Structural Cable Systems

TOKYO ROPE MFG. CO., LTD.
NIHONBASHI FRONT BLDG.
6-2 NIHONBASHI 3-CHOME CHUO-KU TOKYO 103-8306 JAPAN
Structural Cable Department, Overseas Engineering Division
PHONE: +81-3-6366-7733 FAX:+81-3-6366-6870
http://www.tokyorope.co.jp/

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’srisk and no warranty is implied or expressed by us with respect to the use ofinformation contained herein.
The information in this publication is subject to change or modification
without notice. Please contact us for the latest information.
1605-AVNTOKYO ROPE MFG. CO., LTD.

Tokyo Rope is the leading company ofstructural cable systems.
We have manufactured PPWS since 1960's. In 90's, we challenged to apply our technology tothe world longest suspension bridge, Akashi Kaikyo Bridge.
We developed new product, called NEW-PWS, in the 1980’ s. NEW-PWS is specialized for stay
cables, main concept is fully prefabricated parallel wire cable with high fatigue strength sockets
and high density polyethylene sheathing. NEW-PWS has been applied to a lot of cable stayedbridges.

Akashi Kaikyo Bridge

12Structural Cable Systems

High Tensile Galvanized Steel Wire
Major Applications

Property of Galvanized Wire
1570MPa class1570-1770

1770MPa class
1960MPa class1770-1960
1960-2160
75% of G.U.T.S.
4.0% or more
5mm: Min. 14 times / 7mm: Min. 12 times
3d × 8 times, No fracture
300g/m2 or more
5d×2 times

Class of G.U.T.S.
Range of tensile strength
0.2% offset proof stress
Elongation
TorsionDuctility
Winding
Mass
Zinc or ZnAl
alloy coating Adhesion

Main cable for Suspension Bridge
PPWS, Aerial Spinning
Stay Cable, Hanger CableNEW-PWS

G.U.T.S.: Guaranteed Ultimate Tensile Strength

PPWSRed wirePrefabricated Parallel Wire Strand

PPWS consists of high tensile strength wires that are bundled in a hexagonal shape;
sockets are fitted to both ends of the strand, and the strand is bound with a special
plastic tape. Gauge wire measured based on the design length at stable conditions isarranged at a top of hexagonal section, and Red wire is arranged at the other top tocheck no twist during the erection.

Socketing
Both strand ends aresocketed byzinc-cupper alloy.

Galvanized wire

Gauge wirePWS-127

Reeling
The reeling methods
are two ways.

Zinc-copper Alloy

Erection of PPWS
1 The strands wound on reel are set on the unreeler.

2 The strands are drawn from unreelers, and unreeled on catwalks byhauling systems.

3
The sockets at both ends are
fixed at the anchor frames.
The tension and sag are
adjusted by pulling socket.

4

6After all strands are in place,compaction work is carriedout by squeezing machinewith hydraulic jacks to be
circular shape.

After erection ofdeck, wires arewrapped on main
cable for corrosion
protection.

5Cable bands and hanger
cables are installed.
Minami Bisan Seto Bridge

34Structural Cable Systems

NEW-PWS

NEW-PWS possesses all the superb characteristics of PPWS, plus good handlingability, excellent corrosion proofing characteristic, and high fatigue resistance socket
for stay and hanger cable.

High Elastic modulus
NEW-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.
E=196,000N/mm2(20,000kg/mm2) is secured even twisting.

Twist Angle 3.5±0.5 deg

High Fatigue Strength

Cable

Sockets with high fatigue strength are developed for the stay cables. This socket
called as "NS socket" is composed of zinc-cupper 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.
Results of fatigue test

Caulking material
Epoxy resin

40

Stress Amplitude (kgf/mm2)

Heat-shrinkable polyethylene

3530
2520

Galvanized wire

15

Zinc-copper Alloy

More than 2% failuer
Less than 2% failuer

105Socket

No failuer

0100,000

1,000,000

Cycles

10,000,000

Tatara Bridge

Standard Type of Socket
Aerodynamic Measure for mitigating
the Rain Wind Vibration
Small Drag Coefficient, even the surface treatment (Indentedsurface) is applied on the cable. Indented cable can achieve acounter measure without external damper against the rainwind vibration.
Front bearing

Middle bearing

Nut bearing
Indented cable: Cd≒0.7(Cd=0.7 is the same as smooth cable)

Excellent Corrosion ProofingHigh density polyethylene sheath is assembled to eliminate corrosion- proofing work.
Polyethylene is resistant to acids, alkalis and other chemicals, and a carbon content of about 2％ensures greater weatherability.

