Stay cable system installation

Stay cable systems are a proven solution for supporting long-span and complex structures such as bridges, stadiums, and architectural landmarks. First introduced in the mid-20th century, cable-stayed designs quickly became popular for their ability to achieve longer spans with fewer supports compared to traditional suspension bridges.

By transferring loads directly from decks or roof structures to towers or pylons, stay cables enable open, unobstructed spaces while maintaining structural integrity and safety. Modern systems combine high-strength steel strands with protective sheathing and anchorage technology to ensure durability against environmental elements.

DYWIDAG has led stay cable system innovation since the 1970s, beginning with the the first cable-stayed concrete bridge to carry both rail and road traffic (Werksbrücke West Bridge, Germany). Prior to the the launch of the DYNA Grip® System in 2000, our systems were built into the world’s first extradosed bridge in Japan (Odawara Blueway, 1994), the record-setting Kap Shui Mun Bridge in Hong Kong (1997).

We continue to advance cable technology on landmark projects worldwide, such as the Penang Bridge in Malaysia, the iconic Gordie Howe International Bridge, and Taiwan’s Danjiang Bridge, the world’s longest single-mast, asymmetric cable-stayed bridge.

Cable sheathing plays a critical role in protecting stay cables from environmental exposure and ensuring long-term durability. During installation, polyethylene sheathing is precisely prepared and positioned to safeguard the strands and maintain structural integrity.

For projects requiring enhanced protection, DYWIDAG offers a range of optional solutions, including carefully engineered sheathing systems, Cableskin® wrapping, and specialized coatings for corrosion prevention, UV resistance, and ice mitigation. These enhancements help extend cable lifespan, reduce maintenance costs, and preserve aesthetics over decades.

Accurate stressing at the anchorage zone is critical for the long-term performance and durability of stay cable systems. DYWIDAG provides specialized stressing and on-site supervision services to ensure every cable reaches the required forces safely, efficiently, and in full compliance with design specifications.

Using our lightweight ConTen or Gradient Jack equipment, featuring hydraulically coupled monojacks and a precision control unit, each strand is stressed individually, continuously monitored, and adjusted as needed. This process is suitable for any stay cable type or size and eliminates temperature and load variations during installation.

Continuous monitoring is essential for ensuring the long-term performance of stay cable systems. DYWIDAG offers integrated Structural Health Monitoring (SHM) solutions that provide real-time data on cable tension, vibration, and environmental conditions.

Our systems combine advanced sensors, data acquisition units, and analytics platforms to detect anomalies early, predict maintenance needs, and optimize lifecycle performance. By turning data into actionable insights, we help extend service life, reduce costs, and keep structures safe for decades.