NEW-PWS

TOKYO ROPE MFG. CO., Ltd.

W e developed the NEW-PWS, the bridge cable strands for cable stayed and arch bridges. NEW-PWS is
acquiring high market acceptance due to its high performance and its application as the hanger ropes of
suspension bridges has started.
The NEW-PWS possesses all the superb characteristics of PWS, plus it is easier to handle and offers
economical application advantages. The NEW-PWS is made up of steel wire 7 mm in diameter having a zinc
coating of 300 g/m2 or more. It is assembled by twisting at a pitch that does not impair the optimum tensile
strength and modulus of elasticity of the steel wires. The strand is covered with filament tape on which
additional coating of high-density black polyethylene is provided. To meet the need for high fatigue resistance
at both ends of the strand, NS sockets of zinc-copper alloys and epoxy resins are provided. These eliminate
further corrosion protection work to the cables at the job site. We have also developed colored cables so that
the bridge can well blend in with the surroundings and indented cables taken account of countermeasure for
rain vibration on the cables of cable stayed bridges.

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Property of NEW-PWS

N EW-PWS consists of parallel galvanized wires 7mm in diameter assembled while being twisted at a
pitch designed to maintain optimum tensile strength and modulus of elasticity
The cable receives anti-corrosion coating, and then is provided with NS socket of high fatigue strength at both
ends.

Property of Galvanized Wire

Requirements Standard ;φ7 ㎜ High Strength;φ7 ㎜
JIS G 3502*1
Material Quality S87BM or S87AM*2
SWRS 82B
Wire diameter 7.00±0.08 ㎜
Size

Diameter deviation 0.08 ㎜ or less

Tensile strength 160kgf／㎟ or more 180kgf／㎟ or more
Mechanical Properties

118kgf／㎟ or more 140kgf／㎟ or more

Proof stress at 0.7% extension at 0.8% extension
under load*3 under load*3
Elongation 4.0 percent or more Relationship between twist angle and tensile strength
Number of twists 12 times or more
Ductility (Coils) 3d×8 times
Amount applied 300ｇ／㎡ or more
coating
Zinc

Wire diameter increase 0.14 ㎜ or less

Coating adhesion 5d×2 times
Straight

Free coil diameter 4.0ｍor more

-ness

Free ring lift 15 ㎝ or less

Note *1: Japan Industrial Standard
Note *2: Nippon Steel’s Specification

Relationship between twist angle and modulus of elasticity

Note*3: Relationship between strain and stress

σ0.2 stress at 0.2% offset

σ0.7 stress at 0.7% extension

stressσ(N/mm2)

NEW-PWS wound on a reel

0.2 0.7
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Specifications of Cable

PE: Polyethylene
Diameter mm Sectional Minimum Breaking Load
Nominal High Nominal
Strength Strength Unit
Cable size After Area
Strand Class Class Weight
PE Coating 1,570 N/mm2 1,770 N/mm2
mm2 kN kN kg/m
Φ7 x 19 35 45 731 1,150 1,290 6.3
Φ7 x 31 44 54 1,193 1,870 2,110 10.1
Φ7 x 37 49 59 1,424 2,240 2,520 11.9
Φ7 x 55 58 68 2,117 3,320 3,750 19.1
Φ7 x 61 63 73 2,348 3,690 4,160 21.5
Φ7 x 73 68 78 2,809 4,410 4,970 23.1
Φ7 x 85 71 81 3,271 5,140 5,790 26.7
Φ7 x 91 77 87 3,502 5,500 6,200 28.6
Φ7 x 109 81 95 4,195 6,590 7,420 34.7
Φ7 x 121 85 99 4,657 7,310 8,240 38.4
Φ7 x 127 91 105 4,888 7,670 8,650 40.3
Φ7 x 139 92 106 5,349 8,400 9,470 43.9
Φ7 x 151 94 108 5,811 9,120 10,290 47.6
Φ7 x 163 99 113 6,273 9,850 11,100 51.3
Φ7 x 187 105 119 7,197 11,300 12,740 58.7
Φ7 x 199 108 122 7,658 12,020 13,560 62.3
Φ7 x 211 113 133 8,120 12,750 14,370 67.2
Φ7 x 223 116 136 8,582 13,470 15,190 70.9
Φ7 x 241 119 139 9,275 14,560 16,420 76.4
Φ7 x 253 122 142 9,737 15,290 17,230 80.1
Φ7 x 265 127 147 10,198 16,010 18,050 83.9
Φ7 x 283 129 149 10,891 17,100 19,280 89.4
Φ7 x 295 131 151 11,353 17,820 20,090 93.1
Φ7 x 301 133 153 11,584 18,190 20,500 94.9
Φ7 x 313 135 155 12,046 18,910 21,320 98.6
Φ7 x 337 141 161 12,969 20,360 22,960 106.0
Φ7 x 349 142 162 13,431 21,090 23,770 109.7
Φ7 x 361 145 165 13,893 21,810 24,590 113.4
Φ7 x 367 147 167 14,124 22,170 25,000 115.2
Φ7 x 379 149 169 14,586 22,900 25,820 118.9
Φ7 x 397 153 173 15,278 23,990 27,040 124.5
Φ7 x 421 155 175 16,202 25,440 28,680 131.7
Φ7 x 451 163 183 17,357 27,250 30,720 141.0
Φ7 x 499 169 193 19,204 30,150 33,990 156.8
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NS Socket with High Fatigue Strength
R ecent years, demand for cable with high fatigue strength socket
for large cable-stayed bridges or other structures supported by
cables was increased．
We have addressed this need through commercialization of a new
attachment structure “NS socket”, using a zinc-copper alloy and epoxy
resin. Fixing mechanism of the NS socket consist of adhesion between
wire and zinc-copper alloy and wedge effect of an integrated cone
composed of wires and zinc-alloy.

