stay cable 2008
TRANSCRIPT
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V S L S S I 2 0 0 0 STAY CABLE SYSTEM
DESIGN
ENGINEERING
SUPPLY
INSTALLATION
MONITORING
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V S L S S I 2 0 0 0 2 S T A Y C A B L E S Y S T E M
Industrial Ring Road Bangkok, 2006 Stay cables installed strand-by-strand.
VSL: a worldwide networkVSLs organisation as a network of closely-
cooperating regional units allows it to provide
a full range of solutions and services worldwide.
Customers have access to a local presence, while
benefiting from global resources, know-how and
expertise as well as VSLs continuing development
of specialist construction techniques. The VSL
networks valueadded services are combined
to provide fully-customised solutions, from concept
to site works, using highly-trained and experienced
staff working in close partnership with clients.
VSL: a commitment to Quality,Safety and the EnvironmentVSL pursues a strong QSE policy in keeping
with its position as a technical leader in the
industry. Local teams aim continuously toestablish, maintain and improve their pro-
VSL MAINTAINS THE LEAD
IN STAY CABLETECHNOLOGY
active management systems and high
performance standards.
VSL recognizes that employees are the key to
competitiveness and effective working prac-
tices. The company is committed to safety
first and strives for zero accident, with
employees motivated to take the necessary
responsibilities to achieve this goal.
Clearly-defined measures are in place to
promote sustainable development as part of
VSLs contribution to environmental protection.
VSL: a specialiststay cable contractorAs leader in stay cable technology, VSL paves
the way with new developments. The last
10 years in particular have seen a boom in
stay cables, with a considerable increase inthe span lengths that can now be achieved as
well as faster installation and erection cycles
thanks to VSLs construction techniques.
VSL has experience of more than
130 cable-stayed bridges, including 40 in the
last eight years, and its close participation
with clients and builders has resulted in a
next-generation technical solution.
The VSL SSI 2000 System described here
combines the latest developments with VSLs
best solutions, and has already been used for
dozens of bridges. The system offers high
fatigue resistance, excellent corrosion
protection and cable-force monitoring, as well
as allowing adjustment, inspection and
replacement of the strands. It maintains
stringent durability standards, whilst
incorporating new features for greater
flexibility and simpler, more slender cablesand anchorages.
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V S L S S I 2 0 0 0 3 S T A Y C A B L E S Y S T E M
Las Glorias Footbridge - Spain, 1991Supply of the stay cables and supervision at installation.
Uddevalla Bridge Sweden, 1998
Stay cables installed strand-by-strand and equipped with anti-vibration
friction dampers.
La Unidad Bridge Mexico, 2003
Full scope of bridge construction.
Liebrueti Bridge Switzerland, 1978
First VSL Stay cable bridge
Cable installation with
VSL lightweight equipment
Recent VSL developmentsin stay cable technologyVSL Saddle, a patented solution allowing muchsimpler pylon design resulting in enhanced bridge
aesthetics;
Compact anchorage, leading to simplified designand construction of the pylon and superstructure;
Compact stay cable system, resulting in a tighterarrangement of the strands and hence a reducedcable diameter and a lower cable wind load;
Cable protected by dehumidificationtechniques, a patented solution offeringthe lowest wind load on strand cables,with a permanent monitoring;
A choice of cable-vibration damping systems,which permits optimum load adaptation for eachstructure.
Modern engineering:stringent standardsDesigners and regulators throughout the worldare demanding:
increased durability of stay cables, includingcorrosion protection of both cable andanchorage, leak-proofing of the anchorageassembly, good anchorage conditions, easyinspection and maintenance, cablereplacement with minimal traffic interruption,cable vibration control and a compact staybundle with a reduced wind drag-coefficient;
outstanding fatigue and static loadperformance levels (200MPa and 300MPastress range fatigue test for the SSI 2000anchorage assembly and components);
improved aesthetics arising from theavailability of saddles, compact anchoragesand coloured cables;
incorporation of damping systems into theanchorage.
Main contractors also look for optimalconstruction schedules such as:
a design that takes into account the closerelationship between deck erection and staycable installation;
lightweight installation equipment to enableeasier operations and a more flexible erectionprogramme.
Clients benefit from:
enhanced durability that is built in;
easier long-term maintenance, providingsubstantial savings.
The VSL SSI 2000 stay cable system is designedto meet all of these demanding requirements.
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V S L S S I 2 0 0 0 4 S T A Y C A B L E S Y S T E M
High fatigue performanceAnchorages include design features to filter
out vibrations and bending stresses in the
cable before they can reach the anchorage
wedges. Sample stay cables have been
subjected to fatigue testing with cable angular
deviations as defined in the latest PTI and fib
recommendations. Anchorages can be
equipped with additional cable protection
systems where unusual cable deviations need
to be taken into account (see page 6).
High durability and a newstandard of protection
a) For the corrosion protection of the steelanchorage components, VSL has developed
a new system that provides the best protection
in the most aggressive environments. It enables
100 years of maintenance-free operation for
non-accessible components.
b) Individual encapsulation of each strand
within the anchorage avoids the risk of
corrosion migration between strands. Full
encapsulation is achieved by providing each
strand with its own protection system.
c) Complementary barriers provide a degree of
redundancy to ensure the leak-tightness of the
anchorage. The sealing system has passed the
various tests as defined by fiband PTI.
Cable replacementwithout traffic interruptionThe very compact nature of the anchorages
allows installation in confined spaces within
box girders and pylons. The single strand
installation method and stressing operations
have been optimised to facilitate cable
installation using very lightweight equipment
for greater flexibility in construction.
Easy incorporationof a VSL internal damping systemThe stay cable system can be designed with
provision for later installation of a VSL
vibration damping system, should it provenecessary (see page 14).
SSI 2000: VSL STAY CABLE TECHNOLOG
Individual encapsulationEach strand separately protected
inside the anchorage
Severalcomplementary
barriersFor anchorage water
tightness system
Individual strand deviation deviceFiltering cable bending stress at the anchorage device
Increased corrosion
protectionFactory applied individual protection
treatments, for a design life of 100 years
in the most aggressive environments,
without maintenance
High fatigue performanceVSL strandsHigh fatigue performance over 300 MPa
stress range at 2 millions cycles.
