Stay cable protection
Our expert teams deliver tailored stay cable protection using proven solutions such as Cableskin®, HDPE sheathing, and double sheathing systems. We keep your cable-stayed structures safe and performing at their best by providing in-depth technical advice and advanced repair technologies customized to your project's unique conditions. From robotic welding to rope access, we ensure reliable, corrosion-resistant performance and long-term durability of cable-stayed infrastructure.
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Lifespan Service Range - Brochure
Cableskin
Cableskin
Cableskin® (Base)
What is stay cable protection?
Stay cable protection refers to the use of materials and systems designed to shield the cables of cable-stayed bridges from environmental and mechanical damage. This includes protection from corrosion, UV radiation, temperature fluctuations, and physical wear.
How does it work?
Protection methods typically involve the application of external barriers such as HDPE sheathing, double sheathing systems, or specialized protective wraps. These layers act as a shield against moisture, pollutants, and other corrosive elements. Installation can be carried out manually or with robotic systems, depending on the design and complexity of the structure.
Why is it important?
Proper protection of stay cables is essential for ensuring the long-term safety, performance, and durability of bridge structures. It helps reduce maintenance needs, extend the service life of the cables, and lower overall lifecycle costs for infrastructure assets.
How is protection maintained?
Stay cable maintenance is essential to safeguarding the long-term performance, safety, and serviceability of cable-stayed bridges & infrastructure. A disciplined inspection and assessment program is the foundation for proactive asset management, enabling early identification of deterioration and proactive maintenance, before it escalates into costly interventions. Our expert team offers stay cable protection services to support you at every stage of asset life, from the installation to inspection and maintenance of protective materials.
Your trusted partner for robust stay cables
At DYWIDAG, we know that no two bridges are alike. That’s why our cable protection services combine smart technology with customized execution to strengthen new and ageing stay cables from installation, through to maintenance and ongoing monitoring—ensuring your unique bridge configuration gets exactly what it needs to stand the test of time.
Unlike one-size-fits-all approaches, we start with a detailed site survey to assess structural and environmental conditions. Then, we design a bespoke protection plan, executed by our specialist teams using precision robotics or skilled manual application—always with minimal traffic disruption.
Our global network of civil engineers and bridge experts has supported over 500 bridge projects, including some of the world’s longest stay cable structures. Backed by German engineering and recyclable materials, we also offer post-installation inspections and dehumidification system integration to extend your asset’s lifespan and reduce long-term maintenance.
Types of protection
Corrosion and UV protection
Steel cables and HDPE pipes degrade over time when exposed to harsh environments. Our high-performance wrapping systems prevent corrosion and UV damage, ideal for both maintenance and strengthening on new or existing bridges
Vibration and fatigue
Constant movement from wind and traffic can lead to long-term fatigue. We offer retrofit dampers, welded helical fillets, and engineered solutions to control vibrations and extend cable lifespan.
Fire Exposure
Stay cables need protection in high-temperature or fire-risk zones. Our fire-resistant wraps and coatings help safeguard structural performance and meet strict fire safety requirements.
Blast and impact
In critical or high-risk areas, stay cables must be ready for more than environmental stress. We provide blast protection systems that increase resilience against impact and intentional attack.
Ultimate protection with Cableskin® by DYWIDAG
DYWIDAG’s Cableskin® technology brings a time-proven pipeline coating method to bridge stay cables. Originally used on large-diameter pipelines since the 1960s, Cableskin® was re-engineered in 2004 for both new and aging stay cables, fusing multilayer butyl-rubber tapes into a single, seamless sheath.
Rather than relying on scaffolding or extensive surface prep, our self-driving CE-certified and semi-automated wrapping robots — alongside small, specialized crews — apply Cableskin® quickly, often completing a bridge in weeks instead of months. The system locks out moisture and pollutants, provides UV resistance, and is available in a variety of top-coat colors to suit aesthetic or project requirements.
