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

DESIGN
ENGINEERING
SUPPLY
INSTALLATION
MONITORING

VSL MAINTAINS THE LEAD

IN STAY CABLE
TECHNOLOGY

Industrial Ring Road Bangkok, 2006 Stay cables installed strand-by-strand.

VSL: a worldwide network

active management systems and high

performance standards.
VSL recognizes that employees are the key to
competitiveness and effective working practices. The company is committed to safety
first and strives for zero accident, with
employees motivated to take the necessary
responsibilities to achieve this goal.
Clearly-defined measures are in place to
promote sustainable development as part of
VSLs contribution to environmental protection.

VSLs organisation as a network of closelycooperating regional units allows it to provide

a full range of solutions and services worldwide.
Customers have access to a local presence, while
benefiting from global resources, know-how and
expertise as well as VSLs continuing development
of specialist construction techniques. The VSL
networks valueadded services are combined
to provide fully-customised solutions, from concept
to site works, using highly-trained and experienced
staff working in close partnership with clients.

VSL: a specialist
stay cable contractor

VSL: a commitment to Quality,

Safety and the Environment

As leader in stay cable technology, VSL paves

the way with new developments. The last
10 years in particular have seen a boom in
stay cables, with a considerable increase in
the span lengths that can now be achieved as

VSL pursues a strong QSE policy in keeping

with its position as a technical leader in the
industry. Local teams aim continuously to
establish, maintain and improve their pro-

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

well as faster installation and erection cycles

thanks to VSLs construction techniques.
VSL has experience of more than
130 cable-stayed bridges, including 40 in the
last eight years, and its close participation
with clients and builders has resulted in a
next-generation technical solution.
The VSL SSI 2000 System described here
combines the latest developments with VSLs
best solutions, and has already been used for
dozens of bridges. The system offers high
fatigue resistance, excellent corrosion
protection and cable-force monitoring, as well
as allowing adjustment, inspection and
replacement of the strands. It maintains
stringent durability standards, whilst
incorporating new features for greater
flexibility and simpler, more slender cables
and anchorages.

Recent VSL developments

in stay cable technology
VSL Saddle, a patented solution allowing much
simpler pylon design resulting in enhanced bridge
aesthetics;
Compact anchorage, leading to simplified design
and construction of the pylon and superstructure;
Compact stay cable system, resulting in a tighter
arrangement of the strands and hence a reduced
cable diameter and a lower cable wind load;
Cable protected by dehumidification
techniques, a patented solution offering
the lowest wind load on strand cables,
with a permanent monitoring;
A choice of cable-vibration damping systems,
which permits optimum load adaptation for each
structure.

Uddevalla Bridge Sweden, 1998

Stay cables installed strand-by-strand and equipped with anti-vibration
friction dampers.

Modern engineering:
stringent standards
Designers and regulators throughout the world
are demanding:
increased durability of stay cables, including
corrosion protection of both cable and
anchorage, leak-proofing of the anchorage
assembly, good anchorage conditions, easy
inspection and maintenance, cable
replacement with minimal traffic interruption,
cable vibration control and a compact stay
bundle with a reduced wind drag-coefficient;
outstanding fatigue and static load
performance levels (200MPa and 300MPa
stress range fatigue test for the SSI 2000
anchorage assembly and components);
improved aesthetics arising from the
availability of saddles, compact anchorages
and coloured cables;
incorporation of damping systems into the
anchorage.
Main contractors also look for optimal
construction schedules such as:
a design that takes into account the close
relationship between deck erection and stay
cable installation;
lightweight installation equipment to enable
easier operations and a more flexible erection
programme.

La Unidad Bridge Mexico, 2003

Full scope of bridge construction.

Liebrueti Bridge Switzerland, 1978

First VSL Stay cable bridge

Clients benefit from:

enhanced durability that is built in;
easier long-term maintenance, providing
substantial savings.
The VSL SSI 2000 stay cable system is designed
to meet all of these demanding requirements.

Las Glorias Footbridge - Spain, 1991

Supply of the stay cables and supervision at installation.

Cable installation with

VSL lightweight equipment

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

SSI 2000: VSL STAY CABLE TECHNOLOGY

Several
complementary
barriers

Compact anchorage
Length of a fixed end anchorage
for 127 strands is only 440mm.

d) anchorage
Adjustable (or fixed en

For anchorage water

tightness system

High fatigue performance

VSL strands
High fatigue performance over 300 MPa
stress range at 2 millions cycles.
Compatible with VSL SSI Saddle

Individual strand deviation device

Filtering cable bending stress at the anchorage device

High fatigue resistance

VSL anchorage
Demonstrated by fib and PTI fatigue tests
with combined tension and bending action.

Increased corrosion
protection
Factory applied individual protection
treatments, for a design life of 100 years
in the most aggressive environments,
without maintenance

Individual encapsulation
Each strand separately protected
inside the anchorage

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

a new system that provides the best protection

in the most aggressive environments. It enables
100 years of maintenance-free operation for
non-accessible components.

Anchorages include design features to filter

out vibrations and bending stresses in the
cable before they can reach the anchorage
wedges. Sample stay cables have been
subjected to fatigue testing with cable angular
deviations as defined in the latest PTI and fib
recommendations. Anchorages can be
equipped with additional cable protection
systems where unusual cable deviations need
to be taken into account (see page 6).

b) Individual encapsulation of each strand

within the anchorage avoids the risk of
corrosion migration between strands. Full
encapsulation is achieved by providing each
strand with its own protection system.
c) Complementary barriers provide a degree of
redundancy to ensure the leak-tightness of the
anchorage. The sealing system has passed the
various tests as defined by fib and PTI.