Compatible with VSL SSI Saddle
Compact anchorageLength of a fixed end anchorage
for 127 strands is only 440mm.
High fatigue resistance
VSL anchorageDemonstrated by fiband PTI fatigue tests
with combined tension and bending action.
The SSI 2000 Stay Cable System is based on proven stay cable wedge/strandanchorage technology, which has been in use for more than 30 years. It meets
the most stringent requirements and has been used on more than 120 stay
cable projects. The system has successfully passed extensive full-scale fatigue
testing, including the new leak-tightness tests required by the PTI and fib.
Adjustable(orfixedend)anchorage
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V S L S S I 2 0 0 0 5 S T A Y C A B L E S Y S T E M
Reduced cable wind loadsThe VSL stay pipes installed on the bridges are
generally equipped with external helical ribs to
suppress vibrations induced by rain and wind.
Wind tunnel testing has demonstrated the
efficiency of the VSL-designed helical ribs in
reducing drag at wind speeds up to 70m/s.
The VSL compact system:SSI 2000-C for long cablesWind load on the cables can be an important
parameter for the structural design of bridges with
very long cables. For these cables, VSL has
developed SSI 2000-C, an adaptation of the
standard SSI 2000. It uses the same anchoragesand connections but features a 20% reduction in
FOR BRIDGES
VersatilityDesigned to accommodate a VSLs vibration damping
system which can be installed retro-activelyLow drag coefficientMeasured in wind tunnel
Replaceable stay cable systemEach strand can be individually checked
and at any time, replaced and re-installed.
Complete cable is replaced with closure
of only one traffic lane.
Versatile tension ringMay be used as a guide deviator
for increased cable angular
deviations
cable diameter. Reduced wind loads result from its
use in combination with the lower wind drag
coefficient of the VSL stay pipe.
The VSL SSI 2000-D:dry air system for lower wind loadsVSL SSI 2000-D is an adaptation of the
standard system, using the same
wedge/strand anchorage technology. Its main
feature is a greatly-reduced cable diameter of
about 30% less than standard, which results
in significantly lower wind loading. SSI 2000-D
cables are protected by dry air using the same
technology as found in the protection of many
steel bridge decks and suspended cables(see page 10).
The VSL SSI 2000 Saddle allowingreplacement of strandVSL has developed a patented new pylon saddle
for its SSI 2000 Stay Cable System, designed for
use with the standard sheathed strand used on
extradosed and cable-stayed bridges.
The compact saddle allows strand by strand
installation and replacement of each strand.
Tests have demonstrated that the saddles
fatigue performance is the same as for
anchorages. High friction of the cable on the
saddle allows its use in pylons subjected to
significant unbalanced cable loads (see page 12).
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V S L S S I 2 0 0 0 6 S T A Y C A B L E S Y S T E M
Cable equipped with the VSL friction damper
In the event of unexpected cable vibrations,a choice of VSL damping systems - friction
damper or Gensui damper - can be
installed without modification to the
cable assembly.
Connection detail for subsequent installation of
a VSL damping system
The flange welded to the end of the guide pipe
and the increased diameter of the anti-
vandalism pipe are designed to allow for
later installation of a VSL damping
system, should cable vibrations need
to be rectified. The cable can be
equipped with a guide deviator
(see figure)or, moregenerally, with a tension
ring.
Cable equipped with a guide deviator
This provides the anchorage with a greater level of
protection in case the cable is subjected to higher
angular deviations such as seismic events. For
long guide pipes the guide deviator protects
the cable from contact, whatever the
amplitude. It also allows for the guidepipe assembly to be installed with
increased tolerances.
VSL SSI 2000 MAIN DIMENSIONS
DECK ANCHORAGE
with adjustable or fixed end anchorages
ADJUSTABLE ANCHORAGE
H1 miniG1
F1
D1
L1 mini
Guide pipeE1
B1
A1
C1
DECK CONNECTIONDesigned with a tension ring or a guide deviator,
and a VSL damping system if required.
Cable equipped with a tension ring
Designed to accommodate a cable
angular deviation of 25mrd
(1.4 degrees) on entry to the
anchorage, as per the PTI
and fibrecommendations.
L1mini
1.4m
PYLON ARRANGEMENTDistance between facing fixed end
anchorages is 1.4m. Distance of
approx. 3.5m is recommended when
stressing jacks are used.
L1mini
L1mini
L*
L1
mini
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V S L S S I 2 0 0 0 7 S T A Y C A B L E S Y S T E M
ADJUSTABLE ANCHORAGE (at deck or pylon) FIXED END ANCHORAGE (at deck or pylon)TENSION
RING
Anchorage Number A1 B1 C1 D1 E1 F1 G1 H1 mini
unit of strands mm mm mm mm mm mm mm mm
6-12 12 190 230 290 219.1 / 6.3 196 500 30 325
6-19 19 235 285 355 267 / 6.3 241 500 35 350
6-22 22 255 310 385 298.5 / 7.1 261 500 40 360
6-31 31 285 350 440 323.9 / 7.1 291 700 45 410
6-37 37 310 380 485 355.6 / 8 316 700 50 440
6-43 43 350 425 540 406.4 / 8.8 356 700 55 455
6-55 55 385 470 585 419 / 10 391 700 60 495
6-61 61 385 470 600 419 / 10 391 700 65 530
6-73 73 440 530 680 508 / 11 446 700 75 530
6-85 85 440 540 710 508 / 11 446 700 80 590
6-91 91 490 590 760 559 / 12.5 496 700 80 585
6-109 109 505 610 795 559 / 12.5 511 700 90 620
6-127 127 560 670 865 610 / 12.5 566 700 95 650
6-175 175 640 770 1000 711/14.2 646 700 110 730
Valid for nominal concrete strength at stressing to 45% of stay capacity: 45 MPa (cube), 36 MPa (cylinder). Dimension must be checked in case of other bearing conditions. Guide pipe to be checked if use of guide deviator or damping system. Minimum value allows on adjustability of 40 mm.