Beyond installation, Cableskin® integrates with DYWIDAG’s Infrastructure Intelligence suite. Inspection robots capture surface imagery and inner-duct scans, feeding data into digital twins for real-time health monitoring. This end-to-end solution keeps traffic flowing, minimizes downtime, and ensures long-term cable performance backed by German engineering expertise.
What the Cableskin® system delivers
Robust multi-layer protection
Airtight, watertight butyl rubber barrier—impermeable to moisture, oxygen, and UV radiation.
Certified durability
60+ year service life; ETA‑13/0171 and Z‑30.11‑41 certified for C5-M (marine) and C5-I (industrial) environments.
Compatible with monitoring systems
Designed for integration with dehumidification systems and robotic inspection technologies.
Customizable top layer
Available in multiple colors to match aesthetic or project requirements.
HSPE Sheathing for long-term stay cable protection
Beyond Cableskin, DYWIDAG’s HSPE (High-Strength Polyethylene) sheathing provides a durable outer barrier that protects stay cables from UV radiation, moisture, and environmental wear. This outer layer plays a crucial role in preserving the structural integrity of cable-stayed bridges by preventing corrosion and reducing fatigue over the asset’s lifetime.
Repair and Maintenance of PE Sheathing
Over time, exposure to sunlight, temperature cycles, and weathering can cause the sheathing to fade or crack - early signs of material degradation that may allow water to penetrate and compromise the cable system beneath.
DYWIDAG offers a comprehensive HSPE sheathing repair and replacement service to restore and enhance these protective systems. Our solutions include robotic and rope-access welding, section replacement, and retrofitting of helical fillets to improve cable dynamics and ice protection—all performed with minimal disruption and without the need for scaffolding.
Cable fire and blast protection
In critical infrastructure, cable-stayed systems must be designed to withstand not only environmental exposure but also extreme events such as fire and blast. DYWIDAG provides advanced passive protection systems that safeguard structural cables and their anchorage zones against high temperatures and sudden impact loads, preserving the integrity of the structure even under severe conditions.
Our cable fire protection systems are engineered to delay heat transfer to the cable core, maintaining load-bearing capacity during fire exposure and allowing valuable time for safe evacuation or intervention. Using non-combustible, thermally insulating materials and modular assembly methods, these systems can be tailored to new installations or retrofitted to existing stay cables with minimal disruption.
For blast protection, DYWIDAG applies specialized sheathing and energy-absorbing configurations that mitigate shockwave effects and prevent secondary damage to the cable system. Combined with our inspection and maintenance services, these solutions form a comprehensive approach to resilience—ensuring your bridge remains safe, functional, and compliant throughout its lifecycle.
Want to know how our stay cable protection services can support your next project?
More related services
Cable cleaning and surface maintenance
DYWIDAG combines rope-access specialists and robotic technologies to remove surface contaminants, salt deposits, and biological growth to prevent long-term degradation of the sheathing and anchor zones.
Stay cable detensioning and exchange
Our teams are experienced in managing the 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, including the installation of next-generation systems that improve aerodynamic stability and reduce fatigue.
Rope access
DYWIDAG's rope access service offers a safe and efficient alternative allowing the delivery of technically complex work safely and efficiently - even in confined, high, or hazardous environments.
Our related products
We use a range of products to support the protection of stay cables from installation, through to maintenance and continuous monitoring.
Sistema DYNA Grip Standard
Alto desempenho em termos de fadiga e excelente durabilidade.
Sistema de caixa de ancoragem DYNA Link (solução de sela)
Solução de sela com valor agregado.
Ancoragem Clevis
Oferece suporte ao projeto estrutural econômico do pilone.
Revestimentos de cabos de suspensão
Revestimentos de estanqueidade e amortecedores que protegem contra influências ambientais.
Proteção contra incêndios
Evitar falhas nos cabos durante eventos extremos de incêndio.
Soluções de De-Icing
Controle de formação de gelo e descongelamento de cabos de sustentação com soluções passivas e ativas.
Proteção contra explosões
Proteção contra explosões para Stay Cables: Atende plenamente às diretrizes de segurança de pontes da AASHTO.
Amortecedores
Aumento da vida útil de seus cabos.
