Innovative erection methods for long span roofs: two outstanding examples

Brice LE TREUT
Civil Engineer
Freyssinet Int. & Cie
Vlizy, France

Damien DELBOS
Civil Engineer
Freyssinet Int. & Cie
Vlizy, France

Boris COUSIN
Civil Engineer
Freyssinet Int. & Cie
Vlizy, France

brice.letreut@freyssinet.com

damien.delbos@freyssinet.com

boris.cousin@freyssinet.com

Brice Le Treut, born in 1977,

received his civil engineering
degree from the Ecole Spciale
des Travaux Publics (France)
He joined Freyssinet in 2001.

Damien Delbos, born in 1983,

received his civil engineering
degree from the Ecole
Polytechnique (France) and a
Master of Engineering from
Cornell University (USA).
He joined Freyssinet in 2008.

Boris Cousin, born in 1983,

received his civil engineering
degree from the Ecole
Polytechnique (France) and a
Master of Engineering from the
ENPC- ParisTech (France).
He joined Freyssinet in 2006.

Summary
The lens-shaped roof of the S.P. Mukherjee Swimming Pool Complex in New Delhi (India) and the
record breaking BC Place in Vancouver (Canada) with its massive 2000 ton cable structure are two
outstanding examples of long span roofs supported by cable structures. Most of the characteristics
of the two projects are somewhat contrasting: the span (respectively 130 m and 260 m), the cable
technology (respectively Cohestrand and full locked cables), the structural principle (respectively
the lens and the bicycle wheel) and the construction methods. However they do have one feature in
common: the adoption of an innovative erection method well suited to the constraints of the project
(schedule, occupation of the site and available means of erection). All these aspects are presented in
the article.
Keywords: Long span roofs, tensile structures, full locked cables, strands, erection methods.

1.

Introduction

The major feature of the renovation of the S.P. Mukherjee (SPM) Swimming Pool Complex in New
Delhi (India) for the 2010 Commonwealth Games is the lens shaped cable roof covering the pools
and stands. Similarly, the reconfiguration of the BC Place Stadium in Vancouver (Canada) included
the deflation of the existing air supported dome and its replacement with a cable structure including
a retractable roof, implemented shortly after the 2010 winter Olympics ended.
Both projects are good examples of the thriving market for long span stadium roofs, driven by the
growing importance of entertainment and the transformation of stadiums into city landmarks. More
than any other, a cable structure offers the architectural flexibility and the capacity (lightness and
strength) for these signature roofs.
The two stadia studied in this article make use of the pretensioned cable beam principle to support
the roof cladding or membrane. The cable beam consists of two cables with reverse curvatures
linked by hangers or struts. The reciprocal actions of the cables on one another gives stiffness to the
structure, while ensuring that they remain under tension under any load combination.

Fig. 1: 3d rendering of the S.P. Mukherjee

Swimming Pool Complex

Fig. 2: Photo of the BC Place stadium after

completion of the primary roof structure

2.

Usual erection methods

Prestressed cable roof structures allow the covering of wide areas, without the need for intermediate
supports, in a lightweight and elegant way. They are based on the principle of the spoked wheel:
radial cables (the spokes) connect a compression beam (the rim) to a central node (the hub). The rim
is usually a perimeter beam resting above the stands; the central hub can be substituted by a tension
ring where the roof is required to cover the seating area only, or even eliminated as is the case in the
SPM stadium.
In order to ensure vertical stability, the rim or the hub is split in 2 elements, one above the other.
Alternatively, the compression ring can be undulated. As the roof structure is self-anchored, the
support reactions are minimized. Only the self-weight of the roof and the external loads (wind and
snow) are transmitted to the stadium, hence offering savings in associated costs.
The above characteristic of spoked wheel cable roofs leads to a restriction in the design of, and
the erection methods for, these structures.
In order to have an efficient design of the whole structure, the forces transmitted by the radial cables
supporting the roof to the compression ring(s) should not induce significant bending moments in
these rings, under live loads but also during construction stages. Therefore the most commonly
adopted method of erection for the cable roof is the so-called Big-Lift.
Tension ring and radial cables are first rolled out at ground level, on the field and stands, and
connected together with cast steel clamps and deviators. Cables are cut to length and intermediate
clamp positions are marked at the factory with very tight tolerances in order to guarantee the correct
pre-assembly of the net with no tension at the construction site.
Strand jacks are mounted onto the compression ring(s) and connected to the end of the radial cables
with temporary strands.
The Big-Lift consists of simultaneously activating the jacks to pull the radial cables and lift the
pre-assembled cable network. It can be made up of several steps as the operation might stop for
installation of the flying mast between the upper and lower planes of radial cables.
Geometry and forces are carefully controlled with a computerized system in order to respect the
allowable stresses during the operation.
This method can result in a rapid erection of the cable roof structure but requires a tremendous
amount of strand jacks, the access to a large area on the field of play for significant periods, and the
erection of the entire compression ring before the big lift operation.
Some challenging projects do not meet these conditions. It is the case for the S.P. Mukherjee
Swimming Pool Complex and BC Place Stadium where innovative methods had to be implemented.