CABLE DIAMETER (mm)
ANCHORAGE SSI 2000 SSI 2000-C* SSI 2000-D
UNIT
6-12 125 95 85
6-19 140 110 95
6-22 160 125 105
6-31 160 135 115
6-37 180 150 130
6-43 200 170 145
6-55 200 175 150
6-61 225 185 160
6-73 250 200 170
6-85 250 210 180
6-91 280 220 190
6-109 315 235 200
6-127 315 265 225
6-175 355
A2 C2 D2 E2 F2 G2 H2 mini
mm mm mm mm mm mm mm
185 260 177.8 / 4.5 150 300 35 210
230 335 219.1 / 6.3 190 300 50 225
250 355 219.1 / 6.3 205 300 50 225
280 415 244.5 / 6.3 230 300 60 250
300 455 273 / 6.3 255 250 70 275
340 505 323.9 / 7.1 285 250 75 280
380 550 323.9 / 7.1 310 250 75 300
380 585 355.6 / 8 330 200 85 320
430 650 406.4 / 8.8 370 200 95 335
430 685 4 06.4 / 8.8 3 70 200 110 365
480 730 457 / 10 420 200 110 375
495 775 457 / 10 420 200 120 385
550 845 508 / 11 475 200 130 435
620 1000 711/14.3 530 200 150 460
L1 mini
mm
800
1100
1250
1400
1600
1850
1950
2150
2300
2450
2650
2800
3200
3700
*with PTI tightly extruded strand
FIXED END ANCHORAGE
H2 mini
G2
E2
A2
C2
D2
L1 mini F2
Cable diameter
Guide pipe
K CONNECTION
STAY PIPE
FREE LENGHT PYLON CONNECTION
PYLON ANCHORAGE
with adjustable or fixed endanchorages
Customized sizing can be provided for large cables on request.
Stay cable equipped
with a guide deviator
Stay cable equipped
with a tension ring
PYLON CONNECTIONThe pylon connection is similar to the deck
connection and can be designed with either
a tension ring or, in some cases, with aguide deviator.
L1
L1
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V S L S S I 2 0 0 0 8 S T A Y C A B L E S Y S T E M
ENHANCED DURABILITY WITH SSI 2000
Durability of the VSL stay cable systemVSL stay cables are replaceable and have a
design life of 100 years in the most aggressive
environments, as defined by the C4 and C5
categories of the ISO 12944 standard.
VSL specifications for the corrosion-protection
system of steel components are much more
stringent than the durability recommendations
from PTI and CIP. The components which are non-
accessible are manufactured with a protection
system that has a design life of 100 years
without maintenance. The first maintenance
operation on the accessible and replaceable
components is scheduled after 25 years.
Each component and the entire assembly of VSL
anchorages have all been subjected to analysis,
to determine the best materials, component
geometries, assembly type and protection
system to achieve the highest durability.
Accelerated ageing testsCorrect specification and manufacturing is
important to avoid significant variations over
time in the characteristics of the non-steel
components such as the HDPE/PP used for the
stay pipe and strand sheathing.
UV radiation and/or pollution may cause the
colour of the HDPE stay pipe to change over
time. The fading of the colour is controlled
such that it remains invisible to the naked eye.
The evolution of the mechanical and
colourimetric characteristics is verified during
accelerated ageing tests of the VSLs colouredstay pipes.
Anchorage leak-tightness testThe barriers that protect the cable along its free
length are checked by appropriate component
tests. It is important to have efficient measures
in place to prevent ingress of water into the
anchorage interfaces, particularly at the deck.
The VSL anchorages sealing system is designed
with a high degree of redundancy and the
anchorage has passed the leak-tightness tests
as defined by PTI and fib.
Durability at the construction stagesThe durability of each component depends on
its design and choice of material. However, the
durability of the complete cable will also
depend on the quality of the installation works
and the provisions made for easy inspection
and replacement. VSL has incorporated
permanent control systems which allow for the
detection during the strand installation of any
defect that would reduce the stay cables
durability. Any component can be easily
replaced without critical delay to theinstallation schedule.
The SSI 2000 System is now offering new
developments, all leading to enhance cable
durability :
The VSL SSI 2000-D to reduced cablewind loadsVSL SSI 2000-D is an adaptation of the
standard system, using the same
wedge/strand anchorage technology. Its main
feature is a greatly-reduced cable diameter of
about 30% less than standard, which results
in significantly lower wind loading. SSI 2000-D
cables are protected by dry air using the same
technology as found in the protection of many
steel bridge decks and suspended cables (seepage 10).
Adjustable anchorages areprotected by a sprayed
metallic coating.
Checking of a 6-37 anchorage after a PTI leak-tightness
test. After being submitted to mechanical environmentalconstraints, the anchorages were placed in a chamber with
3m-head of dye solution to check the ingress.
Tensile test of a sample HDPEstay pipe which has been
subjected to an ageing test.
Durability and fatigue strength are the two most important requirements forstay cables designed to enable 100 years of maintenance-free operation for
non-accessible components in the most aggressive environments. VSL has
recently developed some new products and services, therefore offering
complementary barriers providing new degrees of redundancy.
VSL colored stay pipe with helical ribs,
tested in a wind tunnel
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V S L S S I 2 0 0 0 9 S T A Y C A B L E S Y S T E M
SYSTEM & DEVELOPMENT
Red color stay pipes
(Sucharskiego Bridge, Poland)
White color stay pipes
(Neva Bridge, Russia)
Gold color stay pipes
(Industrial Ring Road, Bangkok)
Required durability
of stay cablesVarious durability requirements have beendeveloped:
PTI stay cable recommendations are for a75-year design life.
The CIP document says 50 years and100 years for replaceable and non-replaceablecables respectively.
fibs stay cable recommendations are100 years protection against corrosionfor steel components and a design lifeof 50 years for non-metallic components,with replaceability of components.
The VSL SSI 2000 Saddle allowingcable replacementVSL has developed a patented new pylon
saddle for its SSI 2000 Stay Cable System,
designed for use with the standard sheathed
strand used on extradosed and cable-stayed
bridges. The compact saddle allows strand by
strand installation and replacement of
individual strands. Tests have demonstrated
that the saddles fatigue performance is the
same as for anchorages. High friction of the
cable on the saddle allows its use in pylons
subjected to significant unbalanced cable
loads (see page 12).
VSL solutions for cable vibrationVSL is providing two types of internal damping
systems: the VSL Damper and the Gensui
Damper.
