Infrastructure: Maintenance & Inspection

Stay Cable Inspection

Basil Manoj

As cable stayed bridges are becoming common in India, the need to understand the inspection and maintenance of such bridges is
important in present scenario. This paper provides an overview on the methods and techniques used for inspecting the stay cables.
Also, it includes some of the non-destructive tests which are generally conducted on the stay cables are discussed in this paper.

Preface holes in HDPE, exposure& degradation of grout filler, broken

seals, broken transition joints, etc.
In a cable stayed bridge, inspecting and maintaining the stay
cables is an enormous and complicated task, as the wires/ Components Inspected
strands are hidden from the view of the inspectors posing
great difficulty. The high strength steel wire / strand used in Generally inspection of stay cable covers the following:
stay cable are vulnerable to fatigue and corrosion related - Inspection for any longitudinal or transverse crack on the
problems. The problems that could affect the performance outer surface of the stay cable
of stay cables are fatigue, corrosion, excessive vibration, etc.
In this article a brief overview on the inspection of stay cable
is presented.

Need for Inspection

The stay cables in the cable-stayed bridge need to be

inspected on regular intervals during the service period to
ascertain and guarantee its durability or to prevent them from
any type of damage. If any damage is detected in the stay
cable during inspection, special tests shall be conducted
depending on its severity.
As the load carrying wires are not visually seen, it is not
possible to conclude that the employed corrosion protection
is functioning well. Even if inspection ports are opened at
selected locations in the stay cable and observed the condition
visually, it is not sure that the corrosion or fatigue is localized
or for a small distance. In order to obtain a comprehensive
assessment on the challenges associated with accessing
the stay cable, detail visual inspection shall be implemented
combined with the available best technologies.
The general defects occur in the stay cable are rusting of
wires / strands and anchorages, water leakage in anchorage
zones, cracking/splitting of cable ducts / pipes, bulges or
Figure 1 Cable Car for inspecting Stay Cable
Figure 2 Movable Platform for inspecting Anchorages
- Inspection for any bulging or damage on the outer surface
of stay cable
- Inspection of cross-ties and its connections for any
damage or irregularities
- Inspection of dampers and its connections for its proper
functioning or any sort of damage
- Inspection of cable alignment for any waviness or
excessive sag
- Checking of stay cable angle
- Checking of force in stay cable
- Inspection of anti-vandalism tube for any deformation or
damage
- Inspection of stay cable anchorages and its components
for any damage or corrosion due to evidence of moisture
- Inspection of stay cable and anchorage connection for
any deformation or damage
- Inspection for any gap in the boots, clamps and neoprene
rings
- Inspection of stay cable inside the anti-vandalism tube for
any damage or deformation
- Inspection of all connections in the stay cable for its water
tightness and any deterioration

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 Infrastructure: Maintenance & Inspection
- Inspection of drainage holes in the anchorages for its
proper functioning
Inspection and Testing
Basic inspection is generally performed visually without any
tools or equipment. Detailed inspection is generally performed
visually and with tools & equipment at an interval of about five
years. For inspection, stay cable and its components can be
accessed using Cable Cradle, Reach-all Truck, Crane with
Passenger Basket, Lifts, Special Inspection Vehicles, etc.In
some special cases, the stay cable surface can be inspected
by closely viewing the cables using binoculars.
Figure 3 Mobile Crane Basket for inspection
Figure 4 Mobile Platform for inspection
To test the stay cable, there is no single method which will
give fool proof data regarding the condition of stay cable.
Combination of tests has to be conducted together with
the knowledge and experience of the Engineer / Technician
who conducts the test and judges the result.Non-Destructive
Testing shall be carried out on randomly selected stay cables
using any appropriate method.
234 The Masterbuilder - May 2013 www.masterbuilder.co.in
During the inspection, temperature should be recorded in the
surrounding areas of the stay cables and its components.
Some of the general Inspection and testing methods are
discussed hereunder in this article:
Visual Inspection
This is the only method of inspecting the stay cables in most
of the bridges. Inspection is done on the exterior surface of
stay cables & cross-ties including connections, exposed
surface of anchorages, dampers, boots and guide pipe
visually at close range.The caps in the anchorages shall be
removed and the condition of the wedges or button heads
shall be checked. Also any penetration of moisture inside the
anchorage shall be checked.
To inspect the wires in the stay cable, an inspection window
Figure 5 Distortion in Stay Cable
Figure 6 Corrosion in Anchorage
can be cut through the protective HDPE ducts / layers. In case
of grouted cable, the grout is removed to expose the wire /
strand and inspected.
Inspection also includes measurement of cable sag using
optical devices or through video or photo imaging. Stay
cable inclination angle can be measured using inclinometer
at specific points.Boroscopic examination shall be done by
 Infrastructure: Maintenance & Inspection