High durability and a new

standard of protection
a) For the corrosion protection of the steel
anchorage components, VSL has developed

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

Cable replacement
without traffic interruption
The very compact nature of the anchorages
allows installation in confined spaces within
box girders and pylons. The single strand
installation method and stressing operations
have been optimised to facilitate cable
installation using very lightweight equipment
for greater flexibility in construction.

Easy incorporation
of a VSL internal damping system
The stay cable system can be designed with
provision for later installation of a VSL
vibration damping system, should it prove
necessary (see page 14).

Y FOR BRIDGES
Versatility
Designed to accommodate a VSLs vibration damping
system which can be installed retro-actively

Low drag coefficient

Measured in wind tunnel

Versatile tension ring

Replaceable stay cable system

May be used as a guide deviator

for increased cable angular
deviations

Reduced cable wind loads

The VSL stay pipes installed on the bridges are
generally equipped with external helical ribs to
suppress vibrations induced by rain and wind.
Wind tunnel testing has demonstrated the
efficiency of the VSL-designed helical ribs in
reducing drag at wind speeds up to 70m/s.

The VSL compact system:

SSI 2000-C for long cables
Wind load on the cables can be an important
parameter for the structural design of bridges with
very long cables. For these cables, VSL has
developed SSI 2000-C, an adaptation of the
standard SSI 2000. It uses the same anchorages
and connections but features a 20% reduction in

Each strand can be individually checked

and at any time, replaced and re-installed.
Complete cable is replaced with closure
of only one traffic lane.

cable diameter. Reduced wind loads result from its

use in combination with the lower wind drag
coefficient of the VSL stay pipe.

The VSL SSI 2000-D:

dry air system for lower wind loads
VSL SSI 2000-D is an adaptation of the
standard system, using the same
wedge/strand anchorage technology. Its main
feature is a greatly-reduced cable diameter of
about 30% less than standard, which results
in significantly lower wind loading. SSI 2000-D
cables are protected by dry air using the same
technology as found in the protection of many
steel bridge decks and suspended cables
(see page 10).

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

The VSL SSI 2000 Saddle allowing

replacement of strand
VSL has developed a patented new pylon saddle
for its SSI 2000 Stay Cable System, designed for
use with the standard sheathed strand used on
extradosed and cable-stayed bridges.
The compact saddle allows strand by strand
installation and replacement of each strand.
Tests have demonstrated that the saddles
fatigue performance is the same as for
anchorages. High friction of the cable on the
saddle allows its use in pylons subjected to
significant unbalanced cable loads (see page 12).

VSL SSI 2000 MAIN DIMENSIONS

DECK CONNECTION
Designed with a tension ring or a guide deviator,
and a VSL damping system if required.

Cable equipped with a tension ring

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

L1
min
i

ADJUSTABLE ANCHORAGE
L1 mini

Cable equipped with a guide deviator

This provides the anchorage with a greater level of
protection in case the cable is subjected to higher
angular deviations such as seismic events. For
long guide pipes the guide deviator protects
the cable from contact, whatever the
amplitude. It also allows for the guide
pipe assembly to be installed with
increased tolerances.

H1 mini

Guide pipe
D1

E1

A1

B1

C1

F1

G1

L1
min
i

DECK ANCHORAGE
with adjustable or fixed end anchorages

Connection detail for subsequent installation of

a VSL damping system
The flange welded to the end of the guide pipe
and the increased diameter of the antivandalism pipe are designed to allow for
later installation of a VSL damping
system, should cable vibrations need
to be rectified. The cable can be
equipped with a guide deviator
(see figure) or, more
generally, with a tension
ring.

L1
min
i

PYLON ARRANGEMENT

Cable equipped with the VSL friction damper

In the event of unexpected cable vibrations,
a choice of VSL damping systems - friction
damper or Gensui damper - can be
installed without modification to the
cable assembly.

L*

L1
min
i

Distance between facing fixed end

anchorages is 1.4m. Distance of
approx. 3.5m is recommended when
stressing jacks are used.
1.4m

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

Stay cable equipped

with a tension ring

L1

PYLON CONNECTION

L1

The pylon connection is similar to the deck

connection and can be designed with either
a tension ring or, in some cases, with a
guide deviator.

Stay cable equipped

with a guide deviator

FIXED END ANCHORAGE

L1 mini

F2

A2
E2

D2

Guide pipe

C2

Cable diameter

H2 mini
G2

STAY PIPE
FREE LENGHT

DECK CONNECTION

ADJUSTABLE ANCHORAGE (at deck or pylon)

CABLE DIAMETER (mm)

ANCHORAGE
UNIT

SSI 2000

SSI 2000-C*

6-12

125

95

6-19

140

6-22

160

6-31

SSI 2000-D

PYLON ANCHORAGE
with adjustable or fixed end
anchorages

PYLON CONNECTION

Anchorage Number
unit
of strands

D1
mm

A1
mm

B1
mm

C1
mm

E1
mm

F1
mm

G1
mm

TENSION
RING

FIXED END ANCHORAGE (at deck or pylon)