The SSI Stay Cable System can be designed
with provision for later installation of a VSL
vibration damping system, should it prove
necessary (see page 12).
DURABLE BUT ALSO AESTHETIC
VSL structural monitoring servicesVSL monitoring package is offered as an
additional service to provide the client with
long term cost savings. It can be applied to
structures and to cables. In-house R&D has
placed emphasis on durability method,
measurement and sensor configurations to
optimise maintenance; to detect damage and
confirm diagnosis of deterioration; to validate
and memorise know-how for future projects; tooptimise life cycle cost of the structure.
VSL loadcell
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V S L S S I 2 0 0 0 10 S T A Y C A B L E S Y S T E M
THE VSL SSI 2000-D SYSTEM
Permanent monitoringof the corrosion protection
system of the cables:
Temperature
Humidity
Air pressure
No damageof the cable
protection during
installation
Dry air protectionof the cable, the anchorages and
the vibration damping system
Permanent visual controlof the cable corrosion at the
anchorages, without dismantling.
Reduced cost for any
cable replacementNon-sheathed VSL strands
Guide pipe
Bearing plate
Protection cap
Non-sheathed strandsprotected by dry airThe complete stay cable system is designed so
that the strands are located within an airtight
enclosure along their free length and along the
two anchorage lengths.
The cable, anchorages and any vibration
damping system are all protected againstcorrosion.
The airtight HDPE stay pipe is connected at
one end to the pylon and at the other to the
deck anchorage. The cable is composed of
non-sheathed strands manufactured with
a protective coating such as galvanising.
A dehumidifier unit, which is generally placed
inside the pylon, is equipped with air-pushing
fans to maintain a low but permanent pressure
of dry air along the cable length. This permanent
pressure prevents any ingress of water from theoutside environment into the cable.
The dehumidifier unit
placed within the pylon
supplies dry air to the
pylon anchorages.
* Patent pending
SSI 2000 SYSTEM DEVELOPMENT
A stay cable system protected by dry air*
Stay cable
Dry air
supply pipe
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V S L S S I 2 0 0 0 11 S T A Y C A B L E S Y S T E M
Sealing deviceprotected inside the
anti vandal pipe
Reduced cable
diametersStrand cable with the
lowest outer diameter
allowing reduced cable
wind load
Anti vandal pipe
Co-extruded
HDPE stay pipe
with helical rib
Cable with 3 nested
layers of protection
VSL friction
damper
The dehumidifier unit placed within the pylon
supplies the dry air to the pylon anchorages.The dry air flows from the pylon anchorages to
those at the deck. The space between the
strands inside the HDPE pipe allows circulation
of the dry air around the steel strands, with a
pressure at the deck anchorage that is slightly
above atmospheric pressure.
Dry air: a proven solutionThe use of dehumidification or dry air systems
to protect steel decks and suspension cables
was introduced in 1971 and it is now a well-
understood and highly-regarded solution.
The efficiency of dehumidification has also
been demonstrated in the protection of the
cables of several suspension bridges,
including those of the Akashi Kaiko Bridges
1991m-long main span.
The dehumidification equipment used by VSL
for cable protection in the SSI 2000-D System
is based on proven technology. Long-term
experience on steel decks protection has
confirmed the low maintenance costs of
dehumidification systems and their great
reliability. VSL can provide estimates ofrunning costs if required.
Anchorage protection cap allowing visual inspection of cable
The dry air combined protection
Increased layersof corrosion protectionThe main tensile elements of standard stay cable
systems are designed with two levels of protectionwhereas the SSI 2000-D offers three levels:
- (continuous) steel coating of the strand
- (continuous) dry air around the strands
- an airtight enclosure provided by the stay pipe.
Permanent monitoring of the cablecorrosion protection systemPermanent monitoring of the cable protection is
provided. A protection cap is installed at the
deck anchorage and is designed for the
connection of sensors to measure the humidity,
air pressure and air temperature, as well as the
dehumidification control system.
The anchorage protection cap can also be
designed to allow permanent visual inspection
of the strands and wedges without any need to
interfere with the system. This significantly
reduces the time and costs involved in the
long-term maintenance of the cables.
Offering protection for the deckThe SSI 2000-D Dehumidification System can
also be used to achieve complete protection of
bridge decks that are designed as steel boxes.
The dry air flowing along the cables can be fed
into the compartments of the deck.
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V S L S S I 2 0 0 0 12 S T A Y C A B L E S Y S T E M
THE VSL SADDLE
VSL has developed a new concept in saddles that achieves the performanceof stay cable anchorages. Moreover, each strand of the cable can also be
replaced if required.
One of the great advantages of the VSL Saddle
is that it allows designers to simplify the pylon
structure and use very slender profiles to
achieve an attractive appearance.
The new VSL Saddle was developed in response
to issues with existing saddle designs, relating
to fatigue, fretting corrosion and replacement of
the cables. CIP had considered these issues so
serious that it had recommended abandoning
saddles and using anchorages instead.
Two independent corrosionprotection barriersThe compact saddle is composed of a
rectangular steel box filled with a high-strength
Ductal cement grout. The design ensures high
friction between the cable and the saddle.
Cables can be installed or replaced strand
by strand, and the strands can be tensioned
independently. Two separate corrosion protection
barriers protect the cable inside the saddle:
- a protective strand coating such as
galvanising;
- a special flexible filler injected around the
strands, using the same material that protects
the strands within VSL anchorages.
Independent replaceable strandsEach strand of the cable is free and completely
independent in the VSL Saddle. Instead of the
usual design, the VSL Saddle has no corrosion-
susceptible individual tubes. Each strand of
the cable passes through the saddle in an
independent hole in the cement grout. Special
VSL formwork has been designed for this. The
number of holes in the saddle will generally
correspond to the number of cable strands.
However, additional holes can be provided for
extra strands, such as a reference strand for
later inspection.
V shaped holes for high frictionAn important feature of the VSL Saddle is the
shape of its strand holes. The holes are V
shaped, instead of the circular ones used on
saddles with individual tubes. This special
hole geometry is the result of extensive testing
carried out in VSLs laboratories to define the
optimum shape to achieve high friction
between the strand and the saddle while
avoiding fretting and allowing easy strand
installation.
