Stay cable sheathing repair
DYWIDAG offers essential stay cable sheathing repair and replacement services to keep your structures safe and performing at their best. Our solutions include robotic and rope-access welding, section replacement, and retrofitting of helical fillets to improve cable dynamics and ice protection - all with minimal disruption and reduced need for scaffolding.
How HSPE Sheathing prevents stay cable corrosion
Stay cables are vital to bridge performance, and their durability depends on effective protection. DYWIDAG's High-Density Polyethylene (HSPE) sheathing acts as a critical barrier against stay cable corrosion, UV exposure, moisture, and mechanical damage - safeguarding the internal steel strands that carry the bridge’s load.
Over time, HSPE sheathing pipes can suffer from cracks, abrasions, or joint separations caused by weathering, vibration, or impact. Left unchecked, these defects can allow contaminants to reach the steel beneath, accelerating corrosion and structural deterioration.
DYWIDAG provides complete stay cable protection solutions — from the supply and installation of HSPE pipes and CableSkin™ wrapping to inspection, maintenance, and advanced repair. Using robotic and rope access techniques, we restore or replace damaged sheathing with minimal disruption, ensuring your cables remain protected and performing for the long term. And so, stay cable sheath repair should be considered a vital part of stay cable maintenance practices.
Identifying HSPE Sheath ageing and damage
HSPE and PE sheathing pipes form the outermost protective barrier around structural cables, shielding them from UV radiation, moisture, and environmental exposure. Over time, however, these pipes naturally age through thermal cycling, movement, and prolonged weathering, leading to visible and hidden signs of deterioration.
The most common visible change is colour fading; more than just an aesthetic issue, it can also signal material degradation or reduced UV resistance. More critically, cracks, punctures, or surface splits may develop, allowing water to penetrate the cable system. Depending on the cable type, this can pose significant risks; in grouted systems, for instance, water ingress can dissolve grout, leaving parallel wires exposed to corrosion.
DYWIDAG’s stay cable maintenance and inspection services combine robotic, visual, and non-destructive testing methods such as Magneto-inductive testing to identify early-0stage damage - both to the HSPE sheathing and the stay cable beneath. Working in synergy with our repair and maintenance services, these inspection insights enable us to plan and execute precise, efficient interventions, ensuring minimal disruption. By detecting issues before they escalate, we enable timely HSPE sheath repair or replacement, preserving the long-term integrity and service life of your stay cables.
Common signs of HSPE Sheath deterioration
Color fading
Often the earliest visible change, fading can indicate UV exposure and material degradation. While initially cosmetically poor, it can also signal that the sheath is losing its protective properties and becoming more brittle over time.
Surface cracking or splitting
Caused by thermal cycling, vibration, or aging, these fractures can allow water and contaminants to enter the system. Even fine cracks can propagate quickly, compromising the sheath’s integrity and increasing corrosion risk.
Punctures or impact damage
Typically resulting from debris, construction activity, or accidental contact, punctures create direct pathways for moisture and pollutants to reach the steel tendons beneath. Left unrepaired, they can accelerate localized corrosion.
Joint separation or distortion
Expansion and contraction, combined with mechanical stress, can cause gaps or misalignment at sheath joints. These openings allow continuous water ingress, especially in exposed bridge environments, leading to progressive cable deterioration
Our approach to stay cable sheathing repair
We offer a comprehensive portfolio of repair and enhancement solutions tailored to various cable types, including grouted parallel wire and strand cable systems. Depending on the type and extent of damage, our teams deploy the most suitable repair method to restore integrity quickly and safely:
Robotic or manual welding of cracks – For localized repairs, our technicians perform precision welding directly on site, even in difficult-to-access areas, our robots and rope access team minimize downtime and reduce the need for scaffolding or lane closures.
Replacement of damaged pipe sections – When cracks or punctures extend beyond repair, we remove and replace HSPE and PE pipe sections with high-performance materials that fully restore protection and appearance.
Re-grouting of cable systems – In grouted stay cables where water ingress has occurred, we carry out re-grouting to re-establish complete encapsulation of the steel wires. Using corrosion-inhibiting grout materials, our process fills internal voids, restores bond strength, and prevents future corrosion.