H1 mini
mm

A2
mm

C2
mm

D2
mm

E2
mm

F2
mm

G2
H2 mini
mm
mm

L1 mini
mm

85

6-12

12

190

230

290 219.1 / 6.3 196

500

30

325

185

260

177.8 / 4.5

150

300

35

210

800

110

95

6-19

19

235

285

355 267 / 6.3 241

500

35

350

230

335

219.1 / 6.3

190

300

50

225

1100

125

105

6-22

22

255

310

385 298.5 / 7.1 261

500

40

360

250

355

219.1 / 6.3

205

300

50

225

1250

160

135

115

6-31

31

285

350

440 323.9 / 7.1 291

700

45

410

280

415

244.5 / 6.3

230

300

60

250

1400

6-37

180

150

130

6-37

37

310

380

485 355.6 / 8 316

700

50

440

300

455

273 / 6.3

255

250

70

275

1600

6-43

200

170

145

6-43

43

350

425

540 406.4 / 8.8 356

700

55

455

340

505

323.9 / 7.1

285

250

75

280

1850

6-55

200

175

150

6-55

55

385

470

585

419 / 10

391

700

60

495

380

550

323.9 / 7.1

310

250

75

300

1950

6-61

225

185

160

6-61

61

385

470

600

419 / 10

391

700

65

530

380

585

355.6 / 8

330

200

85

320

2150

6-73

250

200

170

6-73

73

440

530

680

508 / 11

446

700

75

530

430

650

406.4 / 8.8

370

200

95

335

2300

6-85

250

210

180

6-85

85

440

540

710

508 / 11

446

700

80

590

430

685

406.4 / 8.8

370

200

110

365

2450

6-91

280

220

190

6-91

91

490

590

760 559 / 12.5 496

700

80

585

480

730

457 / 10

420

200

110

375

2650

6-109

315

235

200

6-109

109

505

610

795 559 / 12.5 511

700

90

620

495

775

457 / 10

420

200

120

385

2800

6-127

315

265

225

6-127

127

560

670

865 610 / 12.5 566

700

95

650

550

845

508 / 11

475

200

130

435

3200

6-175

355

6-175

175

640

770

646

700

110

730

620

1000

711/14.3

530

200

150

460

3700

*with PTI tightly extruded strand

1000 711/14.2

Customized sizing can be provided for large cables on request.

Valid for nominal concrete strength at stressing to 45% of stay capacity: 45 MPa (cube), 36 MPa (cylinder). Dimension must be checked in case of other bearing conditions.
Guide pipe to be checked if use of guide deviator or damping system.
Minimum value allows on adjustability of 40 mm.

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

ENHANCED DURABILITY WITH SSI 2000

Durability and fatigue strength are the two most important requirements for
stay cables designed to enable 100 years of maintenance-free operation for
non-accessible components in the most aggressive environments. VSL has
recently developed some new products and services, therefore offering
complementary barriers providing new degrees of redundancy.
Accelerated ageing tests
Correct specification and manufacturing is
important to avoid significant variations over
time in the characteristics of the non-steel
components such as the HDPE/PP used for the
stay pipe and strand sheathing.
UV radiation and/or pollution may cause the
colour of the HDPE stay pipe to change over
time. The fading of the colour is controlled
such that it remains invisible to the naked eye.

VSL colored stay pipe with helical ribs,

tested in a wind tunnel

The evolution of the mechanical and

colourimetric characteristics is verified during
accelerated ageing tests of the VSLs coloured
stay pipes.

Durability of the VSL stay cable system

Anchorage leak-tightness test

VSL stay cables are replaceable and have a

design life of 100 years in the most aggressive
environments, as defined by the C4 and C5
categories of the ISO 12944 standard.

The barriers that protect the cable along its free

length are checked by appropriate component
tests. It is important to have efficient measures
in place to prevent ingress of water into the
anchorage interfaces, particularly at the deck.
The VSL anchorages sealing system is designed
with a high degree of redundancy and the
anchorage has passed the leak-tightness tests
as defined by PTI and fib.

VSL specifications for the corrosion-protection

system of steel components are much more
stringent than the durability recommendations
from PTI and CIP. The components which are nonaccessible are manufactured with a protection
system that has a design life of 100 years
without maintenance. The first maintenance
operation on the accessible and replaceable
components is scheduled after 25 years.

Durability at the construction stages

The durability of each component depends on
its design and choice of material. However, the
durability of the complete cable will also
depend on the quality of the installation works
and the provisions made for easy inspection
and replacement. VSL has incorporated
permanent control systems which allow for the
detection during the strand installation of any
defect that would reduce the stay cables
durability. Any component can be easily
replaced without critical delay to the
installation schedule.

Each component and the entire assembly of VSL

anchorages have all been subjected to analysis,
to determine the best materials, component
geometries, assembly type and protection
system to achieve the highest durability.

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

The SSI 2000 System is now offering new

developments, all leading to enhance cable
durability :

The VSL SSI 2000-D to reduced cable

wind loads
VSL SSI 2000-D is an adaptation of the
standard system, using the same
wedge/strand anchorage technology. Its main
feature is a greatly-reduced cable diameter of
about 30% less than standard, which results
in significantly lower wind loading. SSI 2000-D
cables are protected by dry air using the same
technology as found in the protection of many
steel bridge decks and suspended cables (see
page 10).

Adjustable anchorages are

protected by a sprayed
metallic coating.

Tensile test of a sample HDPE

stay pipe which has been
subjected to an ageing test.

Checking of a 6-37 anchorage after a PTI leak-tightness

test. After being submitted to mechanical environmental
constraints, the anchorages were placed in a chamber with
3m-head of dye solution to check the ingress.

SYSTEM & DEVELOPMENT

DURABLE BUT ALSO AESTHETIC

The VSL SSI 2000 Saddle allowing

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

Red color stay pipes

(Sucharskiego Bridge, Poland)

White color stay pipes

(Neva Bridge, Russia)

Gold color stay pipes

(Industrial Ring Road, Bangkok)

VSL solutions for cable vibration

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

Required durability
of stay cables

VSL loadcell

Various durability requirements have been

developed:
PTI stay cable recommendations are for a
75-year design life.
The CIP document says 50 years and
100 years for replaceable and non-replaceable
cables respectively.
fibs stay cable recommendations are
100 years protection against corrosion
for steel components and a design life
of 50 years for non-metallic components,
with replaceability of components.

VSL structural monitoring services

VSL monitoring package is offered as an
additional service to provide the client with
long term cost savings. It can be applied to
structures and to cables. In-house R&D has
placed emphasis on durability method,
measurement and sensor configurations to
optimise maintenance; to detect damage and
confirm diagnosis of deterioration; to validate
and memorise know-how for future projects; to
optimise life cycle cost of the structure.