Transfer of high cable differential
forces into the pylonThe cable passing through the saddle can be
subjected to differential forces from opposite
sides of the pylon. These forces could induce a
sliding of the cable within the saddle but this
is prevented by the friction of the individual
strands inside the saddle. The laboratory tests
measured the friction coefficient as varying
from 0.4 to 0.7, depending mainly on the
loading conditions.
Angular deviations of the cableat the saddleOn some cable-stayed bridges, the cable can
be subjected to non-negligible angular
deviations at the pylon. These deviations may
gradually cause deterioration in the cable
protection and in its mechanical strength.
In order to withstand these angular deviations,
the prefabricated VSL Saddle incorporates a
special elastomeric casting resin where the
cables exit the saddle.
No degradation of the cables fatigueperformance
Fatigue tests were carried out on small cableunits in order to determine any effect of theFatigue testing of the VSL saddle
Saddle section, with the V shaped strand hole
SSI 2000 SYSTEM DEVELOPMENT
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V S L S S I 2 0 0 0 13 S T A Y C A B L E S Y S T E M
saddle on the cables fatigue performance. The
strands were tensioned to the cable-breaking
load after two million fatigue cycles with a
stress range of 200MPa and a maximum load
of 45% of cable capacity. No wire breaks were
observed in the saddle and subsequent
dismantling of the strands showed that they
were in very good condition and confirmed the
feasibility of strand replacement.
Cost saving cableThe VSL Saddle uses the same standard
tightly-extruded sheathed strand as for stay
cables. No special treatment of the strand is
required and cable replacement can be carried
out with the same standard strand.
A (mm) B (mm)
6-12 175 1956-19 230 240
6-22 245 250
6-31 185 285
6-37 315 320
6-43 360 340
6-55 365 360
6-61 395 400
6-73 445 420
6-85 455 430
6-91 475 480
6-109 540 4906-127 550 535
Cable unit Saddle section
VSL Saddle design with
cable connection
Woonam Bridge, Korea (2008) :
installation of the VSL Saddle
Main dimensions(using VSL SSI 2000)
Manufactured saddle
for SSI strand cable
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V S L S S I 2 0 0 0 14 S T A Y C A B L E S Y S T E M
VSL SOLUTIONS FOR CABLE VIBRATION
As indicated in the PTI stay cable
recommendations, the mechanisms of dynamic
excitation are particularly complex and it is not
easy to produce reliable predictions. The first
difficulty for the designer is to assess the risk
of cable vibrations. Various stability criteria
are available to estimate this risk and to
evaluate any damping that is required. The
main approach used by VSL is the net damping
criterion defined by I. Kovacs*.
The design of the VSL SSI 2000 Stay Cable
System allows implementation of additional
measures (such as dampers or cross-ties) in
case of unforeseen vibrations.
The VSL damping solutions
1. Modifications to the cable surface
Stay pipes can be manufactured with helical
ribs. The rib dimensions have been optimised in
wind tunnel testing for maximum efficiency in
suppressing the risk of excitations from rain
and wind while minimising the effect on drag.
2. Use of dampers to increase the structural
damping of the cable
Two different types of dampers are provided by
VSL: the Friction Damper and the Gensui
Damper. Key advantages of these dampers
include their efficiency, their durability and
their low maintenance costs. The two types
complement each other, allowing
implementation of the most suitable solution
depending on the characteristics of the stay
cables, the critical types of vibrations and the
required performance. The Gensui Damper is
optimised for extradosed bridges and for
medium cable lengths on cable-stayed bridges.
It is well-suited for use as an external damper.
The VSL Friction Damper will be the most
efficient solution for more critical cases
including long cables or where there is a risk ofparametric excitations.
VSLs experience in suspended structures and the development of dampingsystems enables it to assist the bridge designer in carrying out risk analysis
of the cables vibration and in proposing the most appropriate solution.
Key benefits ofthe VSL Friction DamperGreat durability: This great durability is due to thefact that the damper is designed to work only whennecessary, only when the level of the cable
vibrations is considered critical. At that stage, thefriction damper immediately achieves its maximumdamping effect to stabilise the cable.
High efficiency: Several comparative tests on staycables have demonstrated the efficiency of the VSLfriction damper. For example, a friction damperinstalled at 6m from the deck anchorage on a214m-long 97-strand cable achieved a measureddamping (Log. decrement) of more than 9%.
Aesthetics: Installation of damping systems on acable-stayed bridge has to avoid any detrimentalimpact to the bridges appearance, as this is often akey feature. The efficiency and compact natureof friction dampers generally allows them to beinstalled near the deck anchorage, where they canbe fully integrated. Other, less efficient, systemsrequire installation externally on additional supports.
Other advantages of the VSL friction damperinclude:
easy access, simplifying inspection duringmaintenance operations;
adjustment of the friction force without any needfor dismantling;
it can be installed on any type of cable onexisting bridges where cables are subjected tounexpected vibrations;
all components of the damper can be dismantledand/or replaced on site;
damping characteristics are not affected by thetemperature or vibration frequency.
VSL Friction Damper
SSI 2000 SYSTEM DEVELOPMENT
VSL Friction Damper with
anti-vandalism component
* Dr. Ing. Imre Kovacs / Dynamic Consulting
Cables with
VSL Friction Damper
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V S L S S I 2 0 0 0 15 S T A Y C A B L E S Y S T E M
3. Installation of stabilising cables:
This solution can be used where the other two
approaches would not be efficient. The
installation of stabilising cables onto the stay
cables is not an easy operation.
VSL has an impressive portfolio of reference
projects. The VSL friction damper has beensubjected to several comparative tests on stay
cables (by organisations including ShanghaiTongji University, Hong Kongs Highways
Authorities and the Korean Highways
Corporation). Friction dampers have been
installed on a number of cable-stayed bridges,
and to date no cable vibration has been observed
and no damper has needed to be replaced.
More than 40 cable-stayed bridges were
equipped with the Gensui Damper in 2007.
In 2008, 20 Gensui Dampers have been
installed on the cables of the North Arm Bridge
in Vancouver.
Key benefits ofthe Gensui DamperHigh-damping rubber:The Gensui damper is composed of severalrubber pads and the cables vibration energy isabsorbed by shear deformation of the pads. Eachpad is made of a high-damping rubbermanufactured by Sumitomo Rubber Industries.
