Mining. Specialist rope solutions for the world s most demanding applications

Transcription

1 Miig Specialist rope solutios for the world s most demadig applicatios

2 Global techology leader i the maufacture of wire ad rope solutios for the world s most demadig applicatios Drawig from a backgroud of log stadig experiece ad techology, Brido is a ackowledged world leader i the desig, maufacture, developmet ad supply of steel wire ropes to meet the eeds of the miig idustry. Miig Why Choose Brido? Brido O-Site Services Product Selectio Product Tables Techical Iformatio Cotacts Miig

3 INTRODUCTION We are happy to recommed Brido as a reputable maufacturer ad supplier of wire ropes i challegig key applicatio areas, we use their wire ropes o our key equipmet ad the uptime is very essetial for us as a successful miig operator. Brido also provides excellet traiig to our maiteace persoel o key aspects of wire rope usage ad maiteace. Brido products have stood up to our expectatios from a world class wire rope maufacturer. DISCLAIMER Whilst every effort has bee made to esure the accuracy of iformatio i this publicatio, o guaratee or warraty (express or implied) is give with respect to the accuracy or completeess of the iformatio cotaied withi. This publicatio ad the products described herei may be chaged or updated without otice. Ay ad all liability whatsoever for ay loss or damage arisig, directly or idirectly, out of or i coectio with the use of this publicatio, is excluded to the fullest extet permitted by law. The user must determie the suitability of the product for their ow particular purpose, either aloe or i combiatio with other products ad shall assume all risk ad liability i coectio therewith. This documet is published by Brido Iteratioal Limited i the Uited Kigdom. Use of this publicatio shall be govered i accordace with the laws of Eglad & Wales ad the Eglish courts shall have exclusive jurisdictio over ay dispute cocerig your use of this publicatio. INTELLECTUAL PROPERTY All rights reserved. No parts of this publicatio may be reproduced or trasmitted i ay form or by ay meas without the prior writte permissio of the copyright holder, applicatio for which should be addressed to Brido Iteratioal Limited. All trademarks used i this publicatio belog to Brido or the registered proprietors of such marks. All rights relatig to such trademarks, copyright ad ay other itellectual property rights are reserved for Brido or the perso/orgaisatio cotributig the relevat materials. Miig 03

4 WHY CHOOSE BRIDON? For more tha 100 years, Brido has bee committed to maufacturig excellece, leadig the field i egieered superior rope solutios, offerig urivalled products developed specifically to miimise operatig costs ad maximise productivity. There ca be o compromise o the quality of rope you choose, at Brido we uderstad that safety ad operatig costs are critical to your busiess, that s why we are cotiuously ivestig i our expertise to esure the highest stadards i the developmet of wire ad rope solutios. It has ever bee so importat to choose the best rope, so make sure you make the right choice. Come ad talk to us to esure you have the ultimate performig product. Your success is our success 04 Miig

5 WHY CHOOSE BRIDON? BRIDON ENGINEERED At Brido we set our maufacturig stadards higher tha At Brido we are costatly strivig to improve our existig the idustry stadards, producig our ow wire used i products ad services i order to satisfy the dyamic the maufacture of our ropes to esure exceptioal quality markets we serve. Sice we cotrol our productio process cotrol. Therefore, we ca adjust maufacturig requests from raw material to fiished product, every step of to meet exactig requiremets for specific applicatios ad maufacturig is subject to improvemet ad iovatio. esure icredible urivalled performace. At the Brido Techology Cetre, a world leadig cetre of excellece i steel ad sythetic fibre rope techology developmet ad testig, we haress the wealth of kowledge acquired by servig global idustries for more tha a cetury. It has ever bee so importat to choose the best rope, so make sure you make the right choice. Come ad talk to us to esure you have the ultimate performig product. Your success is our success We add to this sigificat ivestmets i persoel, test equipmet ad foresic laboratories. This is a clear demostratio of Brido s commitmet towards ext geeratio, iovative rope techology ad developmet to meet the ever icreasig demads ad challeges of the markets we serve. The Brido Techology cetre will accelerate the developmet of rope techology which will icrease the safety, performace ad operatioal life of ropes workig i demadig ad hostile eviromets, specifically desiged for Oil ad Gas, Miig, Costructio ad Fishig sectors. BRIDON ASSURED We focus o the quality of our reputatio as strogly as o the quality of our rope. Our busiess values, idustry leadership, customer service, ad techical expertise are respected aroud the globe. We re costatly researchig ad developig. We offer the most i-depth urivalled rage of wire rope products for Oil & Gas, Miig, Costructio ad Fishig sectors. Quality cotrol systems have bee developed ad implemeted which combie process cotrol ad product ispectio esurig that oly fully coformig product progresses through maufacturig. Records of these activities are maitaied ad iclude full traceability to the raw materials used. Miig 05

6 BRIDON ON-SITE SERVICES Brido O-Site Services provide expert operatioal support to help you get the optimum performace from your ropes. Our highly competet rope techicias ad egieers offer flexible services to suit your eeds. Global Support Brido O-Site Services cover a extesive rage of applicatios globally, icludig: Equipmet Hire; NDE devices, Motorised Reel Stads & Wiches Periodic ad aual examiatios icludig NDE ad rope sample testig Flexibility - outsource egieers by day, week or project Maufacturig records & certificatio maagemet Post-retiremet examiatio & feedback systems Traiig Lear from the experts, i additio to our extesive service & retal equipmet portfolio, we also build tailored traiig packages to meet specific customer eeds or complete rope maagemet courses coverig; Examiatio Lubricatio & Corrosio Protectio Istallatio Termiatio Choose from: Total Rope Solutios Rope Ispectio ad No-Destructio Examiatio (NDE) Services Istallatio & Rope Commissioig Supervisio Services Rope Splicig, Riggig ad Termiatio Services Rope Pressure Lubricatio ad Corrosio Protectio Services 06 Miig

7 BRIDON ON-SITE SERVICES EXPERT SUPPORT TO MAXIMISE ROPE LIFE From iitial specificatio through istallatio ad maiteace Brido ca offer expert advice ad O-Site Services to esure your ropes provide safe reliable performace eve i the most demadig applicatios. Selectio & specificatio Rope record maagemet Storage & trasport Guidace o discard & feedback Total Service Solutios We provide cost effective support to maximise the operatioal life of our customers ropes. Istallatio Tesile testig Maiteace Ispectio & examiatio Would you like to kow more? Please cotact: Service Desk UK: + 44 (0) services@brido.com Miig 07