Galvanized wire
Filament tape
Polyethylene layer

100%Carbon content

50

00.1%
0.5%
02000

4000

Elapse of Time5

Erection of NEW-PWS

Results of whether-meter accelerated test
Rate Residual Elongation

Polyethylene layer(Coloring)

Applicable to color cable

1.0%
2.0%

6000
hrs

1 Setting a cable reel on Unreeler

2 Unreeling of cable

3 Drawing & fixing of dead anchor

4 Tensioning

6Structural Cable Systems

Locked Coil Rope

Structural Wire Rope

Strand Rope

Spiral Rope

End fitting
Socket TypeNut bearing socket

Swaging TypeOpen socket

Swaged socket with thread

Fork end type swaged socket

Locked Coil Rope

Type C●Shaped wires (Z and T wire) are used in the outer layers.
●Rope itself has an excellent anti-corrosion performance.
●Endfitting is limited to socket type.
●Modulus of elasticity: ≧1.57×105N/mm2●Diameter 34～100mm

Spiral Rope
●The strength is higher than any other structural ropeof the same diameter, except PPWS and NEW-PWS.
1×91●Swaged socket is applicable up to 40mm
●Modulus of elasticity: ≧1.57×105N/mm2●Diameter 14～100mm

Strand Rope

7×377Color Coated Structural Wire Rope “Tuff Coated Rope”
Tuff Coated Rope has a high anticorrosive function due to two corrosion
proofing layers, galvanizing and modified saturated polyester resin.
Various color is available.
Exposure test at Mt. Aso.
At first

6 months later1 year later2 years laterZn●Good flexibility, Easy handling●Swaged socket is applicable●Modulus of elasticity: ≧1.37×105N/mm2●Diameter 9～71mm
Tuff Coated8Structural Cable Systems

S-shaped Wrapping Wire

Manufacturing Process of PPWS, NEW-PWS and Structural RopeCorrosion Protection System for Main Cable

Coating (elastic type)

The new corrosion system that gives longer service life to the main
cable, the key components of a suspension bridge, consists ofGalvanized wire + Wrapping wire + Heavy-duty corrosion protection
coating.

Main cable steel wire(galvanized steel wire)

Wrappig wire

Ingot molding

BilletReheatingBlooming

Billet refining

LD converter
Continuoue casting

Wrapping Wire
The new wrapping wire has an S-shaped sectional configuration, and its standard size is as shown in the figure below.
S-shaped Wrapping Wire
Coating

Wrapping wire

7mm

3mm

4.5mm

Main Cable steel wire (galvanized steel wire)Round Wire

Paint cracks

Roughing

This S-shaped wrapping wire prevents crackingof coating by mean of the effect of interlockingof turns. The adoption of coating agent having
an excellent elongation performance preventsfrom cracking due to expansion of cables andat the same time prevents the infiltration ofrain water and others.

Finish roughing

Wire RodMaterial inspection

Lead tank

Wire mounting
frame

Washing tank

Hydrochloric
acid tank

Washing tank

Surfacetreatment tankCoating
Preliminarytake-up reel

Main Cable steel wire (galvanized steel wire)

Galvanizing

DrawingSpecial anti-corrosion
treatment

Wire inspection
PPWS

Reeling plate

Forming roller

Stranding

CoilNEW PWS

Wrapping filament tapeWire

Measuring gauge wire

Stranding

ExtruderPolyethylene coating

Structural Rope

Pretension and measuring

Stranding

Socketing

Socketing

JackSocket

Finished ProductPre-load

Kurushima Bridge

910