Great simplicity:The damper is modular, with the number of padsused depending on the cable characteristics.A main feature of this damper is its simplicity.It can be easily installed and configured onexisting bridges.
Great durability with minimal maintenance:The high-damping rubber pads provide for along design life. Accelerated ageing tests haveshown a life expectancy of 60 years. The damperrequires only minimal maintenance during its
lifetime. This allows dampers to be installed, ifnecessary, at the pylon, where maintenanceaccess is difficult and expensive.
Performance:The performance of the damper depends on thedamping capacity of the rubber pad and can beadjusted by varying the number of pads. Thedampers performance is ideal for short andmedium cable lengths. Performance can beincreased by moving the damper away from thedeck anchorages and/or installing a seconddamper at the pylon. The performance does notdepend on the cables mode of vibration and it isnot sensitive to variations in temperature.
An aesthetic solution:
The Gensui Damper is installed around the cableand has compact dimensions, which ensuresthat it integrates well. The damper can be easilyused as external damper, installed on anadditional support. Installation of Gensui Damper
Gensui Damper
on PWS cable
Gensui Damper protected
with neoprene boot
North Arm Bridge, Canada (2008)
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STRAND BY STRAND METHOD FOR INST
OR REPLACEMENT OF CABLESVSLs first experiences of cable installation werewith fully-prefabricated cables which required
transport and lifting of heavy components.
A 500m prefabricated cable on its reel can
weigh up to 80t.
The strand by strand erection of cables requires
only light equipment. It can be slightly more
time consuming, but gives advantages when
the plant required for installation is taken into
account.
Operating with the strand by strandinstallation methodAll the cable installation operations are carried
out using VSL equipment, enabling any tower
cranes used for pylon construction to be
dismantled as soon as the pylon is complete.
Strands supplied from strand coils placed on
the deck are prepared on a working bench.
All the stressing operations are carried out
using the AMS monostrand jack. A compact
VSL stay multistrand jack is only used when a
final de-tensioning operation is unavoidable.The final operation is the power seating for
each strand and anchorage to ensure that
there is no risk of strand slippage at the
wedges anchored at low tension forces.
The strand by strand method developed by
VSL is well adapted for efficient use on any
project, whatever the bridges environmental
conditions are.
Replacement of a 298m cable
In May 2002, VSL mobilised a crew and light equipment to
check some cables and replace a 298m cable on the Ching
Chau Min Jiang Bridge. The stays had been damaged when a
barge collided with the bridge during a typhoon. Site conditions
did not allow access for a mobile crane and all the VSL
equipment had to be man-handled into position. Strands were
replaced strand by strand with the same light equipment used
for cable installation. This benchmark operation demonstratedthat long cables can be replaced without interrupting the traffic
only one traffic lane needed to be closed.
V S L S S I 2 0 0 0 16 S T A Y C A B L E S Y S T E M
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Optimised solutionswith the VSL SaddleThe use of independent strands permits the
strand by strand installation of the cable. After
installation of the two HDPE stay pipes on each
side of the pylon, each strand of the cable is
raised inside the stay pipe from the deck to the
pylon. It is then threaded through one hole of
the saddle and pulled down inside the other
stay pipe for connection to the opposite deck
anchorage. Installation of the strands is
achieved through the use of three VSL winches.
LLATION
PYLON
Jack
Chair
B
Amini
PYLON
Amini
870720
Dimensions (mm)of multistrand jack and chair.
TENDON 6-12 6-22 6-31 6-55 6-85 6-109 6-127
UNIT 6-19 6-37 6-61 6- 91
6-43 6-73
A mini 1000 1000 1100 1200 1300 1350 1500
B 490 620 620 780 780 970 970
Dimensions (mm) of monostrand jack.
TENDO N 6-12 6-31 6-61 6-91 6-127
UNIT to 6-22 to 6-55 to 6-85 to 6-109
A mi ni 1 000 1 05 0 11 00 1 15 0 1 200
Jack clearance for the
cable stressing operations
V S L S S I 2 0 0 0 17 S T A Y C A B L E S Y S T E M
The strands are tensioned one by one with a VSL monostrand
jack connected to a VSL Automatic Monostrand Stressing
system (AMS). The AMS processor controls and registers
the parameters of the stressing operation to achieve either
the required tension or the correct elongation of the strands.
A typical cycle of five to seven days can be achieved for deck segment
erection on cable-stayed bridges. VSL-trained staff and VSL tailor-made
equipment can execute the simultaneous installation of two cables on the
main span (or back span) in a single day with one shift on each cable.
Demanding challenges can be met thanks to close cooperation between the
partners, as on the Liz Bridge where 18 stays were installed in the record time
of just one week.
Main advantagesof the VSL strand by strandinstallation There is total flexibility to adjust the cable
length during installation. This length can beadjusted to cater for variations in the bridgegeometry during construction.
The light equipment induces only smallconstruction loads. The maximum componentweight is about 4t.
On a composite deck, just one part of the cablecan be installed as a first step to give support topart of the steel deck during its assembly.
The use of light equipment fitted to the pylonallows the installation of the pylon anchorageswhile the pylon is under construction.
The stressing anchorages can be installed inconfined spaces inside the pylons as theinstallation equipment is small.
The maximum weight of the monostrand jacktensioning equipment is 20kg. Heaviermultistrand jacks are used only in special cases.
Only light equipment is required for any futurere-tensioning of the stays.
The method is well-suited to pylons equippedwith the VSL Saddle.
The necessary equipment can be moved easilyon site, giving greater flexibility in theinstallation schedule.