Features
1. Superb Fatigue Characteristics
NS socket is composed of an epoxy resin filler, a zinc-copper
alloy filler and a main steel body. The NS socket eliminates the
causes of fatigue failure mentioned below and has excellent high
fatigue strength with stress amplitude of 245(25kgf/mm2) to
294MPa(30kgf/mm2) at 2 million cycles．(Refer to the figure of
Results of Fatigue Test at bottom)
And also it has been verified that the NS socket has a bending
fatigue strength of ±0.6 degrees bending angle at 2 million
cycles.

● Prevent Fretting Corrosion Related Fatigue Strength Loss

The epoxy resin with high filling characteristics is put in the front NEW-PWS 139(7φ) Tensile Fatigue Test
side of socket where voids among wires are very small in order to
resist the Fretting Corrosion damage. (“Fretting Corrosion” refers to
corrosion damage at the asperities of contact surfaces. This damage
is induced under load and in the presence of repeated relative surface
motion, as induced for example by vibration.)

● Reduce Stress Concentration in the front area of socket

The wire curvature radius is controlled numerically without plasticity
damage in order to reduce local stress concentration and also lateral
pressure to the wires at the front area of socket．

● Avoid Heat-Affect on the wire in the front area of socket

In order to avoid heat affect on the wires in the front side of socket,
the epoxy resin which can fill up at normal temperature is applied in
the front side of socket.

NEW-PWS 139(7φ) Bending Fatigue Test

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2 . Outstanding Safety
Anchoring of cable by molten zinc is used widely and conventional zinc-copper alloy for fastening
wires ensures excellent performance and safety. In addition, the zinc-copper alloy is an excellent filler
material which creep characteristics is improved comparing with the zinc filler.

Structure

① Position of radially-disposed wires and curvature radius of wires are controlled numerously in order to
prevent localized bending stress of the wire.
② Epoxy resin are filled in order to prevent the fretting corrosion at the front side of socket．
③ The wires are fastened with the zinc-copper alloy filler.
Zinc-Copper alloy：Zinc（Zn）98％ Copper（Cu）2％（HBS*-G3503-1979）
* HBS: Honshu-Shikoku Bridge Standard
④ Connection part between socket and cable with polyethylene is composed of caulking material and
heat-shrinkage polyethylene in order to keep out water.