8 Product Selectio 08 Miig

9 PRODUCT SELECTION Hoist Ropes Parallel Drum Hoist Tiger 6R Tiger Dyform 6R Tiger 6T Compoud / Bristar Tiger Dyform 18M/PI Tiger 24LS/PI Tiger Dyform 24LS/PI Tiger Dyform 34LR MAX Tiger Dyform 34LR / PI Class Tiger Full Lock Widig Rope Applicatio Hoist Rope FLCWR Costructio Covetioal Multi-Strad Dyform Resistace Rotatio Resistat Suitable for Multi-Layer Spoolig Reduced Stretch High Breakig Force Performace High Performace Log Service Life Ehaced Wear Resistace Applies to PI products oly. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 09

10 Hoist Ropes Blair Hoist Tiger 6R Tiger Dyform 6R Tiger 6T Compoud / Bristar Tiger Dyform 18M/PI Tiger 24LS/PI Tiger Dyform 24LS/PI Tiger Dyform 34LR MAX Tiger Dyform 34LR / PI Class Tiger Full Lock Widig Rope Applicatio Hoist Rope FLCWR Costructio Covetioal Multi-Strad Dyform Rotatio Resistat Resistace Suitable for Multi-Layer Spoolig Reduced Stretch High Breakig Force Performace High Performace Log Service Life Ehaced Wear Resistace Applies to PI products oly. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 10 Miig

11 PRODUCT SELECTION Hoist ad Balace Ropes Groud Mouted Frictio Hoist Flat Balace Rope Tiger Superflex Tiger 34M SPI Tiger 34M Tiger 24LS/PI Tiger Dyform 6R Tiger 6T Compoud / Bristar Tiger Dyform 24LS/PI Tiger Dyform 34LR / PI Class Tiger Full Lock Widig Rope Applicatio Hoist Rope Balace Rope FLCWR Costructio Covetioal Multi-Strad Dyform Resistace Rotatio Resistat Reduced Stretch High Breakig Force Performace High Performace Log Service Life Good Wear Resistace Applies to PI products oly. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 11

12 Hoist ad Balace Ropes Tower Mouted Frictio Hoist with Deflectors Flat Balace Rope Tiger Superflex Tiger 34M SPI Tiger 34M Tiger 24LS/PI Tiger Dyform 6R Tiger 6T Compoud / Bristar Tiger Dyform 24LS/PI Tiger Dyform 34LR / PI Class Tiger Full Lock Widig Rope Applicatio Hoist Rope Balace Rope FLCWR Costructio Covetioal Multi-Strad Dyform Resistace Rotatio Resistat Reduced Stretch High Breakig Force Performace High Performace Log Service Life Good Wear Resistace Applies to PI products oly. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 12 Miig

13 PRODUCT SELECTION Guide & Rubbig Ropes Tiger Half Lock Guide Rope Applicatio Guide & Rubbig Rope Costructio Spiral Costructio Corrosio Resistat Resistace Wear Resistat Reduced Stretch High Performace Performace Log Service Life Decreased Dowtime This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 13

14 Rope Drive Coveyor (RDC) Tiger 6 CDR Tiger Dyform 6 CDR Dyform Bristar Zebra Applicatio Rope Drive Coveyor (RDC) Costructio Dyform / Compacted Plastic Techology Wear Resistat Resistace Reduced Vibratio ad Noise Reduced Stretch High Performace Performace Log Life Decreased Dowtime This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 14 Miig

15 PRODUCT SELECTION Haulage Ropes Tiger 6 R Tiger 6T Compoud Tiger Dyform 6 R Applicatio Haulage Rope Costructio Dyform Crush Resistat Resistace Wear Resistat Reduced Stretch This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 15

16 Stage Sikig Ropes Tiger Dyform 34LR MAX Tiger Dyform 34LR/PI Tiger Dyform 24LS/PI Tiger 24LS/PI Applicatio Stage Sikig Ropes Kibble Ropes Multi-Strad Costructio Dyform Roller Compacted Plastic Techoology Rotatio Resistat Resistace Crush Resistat Reduced Stretch Ehaced Breakig Load Performace High Breakig Force High Performace Applies to PI products oly. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 16 Miig

17 PRODUCT TABLES Product Tables Miig 17

18 Tiger Full Lock Widig Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC WSC Available as stadard. Variable Torque ad Tur characteristics available by desig Nomial Diameter Nomial Legth Mass Calculated Aggregate Breakig Force Stadard Grade Higher Grade Calculated Miimum Breakig Force Stadard Grade Higher Grade mm kg/m The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 18 Miig

19 PRODUCT TABLES Tiger Dyform 34LR/PI Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv WSC Diameter Approx Mass 1570 N/ mm 2 Calculated Aggregate Breakig Force 1770 N/ mm N/ mm N/ mm N/ mm N/ mm 2 Calculated Miimum Breakig Force 1770 N/ mm N/ mm N/ mm N/ mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 19

20 Tiger Dyform 34LR MAX Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC WSC Nomial Diameter Nomial Legth Mass Grade 2060 N/mm 2 Calculated Miimum Breakig Force Grade 2160 N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 20 Miig

21 PRODUCT TABLES Tiger Dyform 24 LS - Hoist Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC Nomial Diameter Approx. Mass 1570 Calculated Aggregate Breakig Force Calculated Miimum Breakig Force mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 21

22 Tiger Dyform 24 LS PI (Plastic Impregated) - Hoist Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Bright Galv NFC SFC Nomial Diameter Approx. Mass 1570 Calculated Aggregate Breakig Force Calculated Miimum Breakig Force mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 22 Miig

23 PRODUCT TABLES Tiger 24 LS PI (Plastic Impregated) - Hoist Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC Nomial Diameter Approx. Mass 1570 Calculated Aggregate Breakig Force Calculated Miimum Breakig Force mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 23

24 Tiger 24 LS - Hoist Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Bright Galv NFC SFC Nomial Diameter Approx. Mass 1570 Calculated Aggregate Breakig Force Calculated Miimum Breakig Force mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 24 Miig

25 PRODUCT TABLES Tiger 24 LS - Balace Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Bright Galv NFC SFC Nomial Diameter Approx. Mass 1180 Calculated Aggregate Breakig Load Calculated Miimum Breakig Load mm kg/m The omial legth mass values are for fully lubricated ropes. Balace ropes are ormally desiged to achieve a desired weight. Ropes with the required weight ad stregth will be desiged to meet particular shaft requiremets. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 25

26 Tiger Dyform 6R 6x36(WS) Bristar Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC IWRC BRISTAR Available as stadard. IWRC values available o request Diameter Approx Mass Calculated Aggregate Breakig Force 1570 N/mm N/mm N/mm 2 Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 26 Miig

27 PRODUCT TABLES Tiger 6R 6x36(WS) Bristar Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC IWRC BRISTAR Available as stadard. IWRC values available o request Diameter Approx Mass Calculated Aggregate Breakig Force 1570 N/mm N/mm N/mm 2 Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 27