VSL lifting winch
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V S L S S I 2 0 0 0 18 S T A Y C A B L E S Y S T E M
Puente de la Unidad Bridge, Mexico (2003)
In a 50/50 JV, VSL provided project
management, complete technical and
method support and part of the production
management. VSL Mexico also supplied
and installed the post-tensioning, and the
SSI 2000 Stay Cable System
Ponte Europa Bridge, Portugal (2002)
186m main span length - 91 strand cables
Badajoz Bridge, Spain (1994)
Cables equipped with friction dampers
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V S L S S I 2 0 0 0 19 S T A Y C A B L E S Y S T E M
Papendorpse Bridge, Netherlands (2002)
120 strand cables
Sungai Johor Bridge, Malaysia (2008)
85 strand cables with length up to 275m
Batam Tonton Bridge, Indonesia (1997)
Package: design, supply and installation of stay cables, deck form-travellers and pylon
formwork. Construction engineering for the superstructure construction
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V S L S S I 2 0 0 0 20 S T A Y C A B L E S Y S T E M
Sucharskiego Bridge, Poland (2001)
Supply and installation of stay cables,
with VSL Friction Dampers
Centenario Bridge, Spain (1991)
552m bridge length, with 264m for the main span
Second Vivekananda Bridge, India (2007)
Extradossed bridge with pylon saddles and grouted stay cables
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V S L S S I 2 0 0 0 21 S T A Y C A B L E S Y S T E M
Yichong Yiling Bridge, China (2001)
Supply of stay cable system, erection equipment, stay cable
engineering, site management and site supervision
Wadi Abdoun Bridge, Jordan (2006)
Curved deck with inclined pylon
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V S L S S I 2 0 0 0 22 S T A Y C A B L E S Y S T E M
Neva 1 Bridge, Russia (2002)
All cables equipped with VSL Friction Dampers
Koshiki Daimyojin Bridge, Japan (1993)
Technical consultation and supply of the prefabricated stay cables
Houston Ship Channel Bridge, USA (1995)
Supply of stay cables and supervision at installation
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V S L S S I 2 0 0 0 23 S T A Y C A B L E S Y S T E M
Neva 2 Bridge, Russia (2007)
Supply and installation of stay cables with VSL Friction Dampers
Sunshine Skyway Bridge, USA (1986)
Supply of post-tensioning and stay cables. Cables anchored to the pylon
by saddles and equipped with hydraulic dampers
Pakse Bridge, Laos (2000)
Production and erection of the precast segmental
deck, including: design, supply and operation of
casting cells and launching gantry; construction of
cast-in-situ pier tables; geometry control; supply and
installation of post-tensioning and stay cables
Merida Arch Bridge, Spain (1991)
Supply and installation of the stay cables
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V S L S S I 2 0 0 0 24 S T A Y C A B L E S Y S T E M
Pastaza Bridge, Ecuador (2005)
Supply and installation of the stay cablesZizkova Footbridge, Czech Republic (2007)
Installation of stays and post-tensioning
Rades-la-Goulette Bridge, Tunisia (2007)
Extensive equipment and services
Unimas-Sarawak Bridge, Malaysia (2007)
Supply and installation of cables
Kien Hai Phong Bridge, Vietnam (2003)
Supply and installation of bearings and stay cables
J
oseCartelloneConstruct
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V S L S S I 2 0 0 0 25 S T A Y C A B L E S Y S T E M
Peldar Bridge, Columbia (2002)
VSL Saddle and monitoring services
Liz Bridge, Portugal (2004)
18 stay cables installed in one week
Woonam Bridge, South Korea (2008)
VSL pylon saddles designed to allow cable replacement
Safti Bridge, Singapore (1995)
An inclined pylon is stabilised by back-stay cables
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V S L S S I 2 0 0 0 26 S T A Y C A B L E S Y S T E M
VSL SERVICES FOR BRIDGE CONSTRU
Wind speedmeasured in 3 directionsexpressed in m/s
Temperature of cables, concrete
expressed in C
Humidityexpressed in %
Rain intensityexpressed in mm
Air quality
expressed in CO, NOX, O3, SO2...
Structural vibrationacceleration expressed in gvibration modes expressed in Hz
Angular movementtwo directions expressed in
Stress and deformationexpressed in m/m and in mm
Inspection and investigationpaper and multimedia reportslaboratory or in situ tests
Trafficexpressed in km/h, veh./h, t, type...
Cable forceexpressed in kN
Sun intensityexpressed in W/m2
Material ageingexpressed in Cl-, mV
OPERATINGCOST MAINTENANCE COST
www.v
sl-mo
nitor
ing.
com
Relevant information is sent
straight back to the users desk.
The system works with any IT
and measurement solution.
The Consultant
VSL
Remote server
The Owner
MYBRIDGE
MONITORING
LAUNCHING GANTRIES HEAVY LIFTING
DeMon system allows wireless connection from clients office to any type
of sensors on site through internet and wireless devices.
Shenzhen Western Corridor - Hong KongTaiwan High Speed Rail - Taiwan Nanjing Bridge Heavy Lifting - China
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V S L S S I 2 0 0 0 27 S T A Y C A B L E S Y S T E M
VSL products and servicesAs a specialist stay cable contractor,VSL provides comprehensive technicalassistance from the earliest stage ofthe preliminary studies right through tothe detailed design and constructionphases:
consulting services to owners,
engineers and contractors;
static analysis of the structure
(in cooperation with the Engineer);
assistance in the dynamic analysis
of cable vibrations and the
recommendation of solutions;
construction engineering;
geometry control during
construction and final adjustment
of cable forces;
method statements for the
construction of the structure andcable installation;
supply and installation of stay
cables, including anti-vibration
systems;
design and supply of specialist
equipment such as formwork,
launching trusses, climbing forms,
etc;
products and services for
monitoring, inspection,
maintenance and repair works.
TION
FORM TRAVELLERS & LIFTING FRAMES
BEARINGS REPAIR
DUCTAL
Angara Bridge - Russia
Pot Bearing
Figueira Da Foz Bridge repair - Portugal
Seonyu Footbridge - Korea
Preloaded seismic bearing
West Tsing Yi - Hong Kong Deep Bay Link - Hong Kong
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Copyright 2008, VSL International Ltd.
Printed in France patented.
The information set forth in this brochure including technical and engineering data is presented for
general information only. While every effort has been made to insure its accuracy, this information should
not be used or relied upon for any specific application without independent professional examination
VSL LOCATIONS HEADQUARTERSVSL International Ltd.
