Transition Region

Cable Free Length

125
 Stay Cable Care

Assessment

Step 2: Survey
Force Measurement

• Lift-off Tests: Measure tensile forces in cables and detect loss of tension.
• Plug Test: Estimate cable force.

NDT Diagnostics - Primary Methods:

• Ultrasonic Testing (UT): Detects steel cracks and internal flaws using ultrasonic waves.
• Magnetic Flux Leakage (MFL): Identifies wire breaks and corrosion in steel elements.
• Ground Penetrating Radar (GPR): Effective for detecting grouting defects and voids in the cable free length.

126
Stay Cable Care: Non-Destructive Testing

Anchorage Region

Transition Region

Cable Free Length

127
 Stay Cable Care

Assessment

Step 2: Survey
NDT Survey - Additional Methods:

• Acoustic Emission Monitoring: Detects cracks and defects through sound wave analysis.
• Eddy Current Testing: Identifies surface defects in metallic components.
• Radiographic Testing: Uses X-rays or gamma rays to detect internal defects.
• Impact Echo Testing: Assesses material properties and detects voids or delaminations.
• Electromagnetic Testing: Uses eddy currents to identify surface defects.
• Potential Measurement: Assesses corrosion susceptibility.
• Monitoring Sensors: Install sensors for continuous monitoring of structural health.

128
 Stay Cable Care

Assessment

Step 3: Analytics
Chemical Analysis:

• Cementitious Materials: Assess strength, durability, and corrosion potential.

• Polymers: Evaluate flexibility, adhesion, and chemical resistance.
• Injected Fillers (wax, grease): Check consistency and corrosion resistance.

Extracting Single Tensile Elements:

• Sampling: Extract wires/strands for testing.

• Tensile Testing: Measure tensile strength, yield strength, and elongation.
• Fatigue Testing: Simulate cyclic loading and determine remaining life.
• Fractography: Analyze failure modes, fatigue, and corrosion.

129
 Stay Cable Care

Assessment

Step 3: Analytics
Structural Analysis:

• Finite Element Modeling: Conduct detailed structural analysis using techniques like finite element modeling.
• Decision Support: Use structural analysis results to inform conservation and upgrade decisions.

Processing:

• Data Integration: Integrate and analyze results from various tests to identify patterns and areas of concern.
• Predictive Analysis: Utilize data analytics tools to predict potential issues and plan preventive measures.

130
 Stay Cable Care

Conservation and Upgrade

Step 4: Preparation
• Planning & Proposing Methods: Develop plans for necessary conservation or upgrades based on the analyzed data.
• Reporting: Compile a detailed report summarizing findings, proposed plans for conservation or upgrades.
• Follow-up Actions: Plan and track follow-up checks to ensure the effectiveness of conservation or upgrades.

131
 Stay Cable Care

Conservation and Upgrade

Step 5: Execution
• Execution of Conservation Measures: Implementing the planned conservation measures while ensuring minimal impact on
the structure’s integrity. This may involve repairing cracks, treating corrosion, and restoring original materials.
• Execution of Upgrades: Carrying out the necessary upgrades to enhance the structure’s performance and longevity. This may
involve reinforcing structural elements, updating safety features, and integrating modern technologies.
• Documentation and Reporting: Maintaining detailed records of all conservation and upgrade activities in the Smart Asset
Model to document progress and outcomes.

132
 Stay Cable Care

Conservation and Upgrade

Step 6: Verification
• Quality Assurance: Conducting evaluations to ensure conservation and upgrade activities meet goals and specifications.
• Performance Validation: Implementing tests to confirm that functionality and performance align with intended outcomes.
• Documentation and Reporting: Maintaining detailed records in the Smart Asset Model.

133
 Stay Cable Care

GOAL: Health Record + Continuous Care

The ultimate goal of this process is to maintain an up-to-date Smart Asset Model* of the stay cable structure. This Smart Asset
Model will reflect the structure’s current health condition and serve as the central platform for all ongoing assessments,
conservation activities, and upgrades.

By leveraging the Smart Asset Model, we ensure continuous monitoring and tracking of the structure’s health. This platform allows
for the collection of structured data periodically, which is crucial for tracking health indicators. Automated alerts can notify
stakeholders of any issues that arise, enabling timely interventions.

Conservation planning is informed by trend analysis, which helps identify potential concerns before they become critical. Routine
conservation tasks are performed to keep the structure in optimal condition, and significant issues are addressed through major
upgrades when necessary.

All conservation activities are meticulously documented within the Smart Asset Model, providing a comprehensive record of the
structure’s history and interventions. This documentation ensures transparency and accountability, making it easier to review and
evaluate the effectiveness of the conservation plan.

* for example: Eagle Inspect from Screening Eagle Technologies

134
 Stay Cable Care

GOAL: Health Record + Continuous Care

Stakeholder communication is a key aspect of this process. Regular updates and feedback mechanisms keep all relevant parties
informed about the structure’s condition and any planned activities. This continuous loop of communication ensures that
everyone is aligned, and any concerns are promptly addressed.

Periodic evaluations of the conservation plan’s effectiveness are conducted to ensure ongoing efficiency and effectiveness.
Adjustments are made as needed based on these evaluations, ensuring that the care process remains responsive to the
structure’s needs.

By maintaining a detailed and accurate Smart Asset Model, we create a robust foundation for continuous assessment,
conservation, and upgrades. This proactive approach ensures that stay cables and related structures remain safe, functional, and
durable over time, enhancing the efficiency and effectiveness of the management of the built environment.

By following this detailed care process, stakeholders can ensure that stay cables and related structures remain safe, functional,
and durable over time. The integration of a central Smart Asset Model platform, enhances the efficiency and accuracy of each
step, enabling continuous improvement and effective management of the built environment.

135
Building stakeholder value by
decarbonizing the built world.

136 136