V S L

S S I

2 0 0 0

S T AY C A B L E S Y S T E M

SSI 2000 SYSTEM DEVELOPMENT

THE VSL SSI 2000-D SYSTEM

A stay cable system protected by dry air*
Reduced cost for any
cable replacement
Non-sheathed VSL strands

Permanent visual control

of the cable corrosion at the
anchorages, without dismantling.

Bearing plate

Protection cap

No damage
of the cable
protection during
installation

Guide pipe

Dry air protection

of the cable, the anchorages and
the vibration damping system

Permanent monitoring
of the corrosion protection
system of the cables:
Temperature
Humidity
Air pressure

The dehumidifier unit

placed within the pylon
supplies dry air to the
pylon anchorages.

The airtight HDPE stay pipe is connected at

one end to the pylon and at the other to the
deck anchorage. The cable is composed of
non-sheathed strands manufactured with
a protective coating such as galvanising.

Non-sheathed strands
protected by dry air
The complete stay cable system is designed so
that the strands are located within an airtight
enclosure along their free length and along the
two anchorage lengths.

A dehumidifier unit, which is generally placed

inside the pylon, is equipped with air-pushing
fans to maintain a low but permanent pressure
of dry air along the cable length. This permanent
pressure prevents any ingress of water from the
outside environment into the cable.

The cable, anchorages and any vibration

damping system are all protected against
corrosion.
* Patent pending

V S L

S S I

2 0 0 0

10

S T AY C A B L E S Y S T E M

Dry air
supply pipe

Stay cable

Co-extruded
HDPE stay pipe
with helical rib
Cable with 3 nested
layers of protection
Anti vandal pipe

Reduced cable
diameters
Strand cable with the
lowest outer diameter
allowing reduced cable
wind load

VSL friction
damper

Sealing device
protected inside the
anti vandal pipe

Increased layers
of corrosion protection

Anchorage protection cap allowing visual inspection of cable

The dehumidifier unit placed within the pylon

supplies the dry air to the pylon anchorages.
The dry air flows from the pylon anchorages to
those at the deck. The space between the
strands inside the HDPE pipe allows circulation
of the dry air around the steel strands, with a
pressure at the deck anchorage that is slightly
above atmospheric pressure.

The main tensile elements of standard stay cable

systems are designed with two levels of protection
whereas the SSI 2000-D offers three levels:
- (continuous) steel coating of the strand
- (continuous) dry air around the strands
- an airtight enclosure provided by the stay pipe.

Dry air: a proven solution

Permanent monitoring of the cable protection is

provided. A protection cap is installed at the
deck anchorage and is designed for the
connection of sensors to measure the humidity,
air pressure and air temperature, as well as the
dehumidification control system.

The use of dehumidification or dry air systems

to protect steel decks and suspension cables
was introduced in 1971 and it is now a wellunderstood and highly-regarded solution.
The efficiency of dehumidification has also
been demonstrated in the protection of the
cables of several suspension bridges,
including those of the Akashi Kaiko Bridges
1991m-long main span.
The dehumidification equipment used by VSL
for cable protection in the SSI 2000-D System
is based on proven technology. Long-term
experience on steel decks protection has
confirmed the low maintenance costs of
dehumidification systems and their great
reliability. VSL can provide estimates of
running costs if required.

Permanent monitoring of the cable

corrosion protection system

The dry air combined protection

V S L

S S I

2 0 0 0

11

S T AY C A B L E S Y S T E M

The anchorage protection cap can also be

designed to allow permanent visual inspection
of the strands and wedges without any need to
interfere with the system. This significantly
reduces the time and costs involved in the
long-term maintenance of the cables.

Offering protection for the deck

The SSI 2000-D Dehumidification System can
also be used to achieve complete protection of
bridge decks that are designed as steel boxes.
The dry air flowing along the cables can be fed
into the compartments of the deck.

SSI 2000 SYSTEM DEVELOPMENT

THE VSL SADDLE

VSL has developed a new concept in saddles that achieves the performance
of stay cable anchorages. Moreover, each strand of the cable can also be
replaced if required.

Two independent corrosion

protection barriers

One of the great advantages of the VSL Saddle

is that it allows designers to simplify the pylon
structure and use very slender profiles to
achieve an attractive appearance.
The new VSL Saddle was developed in response
to issues with existing saddle designs, relating
to fatigue, fretting corrosion and replacement of
the cables. CIP had considered these issues so
serious that it had recommended abandoning
saddles and using anchorages instead.

The compact saddle is composed of a

rectangular steel box filled with a high-strength
Ductal cement grout. The design ensures high
friction between the cable and the saddle.
Cables can be installed or replaced strand
by strand, and the strands can be tensioned
independently. Two separate corrosion protection
barriers protect the cable inside the saddle:
- a protective strand coating such as
galvanising;
- a special flexible filler injected around the
strands, using the same material that protects
the strands within VSL anchorages.

Independent replaceable strands

Each strand of the cable is free and completely
independent in the VSL Saddle. Instead of the
usual design, the VSL Saddle has no corrosionsusceptible individual tubes. Each strand of
the cable passes through the saddle in an
independent hole in the cement grout. Special
VSL formwork has been designed for this. The
number of holes in the saddle will generally
correspond to the number of cable strands.
However, additional holes can be provided for
extra strands, such as a reference strand for
later inspection.

V shaped holes for high friction

An important feature of the VSL Saddle is the
shape of its strand holes. The holes are V
shaped, instead of the circular ones used on
saddles with individual tubes. This special
hole geometry is the result of extensive testing
carried out in VSLs laboratories to define the
optimum shape to achieve high friction
between the strand and the saddle while
avoiding fretting and allowing easy strand
installation.