3.

Construction of the S.P. Mukherjee Swimming Pool Complex in New Delhi

3.1
Presentation of the structure
In plane, the roof of the SPM stadium is confined by an oval concrete compression beam with
major diameter 130m. Its steel cladding is supported by a lens shaped cable structure made up of a
lower supporting cable net and an upper stabilizing cable net, each being separated from the other
by groups of flying masts of varying heights.
Each net resembles an orthogonal grid, with 16 cables oriented along the smaller axis and 14 cables
oriented along the greater axis of the oval. The cross section of the cable structure along one of its
axes is a prestressed cable beam (as defined in the introduction). In this configuration, the cable
beam spanning from one side of the compression ring to the other, the hub (or central node) is
eliminated.
The system is self anchored - the cables tensioned across the ring beam inducing favourable
compression forces in the concrete (like in a radial structure). As indicated by their respective
names, the lower net supports all the weight of the structure, while the upper net brings the
prestressing that stiffens it.

Fig. 3: Cross section of SPM stadium

Fig. 4: Top view of SPM stadium

3.2
Components of the cable structure
When compared to other cable roof structures, the SPM stadium stands out due to the technology
used. It is based on the Cohestrand technology, developed and patented by Freyssinet.
The Cohestrand technology derives from parallel strand cable stay
technology. Each cable is made up of a bundle of Cohestrand strands
(13 strands in the lower nets, 25 strands in the upper net).
With these 7-wire strands being individually sheathed with HDPE,
their resistance to the chlorinated atmosphere of a swimming pool is
greatly increased compared to bare galvanized cables.
An epoxy resin bonds the HDPE coating to the wires in order to
transfer the longitudinal forces from the flying masts to the steel
strands. In addition, plastic inserts are placed inside the clamps
connecting the flying masts to the cables in order to avoid damaging
the HDPE sheath.
The strands are individually anchored in the anchorages located inside
the concrete beam.
Fig. 5: Roof structural elements: roof steel
structure, upper cable net, flying mast,
lower cable net

3.3

Erection methods

3.3.1 Introduction
It was clear from the beginning of the project that a big lift was not suited to the erection of such a
structure, with the connection of four cable nets (upper and lower, transverse and longitudinal) at
208 intersections. The erection method also had to be compatible with the construction planning of
the contractor, which required that the pools and roof be built simultaneously.
To cope with these difficulties, a two-step airborne erection method was developed for the project.
Both steps were used for the first time ever in the construction of a cable roof.
3.3.2 Step 1: installation of cables and clamps
All the cable equipment and material was installed on the concrete ring beam - an area 30m above
the ground that could easily be reserved for cable works. The teams could work independently
whilst ensuring that the strands were protected from the works happening simultaneously below.

A first strand was manually pulled across the stadium and adjusted early morning, when the thermal
state of the structure was as uniform as possible. The adjustment process was similar to that used on
suspension bridges. Its sag was calculated using bespoke software and measured in-situ by a
surveying team. The target sag was reached by adjusting the strand
length using a portable monostrand jack.
A winch and cradle system was then installed, pulling the strands
across the stadium by consecutive back and forth movements, until a
full bundle was installed. By adjusting the sag of each individual
strand relatively to the first one the teams equalized their free length.
The installation of all the strands (more than 1000) was completed
in one and a half months.
The lower and upper cable nets were then formed by installing and
interconnecting the clamps on the strand bundles. These operations
were spread all over the cable net. Access at any point of the net was
made possible by designing specific platforms, placed by the tower
cranes at the required working area. Once secured, a cherry picker
brought the workers to the platforms. The designed method, together
Fig. 6: Pulling of the strands with individual protection equipment (harnesses), ensured the safety
of the workers.
across the stadium
3.3.3 Step 2: installation of the flying masts
After completion of step 1, the cable nets resembled a simply suspended structure, all cables being
adjusted to their final length. The second step, the most impressive one, involved the introduction of
the cable masts in-between the two cable nets. Again this operation was performed without support
from the ground by using specifically designed temporary structures called separation towers.
The most efficient way of separating two cable nets is by reproducing the effect of an arrow on a
bow, simultaneously lowering the bottom net and lifting the upper one until the flying mast can be
inserted.
The final separation towers comprised a structural truss column equipped with a pair of strand jacks
able to provide the 85 tonne separation force. Working platforms and access ladders running all
along the structure were incorporated in the design to enable installation and removal of the
structure without auxiliary platforms, as well as the installation of the flying masts.
It is worth noting that, in order to accommodate the ever changing shape of the cable structure
during separation, the connections of the separation towers to the cable nets were articulated in both
longitudinal and transverse directions. This provision limited the bending stresses in the strands and
avoided unbalanced
separation forces between
the sides of a separation
tower.
The separation of the
cable nets was performed
with 4 separation towers
located symmetrically
around the cable structure.
During the first step, the
vertical distance between
cable nets was increased
from 1.5 to 11.5 meters in
3 hours. A total of 14
separation phases and 3
weeks were necessary to
perform the installation of
all the flying masts.
Fig. 7: Upper and lower cable nets after the first separation step