28 Tiger Dyform 6R 6x19(S) Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC IWRC Available as stadard. IWRC values available o request Diameter Approx Mass Calculated Aggregate Breakig Force 1570 N/mm N/mm N/mm 2 Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 28 Miig

29 PRODUCT TABLES Tiger 6R 6x19(S) Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC IWRC Available as stadard. IWRC values available o request Diameter Approx Mass Calculated Aggregate Breakig Force 1570 N/mm N/mm N/mm 2 Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 29

30 Tiger 6R 6x7 Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC IWRC Available as stadard. IWRC values available o request Diameter Approx Mass Calculated Aggregate Breakig Force 1570 N/mm N/mm 2 Calculated Miimum Breakig Force 1570 N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 30 Miig

31 PRODUCT TABLES Tiger 6T Compoud Layer 6x26, 6x27, 6x28 Tiger 6T Compoud Layer 6x26, 6x27, 6x28 (Bristar) Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC BRISTAR Diameter Approx Mass Calculated Aggregate Breakig Force Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm N/mm N/mm N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 31

32 Tiger 6T Compoud Layer 6x22, 6x23, 6x25 (9/12/Bragle) Tiger 6T Compoud Layer 6x22, 6x23, 6x25 (Bristar) Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC BRISTAR Diameter Approx Mass Calculated Aggregate Breakig Force Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 32 Miig

33 PRODUCT TABLES Tiger 6T Sigle Layer 6x8(7/Bragle), 6x10(9/Bragle) Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC Diameter Approx Mass Calculated Aggregate Breakig Force Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Ropes for frictio widig applicatio will weigh approximately 2% less tha the above quoted weights. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 33

34 Tiger Dyform 18M/PI Class Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC WSC Diameter Approx Mass Calculated Aggregate Breakig Force 1570 N/mm N/mm N/mm 2 Calculated Miimum Breakig Force 1570 N/mm N/mm N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 34 Miig

35 PRODUCT TABLES Tiger 34M Hoist ad Balace Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC WSC Diameter Approx Mass Balace 1180 N/mm 2 Calculated Aggregate Breakig Force Balace 1370 N/mm 2 Balace & Hoist 1570 N/mm 2 Hoist 1770 N/mm 2 Hoist 1960 N/mm 2 Balace 1180 N/mm 2 Calculated Miimum Breakig Force Balace 1370 N/mm 2 Balace & Hoist 1570 N/mm 2 Hoist 1770 N/mm 2 Hoist 1960 N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Balace ropes are ormally desiged to achieve a desired weight. Ropes with the required weight ad stregth will be desiged to meet particular shaft requiremets. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 35

36 What is oe pass techology? Brido s proprietary techology to maufacture our 34M SPI Extruded Roud Balace Rope i oe pass allowig a homogeous sheathig ad plastic impregatio process. The result: a superior rope performace, reliability ad safety. Tiger 34M SPI Balace Rope (Fully Sheathed ad Plastic Impregated rope) Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC WSC Nomial Plasticated Diameter Nomial legth mass Calculated Aggregate Breakig Force Calculated Miimum Breakig Force Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade mm kg/100m The omial legth mass values are for fully plasticated ropes. Subject to a tolerace of mius 2% to plus 5%. Balace ropes are ormally desiged to achieve a desired weight. Ropes with the required weight ad stregth will be desiged to meet particular shaft requiremets. Diameter: Off tesio diameter subject to a tolerace of mius 0% to plus 4.5%. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 36 Miig

37 PRODUCT TABLES Tiger Superflex Balace Rope 17x6, 20x6 Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC IWRC Available as stadard. Nomial Diameter Nomial Legth Mass Calculated Aggregate Breakig Force Calculated Miimum Breakig Force N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2 mm kg/m 17x x The omial legth mass values are for fully lubricated ropes. Balace ropes are ormally desiged to achieve a desired weight. Ropes with the required weight ad stregth will be desiged to meet particular shaft requiremets. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. Read page 74 cautioary otice - Restrictios o the use of large diameter multi-strad ropes. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 37

38 Flat Balace Rope 8x4x7, 6x4x12, 8x4x12, 8x4x14, 8x4x19 Costructio Fiish Sigle Stitched Double Stitched Clamped Bright Galv Available as stadard. Nomial Dimesios Width x b x Thickess s Double Stitched (d) Sigle Stitched (e) or Clamped (k) Nomial Diameter of the Load Carryig Wires Sum of the Nomial Cross- Sectioal Areas of the Load Carryig Wires Double Stitched (d) Calculated Mass Per Uit Legth of the Lubricated Rope Sigle Stitched (e) Clamped (k) Nomial Aggregate Breakig Load at a Tesile Grade of the Wires of N/mm 2 N/mm 2 mm mm mm mm 2 kg/m kg/m kg/m Rope Costructio 8 x 4 x 7 = 8 Legs with 4 Strads each havig 1+6 Wires = 224 wires 110 x x x x x x x x x x x x x x Rope Costructio 6 x 4 x 12 = 6 Legs with 4 Strads each havig 3+9 Wires = 288 wires 112 x x x x x x x x x x x x x x Rope Costructio 8 x 4 x 12 K= 8 Legs with 4 Strads each havig 3+9 Wires = 384 wires 146 x x x x x x x x x x x x x x Rope Costructio 8 x 4 x 14 K= 8 Legs with 4 Strads each havig 4+10 Wires = 448 wires 168 x x x x x x x x x x Rope Costructio 8 x 4 x 19 K= 8 Legs with 4 Strads each havig Wires = 608 wires 186 x x x x x x x x x x x x x x The omial legth mass values are for fully lubricated ropes Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 38 Miig

39 PRODUCT TABLES Tiger Half Lock Guide/Rubbig Rope Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC WSC Nomial Diameter Nomial Legth Mass Calculated Aggregate Breakig Force Stadard Grade Higher Grade Calculated Miimum Breakig Force Stadard Grade Higher Grade mm kg/m The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 39

40 Tiger 6CDR 6x19(S)(9/9/1), 6x25(F)(12/6+6F/1) Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC Bristar Available as stadard. Bristar values available o request Nomial Diameter Nomial Legth Mass Grade 1670 N/mm 2 Calculated Miimum Breakig Force Grade 1820 N/mm 2 mm kg/m The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 40 Miig

41 PRODUCT TABLES Tiger Dyform 6CDR Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv NFC SFC Bristar Available as stadard. Bristar values available o request Nomial Diameter Nomial Legth Mass Grade 1670 N/mm 2 Calculated Miimum Breakig Force Grade 1820 N/mm 2 mm kg/m 6x19S 6x31WS The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 41

42 Tiger Dyform Bristar Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv BRISTAR Nomial Diameter Rope Weight Calculated Aggregate Breakig Load Calculated Miimum Breakig Load mm kg/m 6x19S x25WS x31WS The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido 42 Miig