Saddle section, with the V shaped strand hole

Transfer of high cable differential

forces into the pylon
The cable passing through the saddle can be
subjected to differential forces from opposite
sides of the pylon. These forces could induce a
sliding of the cable within the saddle but this
is prevented by the friction of the individual
strands inside the saddle. The laboratory tests
measured the friction coefficient as varying
from 0.4 to 0.7, depending mainly on the
loading conditions.

Angular deviations of the cable

at the saddle
On some cable-stayed bridges, the cable can
be subjected to non-negligible angular
deviations at the pylon. These deviations may
gradually cause deterioration in the cable
protection and in its mechanical strength.
In order to withstand these angular deviations,
the prefabricated VSL Saddle incorporates a
special elastomeric casting resin where the
cables exit the saddle.

No degradation of the cables fatigue

performance
Fatigue tests were carried out on small cable
units in order to determine any effect of the

Fatigue testing of the VSL saddle

V S L

S S I

2 0 0 0

12

S T AY C A B L E S Y S T E M

saddle on the cables fatigue performance. The

strands were tensioned to the cable-breaking
load after two million fatigue cycles with a
stress range of 200MPa and a maximum load
of 45% of cable capacity. No wire breaks were
observed in the saddle and subsequent
dismantling of the strands showed that they
were in very good condition and confirmed the
feasibility of strand replacement.

Cost saving cable

VSL Saddle design with

cable connection

The VSL Saddle uses the same standard

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

Manufactured saddle
for SSI strand cable

Main dimensions
(using VSL SSI 2000)
Cable unit
6-12
6-19
6-22
6-31
6-37
6-43
6-55
6-61
6-73
6-85
6-91
6-109
6-127

Saddle section
A (mm)
B (mm)
175
195
230
240
245
250
185
285
315
320
360
340
365
360
395
400
445
420
455
430
475
480
540
490
550
535

Woonam Bridge, Korea (2008) :

installation of the VSL Saddle

V S L

S S I

2 0 0 0

13

S T AY C A B L E S Y S T E M

SSI 2000 SYSTEM DEVELOPMENT

VSL SOLUTIONS FOR CABLE VIBRATION

VSLs experience in suspended structures and the development of damping
systems enables it to assist the bridge designer in carrying out risk analysis
of the cables vibration and in proposing the most appropriate solution.
As indicated in the PTI stay cable
recommendations, the mechanisms of dynamic
excitation are particularly complex and it is not
easy to produce reliable predictions. The first
difficulty for the designer is to assess the risk
of cable vibrations. Various stability criteria
are available to estimate this risk and to
evaluate any damping that is required. The
main approach used by VSL is the net damping
criterion defined by I. Kovacs*.

VSL Friction Damper

Key benefits of
the VSL Friction Damper
Great durability: This great durability is due to the
fact that the damper is designed to work only when
necessary, only when the level of the cable
vibrations is considered critical. At that stage, the
friction damper immediately achieves its maximum
damping effect to stabilise the cable.
High efficiency: Several comparative tests on stay
cables have demonstrated the efficiency of the VSL
friction damper. For example, a friction damper
installed at 6m from the deck anchorage on a
214m-long 97-strand cable achieved a measured
damping (Log. decrement) of more than 9%.
Aesthetics: Installation of damping systems on a
cable-stayed bridge has to avoid any detrimental
impact to the bridges appearance, as this is often a
key feature. The efficiency and compact nature
of friction dampers generally allows them to be
installed near the deck anchorage, where they can
be fully integrated. Other, less efficient, systems
require installation externally on additional supports.
Other advantages of the VSL friction damper
include:
easy access, simplifying inspection during
maintenance operations;
adjustment of the friction force without any need
for dismantling;
it can be installed on any type of cable on
existing bridges where cables are subjected to
unexpected vibrations;
all components of the damper can be dismantled
and/or replaced on site;
damping characteristics are not affected by the
temperature or vibration frequency.

The design of the VSL SSI 2000 Stay Cable

System allows implementation of additional
measures (such as dampers or cross-ties) in
case of unforeseen vibrations.

The VSL damping solutions

1. Modifications to the cable surface
Stay pipes can be manufactured with helical
ribs. The rib dimensions have been optimised in
wind tunnel testing for maximum efficiency in
suppressing the risk of excitations from rain
and wind while minimising the effect on drag.
2. Use of dampers to increase the structural
damping of the cable
Two different types of dampers are provided by
VSL: the Friction Damper and the Gensui
Damper. Key advantages of these dampers
include their efficiency, their durability and
their low maintenance costs. The two types
complement each other, allowing
implementation of the most suitable solution
depending on the characteristics of the stay
cables, the critical types of vibrations and the
required performance. The Gensui Damper is
optimised for extradosed bridges and for
medium cable lengths on cable-stayed bridges.
It is well-suited for use as an external damper.
The VSL Friction Damper will be the most
efficient solution for more critical cases
including long cables or where there is a risk of
parametric excitations.

VSL Friction Damper with

anti-vandalism component

Cables with
VSL Friction Damper

* Dr. Ing. Imre Kovacs / Dynamic Consulting

V S L

S S I

2 0 0 0

14

S T AY C A B L E S Y S T E M

Key benefits of
the Gensui Damper
High-damping rubber:
The Gensui damper is composed of several
rubber pads and the cables vibration energy is
absorbed by shear deformation of the pads. Each
pad is made of a high-damping rubber
manufactured by Sumitomo Rubber Industries.
Great simplicity:
The damper is modular, with the number of pads
used depending on the cable characteristics.
A main feature of this damper is its simplicity.
It can be easily installed and configured on
existing bridges.
Great durability with minimal maintenance:
The high-damping rubber pads provide for a
long design life. Accelerated ageing tests have
shown a life expectancy of 60 years. The damper
requires only minimal maintenance during its
lifetime. This allows dampers to be installed, if
necessary, at the pylon, where maintenance
access is difficult and expensive.

