The SATA Group operates the legendary French ski resorts of Alpe d’Huez, Les 2 Alpes, and La Grave in the Isère department. A particularly notable ropeway is the TPH160 du Dôme des Petites Rousses I-II, a high-capacity reversible aerial tramway in two sections that connects the Alpe d’Huez ski area with the resort of Vaujany.

For this installation – specifically for the four full-locked carrying ropes – the operator relies on the full service provided by Teufelberger-Redaelli.

Customer benefits of full service

As with other mountain ropeways, the decisive added value for the SATA group materializes through the takeover of the complexity management of the whole rope replacement process through one partner avoiding multiple interfaces.

From consulting on product selection and rope production to after-sales, Teufelberger-Redaelli supports ski resorts and urban installations from the very first moment across the entire rope lifecycle.

Instead of dealing with a multitude of interfaces and the associated frictional losses, the customer benefits from a single, central point of contact. This “one-stop-shop“ approach significantly reduces coordination efforts and creates clear responsibilities at every project step. For the operator, this primarily means much higher planning security.

“Instead of managing multiple subcontractors themself, ropeway operators benefit from our all-in-one integrated solution“ says Johannes Smetana, Head of Business Unit Cableways at Teufelberger-Redaelli: “We view the customer as an active partner to jointly ensure the optimal performance and longevity of the ropeway ropes.“

Technical consulting & on-site support

From initial consulting and precise calculations to selecting the optimal rope: for Teufelberger-Redaelli, customer orientation means personal support directly on-site by Area Sales Managers and experts from well known collaboration partners, as well as coordination with authorities to ensure rapid project implementation.

A good example is the aforementioned aerial tramway in Alpe d’Huez: after 35 years, one of the total of eight full-locked track ropes had to be replaced. These ropes, with a diameter of 68 millimeters, are installed on both sections of the ropeway.

In June 2025, the SATA Group decided to rely on Teufelberger-Redaelli, as Smetana reports: “Thanks to our longstanding cooperation with our partners in France, we were invited to present our solutions and worldwide references for the Stressless track rope.“

The replacement of carrying ropes can sometimes be more demanding than a new installation. For this reason, technical parameters and installation preparations were comprehensively reviewed and coordinated by all parties involved.

Rope production and digital manufacturing monitoring

The result was an order for an 80-ton carrying rope. This was manufactured in the Austrian/Italian production network, just like all other Teufelberger-Redaelli ropeway ropes. High-quality materials are processed into high-performance steel ropes using modern manufacturing technologies.

“Our know-how in strand compaction reliably increases the breaking force of small rope diameters, and our longstanding experience with socketing ensures high-performance connections,“ Smetana explains.

During production, the rope geometry is digitally and permanently monitored over the entire length using stationary GLD (Geometric LED Detection) and extensively tested in the company‘s own test rig and by renowned institutes. All products are CE certified.

Transport & logistics

Back to Alpe d’Huez: After the rope was completed in October 2025, the challenging transport of the 2,850-meterlong cable from the plant in Gardone (Brescia) to the valley station was carried out.

As with all projects, the Teufelberger-Redaelli service team inspected the construction on-site to define the ideal transport route, ensuring safe delivery even in difficult weather conditions.

“We take over the ‘last mile‘ for the customers and transport the rope to the final station on the mountain exclusively with well known and reliable freight forwarding partners,“ emphasizes Smetana.

In this specific case, the forwarder implemented a transport solution where the weight was split between two special trucks. Installation work was completed on time before the winter season. This is where the rope journey ends and the actual story begins.

Assembly: rope pulling and splicing

Teufelberger-Redaelli handles approximately 600 assembly assignments worldwide per year. The company organizes rope pulling and assembly, assists in the selection of tools, and takes over installation supervision in accordance with local safety regulations.

“The rope geometry is closely monitored by our assembly team or in cooperation with partner companies during installation. Two specialized splicing teams perform the new splice,“ says Smetana, describing the global procedure. The continuous, seamless installation service ensures maximum planning security – no interfaces, no delays.

Service & support during operation: maintenance and repair

The portable GLD (Geometric LED Detection), designed and patented by Teufelberger-Redaelli, analyzes the rope geometry over its entire length during operation. The R&V sensor, also developed by Teufelberger-Redaelli, measures rotation and vibration.

Additionally, high-speed cameras detect vibrations of structures and loose or elastic behavior of installation components. “The use of drones for inspections is already proven, providing access to all areas to be inspected, improving inspector safety, and reducing costs for renting mobile work platforms,“ says Smetana.

AI-powered monitoring

The AI-powered AIM tool (Alliance for Intelligent Rope Monitoring) combines MRT, GLD, and AI technologies. The all-in-one device detects rope anomalies, defects, and corrosion at an early stage. Data is available in real-time and regardless of location. With AIM, Teufelberger-Redaelli and its partners are opening up entirely new possibilities for camera-based, visual condition monitoring.

The AI-powered monitoring increase the system availability for operators, reduce downtime, and enable predictive maintenance, Smetana concludes: “When operators choose us, they choose more than just technology. They choose a partnership focused on mutual success.“