43 PRODUCT TABLES CDR Lay Type Lay Directio Fiish Core Ord Lags Right Had Left Had Bright Galv Modified Core Nomial Diameter Nomial Legth Mass Grade 1670 N/mm 2 Grade 1670 N/mm 2 Calculated Miimum Breakig Load Grade 1820 N/mm 2 Grade 1820 N/mm 2 mm kg/m toes toes 6x19S x26WS x31WS The omial legth mass values are for fully lubricated ropes. Read pages Product Safety Istructios ad Warigs o the use of steel wire rope before selectig or usig this product. This table is for guidace purposes oly with o guaratee or warraty (express or implied) as to its accuracy. The products described may be subject to chage without otice, ad should ot be relied o without further advice from Brido Miig 43

44 Techical Iformatio 44 Miig

45 PRODUCT TABLES 1. Hoist Ropes Various costructios of ropes may be used for hoistig, the fial choice usually beig decided upo ecoomic grouds. What may be a satisfactory life o a shallow high frequecy hoist, may be completely uecoomic o a deep low frequecy istallatio, ad therefore the rope desigs as well as their sizes must be cosidered. 1.1 Drum Hoists 6 Straded Ropes both roud ad triagular strad are satisfactory for all depths of shafts, although perhaps best suited for those up to 1000m i depth with fixed guides. They are ot suitable for shafts deeper tha 600m with rope guides, as their atural tedecy to twist causes the coveyace to tur. As a rough guide to the costructio of the rope, the ratio of drum or sheave diameter to outer wire diameter should be betwee 1000 ad 1500:1, although if abrasio is severe this ca be reduced slightly at the expese of a lower fatigue life. For maximum resistace to wear ad crossover damage the use of Lag s lay is recommeded. Multi-Strad Rotatio Resistat Ropes are ow used o permaet drum hoist istallatios, except where multi-layer coilig is employed, due to their relatively low resistace to compressive forces. Certai costructios are suitable for sikig purposes. Multi-strad ropes with Dyformed (compacted) strads have icreased resistace to crushig over ropes with covetioal strads. Locked Coil Ropes have gaied i popularity ad are extesively used throughout the UK. They ca be used to advatage o ay depth of shaft with either fixed or rope guides. As they are virtually o-rotatig uder ormal loadig coditios they are cosidered to be the best rope to operate i shafts deeper tha 700 metres equipped with rope guides. regio of 100 to 120:1 for satisfactory service life o mai shaft widers ad for kibble ropes used i shaft sikig. Ratios as low as 50:1 ca be tolerated o small ropes i shallow shafts, staple shafts ad sikig stage widers. 1.2 Frictio or Koepe Hoists 6 Straded Ropes are suitable to depths of 1000 metres. Beyod that the torque i these ropes ca result i premature torsioal fatigue of the wires. Triagular strads are more suited due to the lower cotact pressures o the frictio liigs although Lag s lay equal laid roud strad ropes are quite suitable for shallow shafts. Roud strad ropes with Dyformed (compacted) strads are becomig more popular as they offer higher breakig loads, icreased fatigue life ad reduced cotact pressures over ropes with covetioal strads. With rope guided shafts, alterate left ad right had lay ropes are employed to prevet coveyace twist. Tread pressures with straded ropes are limited to 17.5 kgf/ cm2 (1.72Mpa) to avoid excessive wear of the frictio liigs. Multi-Strad Rotatio Resistat Ropes ca be usefully employed at all depths of shaft ad geerally satisfactory lives are obtaied. Earlier desigs of the ropes were subject to severe iteral cross-cuttig. However moder desigs icorporatig Dyformed (compacted) strads ad plastic ehacemet coupled with moder maufacturig techiques. Tread pressure limits are similar to those of 6 straded ropes. Locked Coil Ropes are widely used o this type of hoist particularly i the UK. The advatages offered by ropes of this costructio make them particularly suited for this type of hoist especially if rope guides are employed. Due to the large smooth surface area of locked coil ropes, tread pressures of up to 28.0 kgf/cm2 (2.75MPa) ca be tolerated. The limit is used to miimise frictio lier wear, the rope beig able to withstad much higher pressures. The cross sectio is extremely compact ad as a result such ropes ca withstad very high radial ad compressive forces This property coupled with their smooth outer surface eables them to be used to advatage o multi-layer coilig istallatios. Because of their compact cross sectio, it is desirable that the drum or sheave diameter to rope diameter ratio should be i the Miig 45

46 1.3 Recommeded Rope Costructios for various wider applicatios Type of wider applicatio Small drum hoist operatig at less tha 2.5m/s i a vertical shaft with fixed guides Small Drum hoist operatig i a vertical shaft with rope guides Large drum hoist operatig i a vertical shaft with fixed guides Large drum hoist operatig i a vertical shaft with rope guides Blair multi-rope hoist Rope Costructio 6x19(9/9/1) FC Lags Lay Full Locked Coil Multi-strad Rotatio Resistat Full Locked Coil Compoud Triagular Strad Lags Lay Full Locked Coil Dyform 6R Ordiary/Lags Lay Multi-strad Rotatio Resistat Full Locked Coil 2. Sikig Ropes Kibble Ropes Ropes used for these duties must be rotatio resistat, to prevet excessive spi of the kibble or bucket i the shaft. Providig the hoist equipmet is suitable, flexible full locked coil ropes meet these requiremets admirably, ad have bee used successfully for may years. Where very small diameter sikig drums ad sheaves are employed, or where a sheave is fitted above the kibble to eable two parts of rope to support the load, multi-strad rotatio resistat ropes are recommeded. Brido s dedicated Miig Departmet will be pleased to discuss ad recommed the best rope costructio for optimum performace o your kibble wider. Stage Ropes There are several methods of suspedig the sikig stage or platform ad this ca gover the choice of rope costructio. Frictio hoist operatig to a depth of 500m Frictio hoist operatig to a depth betwee 500m ad 1000m Frictio Hoists above 1000m Sikig stage wider Kibble wider Compoud Triagular Strad Lags Lay Full Locked Coil 6 strad Ordiary/Lags Lay Compoud Triagular Strad Lags Lay Multi-strad Rotatio Resistat Full Locked Coil Dyform 6R Ordiary/Lags Lay 6 Strad Ordiary/Lags Lay Compoud Triagular Strad Lags Lay Multi-strad Rotatio Resistat Full Locked Coil Dyform 6R Ordiary/Lags Lay Locked Coil Widig Ropes Mult-strad Rotatio Resistat Dyform 6R Ordiary/Lags Lay Compoud Triagular Strad Lags Lay Multi-strad Rotatio Resistat Full Locked Coil Alterate Lay Triagular Strad Lags Lay Stage ropes are ormally required to act has guide ropes for the kibble, so resistace to wear is a ecessary characteristic. I additio, a good resistace to crushig o multi-layer drum coilig is required. Full locked coil ropes offer excellet performace o the correct desig of equipmet. Where smaller drums ad sheaves are employed multi-strad rotatio resistat ropes with relatively large outer wires or triagular strads with equal umbers of left ad right had lay ca be used. With triagular strad ropes however, problems ca be experieced with cotrollig the tur if slack rope coditios occur. Brido s dedicated Miig Departmet will be pleased to discuss ad recommed the best rope costructio for optimum performace o your stage wider. Uder ormal circumstaces it is recommeded that ropes for both applicatios, but i particular stage ropes, should be maufactured from galvaised material. However, where higher tesile grades of wire are required galvaised material is ot always available. I these cases it is strogly recommeded that the ropes are regularly cleaed ad re-lubricated with emphasis o the evaluatio of corrosio durig examiatio. Multi-strad Rotatio Resistat Full Locked Coil Multi-strad Rotatio Resistat Superflex Flat rope Miig