North Arm Bridge, Canada (2008)

cables (by organisations including Shanghai

Tongji University, Hong Kongs Highways
Authorities and the Korean Highways
Corporation). Friction dampers have been
installed on a number of cable-stayed bridges,
and to date no cable vibration has been observed
and no damper has needed to be replaced.

Performance:
The performance of the damper depends on the
damping capacity of the rubber pad and can be
adjusted by varying the number of pads. The
dampers performance is ideal for short and
medium cable lengths. Performance can be
increased by moving the damper away from the
deck anchorages and/or installing a second
damper at the pylon. The performance does not
depend on the cables mode of vibration and it is
not sensitive to variations in temperature.
An aesthetic solution:
The Gensui Damper is installed around the cable
and has compact dimensions, which ensures
that it integrates well. The damper can be easily
used as external damper, installed on an
additional support.

More than 40 cable-stayed bridges were

equipped with the Gensui Damper in 2007.
In 2008, 20 Gensui Dampers have been
installed on the cables of the North Arm Bridge
in Vancouver.

Installation of Gensui Damper

3. Installation of stabilising cables:

This solution can be used where the other two
approaches would not be efficient. The
installation of stabilising cables onto the stay
cables is not an easy operation.
VSL has an impressive portfolio of reference
projects. The VSL friction damper has been
subjected to several comparative tests on stay

Gensui Damper
on PWS cable

V S L

Gensui Damper protected

with neoprene boot

S S I

2 0 0 0

15

S T AY C A B L E S Y S T E M

STRAND BY STRAND METHOD FOR INSTA

OR REPLACEMENT OF CABLES
The strand by strand method developed by
VSL is well adapted for efficient use on any
project, whatever the bridges environmental
conditions are.

VSLs first experiences of cable installation were

with fully-prefabricated cables which required
transport and lifting of heavy components.
A 500m prefabricated cable on its reel can
weigh up to 80t.
The strand by strand erection of cables requires
only light equipment. It can be slightly more
time consuming, but gives advantages when
the plant required for installation is taken into
account.

Operating with the strand by strand

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

Replacement of a 298m cable

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

V S L

S S I

2 0 0 0

16

S T AY C A B L E S Y S T E M

TALLATION
Main advantages
of the VSL strand by strand
installation

ini
Am

720
870

PYLON

Dimensions (mm) of monostrand jack.

TENDON
UNIT

6-12
6-31
to 6-22 to 6-55

6-61
6-91
to 6-85 to 6-109

6-127

A mini

1000

1100

1200

1050

1150

The strands are tensioned one by one with a VSL monostrand

jack connected to a VSL Automatic Monostrand Stressing
system (AMS). The AMS processor controls and registers
the parameters of the stressing operation to achieve either
the required tension or the correct elongation of the strands.

k
Jac
ir
Cha

There is total flexibility to adjust the cable

length during installation. This length can be
adjusted to cater for variations in the bridge
geometry during construction.
The light equipment induces only small
construction loads. The maximum component
weight is about 4t.
On a composite deck, just one part of the cable
can be installed as a first step to give support to
part of the steel deck during its assembly.
The use of light equipment fitted to the pylon
allows the installation of the pylon anchorages
while the pylon is under construction.
The stressing anchorages can be installed in
confined spaces inside the pylons as the
installation equipment is small.
The maximum weight of the monostrand jack
tensioning equipment is 20kg. Heavier
multistrand jacks are used only in special cases.
Only light equipment is required for any future
re-tensioning of the stays.
The method is well-suited to pylons equipped
with the VSL Saddle.
The necessary equipment can be moved easily
on site, giving greater flexibility in the
installation schedule.

Jack clearance for the

cable stressing operations

ini
Am

Optimised solutions
with the VSL Saddle
The use of independent strands permits the
strand by strand installation of the cable. After
installation of the two HDPE stay pipes on each
side of the pylon, each strand of the cable is
raised inside the stay pipe from the deck to the
pylon. It is then threaded through one hole of
the saddle and pulled down inside the other
stay pipe for connection to the opposite deck
anchorage. Installation of the strands is
achieved through the use of three VSL winches.

PYLON

Dimensions (mm)
of multistrand jack and chair.
TENDON
UNIT

6-12
6-19

6-22

A mini

1000 1000 1100 1200 1300 1350 1500

490

620

6-31
6-37
6-43

620

6-55
6-61
6-73

780

6-85 6-109 6-127

6-91

780

970

970

VSL lifting winch

V S L

S S I

2 0 0 0

17

S T AY C A B L E S Y S T E M

A typical cycle of five to seven days can be achieved for deck segment
erection on cable-stayed bridges. VSL-trained staff and VSL tailor-made
equipment can execute the simultaneous installation of two cables on the
main span (or back span) in a single day with one shift on each cable.
Demanding challenges can be met thanks to close cooperation between the
partners, as on the Liz Bridge where 18 stays were installed in the record time
of just one week.