3.3.4 Planning
The cable structure was erected in three months, achieving the target set by the contractor.
Nonetheless, the greatest achievement of the teams was to design and implement an erection
method independent from the ground conditions.

4.

Innovative methods to build the BC Place stadium roof

4.1 A particular spoke wheel structure

This new roof replaced the aging inflated membrane that covered the existing stadium up to and
including the winter Olympics in 2010. The construction was therefore a refit and this imposed
significant constraints on both the design and construction methods.
The cross-section in figure 8 below reveals a structural arrangement similar to a suspension bridge.
Nevertheless a suspension bridge would require a back span to balance its pylons. The 50m-high
masts of the BC Place stadium are balanced by a back stay anchored at its base. The existing
concrete structure being relatively weak, the new structure was designed as self-anchored thanks to
a massive tension ring linking the mast bases together. The mast bases rest on sliding bearings,
isolating the concrete substructure from horizontal forces.
220m

Fig. 8: Cross section of the BC Place stadium

The compression ring (red square) offers the global stability and may be seen as the pivot point of
the mast. With the mast resting on a sliding bearing (blue square), the tension ring (green circle)
balances the effect of the cable net (orange parallelogram) on the mast. A total of 36 such radii
constitute the cable network. The central node gathers no less than 144 main structural cables in a
very compact geometry.
One of the main consequences of this design is that the steel structure supporting the cables is not
self-stable. The location of the facility, sited snugly within the city, precludes the use of temporary
supports from the outside of the stadium. Additionally, the available time for construction prevented
erecting the steel structure first and then preparing
the cable structure in the field of play, as a biglift would require. Facing all these constraints, it
was decided to use a radius by radius approach
to erect the roof.
Before describing this sequence in detail, the main
figures of the steel and cable structure are:
- Total weight of steel: around 20,000 tons
- Weight of cables: around 2,000 tons
- Masts height: around 50 m, (top of the masts
90 m above the podium)
- Tension ring: 10 cables, diameter 126 mm
- Mass of the heaviest steel parts to lift:
around 150 tons
Fig. 9: Photo of the network of cables during construction
- Mass of one cable net at erection: 30 tons

4.2 A daring sequence of works

Erecting this structure following a radius by radius sequence requires first of all the installation of
the central node on a temporary supporting tower and the fixing of the masts bases to the concrete
structure.
Then the sequence requires the identification of the weak elements of the structure. Blocking the
masts bases exposes the concrete substructure to horizontal reactions potentially higher than in
service conditions. As for the steel compression ring, partially loading it before its completion
induces non axial forces for which it has not been designed, exposing the steel beams and
connections to challenging load cases.
In order to cope with these constraints, the tensioning of the structure was to be achieved as
uniformly as possible, the structure being subjected to minimal loads before both compression and
tension rings are completed. The sequence adopted, which respects these constraints and allows a
fast enough construction, is described in the following paragraphs.
The central node was installed on a temporary tower, 11.5 m higher than its final position. Then the
first masts were erected, resting on a blocked bearing. They were stabilized by two lateral cables
anchored on the neighbouring mast bases and a long radial cable anchored to the central node.
These temporary cables were multi-strand cables, based on the Freyssinet stay cable system, and
were adjustable to allow for fine geometrical
tuning of the structure.
Once enough masts were in place, the first
segments of the compression ring were
installed. A careful control of the out of balance
of the structure was required to remain within
the acceptable limits for the central tower.
Masts and compression beam erection were
carried out in parallel.
The first cable nets were erected before closing
the compression ring. Their innovative method
of erection is presented in section 4.3 below.
Congestion in the field of play was then at its
Fig. 10: Central tower during construction
peak. The tension in the cable nets was kept
low thanks to the high position of the central
node and to the loose connection between the lower cord of the net and the mast. The construction
engineering studies required to achieve the safe erection of all these elements in parallel was
performed by Buckland & Taylor, the Vancouver based bridge engineering firm.