47 TECHNICAL INFORMATION 3. Balace Ropes Geerally balace ropes are required to have the flexibility to suit the particular cage cetres, adequate rotatio resistat properties combied with good resistace to wear ad corrosio. Brido s rage of multi-strad rotatio resistat ad Flat Balace ropes have the capability to meet the eeds for all balace rope applicatios. Brido s Superflex balace ropes were developed for istallatios where maximum flexibility is required combied with optimum resistace to wear ad corrosio. The rage of ropes is almost completely o-rotatig, however it is commo idustry practice to also use a swivel withi the attachmet assembley. As a result there is o torsioal effect either at the termial eds or at the loop ad therefore the oset of fatigue at these poits is almost etirely elimiated. However it is commo idustry practice to also icorporate a balace rope swivel withi the rope attachmet assembly Where maximum flexibility is ot required alterative costructios are available to suit the specific widig coditios ad provide optimum service life. The graph below gives the miimum recommeded loop diameter to rope diameter ratio for various costructios. 15 Flat Rope 25 20x6SF Miimum Loop D:d Ratios For advice o the best rope for your istallatios cotact Brido s dedicated Miig Departmet. 35 Costructio 4. Guide ad Rubbig Ropes x6SF 14x6SF 34x19NF 18x19 34x7 34M SPI 24LS 18x7 Brido s Tiger Brad rage of guide ad rubbig ropes are ormally costructed of a cetral kig wire, covered by oe or two layers of roud wires which are closed i a fial layer of half lock ad roud wires. The precise costructio depeds upo the diameter ad the tesile grade of wires used to meet the breakig force requiremet. Brido s CAD rope desig system esures that the largest possible outer half lock ad roud wires are used to give maximum resistace to wear ad corrosio. The choice of size ad breakig load depeds upo the local regulatios for factor of safety ad the tesioig required. A typical arragemet is a factor of safety of 5:1 at the poit of suspesio with the guides tesioed o the basis of 3000kg plus 500kg for each 100m of shaft depth. The tesios are ormally varied i the rage plus or mius 10% to limit harmoic vibratio. I wet ad corrosive shafts the use of galvaised material is recommeded. Types of tesioig arragemet, termiatios ad methods of istallatio are may ad varied, Brido s dedicated Miig Departmet will be pleased to give advice o these aspects alog with types of layouts, methods of lubricatio, ispectio procedures ad maiteace. 5. Haulage Ropes The moder rope haulage system is a itegral part of the system for both the trasportatio of me ad the supply of materials to the mie face. Haulage systems fall ito 3 mai categories Edless Direct Mai ad Tail Brido s Tiger Brad rage has the rope to suit your system. I geeral, haulage ropes are required to have excellet resistace to wear ad i some istaces corrosio. To achieve this they ted to be of the more simple costructio with fewer larger outer wires. These ca be sigle layer roud strad costructio or triagular strad costructio. O the majority of systems where the legth of travel is high ad the frequecy of cycle is small, fatigue is geerally ot a critical deterioratig factor. 5.1 Sigle Costructio Roud Strad 6x7(6/1) Fibre Core Lags lay is recommeded to maximise the resistace to wear. Triagular Strad 6x8TS, 6x9TS, 6x10TS. However, whe travel distaces become shorter ad the cycle frequecy is higher the fatigue ca become a factor dictatig rope removal, particularly whe drive wheels, drums ad sheaves are smaller. To combat this, more complex (compoud costructios) with smaller outer wires ca be used. 5.2 Compoud Costructio Roud Strad 6x7, 6x19(S), Dyform 6x19(S), 6x22(TS). Triagular Strad 6x22TS, 6x23TS, 6x25TS, 6x28TS. Where wet ad corrosive coditios exist the use of galvaised ropes, ma made fibre cores or a combiatio of both is recommeded. Miig 47