Puente de la Unidad Bridge, Mexico (2003)

In a 50/50 JV, VSL provided project
management, complete technical and
method support and part of the production
management. VSL Mexico also supplied
and installed the post-tensioning, and the
SSI 2000 Stay Cable System

Badajoz Bridge, Spain (1994)

Cables equipped with friction dampers

Ponte Europa Bridge, Portugal (2002)

186m main span length - 91 strand cables

V S L

S S I

2 0 0 0

18

S T AY C A B L E S Y S T E M

Batam Tonton Bridge, Indonesia (1997)

Package: design, supply and installation of stay cables, deck form-travellers and pylon
formwork. Construction engineering for the superstructure construction

Sungai Johor Bridge, Malaysia (2008)

85 strand cables with length up to 275m
Papendorpse Bridge, Netherlands (2002)
120 strand cables

V S L

S S I

2 0 0 0

19

S T AY C A B L E S Y S T E M

Centenario Bridge, Spain (1991)

552m bridge length, with 264m for the main span

Sucharskiego Bridge, Poland (2001)

Supply and installation of stay cables,
with VSL Friction Dampers

Second Vivekananda Bridge, India (2007)

Extradossed bridge with pylon saddles and grouted stay cables

V S L

S S I

2 0 0 0

20

S T AY C A B L E S Y S T E M

Wadi Abdoun Bridge, Jordan (2006)

Curved deck with inclined pylon
Yichong Yiling Bridge, China (2001)
Supply of stay cable system, erection equipment, stay cable
engineering, site management and site supervision

V S L

S S I

2 0 0 0

21

S T AY C A B L E S Y S T E M

Neva 1 Bridge, Russia (2002)

All cables equipped with VSL Friction Dampers

Houston Ship Channel Bridge, USA (1995)

Supply of stay cables and supervision at installation

Koshiki Daimyojin Bridge, Japan (1993)

Technical consultation and supply of the prefabricated stay cables

V S L

S S I

2 0 0 0

22

S T AY C A B L E S Y S T E M

Pakse Bridge, Laos (2000)

Production and erection of the precast segmental
deck, including: design, supply and operation of
casting cells and launching gantry; construction of
cast-in-situ pier tables; geometry control; supply and
installation of post-tensioning and stay cables

Merida Arch Bridge, Spain (1991)

Supply and installation of the stay cables

Sunshine Skyway Bridge, USA (1986)

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

Neva 2 Bridge, Russia (2007)

Supply and installation of stay cables with VSL Friction Dampers

V S L

S S I

2 0 0 0

23

S T AY C A B L E S Y S T E M

 Jose Cartellone Construct

Pastaza Bridge, Ecuador (2005)

Supply and installation of the stay cables

Zizkova Footbridge, Czech Republic (2007)

Installation of stays and post-tensioning

Rades-la-Goulette Bridge, Tunisia (2007)

Extensive equipment and services

Kien Hai Phong Bridge, Vietnam (2003)

Supply and installation of bearings and stay cables

Unimas-Sarawak Bridge, Malaysia (2007)

Supply and installation of cables

V S L

S S I

2 0 0 0

24

S T AY C A B L E S Y S T E M

Woonam Bridge, South Korea (2008)

VSL pylon saddles designed to allow cable replacement

Safti Bridge, Singapore (1995)

An inclined pylon is stabilised by back-stay cables

Peldar Bridge, Columbia (2002)

VSL Saddle and monitoring services

Liz Bridge, Portugal (2004)

18 stay cables installed in one week

V S L

S S I

2 0 0 0

25

S T AY C A B L E S Y S T E M

VSL SERVICES FOR BRIDGE CONSTRUC

Wind speed
measured in 3 directions
expressed in m/s

MONITORING

Temperature of cables, concrete

expressed in C

Relevant information is sent

straight back to the users desk.
The system works with any IT
and measurement solution.

Humidity
expressed in %
Rain intensity
expressed in mm

VSL

Sun intensity
expressed in W/m2

Remote server

Traffic
expressed in km/h, veh./h, t, type...
Air quality
expressed in CO, NOX, O3, SO2...

Cable force
expressed in kN

www

.vsl

ni
-mo

tor

ing

co

Structural vibration
acceleration expressed in g
vibration modes expressed in Hz

OPERATING COST

MAINTENANCE COST

MY
BRIDGE

The Consultant

Angular movement
two directions expressed in
Stress and deformation
expressed in m/m and in mm
Material ageing
expressed in Cl-, mV
Inspection and investigation
paper and multimedia reports
laboratory or in situ tests

The Owner

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

LAUNCHING GANTRIES

Taiwan High Speed Rail - Taiwan

HEAVY LIFTING

Shenzhen Western Corridor - Hong Kong

V S L

S S I

2 0 0 0

26

S T AY C A B L E S Y S T E M

Nanjing Bridge Heavy Lifting - China

CTION
FORM TRAVELLERS & LIFTING FRAMES

Angara Bridge - Russia

West Tsing Yi - Hong Kong

BEARINGS

Deep Bay Link - Hong Kong

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

Figueira Da Foz Bridge repair - Portugal

DUCTAL

Pot Bearing

Seonyu Footbridge - Korea

Preloaded seismic bearing

V S L

S S I

2 0 0 0

27

S T AY C A B L E S Y S T E M

VSL LOCATIONS

HEADQUARTERS
VSL International Ltd.
Scheibenstrasse 70 Bern
CH-3014 Switzerland
Phone: +41 58 456 30 30
Fax:
+41 58 456 30 35

www.vsl.com

Americas

Europe

ARGENTINA

AUSTRIA

SPAIN

BRUNEI

THAILAND

VSL Sistemas Especiales de

Construccin Argentina SA
BUENOS AIRES
Phone: +54 11 4326 06 09
Fax: +54 11 4326 26 50

Grund-Pfahl- und Sonderbau GmbH

HIMBERG
Phone: +43 2235 87 777
Fax: +43 2235 86 561

CTT Stronghold
BARCELONA
Phone: +34 93 289 23 30
Fax: +34 93 289 23 31

VSL Systems (B) Sdn. Bhd.

BRUNEI DARUSSALAM
Phone: +673 2 380 153 / 381 827
Fax: +673 2 381 954

VSL (Thailand) Co. Ltd.

BANGKOK
Phone: +66 2 679 76 15 - 19
Fax: +66 2 679 76 45

CZECH REPUBLIC

TURKEY

VSL Systems (CZ) Ltd.