Scheibenstrasse 70 Bern
CH-3014 Switzerland
Phone: +41 58 456 30 30
Fax: +41 58 456 30 35
www.vsl.com
THAILANDVSL (Thailand) Co. Ltd.BANGKOKPhone: +66 2 679 76 15 - 19F ax : + 66 2 6 79 76 45
TURKEYMega Yapi Construction & Trade Co. LtdANKARAPhone: +90 312 490 90 66Fax : +90 312 490 90 55
VIETNAMVSL Vietnam Ltd.HANOIPhone: +84 4 976 50 88F ax : + 84 4 9 76 50 89
Ho Chi Minh CityPhone: +84 8 8106 817Fax: +84 8 8106 818
Australia
VSL Australia Pty. Ltd.NEW SOUTH WALESPhone: +61 2 9 484 59 44Fax: +61 2 9 875 38 94
QUEENSLANDPhone: +61 7 3265 64 00Fax: +61 7 3265 75 34
VICTORIAPhone: +61 3 979 503 66Fax : +61 3 979 505 47
AmericasARGENTINAVSL Sistemas Especiales deConstruccin Argentina SABUENOS AIRESPhone: +54 11 4326 06 09Fax : +54 11 4326 26 50
BOLIVIAPostensados de BoliviaSan Miguel, LA PAZPhone: +591 2 27 70 338Fax: +591 2 27 96 183
CHILEVSL Sistemas Especiales deConstruccin S.A.SANTIAGO
Phone: +56 2 571 67 00F ax : + 56 2 2 33 67 39
COLOMBIASistemas Especiales de Construccin Ltda.BOGOTAPhone: +57 1 620 96 34F ax : + 57 1 6 20 58 16
MEXICOVSL Corporation Mexico S.A de C.VMEXICOPhone: +52 5 511 20 36F ax : + 52 5 5 11 40 03
UNITED STATESVStructural LLCBALTIMORE, MDPhone: +1 410 850 7000Fax : +1 410 850 411 1
VENEZUELAGestin de Obras y Construcciones C.A.CARACASPhone: +58 212 941 86 75Fax: +58 212 941 86 75
Africa
EGYPTMatrix Engineering CompanyCAIROPhone: +20 2 344 19 00Fax: +20 2 346 04 57
MOROCCORenfor-BatTANGIERPhone: +212 39 95 80 87Fax : +212 39 95 80 85
SOUTH AFRICATsala-RMS Construction Solutions (Pty) LtdJohannesburgPhone: +27 11 878 6820Fax: +27 11 878 6821
EuropeAUSTRIAGrund-Pfahl- und Sonderbau GmbHHIMBERGPhone: +43 2235 87 777Fax : +43 2235 86 561
CZECH REPUBLICVSL Systems (CZ) Ltd.PRAGUEPhone: +420 2 51 09 16 80Fax : +420 2 51 09 16 99
FRANCEVSL France S.A.LABGEPhone: +33 05 61 00 96 59Fax : +33 05 61 00 96 62
GERMANYVSL Systems GmbHBERLINPhone: +49 30 53 01 35 32Fax : +49 30 53 01 35 34
GREAT BRITAINVSL Systems (UK) Ltd.BEDFORDSHIREPhone: +41 58 456 30 30Fax : +41 58 456 30 35
NETHERLANDSHeijmans Beton en Waterbouw B.V.ROSMALENPhone: +31 73 543 66 02Fax : +31 73 543 66 1 1
NORWAYVSL Norge A/SSTAVANGERPhone :+47 51 52 50 20Fax : +47 51 56 27 21
PORTUGALVSL Sistemas PortugalPre-Esforo, Equipamentoe Montagens S.A.S. DOMINGOS DE RANAPhone: +351 21 445 83 10Fax : +351 21 444 63 77
VSL GEOSistemas de Aplicao em Geotecnia SAS. DOMINGOS DE RANAPhone: + 351 21 445 83 10Fax: + 351 21 445 83 28
AsiaBRUNEIVSL Systems (B) Sdn. Bhd.BRUNEI DARUSSALAMPhone: +673 2 380 153 / 381 827F ax : + 67 3 2 38 1 9 54
CHINA PRCVSL (China) Engineering Corp., Ltd.HEFEIPhone: +86 551 382 29 18Fax : +86 551 382 28 78
HONG KONGVSL Hong Kong Ltd.CHAI WANPhone :+852 2590 22 88Fax : +852 2590 02 90
Intrafor Hong Kong Ltd.CHAI WANPhone :+852 2836 31 12Fax : +852 2591 61 39
FT Laboratories Ltd.PING CHEPhone: +852 2758 48 61Fax: +852 2758 89 62
INDIAVSL India PVT Ltd.CHENNAIPhone: +91 44 4225 11 11Fax : +91 44 4225 10 10
INDONESIAPT VSL IndonesiaJAKARTA
Phone: +62 21 570 07 86Fax : +62 21 573 12 1 7
JAPANVSL Japan CorporationTOKYOPhone: +81 3 3346 8913Fax: +81 3 3345 9153
KOREAVSL Korea Co. Ltd.SEOULPhone: +82 2 553 8200F ax : + 82 2 5 53 82 55
MALAYSIAVSL Engineers (M) Sdn. Bhd.KUALA LUMPURPhone: +603 7981 47 42Fax : +603 7981 84 22
PHILIPPINESVSL Philippines Inc.PASIG CITYPhone: +632 672 17 03F ax : + 63 2 6 72 13 95
SINGAPOREVSL Singapore Pte. Ltd.SINGAPOREPhone: +65 6559 12 22F ax : + 65 62 57 77 51
TAIWANVSL Taiwan Ltd.TAIPEIPhone: +886 2 2759 6819Fax : +886 2 2759 6821
SPAINCTT StrongholdBARCELONAPhone: +34 93 289 23 30Fax : +34 93 289 23 31
VSL-SPAM, S.A.BARCELONAPhone: +34 93 846 70 07Fax : +34 93 846 51 97
SWEDENInternordisk Spnnarmering ABVSTERHANINGEPhone: +46 8 5007 3820F ax : + 46 8 7 53 49 73
SWITZERLANDVSL (Switzerland) Ltd.SUBINGENPhone: +41 58 456 30 30Fax : +41 58 456 30 35
VSL (Suisse) SASAINT LEGIERPhone: +41 58 456 30 00Fax : +41 58 456 30 95
Middle East
UNITED ARAB EMIRATESVSL Middle East LLCDUBAI, UAEPhone: +971 4 333 6262Fax : +971 4 333 0008