48 O certai istallatios where resistace to crushig is required, the the use of ropes with steel IWRC cores should be cosidered. O edless systems, ropes with special preformig are supplied to facilitate log splicig. The performace of roud strad ropes ca be ehaced by the use of Dyformed strads. Dyform ropes offer the followig improvemets:- Higher breakig loads Improved fatigue life Icreased resistace to crushig Reduced iterferece o drums ad Clifto (surge) wheels Bristar Cores offer the followig improvemets:- Reduced stretch Icreased fatigue life Icreased dimesio stability (diameter retetio) Cotact our dedicated Miig Departmet for advice o the best costructio for your haulage applicatio. 6. Coveyor Drive Ropes Brido has had a close workig relatioship with the OEM s of cable drive coveyors for may years. This has resulted i Brido beig the major supplier of cable belt drivig ropes world wide. Extesive research ad developmet has resulted i Brido s Tiger Brad rage of drivig ropes such that Brido ca offer rope solutios to give optimum lowest cost coveyig of material. The Tiger Brad rage offers the followig rope optios:- Covetioal Drivig Ropes 6x19S, 6x26WS, 6x25F, 6x31WS, 6x36WS. The type of costructio used depeds upo the diameter, stress levels, the type of coveyor ad it s layout. Dyform Drivig Ropes 6x19S Dyform, 6x26WS Dyform, 6x31WS Dyform, 6x36WS Dyform. Dyform Drivig Ropes offer the followig advatages:- Higher breakig forces Icreased fatigue life Icreased resistace to wear Reduced lie stad pulley wear durig the early part of service life Drivig ropes are geerally supplied i galvaised material although ropes maufactured from bright wire are available. They are produced uder the highest quality system from high specificatio wire ad cores specially desiged ad maufactured for use o rope drive coveyors. All ropes have specific strad preformatio to facilitate log splicig ad maximise splice life. I both covetioal ad Dyform drive ropes, alterative cores ad maufacturig lubricatio are available to best suit your coveyor coditios to esure maximum ecoomic operatig performace. These iclude the followig:- Ma made fibre cores for use i wet coditios Bristar cores offerig lower stretch, icreased fatigue life ad improve diameter retetio Special lubricatio, both maufacturig ad service, to esure maximum life i severe corrosive coditios Zebra Drive Ropes Joit developmet with rope drive coveyor maufacturers ad operators has resulted i Brido s Zebra rage of coveyor drive ropes. Extesive laboratory ad o site testig has show the followig advatages of Zebra over covetioal ad Dyform drive ropes: Icreased fatigue life. I excess of 10 times covetioal cables i laboratory tests Equivalet or icreased breakig loads Reduced stretch both costructioal ad elastic Superior diameter retetio Smooth outer surface Reduced tread pressures Superior resistace to iteral corrosio These improvemets i physical properties have realised the followig prove cost savig advatages: Zebra ca be retro fitted to existig coveyors at miimal cost Reduced lie pulley wear Reduced steel termial pulley ad surge/koepe liig maiteace Reduced vibratio ad oise Exteded rope life Exteded splice life For a assessmet of potetial cost savig o your coveyor cotact Brido directly. Brido s commitmet to lowest cost coveyig does t stop there. O log coveyors splicig ad splice maiteace ca be both icoveiet ad costly. Brido s uique Service Departmet ca provide expert egieers to istall, splice, ispect ad maitai your drive cables. Drivig ropes are a major cost compoet part of the coveyor. LOOK AFTER THEM! I additio Brido recogised the implicatios of dow time ad cost of splicig o log coveyors with umerous splices. To miimise splicig ad splice repairs Brido icreased its productio capacity from piece weights of 60 toes to piece weights of approximately 135 toes. If you thik loger ropes ca assist i reducig operatig costs cotact our Miig Departmet who will be pleased to discuss the various optios. 48 Miig

49 TECHNICAL INFORMATION 7. Properties of Extesio of Steel Wire Ropes Ay assembly of steel wires spu ito a helical formatio, either as a strad or wire rope, whe subjected to a tesile load, ca exted i three separate phases, depedig o the magitude of the applied load. There are also other factors which produce rope extesio which are very small ad ca ormally be igored. Phase 1 - Iitial or Permaet Costructioal Extesio At the commecemet of loadig a ew rope, extesio is created by the beddig dow of the assembled wires with a correspodig reductio i overall diameter. This reductio i diameter creates a excess legth of wire which is accommodated by a legtheig of the helical lay. Whe sufficietly large bearig areas have bee geerated o adjacet wires to withstad the circumferetial compressive loads, this mechaically created extesio ceases ad the extesio i Phase 2 commeces. The Iitial Extesio of ay rope caot be accurately determied by calculatio ad has o elastic properties. The practical value of this characteristic depeds upo may factors, the most importat beig the type ad costructio of rope, the rage of loads ad the umber ad frequecy of the cycles of operatio. It is ot possible to quote exact values for the various costructios of rope i use, but the followig approximate values may be employed to give reasoably accurate results. The above figures are for guidace purposes. More precise figures are available upo request. Locked Coil Hoist Ropes % of rope legth Immediate permaet extesio Fibre Core Steel 0.08 Core Additioal Lightly loaded iitial extesio Gradual Factor permaet of safety about extesio 8: Total Normally extesio loaded approx Factor of safety about 5:1 Phase 2 - Elastic Extesio Heavily loaded Followig Factor of Phase safety 1, about the rope 3:1 exteds i a maer which complies approximately Heavily loaded with Hookes Law (stress Up is to proportioal 2.00 Up to strai) to 1.00 util with the may Limit beds of Proportioality or Elastic Limit is reached. ad/or deflectios It is importat to ote that wire ropes do ot possess a Youg s Modulus of Elasticity, however a apparet Modulus of Elasticity ca be determied betwee two fixed loads. The Modulus of Elasticity also varies with differet rope costructios, but geerally icreases as the cross-sectioal area of steel icreases. By usig the values give, it is possible to make a reasoable estimate of elastic extesio, but if greater accuracy is required it is advisable to carry out a modulus test o a actual sample of the rope. As rope users will fid it difficult to calculate the actual metallic steel area, the values ormally quoted are based o the circumscribed rope area (area of a circle, related to the omial diameter of the rope). Elastic Extesio = W = load applied (kgs) L = rope legth (mm) E = elastic modulus (kg/mm 2 ) A = circumscribed rope area (mm 2 ) Phase 3 - Permaet Extesio The permaet, o-elastic extesio of the steel caused by tesile loads exceedig the yield poit of the material. If the load exceeds the Limit of Proportioality, the rate of extesio will accelerate as the load is icreased, util a loadig is reached at which cotiuous extesio will commece, causig the wire rope to fracture without ay further icrease of load. Thermal Expasio ad Cotractio The coefficiet of liear expasio ( ) of steel wire rope is = (12.5 x10-6 ) per o C, therefore the chage i legth of 1 metre of rope produced by a temperature chage of t o C would be; Chage i legth = o t where WL (mm) EA = coefficiet of liear expasio o = origial legth of rope (m) t = temperature chage ( o C) The chage will be a icrease i legth if the temperature rises ad a decrease i legth if the temperature falls. Extesio due to Rotatio The elogatio caused by a free rope ed beig allowed to rotate. Extesio due to Wear The elogatio due to iter-wire wear which reduces the crosssectioal area of steel ad produces extra costructioal extesio. Example: What will be the total elogatio of a 200 metre legth of 28mm diameter Tiger 6R wire rope at a tesio of 10 toesf (tf) ad a icrease i temperature of 20 oc. Permaet Costructioal Extesio = 0.25% of rope legth = 500mm WL x Elastic Extesio = = = 540mm EA 6000 x Thermal Expasio = 1 = o t = x 200,000 x 20 = 50mm Therefore total extesio = = 1090mm Miig 49