Fig. 11: Photos of the erection of the cable net

The closing of the compression ring was a major milestone. It was successful thanks to careful
geometry control and adjustment. Erection of the cable nets proceeded whilst preparatory works for
the erection of the tension ring were performed. This tension ring cable is made up of 10 locked coil
cables. Their diameter (125 mm) makes them heavy. A system of clothes-lines was developed to

uncoil, splice and then clamp them into their cast connectors. Final closure and adjustment was only
possible by pushing the mast bases inwards in order to reduce the length of the polygon formed by
the connectors. This sensitive operation was achieved under constant control of forces and
movements and offered the precious centimetres required to close the massive cable rings.
Once tension and compression rings were completed and all the cable nets were in place, the
conditions required to prestress the structure were achieved. The operation started with the release
of the bearings, transferring the horizontal forces from the masts bases to the tension ring and
therefore protecting the concrete substructure from these loads. The central node was then lowered
thanks to the telescopic part of the central tower.
This operation increased the loads in the
compression and tension rings, and in all the upper
cords of the cable nets.
Eventually, the central tower was lowered enough
that the central node was not supported anymore.
The final tensioning step was achieved by
connecting the lower cord of the cable nets to the
masts. Up to 400 tons and a precise sequence of
works were required to connect the twin 70 mm
cables to the masts.
The structure behaved as expected and the final
position of the central node was in perfect
agreement with the theoretical predictions.
4.3

Fig. 12: Tensioning of lower cord

An innovative method for cable net

installation

Amongst the many challenges set by the chosen sequence of works, one of the most complex was to
erect the cable nets radius by radius with other works
taking place in the field of play, including major lifting
operations.
Each of the 36 cable nets of the BC Place roof is made of a
pair of upper cables, one above each other, a pair of lower
cables, one next to the other, and 15 hangers connecting
lower to upper pairs. The connections are made of cast
steel clamps with complex geometries. A complete cable
net is made of several hundreds of elements (including
cables, clamps, pins and connection plates), all different
from one another. Typically, a cable net is 130 m long, and
weights 30 tons.
Fig. 13: one of the 18 trolleys of the cable net
The first innovation was to pre-assemble the nets outside
the stadium. Cables were uncoiled on trolleys, which
served as supports during installation of the clamps. The cable net was then carried inside the
stadium using this little train.
In order to minimize the forces in play during the operations at the highly congested central node,
the cable net was first connected to this hub. A custom-made lifting deviator was used to lift the net
to the central node and connect the socketed ends of the lower and upper cables to it. To facilitate
their handling, the cables were fixed by clamps to the deviator. The clamping positions were
precisely calculated for each radius, in order to allow a safe release of the lifting deviator at the end
of the operation.
Once the deviator was released, the lifting of the other end of the net could start. The operation was
a complex lifting process, involving a crane and four strand jacks.
Due to the geometry of the stands, it was not possible to use only the strand jacks. The capacity of
the lifting means, the safety and the equilibrium of the operation were carefully assessed from a
complete, specially developed, non linear model. The model included the exact catenary behaviour

of each cable and the rotation stability of the lifting tool.

This second lifting tool was designed to connect the
cable net to the crane and to the group of four lifting
jacks.
The crane was released when the lifting tool came close
to the mast. During the final approach, some complex
load transfer operations were performed. First of all,
the tension in the top cords of the cable net was
transferred from the lifting tool to the mast. Secondly,
the extra loads induced on the mast had to be
compensated for by partly releasing the tension in the
Fig. 14: Sketch of the net lifting at the top
temporary radial cable. This adjustment protected the
mast node
concrete substructure and the compression ring
connections.
The general process and many complex details of the cable net installation were innovative. In spite
of the high congestion of the field of play, this methodology enabled fast radius by radius erection
of the cable nets. On average, two cable nets were erected every week and the operations were, on
occasions, as fast as 3.5 nets per week.

5.

Conclusion

A majority of the cable roof structures installed around the world are designed for the Big Lift
erection method. However alternative methods offer additional possibilities, enabling to respect the
constraints imposed by the technology, the schedule and the available means. The S.P. Mukherjee
Swimming Pool Complex and the BC Place stadium are two striking examples, but certainly not the
only examples where alternatives are the solution!