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 Various type of socket

Standard type Other type (Option)

・Front

・Rod

・Middle

・Pin

・Nut

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 Front Bearing Socket

Front Bearing Socket

固定側

調整側

Front Bearing Socket Unit : mm, kg

Cable Nozzle Anchor Screw Total Weight
Size Do Lo D Lf Lm Ds Ls p Dead Live
19 75 100 130 340 345 105 35 6 32.5 32.7
31 84 120 150 340 350 125 40 6 42.5 43.0
37 89 120 155 340 355 135 45 6 44.7 45.3
55 98 120 180 340 360 160 50 6 59.1 60.1
61 103 120 185 340 365 165 55 6 62.1 63.4
73 108 120 200 350 380 180 60 6 74.4 76.0
85 111 140 210 380 415 190 65 6 88.8 90.8
91 117 140 220 385 420 200 65 6 98.8 100.9
109 127 140 240 415 455 215 70 6 126.7 129.8
121 131 140 250 435 480 225 75 6 143.6 147.2
127 137 140 255 440 485 230 75 6 150.8 154.5
139 138 140 270 465 515 240 80 6 179.6 184.8
151 140 140 280 490 540 250 80 6 203.3 208.7
163 145 160 290 505 560 260 85 6 225.2 231.4
187 151 160 310 545 605 275 90 6 277.9 286.1
199 154 160 315 560 625 280 95 8 293.8 303.1
211 167 160 330 560 625 295 95 8 322.7 332.4
223 170 160 340 580 650 305 100 8 354.9 365.7
241 173 160 350 605 675 315 100 8 391.4 402.5
253 176 160 355 620 695 320 105 8 411.6 423.7
265 181 160 360 630 705 325 105 8 428.9 441.2
283 183 180 375 655 735 335 110 8 486.9 502.2
295 185 180 380 670 750 340 110 8 510.4 525.9
301 187 180 390 675 760 350 115 12 544.1 561.8
313 189 180 395 690 775 355 115 12 569.5 587.5
337 195 180 410 715 805 370 120 12 635.8 655.5
349 196 180 420 730 825 375 125 12 683.2 706.8
361 199 180 425 740 835 380 125 12 708.1 732.0
367 201 180 425 745 840 380 125 12 711.3 735.2
379 203 180 435 760 860 390 130 12 761.7 787.5
397 207 180 440 775 875 395 130 12 792.2 818.3
421 209 200 450 805 910 405 135 12 860.8 888.8
451 217 200 470 830 940 420 140 12 970.9 1004.5
499 229 200 490 865 980 440 145 12 1096.6 1133.2
Wire Dia: φ7mm, Wire strength: 1770N/mm2, Design stress: 0.45Pu
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Middle (Back) Bearing Socket

Middle (Back) Bearing Socket

固定側

調整側

Middle(Back) Bearing Socket Unit : mm, kg

Cable Nozzle Anchor Screw Total Weight
Size Do Lo D L Da Lf Lm Ds Ls p Dead Live
19 75 100 110 120 155 220 225 105 35 6 38.9 39.3
31 84 120 125 120 175 220 230 125 40 6 48.7 49.7
37 89 120 130 120 180 220 235 135 45 6 51.1 52.5
55 98 120 150 120 205 220 240 160 50 6 65.2 67.4
61 103 120 160 120 215 220 245 165 55 6 72.4 75.5
73 108 120 165 120 225 230 260 180 60 6 80.4 84.0
85 111 140 175 135 240 245 280 190 65 6 98.5 103.4
91 117 140 185 135 250 250 285 200 65 6 109.2 114.3
109 127 140 200 150 270 265 305 215 70 6 136.0 142.9
121 131 140 210 155 280 280 325 225 75 6 154.0 162.1
127 137 140 220 160 290 280 325 230 75 6 168.0 177.1
139 138 140 225 170 300 295 345 240 80 6 188.0 198.4
151 140 140 230 180 305 310 360 250 80 6 203.5 213.3
163 145 160 240 185 320 320 375 260 85 6 231.8 244.1
187 151 160 250 200 335 345 405 275 90 6 271.4 285.5
199 154 160 260 205 345 355 420 280 95 8 297.9 315.1
211 167 160 280 205 365 355 420 295 95 8 338.3 357.7
223 170 160 285 215 370 365 435 305 100 8 358.1 378.0
241 173 160 290 225 380 380 450 315 100 8 390.2 410.8
253 176 160 300 230 390 390 465 320 105 8 424.1 448.3
265 181 160 305 235 400 395 470 325 105 8 451.1 477.4
283 183 180 310 245 405 410 490 335 110 8 479.7 506.6
295 185 180 315 250 410 420 500 340 110 8 503.0 530.2
301 187 180 320 250 420 425 510 350 115 12 532.0 562.5
313 189 180 325 260 425 430 515 355 115 12 554.8 585.7
337 195 180 335 270 435 445 535 370 120 12 601.5 633.0
349 196 180 340 275 445 455 550 375 125 12 641.6 677.8
361 199 180 345 280 450 460 555 380 125 12 664.6 701.3
367 201 180 350 280 455 465 560 380 125 12 687.7 727.0
379 203 180 350 285 460 475 575 390 130 12 710.8 750.3
397 207 180 360 290 470 485 585 395 130 12 760.4 803.3
421 209 200 365 305 480 500 605 405 135 12 817.5 863.6
451 217 200 380 315 495 515 625 420 140 12 899.8 949.7
499 229 200 400 330 520 535 650 440 145 12 1034.6 1092.8
Wire Dia: φ7mm, Wire strength: 1770N/mm2, Design stress: 0.45Pu