By combining hands-on expertise with advanced robotics DYWIDAG ensures precision, efficiency, and lasting protection in every HSPE and PE pipe repair project.
Manual and robotic welding repair
For more complex or extensive maintenance, DYWIDAG employs robotic welding technology for both longitudinal and 360° radial seams.
Developed in-house in Germany over many years, this proprietary system delivers clean, consistent, and technically precise welds that cannot be replicated manually. The result is a fully sealed and uniform repair — completed faster, safer, and with zero compromise on quality.
In the case of PE and HSPE pipe repair our experts are not welding metal, but thermally fusing polyethylene to recreate a seamless watertight barrier around the stay cable. Using controlled heat and pressure, the material is softened and re-joined, restoring the sheath’s original strength and protection against UV, moisture, and corrosion.
This combination of using both hands-on expertise and automated robotic precision allows DYWIDAG to deliver PE pipe repairs that are clean, consistent, and long-lasting — restoring complete protection while minimizing disruption to bridge operations.
Are your stay cables efficiently protected? Contact our stay cable pipe repair experts for complete peace of mind.
Stay cable anchor maintenance
At DYWIDAG, we take a holistic approach to stay cable protection and stay cable pipe repair — considering not only the sheathing but also the performance of the cable anchors that transfer loads into the structure. Over time, corrosion, grout degradation, or mechanical wear can weaken these critical components and compromise overall structural integrity.
Through visual inspections, non-destructive testing, and load assessments, DYWIDAG identifies potential anchor issues early and applies targeted solutions such as re-grouting, sealing repairs, and corrosion protection. These interventions restore anchor performance, prevent further deterioration, and extend the service life of the entire stay cable system.
By addressing the full protective chain — from the stay cable sheath to the anchorage zone — DYWIDAG ensures lasting reliability and durability for your bridge infrastructure.
Why choose DYWIDAG for cable repair?
Skilled cable experts & certified welders
Our experts hold PE-certified welding licenses and height safety credentials, with proven expertise across various stay cable and sheath types.
Precision repairs with robotic accuracy
For complex or extensive maintenance, our in-house developed robots perform high-quality welds of stay pipes, enhancing safety and consistency,.
Complete protection restoration
Beyond pipe repair, DYWIDAG offers full-system restoration, including section replacement, CableSkin™ retrofitting, and re-grouting — addressing both external damage and internal corrosion risks.
Safer. Stronger. Smarter
Our approach combines innovation, precision, and safety — from advanced inspection and welding systems to proven on-site expertise. Every solution is designed to extend cable life, enhance durability, and deliver long-term structural confidence.
Our related services
Cable cleaning and surface maintenance
Removal of surface contaminants, to prevent long-term degradation of the sheathing and anchor zones.
Stay cable detensioning and exchange
Controlled release and reinstallation of stay cables, ensuring structural stability and safety at every stage.
Damper replacement and retrofit
DYWIDAG offers inspection, replacement, and retrofit services for stay cable dampers.
Rope access
Safe and efficient access alternative allowing the delivery of technically complex work safely and efficiently.
Inspection & Testing
Comprehensive inspection and testing services, including visual surveys, non-destructive testing, and geotechnical assessments.
Bridge Monitoring
Enhance bridge safety and longevity with real-time Structural Health Monitoring (SHM).
Stay Cable Protection
Providing in-depth technical advice and advanced repair technologies customized to your project's unique conditions.
Our related products
Stay Cable Sheathings
Stay sheathings and dampers shielding against environmental influences.
Cableskin
Long-term UV and corrosion protection with minimal traffic disruption.
Blast-Protection
Blast protection for Stay Cables: Fullfills AASHTO bridge security guidelines.
Dampers
Extending service life of your cables.
Integrated Cable Illumination
Integrated LED displays with minimal wind load impact.
Stay Cable Strands
Designed to be maintenance-free.
Clevis Anchorage
Supports economical pylon structural design.
DYNA Grip Standard System
High fatigue performance and excellent durability.
DYNA Link Anchor Box System (Saddle Solution)
Value added saddle solution.