PRAGUE
Phone: +420 2 51 09 16 80
Fax: +420 2 51 09 16 99

VSL-SPAM, S.A.
BARCELONA
Phone: +34 93 846 70 07
Fax: +34 93 846 51 97

CHINA PRC

BOLIVIA

VSL (China) Engineering Corp., Ltd.

HEFEI
Phone: +86 551 382 29 18
Fax: +86 551 382 28 78

Mega Yapi Construction & Trade Co. Ltd

ANKARA
Phone: +90 312 490 90 66
Fax: +90 312 490 90 55

HONG KONG

VIETNAM

VSL Hong Kong Ltd.

CHAI WAN
Phone : +852 2590 22 88
Fax : +852 2590 02 90

VSL Vietnam Ltd.

HANOI
Phone: +84 4 976 50 88
Fax: +84 4 976 50 89

VSL (Switzerland) Ltd.

SUBINGEN
Phone: +41 58 456 30 30
Fax: +41 58 456 30 35

Intrafor Hong Kong Ltd.

CHAI WAN
Phone : +852 2836 31 12
Fax : +852 2591 61 39

Ho Chi Minh City

Phone: +84 8 8106 817
Fax: +84 8 8106 818

VSL (Suisse) SA
SAINT LEGIER
Phone: +41 58 456 30 00
Fax: +41 58 456 30 95

FT Laboratories Ltd.
PING CHE
Phone: +852 2758 48 61
Fax: +852 2758 89 62

Australia

INDIA

VSL Australia Pty. Ltd.

Postensados de Bolivia
San Miguel, LA PAZ
Phone: +591 2 27 70 338
Fax: +591 2 27 96 183

CHILE
VSL Sistemas Especiales de
Construccin S.A.
SANTIAGO
Phone: +56 2 571 67 00
Fax: +56 2 233 67 39

COLOMBIA
Sistemas Especiales de Construccin Ltda.
BOGOTA
Phone: +57 1 620 96 34
Fax: +57 1 620 58 16

MEXICO
VSL Corporation Mexico S.A de C.V
MEXICO
Phone: +52 5 511 20 36
Fax: +52 5 511 40 03

UNITED STATES
VStructural LLC
BALTIMORE, MD
Phone: +1 410 850 7000
Fax: +1 410 850 4111

VENEZUELA
Gestin de Obras y Construcciones C.A.
CARACAS
Phone: +58 212 941 86 75
Fax: +58 212 941 86 75

Africa
EGYPT
Matrix Engineering Company
CAIRO
Phone: +20 2 344 19 00
Fax: +20 2 346 04 57

FRANCE
VSL France S.A.
LABGE
Phone: +33 05 61 00 96 59
Fax: +33 05 61 00 96 62

GERMANY
VSL Systems GmbH
BERLIN
Phone: +49 30 53 01 35 32
Fax: +49 30 53 01 35 34

GREAT BRITAIN
VSL Systems (UK) Ltd.
BEDFORDSHIRE
Phone: +41 58 456 30 30
Fax: +41 58 456 30 35

Asia

SWEDEN
Internordisk Spnnarmering AB
VSTERHANINGE
Phone: +46 8 5007 3820
Fax: +46 8 753 49 73

SWITZERLAND

NETHERLANDS
Heijmans Beton en Waterbouw B.V.
ROSMALEN
Phone: +31 73 543 66 02
Fax: +31 73 543 66 11

NORWAY
VSL Norge A/S
STAVANGER
Phone : +47 51 52 50 20
Fax : +47 51 56 27 21

Middle East
UNITED ARAB EMIRATES
VSL Middle East LLC
DUBAI, UAE
Phone: +971 4 333 6262
Fax: +971 4 333 0008

PORTUGAL
VSL Sistemas Portugal
Pre-Esforo, Equipamento
e Montagens S.A.
S. DOMINGOS DE RANA
Phone: +351 21 445 83 10
Fax: +351 21 444 63 77
VSL GEO
Sistemas de Aplicao em Geotecnia SA
S. DOMINGOS DE RANA
Phone: + 351 21 445 83 10
Fax: + 351 21 445 83 28

VSL India PVT Ltd.

CHENNAI
Phone: +91 44 4225 11 11
Fax: +91 44 4225 10 10

INDONESIA
PT VSL Indonesia
JAKARTA
Phone: +62 21 570 07 86
Fax: +62 21 573 12 17

JAPAN
VSL Japan Corporation
TOKYO
Phone: +81 3 3346 8913
Fax: +81 3 3345 9153

KOREA
VSL Korea Co. Ltd.
SEOUL
Phone: +82 2 553 8200
Fax: +82 2 553 8255

MALAYSIA
VSL Engineers (M) Sdn. Bhd.
KUALA LUMPUR
Phone: +603 7981 47 42
Fax: +603 7981 84 22

MOROCCO

PHILIPPINES

Renfor-Bat
TANGIER
Phone: +212 39 95 80 87
Fax: +212 39 95 80 85

VSL Philippines Inc.

PASIG CITY
Phone: +632 672 17 03
Fax: +632 672 13 95

SOUTH AFRICA
Tsala-RMS Construction Solutions (Pty) Ltd
Johannesburg
Phone: +27 11 878 6820
Fax: +27 11 878 6821

SINGAPORE
VSL Singapore Pte. Ltd.
SINGAPORE
Phone: +65 6559 12 22
Fax: +65 6257 77 51

TAIWAN
VSL Taiwan Ltd.
TAIPEI
Phone: +886 2 2759 6819
Fax: +886 2 2759 6821

Copyright 2008, VSL International Ltd.

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

NEW SOUTH WALES

Phone: +61 2 9 484 59 44
Fax: +61 2 9 875 38 94
QUEENSLAND
Phone: +61 7 3265 64 00
Fax: +61 7 3265 75 34
VICTORIA
Phone: +61 3 979 503 66
Fax: +61 3 979 505 47