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 Nut Bearing Socket

Nut Bearing Socket

固定側

調整側

Nut Bearing Socket Unit : mm, kg

Cable Nozzle Anchor Nut Screw Total Weight
Size Do Lo Dt D Lf Lm Lt P Dn Ln Ds Ls p Dead Live
19 75 100 140 130 340 345 250 8 230 80 105 35 6 52.0 52.2
31 84 120 160 150 340 350 250 8 250 80 125 40 6 64.3 64.7
37 89 120 165 155 340 355 250 8 255 80 135 45 6 67.0 67.7
55 98 120 190 180 340 360 250 8 280 80 160 50 6 84.2 85.2
61 103 120 195 185 340 365 250 8 285 80 165 55 6 87.8 89.0
73 108 120 210 200 350 380 260 8 300 100 180 60 6 107.7 109.3
85 111 140 220 210 380 415 290 8 310 100 190 65 6 124.1 126.0
91 117 140 230 220 385 420 295 8 320 100 200 65 6 135.5 137.6
109 127 140 250 240 415 455 325 8 340 120 215 70 6 173.5 176.6
121 131 140 260 250 435 480 345 8 350 120 225 75 6 192.4 196.1
127 137 140 265 255 440 485 350 8 355 150 230 75 6 211.2 215.0
139 138 140 280 270 465 515 375 8 370 150 240 80 6 243.6 248.7
151 140 140 290 280 490 540 400 8 380 150 250 80 6 269.8 275.1
163 145 160 300 290 505 560 415 8 390 150 260 85 6 294.1 300.2
187 151 160 320 310 545 605 455 8 415 150 275 90 6 355.6 363.8
199 154 160 330 315 560 625 420 12 430 150 280 95 8 382.9 392.2
211 167 160 345 330 560 625 420 12 445 180 295 95 8 430.9 440.6
223 170 160 355 340 580 650 440 12 460 180 305 100 8 471.8 482.6
241 173 160 365 350 605 675 465 12 470 180 315 100 8 512.2 523.3
253 176 160 370 355 620 695 480 12 480 180 320 105 8 539.8 551.9
265 181 160 375 360 630 705 490 12 485 180 325 105 8 559.1 571.4
283 183 180 390 375 655 735 515 12 505 180 335 110 8 628.4 643.7
295 185 180 395 380 670 750 530 12 510 200 340 110 8 667.6 683.1
301 187 180 405 390 675 760 535 12 520 200 350 115 12 705.1 722.8
313 189 180 410 395 690 775 550 12 530 200 355 115 12 739.4 757.3
337 195 180 425 410 715 805 575 12 545 200 370 120 12 812.5 832.2
349 196 180 435 420 730 825 590 12 560 200 375 125 12 871.3 894.8
361 199 180 440 425 740 835 600 12 565 200 380 125 12 898.6 922.5
367 201 180 440 425 745 840 605 12 565 220 380 125 12 918.2 942.0
379 203 180 450 435 760 860 620 12 580 220 390 130 12 981.4 1007.1
397 207 180 455 440 775 875 635 12 585 220 395 130 12 1014.8 1040.9
421 209 200 465 450 805 910 665 12 600 220 405 135 12 1097.3 1125.4
451 217 200 485 470 830 940 690 12 625 240 420 140 12 1246.2 1279.8
499 229 200 505 490 865 980 725 12 650 240 440 145 12 1393.6 1430.3

Wire Dia: φ7mm, Wire strength: 1770N/mm2, Design stress: 0.45Pu

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Corrosion Proofing of NEW-PWS