inserting special camera in the gap between the cable and the inspect the status signals of the inner wires in the stay cable,
guide pipe to check the condition of cable and the presence and the interfering signals are processed and the datais
of moisture if any. obtained. From the recorded data, image of the scatter field
is made along the axis of the cable which is then analyzed.
The surface of the stay cable can also be inspected by the
This method detects the exact location of wire fracture, initial
use of special camera that can move over the entire length of
corrosion and any other damage in the stay cable.
the cable which can be controlled from the ground.
Cable Force Measurement
Video Monitoring
By using Accelerometers and Non-contact sensors such
In this method, video cameras along with sensors and target
as laser vibrometers, stay cable force shall be measured to
tracking software are used to monitor the stay cable. The
determine whether global stiffness changes have occurred in
software captures the images through two cameras and
the cable.For measuring the force in the stay cable direct and
processes the same using photogrammetric algorithms and
indirect methods like lock-off-test andvibration analysis shall
transforms into three-dimensional coordinates, which is then
be carried out.
used to measure the sag in the stay cables.

Magnetic Flux Leakage

This is a non-destructive testing method which can identify

the location and extent of damage on the stay cable of
large diameter on its entire length and this method is more
reliable and cost-effective.This method consists of several
sensor units attached with two permanent magnets which are
attached to the stay cable at equal angles. When the magnetic
field is moved along the length of the cable, the sensors will

Figure 9 Inspection through Window Opening

Figure 7 Damage in HDPE Duct

Figure 10 Inspection of Guide Pipe, Damper & Boot

Ultrasonic Testing

In this method, an ultrasonic transducer is fixed at both ends

of the wire / strand in the stay cable at anchorage location,
and high frequency stress wave is transmitted into the wire
/ strand and the reflections are monitored. This testing is
more effective in individual wires rather than strand due to
Figure 8 Split in Neoprene Boot complexity in transmission of stress waves.

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 Infrastructure: Maintenance & Inspection
Radiography
This method is non-destructive based on radiography using
X-rays or Gamma rays which produces two-dimensional
images. This testing is generally done on the exposed
anchorages to access their condition. As this test involves
heavy equipment combined with huge cost and safety issues,
it has limited use.
Acoustic Monitoring
In this method the sounds in the cable are monitored to
Figure 11 Inspection of Dampers
Figure 12 Inspection of Anchorage Components
Figure 13 Magnetic Induction Test
236 The Masterbuilder - May 2013 www.masterbuilder.co.in
identify the specific acoustic event associated with the failure
of wire in the cable. This is a passive method to detect the wire
breaks in the stay cable and this method detects the accurate
location of wire break.It consists of sensors fixed at selected
points, and if there is a wire breaks, the stress wave travel
in both directions along the length of the cable. The location
of wire break can be determined comparing the arrival time
of shock waves at different sensors. The data acquisition
system acquires data from all the sensors which are then
reviewed at the processing center and the acoustic events
can be determined.
Structural Health Monitoring
Real time monitoring shall be done utilizing wide range / type
of sensors connected to the software.For vibration monitoring,
uniaxial accelerometer is used to capture in-plane vibration,
whereas biaxial accelerometer is used to capture both in-
plane and out-of-plane vibrations. According to the required
vibration modes of interest, sensors are selected to maximize
the desired response. These sensors are connected to the
high speed data acquisition system and monitored.
For measuring the tension in the stay cable, load cells or force
sensors shall be installed at desired location and the data can
be obtained.In case of parallel strand stay cable, the load in
Figure 14 Lift-off Test
Figure 15 Acoustic Monitoring
 Infrastructure: Maintenance & Inspection

the single strand can be determined by Lift-off test. In this

method, mono jack is installed at desired strand location, and
the load of the jack is increased until the movement of the
wedge is observed.
Other Advanced Techniques

In order to achieve more rigorous and thorough inspection

of stay cables, advanced techniques can be used such as
Magnetic induction, Electrical resistivity, Dye penetrant, Strain
Measurements, Vibration Measurements, Impulse Radar,
Laser Vibrometer, Infrared thermography, Measurement of
stress ranges, etc.
References
1. Transportation Research Board, Synthesis 353, Inspection and
Maintenance of Bridge Stay Cable Systems, National Cooperative
Highway Research Program.
2. Michael S. Higgins, Health monitoring combined with visual
inspections Obtaining a comprehensive assessment of cables. Figure 16 Cable Frequency Test

238 The Masterbuilder - May 2013 www.masterbuilder.co.in