50 8. Pressures betwee Ropes ad Sheaves or Drums I additio to the bedig stresses experieced by wire ropes operatig over sheaves or pulleys, ropes are also subjected to radial pressure as they make cotact with the sheave. This pressure sets up shearig stresses i the wires, distorts the rope s structure ad affects the rate of wear of the sheave grooves. Whe a rope passes over a sheave, the load o the sheave results from the tesio i the rope ad the agle of rope cotact. It is idepedet of the diameter of the sheave. Load o bearig = 2T si Ө 2 T = rope tesio (kg) Ө = cotact agle betwee rope ad sheave or drum Assumig that the rope is supported i a well fittig groove, the the pressure betwee the rope ad the groove is depedet upo the rope tesio ad diameter but is idepedet of the arc of cotact. Pressure, P = 2T Dd idetatio ad this i tur will damage the outer wires of the rope ad effect its workig life. As with bedig stresses, stresses due to radial pressure icrease as the diameter of the sheave decreases. Although high bedig stresses geerally call for the use of flexible rope costructios havig relatively small diameter outer wires, these have less ability to withstad heavy pressures tha do the larger wires i the less flexible costructios. If the calculated pressures are too high for the particular material chose for the sheaves or drums or idetatios are beig experieced, cosideratio should be give to a icrease i sheave or drum diameter. Such a modificatio would ot oly reduce the groove pressure, but would also improve the fatigue life of the rope. The pressure of the rope agaist the sheave also causes distortio ad flatteig of the rope structure. This ca be cotrolled by usig sheaves with the correct groove profile which, for geeral purposes, suggests a optimum groove radius of omial rope radius +10%. The profile at the bottom of the groove should be circular over a agle of approximately 120 o, ad the agle of flare betwee the sides of the sheave should be approximately 52 o. P = pressure (kg/cm 2 ) T = rope tesio (kg) D = diameter of sheave or drum (cm) d = diameter of rope (cm) Hardess of Rope Wire Rope grade Approximate Equivalet Approximate Hardess Maximum Permissible Pressures Number of outer wires i strads 5-8 Ordiary lay 5-8 Lag s lay 9-13 Ordiary lay 9-13 Lag s lay Ordiary lay Lag s lay Triagular strad Cast iro kgf/cm Groove material Low carbo cast steel kgf/cm to 13% M steel or equivalet alloy steels kgf/cm Mi. Tesile Stregth 2160N / mm N / mm N / mm N / mm 2 API 9A Grade EEIPS EIPS IPS PS Briel 480 / / / / 425 Suggested pulley hardess: Briell for M steel or equivalet alloy steel. Rockwell C It should be emphasised that this method of estimatio of pressure assumes that the area of cotact of the rope i the groove is o the full rope diameter, whereas i fact oly the crows of the outer wires are actually i cotact with the groove. The local pressures at these cotact poits may be as high as 5 times those calculated ad therefore the values give above caot be related to the compressive stregth of the groove material. If the pressure is high, the compressive stregth of the material i the groove may be isufficiet to prevet excessive wear ad 50 Miig

51 Efficiecy % MBF Number of beds to rope failure Relative Rope Service Life TECHNICAL INFORMATION 9. Bed Fatigue Bed fatigue testig of ropes usually cosists of cyclig a legth of rope over a sheave while the rope is uder a costat tesio as part of its ogoig developmet programme Brido has tested literally thousads of ropes i this maer over the years o its ihouse ow desig bed testig equipmet. Through this work, Brido has bee able to compare the effects of rope costructio, tesile stregth, lay directio, sheave size, groove profile ad tesile loadig o bed fatigue performace uder ideal operatig coditios. At the same time it has bee possible to compare rope life to discard criteria (e.g. as laid dow i ISO 4309) with that to complete failure of the rope, i.e. to the poit where the rope has bee uable to sustai the load ay loger. As part of the exercise, it has also bee possible to establish the residual breakig stregth of the rope at discard level of deterioratio. Effects of D:d Ratio ad loadig o fatigue life - Typical example Dyform 6 10% MBL 20% MBL 5% MBL Sheave D:d ratio What eeds to be recogised, however, is that very few ropes operate uder these cotrolled operatig coditios, makig it very difficult to use this base iformatio whe attemptig to predict rope life uder other coditios. Other ifluecig factors, such as dyamic loadig, differetial loads i the cycle, fleet agle, reevig arragemet, type of coilig o the drum, chage i rope directio, sheave aligmet, sheave size ad groove profile, ca have a equally dramatic effect o rope performace. If desigers or operators of equipmet are seekig optimum rope performace or regard bedig fatigue life as a key factor i the operatio of equipmet, such iformatio ca be provided by Brido for guidace purposes. Service life curve for various D:d ratios D:d ratio Whe cosiderig the use of a steel wire rope aroud a miimum D:d ratio, it is geerally accepted that below 4:1, the effect o the stregth of the rope eeds to be cosidered. Permaet distortios withi the rope will occur whe usig ratios of 10:1 or less, a miimum ratio of 16:1 should be used for a rope operatig aroud sheaves. Approximate loss i breakig stregth due to bedig EB = D:d ratio 0.5 D/d However, the beefit of such testig ca be particularly helpful to the rope maufacturer whe developig ew or improvig existig products. Miig 51

52 10. Fleet Agle Of all the factors which have a ifluece o the widig of a rope o a smooth drum, the fleet agle, arguably, has the greatest effect. Fleet agle is usually defied as the icluded agle betwee two lies, oe which exteds from a fixed sheave to the flage of a drum ad the other which exteds from the same fixed sheave to the drum i a lie perpedicular to the axis of the drum. (See illustratio). Illustratio of Fleet Agle Drum If the drum icorporates helical groovig, the helix agle of the groove eeds to be added or subtracted from the fleet agle as described above to determie the actual fleet agle experieced by the rope. At the drum Fleet agle Sheave Whe spoolig rope oto a drum it is geerally recommeded that the fleet agle is limited to betwee 0.5 O ad 2.5 O. If the fleet agle is too small, i.e. less tha 0.5 O, the rope will ted to pile up at the drum flage ad fail to retur across the drum. I this situatio, the problem may be alleviated by itroducig a kicker device or by icreasig the fleet agle through the itroductio of a sheave or spoolig mechaism. If the rope is allowed to pile up it will evetually roll away from the flage creatig a shock load i both the rope ad the structure of the mechaism, a udesirable ad usafe operatig coditio. Excessively high fleet agles will retur the rope across the drum prematurely, creatig gaps betwee wraps of rope close to the flages as well as icreasig the pressure o the rope at the crossover positios. Eve where helical groovig is provided, large fleet agles will ievitably result i localised areas of mechaical damage as the wires pluck agaist each other. This is ofte referred to as iterferece but the amout ca be reduced by selectig a Lags lay rope if the reevig allows. The iterferece effect ca also be reduced by employig a Dyform rope which offers a much smoother exterior surface tha covetioal rope costructios. makes cotact with the sheave flage. As the rope cotiues to pass through the sheave it moves dow the flage util it sits i the bottom of the groove. I doig so, eve whe uder tesio, the rope will actually roll as well as slide. As a result of the rollig actio the rope is twisted, i.e. tur is iduced ito or out of the rope, either shorteig or legtheig the lay legth of the outer layer of strads. As the fleet agle icreases so does the amout of twist. To reduce the amout of twist to a acceptable level the fleet agle should be limited to 2.5 O for grooved drums ad 1.5 O for plai drums ad whe usig rotatio-resistat low rotatio ad parallelclosed ropes the fleet agle should be limited to 1.5 O. However, for some applicatios it is recogised that for practical reasos it is ot always possible to comply with these geeral recommedatios, i which case the rope life could be affected. 11. Rope Torque The problem of torsioal istability i hoist ropes would ot exist if the ropes could be perfectly torque balaced uder load. The torque geerated i a wire rope uder load is usually directly related to the applied load by a costat torque factor. For a give rope costructio the torque factor ca be expressed as a proportio of the rope diameter ad this is show below. Variatio with rope costructio is relatively small ad hece the scope for dramatically chagig the stability of a hoistig system is limited. Nevertheless the choice of the correct rope ca have a decidig ifluece, especially i systems which are operatig close to the critical limit. It should be oted that the rope torque referred to here is purely that due to tesile loadig. No accout is take of the possible residual torque due, for example, to rope maufacture or istallatio procedures. Good istallatio practises are vital to prevet torque build up i your ew rope. Widig system desigers eed to take this ito cosideratio at the developmet stage. Brido ca advise o all miig istallatio process s. Torsioal Stability The torque factors quoted o page 41 are approximate maximum values for the particular costructios. To calculate the torque value for a particular rope size multiply the rope diameter by the omial rope diameter. Example: for 20mm dia. Tiger 34LR 34x7 Class at 20% of miimum breakig force:- Torque value = torque factor x rope dia. = 0.8% x 20mm = 0.16mm Floatig sheaves or specially desiged fleet agle compesatig devices may also be employed to reduce the fleet agle effect. At the sheave Where a fleet agle exists as the rope eters a sheave, it iitially 52 Miig

