Stay cable ducts

High levels of UV resistance Low drag Great aerodynamic stability Wide range of colours

Proven durability
Technical data sheet reference no.: FT En C I 1 7

Introduction
Freyssinet has designed a special duct for housing stay cables, performing the following functions: Protecting strands from ultraviolet radiation (UV), Ensuring impermeability to runoff water, Providing aerodynamic stability for the stay cable. The sheath is made from high density polyethylene (HDPE). The Freyssinet duct is provided with a helical fillet and offers two vital additional advantages: Excellent durability, Prevention of aerodynamic instability under the combined effect of rain and wind.
Freyssinet stay cable sheath

Dimensions
The table below gives the dimensions of sheaths for standard, compact and super compact stay cables:
Standard stay cable Anchor unit 12 19 27 31 37 48 55 61 75 Max. no. of strands 12 13 19 21 27 31 37 42 48 55 61 69 73 75 91 109 127 169 85 91 102 109 121 127 151 169 355 11.2 320 10.1 315 10 280 8.9 315 10 260 8.2 280 8.9 240 7.6 250 7.9 225 7.1 200 200 225 6.4 6.4 7.1 180 190 200 6 6 6.4 160 160 180 6 6 6 140 150 160 6 6 6 140 6 125 6 Outer diameter (mm) 125 Total thickness (mm) 6 Compact stay cable Outer diameter (mm) 110 Total thickness (mm) 6 Super compact stay cable* Outer diameter (mm) 100 105 120 125 130 140 150 160 170 180 190 200 205 210 225 230 245 250 265 270 290 310 Total thickness (mm) 6 6 6 6 6 6 6 6 6 6 6 6.4 6.5 6.7 7.1 7.3 7.8 7.9 8.4 8.5 9.2 9.8

Description
To guarantee satisfactory mechanical properties and a high level of resistance to physical and chemical attacks, the Freyssinet stay cable duct is coextruded in two connected layers: The 1.5 mm outer layer is coloured with mineral colorants and treated against ultraviolet radiation and chemical and salt attacks using state-of-the-art stabilising additives; The inner layer is made from black HDPE; with a minimum thickness of 4.5 mm, it provides the mechanical strength of the sheath. In order to ensure the aerodynamic stability of the stay cable, a double helical rib the same colour as the duct is incorporated during production. A range of compact and super compact stay cables with smaller diameters is available to reduce stay cable drag. Serebriany Bor, Russia

* Super compact stay cables require the use of compact strands.

The Standard Dimension Ratio (SDR) D/e<32 is optimised for ungrouted stay cables.

Colours
Ducts are available as standard in the following colours, the stability over time of which has been tested (colour chart not contractually binding):
White RAL 9003 Pale grey RAL 7035 Red RAL 3020 Pastel blue RAL 5024 Green RAL 6021 Mediterranean blue RAL 5018 Metallic grey (brushed stainless steel effect)

FT En C I 1 7-v7 - 09/11

Yellow RAL 1016

Stay cable ducts

Durability
HDPE is a material that can withstand most chemical and physical attacks. The main ageing mechanisms of HDPE are photo-oxidation of the polymer chains and environmental stress cracking (ESC). In order to prevent photo-oxidation, the Freyssinet sheath was formulated with anti-oxidant additives. It was then successfully tested in a SEPAP 12-24 chamber for over 8,000 hours, corresponding to a service life of around 100 years in temperate regions. To prevent ESC, the Freyssinet sheath has a telescopic section that enables the main sheath to slide without load, which prevents the development of thermal stress cycles. Nga Tu So, Vietnam

Aerodynamic stability
One of the main causes of stay cable vibration is excitation in light rain combined with a moderate wind. Two streams of water then run down the sheath, one stable on the lower fibre and the other unstable on the upper fibre, changing the aerodynamic profile of the sheath. The double helical ribs on the Freyssinet stay cable sheath divert the streams of water and prevent excitation while providing a low drag coefficient (thus reducing the transverse loads on the structure). The shape of the ribs and the pitch of the helix that they form around the sheath result from a long-term research programme undertaken with the Centre Scientifique et Technique du Btiment (CSTB) for the Pont de Normandie bridge. The curve below, produced during wind tunnel tests, shows the efficiency of the helical rib:

Dynamic efficiency of sheath

Vibration amplitude Without rib

With rib 7 m/s Wind speed 15 m/s

The drag coefficient of the Freyssinet sheath was tested in a wind tunnel, revealing a coefficient of less than 0.6 in wind speeds of up to 50m.s-1. The use of compact and super compact stay cables instead of standard ones decreases the wind resistance of the stay cables by 15 to 20% respectively, whilst reducing the drag and Reynolds number accordingly.

References and Figures Installation

The tubes are delivered to site in 12 metre lengths. They are protected by plastic film so that they don't get dirty during installation. The tubes are mirror welded in accordance with the applicable standards. Particular care is taken to align the helical ribs at the ends of two sections of sheath before they are welded together. Total installed length: 270,000 m Number of colours available: 19 Diameters available (min./max.): 90 mm/400 mm
Bai Chay, Vietnam M0, Hungary

Rion Antirion, Greece

All rights reserved by FREYSSINET. Product names are trademarks of FREYSSINET. The information in this document is subject to change. Whilst it is as accurate as possible, it is not in any way binding on FREYSSINET.

Freyssinet 1 bis, rue du Petit Clamart - Bt C - 78140 Vlizy-Villacoublay - France Ph.:+33 1 46 01 84 84 - Fax:+33 1 46 01 85 85 www.freyssinet.com

FT En C I 1 7-v7 - 09/11