The first engineering application of 10MN CFRP cables in cable-stayed bridge in China

Existing engineering applications typically involve carbon fiber reinforced polymers (CFRP) cables with relatively small ultimate tensile forces (less than 10MN). This study presents the engineering application of China's first thousand-ton-grade CFRP cable-stayed bridge. The optimal steel and CFRP hybrid cable system was determined through a comparative analysis of structural behavior and life cycle cost. Thereafter, the CFRP cable, consisting of 121 strands of φ7 CFRP tendons, along with its anchoring system, was designed and manufactured with a theoretical ultimate tensile strength of 10,710 kN (). Subsequently, the mechanical properties of 7–121 CFRP cable were investigated and experimentally verified. The tensile test revealed a satisfied ultimate tensile bearing capacity of 10,805 kN. Furthermore, after two million fatigue cycles, the CFRP cables retained approximately 90 % of their theoretical ultimate force, highlighting their excellent fatigue resistance. Besides, no damage occurred with a maintained tension force of 0.45 at a temperature of 150 °C for a duration of at least 30 min, meeting the requirements of specification. Moreover, the key procedures of CFRP cable installation were also claimed. This study aims to further promote the application and development of CFRP cables in larger span and even super-long span bridges.