N EW-PWS undergoes corrosion-Proofing at the

factory, eliminating the need for job-site
corrosion-Proofing work．
The corrosion-proofing sheath consists of a high-density
extruded polyethylene sheathing. Polyethylene is
resistant to acids，alkalis and other chemicals，and a
carbon content of about 2 ％ ensures greater
weatherability．

Physical Properties Polyethylene

Item Unit Physical properties

Density g/cm3 0.942 or more

Melt flow rate g/10 min 0.4 or less

Tensile strength Kgf/cm2 200 or more

Elongation % 300 or more

Durometer hardness HDD 60 or more

Vicat softening temperature ℃ 115 or more

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Color Cable

N EW-PWS has polyethylene sheath to protect against corrosion, and the surface color is black with
carbon black.
Hence we developed colored cables covered with fluorine resins so that the bridge could well blend in with the
surroundings twenty years ago.
Nowadays, We acquires a new coloring method using colored polyethylene, which offers both long-term
corrosion resistance and reasonable cost.

Item Color polyethylene (new type)

Color polyethylene Carbon black polyethylene

Cross section

Covered and colored by color polyethylene instead of

Outline
black polyethylene.
Thickness Above 5mm (φ7×19～φ7×91)
Above 7mm (φ7×109～φ7×199)
of colored layer Above 10mm（φ7×211～φ7×499）
Material High density polyethylene
Corrosion resistance Results of accelerated test are
60% or more after 10000 hours.
(elasticity index)
Results of accelerated test are constant after 10000 hours
Discoloration
with our recommending color.
Mechanical properties Equivalence to black polyethylene
・Non-recommendation colors (vivid-color) have a
Features possibility of discoloration.
・Color indented cable is available.

Appearance

※The passage of 10000 hours under the accelerated test, in general, are accounted the
passage of 50 years under the environment.

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Counter measure for rain wind induced vibration
Indented cable for rain wind induced vibration

We already developed a indented cable for suppressing rain wind induced vibration of cable.
Effect of the indentation is to prevent occurrence of rivulet generated by rain falling on the surface of the stay
cables, which causes rain-wind induced vibration. Drag co-efficient is such that less than 0.8 under textured
condition. Wind tunnel testing, which has been carried out in the Tatara Bridge Project, demonstrated that the
drag co-efficient was less than 0.7. This is the basis that the value of 0.7 was applied to the design criteria for
wind attacking of the Tatara Bridge.

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Indent pattern

C onfiguration of the indent on the surface of the HDPE of the stay cables is well arranged according to
study of wind tunnel testing, which is given in the figure. Sufficient experimental study on the
configuration of indent has been carried out and it is concluded so far that oval depression with optimum
proportion and its depth 1mm to 2mm is effective.

Configuration of indent

The drag coefficient of indented stay cable is approximately 0.65, at the maximum wind speed at the test was
55m/s, which was corresponded to Reynolds number of 5.5×105. Large vibration generated by the wind-rain
induced vibration was not found.

◯ smooth surface
▲ uniform roughness
● indent

Drag factor against Re.No.

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Cable Erection
Erection Flow

Transportation of cable

Setting the cable reel on Unreeler

Unreeling of cable

Drawing & fixing of dead anchor

Drawing & fixing of live anchor

Tensioning under designed force

Measuring of cable tension

Correction of cable tension

Completion of cable erection

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Yokohama Bay Bridge (Japan)
Span 200+460+200

Tsurumi Tsubasa Bridge (Japan)

Span 255+510+255

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2nd Jindo Bridge (Korea)
Span 70+345+70

Mubarak Peace Bridge (Egypt)

Span 163+404+163

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Notice:
While every effort has been made to ensure the accuracy of the information contained within this publication,
the use of the information is at the reader’s risk and no warranty is implied or expressed by us with respect to
the use of information contained herein.
The information in this publication is subject to change or modification without notice. Please contact us for
the latest information.

Inquiries:

TOKYO ROPE MFG. CO., LTD.

NIHONBASHI FRONT BLDG.
6-2 NIHONBASHI 3-CHOME CHUO-KU TOKYO 103-8306 JAPAN

Structural Cable Department, Engineering Division

PHONE: +81-3-6366-7733 FAX:+81-3-6366-6870
http://www.tokyorope.co.jp/

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