Structural Systems - Bridon

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Technical InformationBridon’s aim is to assist with your project from the initialconcept through the detailed design and ultimateconstruction. To achieve this aim, certain technicalinformation is pre-requisite.Bridon manufactures in accordance with all majorinternational standards and combines them with a series ofproven in house procedures and specifications. For specifictechnical advice, please refer to Bridon.DesignAll components are designed in-house. This allows Bridonto continually develop its range of cables, end fittings andother components. Bridon have total control of the supplychain from ordering the raw material through to installing thecompleted system and are able to provide bespokesolutions.Our service includes but is not limited to the following:• Strand designBridon design all strand to meet client requirements. As notwo projects are the same, one-off strand designs can beproduced to cater for special needs. Our existing inhouse knowledge of cable design and manufacture is nowsuplemented by the use of ABAQUS® finite elementanalysis software which allows us to examine the internalstresses within a cable whilst considering criticalproperties and long term performance. The strandproperties shown in the tables can be used as a guide.PlanningBridon manufacture the widest range of cable products forthe structural market and therefore are able to offer anunbiased assessment of which particular system is mostsuited to each application. Bridon are able to assist with thefollowing:• Feasibility studies, including cost estimates• Technical information• Maintenance advice• Steelwork interface details• Installation schemes• Buildabilty• Long term performanceFEA on Hammerhead Socket• End termination designBridon design all sockets in house. By using autodesk®inventor 3-d modelling software to assist in the processof designing, the external shape can be altered to providea level of aesthetics not normally associated with this typeof product. The 3-d model produced by Bridon canbe incorporated into the overall design to check forproper interface with connecting steelwork. A finiteelement analysis can be carried out on the 3-d modelusing our ABAQUS® software, this allows physicaldimensions to be optimised. In addition to the Styliterange shown in the tables, Bridon are able to cater forother project-specific needs.• Bespoke designCutting edge architecture can lead to new solutions forproduct design. Just because something has not beendone before does not mean it can’t be done.Bridon have provided unique solutions for many worldfamous structuresRotating Joint forWembley Stadium, LondonHanger Clamp forLokomotiv Stadium, Moscow30BRIDON Structural Systems
Technical InformationKnowledgeBridon are continually enhancing the product range to meetthe demands of modern structural requirements. In additionto using the latest design tools, we also have the benefit ofdecades of experience in the manufacture and testing ofcable systems. Our large database of past test results canbe used to estimate long term properties such as creep,coefficient of friction, claming forces, minimum bendingdiameters, fatigue, etc. For example, our large database oftension-tension fatigue test results allows us to deriveproduct specific S-N curves.Use of this knowledge bank can eliminate the need to carryout certain tests up-front, providing designers with a degreeof confidence in the performance of materials integral totheir design and also removes the need for contractors tocarry out expensive product testing.Corrosion Protection of StrandThe hot dip galvanising process employed by Bridon isunaffected by the phenomenon of hydrogen embrittlement.No instances of failure attributed to hydrogen embrittlementin Bridon’s carbon steel wire have been recorded.Stage 2 – Strand InteriorDuring strand spinning, various compounds can be appliedto fill the voids and coat the wires in order to enhancecorrosion protection. The compounds most readily used forspiral strand and locked coil strand are Bridon Metalcoat,Bridon Brilube 2 and zinc dust compound. These compoundsare also designed to act as a long-term lubricant, reducinginter-wire friction and hence prolonging strand-life.It should be noted that structural strand may exude minoramounts of these compounds under load. Therefore forcertain applications, Bridon recommend that spinningcompound is not used on spiral strand and is only used upto the final two layers on locked coil strand.The corrosion protection of structural strand is of paramountimportance. In order to ensure the optimum corrosion protectionsystem a series of measures and options can be selected.These can be categorised into the following five main stages:Stage 1 – Individual WiresThe individual wires are protected by means of a factoryapplied zinc or zinc alloy coating using the hot dip process.Such coatings provide sacrificial protection to theunderlying carbon steel wire.Wires are available heavy galvanised or Galfan ® coated. Thecoating is applied by the hot dip process under factorycontrolled conditions.Galfan ® coated wires offer a multifold increase in corrosionprotection when compared with the same thickness zinccoated wire. The exact value of the increase depends uponlocal environmental factors.Galfan ® is a binary alloy of zinc and aluminium at theeutectic ratio of 95% zinc and 5% aluminium and is alsoapplied by means of the hot dip process.When selecting the strand interior compound, careshould be taken to ensure compatibility with any externallyapplied coating.Stage 3 – Strand ExteriorApplication of spinning compoundThe “as – supplied” strand will have a dry surface. Additionalmaterial can be painted onto the outside of the strand toprovide an extra level of corrosion protection. Bridonrecommend the use of Metalcoat.For spiral strand cables it is necessary to Galfan ® coat allwires, for locked coil cables it is only necessary to Galfan ®coat the outer two layers of shaped wire.Painting of strand on Millennium Bridge, LondonGalvanising of wireThere has been industry concern about the subject ofpotential carbon steel wire and rod failure due to the effectknown as hydrogen embrittlement during galvanising.Bridon Metalcoat ® was specifically designed to protectstructural strand against corrosion and is a suspension ofaluminium flake incorporated into a hydrocarbon resin carrier,diluted with a solvent for ease of application. The product ishand applied on site and does not dry hard like conventionalpaint systems. Although dry to touch, it remains flexibleallowing for the differential wire movement as the underlyingcables are tensioned in-service, thus eliminating surfacecracking. When selecting the external coating care should betaken to ensure compatibility with the internal compound.BRIDON Structural Systems31
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Structural Systems - Bridon

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