53 TECHNICAL INFORMATION 11. Rope Torque To calculate the torque geerated i a particular rope whe subjected to a tesile load, multiply the load by the torque value ad combie the uits. Example: for 20mm dia. Tiger 34LR 34x7 Class at 6000 kg f load Torque geerated Bedig Loads = torque value x load = = 960 kgf.mm As the rope is bet over the headsheave or drum, a additioal force is iduced ito the steel which must be added to the static ad dyamic tesios to obtai the total force imposed. There are may methods of calculatio for this bedig force, although the oe most commoly used is: Bedig force = EdA D where E = Elastic Modulus as give uder Elogatio of Wire Rope kgf/mm 2 d = diameter of outer wire i rope mm A = Cross sectioal area of rope mm 2 D = Diameter of sheave or drum mm Size of Outer Wires i Rope It is sometimes useful to kow the size of the outer wires i ropes i.e. whe estimatig the amout of exteral wear or calculatig bedig stress. These ca be calculated with reasoable accuracy for all costructios of 6 strad ropes usig the followig formula. 6 strad roud strad Diameter of outer wires = Nomial diameter of rope No. of outer wires per strad + 3 Example: 26mm diameter 6 x 36 (14/7 ad 7/7/1) roud strad No. of outer wires per strad = 14 Diameter of = 26 = 1.5mm outer wire 14+3 Calculatios of Drum Capacity The followig formula gives a approximate idicatio regardig legth of rope of a give diameter (d) which ca be istalled oto a wich/drum. Imperial Rope legth (ft) = (A + B) x A x C x π 12d 2 where A, B, C ad d are quoted i iches. Metric Rope legth (m) = (A + B) x A x C x π x 10 6 d 2 where A, B ad C are quoted i metres ad d quoted i mm. NOTE: Ropes are ormally maufactured to a maximum oversize tolerace of 4%. Therefore the actual diameter d could be omial diameter + 4%. WARNING Wire rope will fail if wor-out, shock loaded, overloaded, misused, damaged, improperly maitaied or abused. Always ispect wire rope for wear, damage or abuse before use Never use wire rope which is wor-out, damaged or abused Never overload or shock load a wire rope Iform yourself: Read ad uderstad the guidace o product safety give i this catalogue; also read ad uderstad the machiery maufacturer s hadbook Refer to applicable directives, regulatios, stadards ad codes cocerig ispectio, examiatio ad rope removal criteria Protect yourself ad others - failure of wire rope may cause serious ijury or death! Left had Fleet agle Right had Fleet agle Left had Fleet Agle: Right had Fleet Agle: Groove Pitch: Groove Radius: No. of Crossovers: Legth of Crossovers: mm mm mm Rope Oscillatio Drum hoists operatig with multiple layers of rope ofte experiece severe oscillatio of the rope betwee the headgear sheave ad the hoist drum durig some part of the hoistig cycle. Advice should be sought from BRIDON S Miig Divisio. Miig 53

54 How to order hoist ropes Customer iformatio I. Particulars of shaft: 1. Suspeded Hoist Rope (From Lowest level to Headgear pulley) 2. Type of vetilatio (upcast/dowcast) 3. Shaft water iflow 4. ph value 5. Chloride cotet 6. Rage of temperature variatio 7. Other coditios affectig the rope II. Particulars of hoistig: 1. Type of hoistig Oe Rope Multirope Multi Layer Coilig No. of Layers Cage Skip Kibble Couterweight 2. Applicatio Mieral Mieral & Maridig 3. Speed of liftig, m/sec 4. Acceleratio of liftig, m/sec 2 5. Prevetative deceleratio, m/sec 2 6. Guides If Available Rope Rigid: Wood Steel Rollers Shoe III. Particulars of the wider: 1. Type Drum Wider Frictio Wider-tower or Groud Mouted Drum 2. Drum diameter 3. Drum width 4. Diameter of Headgear pulley, (mm) 5. Width of Headgear Pulley 6. Diameter tolerace takig ito accout the bottom of the pulley 7. Type of liig 8. Diameter of deflector sheave (Tower mouted Frictio widig oly) 9. Number of hoist ropes 10. Number of balace ropes 11. Type of balace ropes 12. Weight of 1 m of balace ropes 13. Loop radius of balace ropes IV. Particulars of the hoist coveyace: 1. Mass of empty coveyace with suspesio gear of hoist ad balace ropes, toes 2. Mass of coveyace (2) or couterweight with suspesio gear, toes 3 Mass of payload, toes 4 Number of cycles per day/moth V. Particulars of the rope: 1. Rope Specificatio 2. Nomial diameter, mm 3. Costructio 4. Lay Directio 5. Type of core 6. Weight of 1 m, kg 7. Legth of the rope, m 8. Number of idividual legths 9. Preferred Lubricatio 10. Galvaised/Ugalvaised 11. Rope Tesile, /mm Miimum Breakig Load, kgf 13. Nomial Breakig Load, kgf 14. Aggr. Breakig Load of all wires, kgf 15. Lubricatio Core: Strads: Rope: 16. Miimum Safety Factor Required Aggregate Breakig Load Miimum Breakig Load Please tick oe 17. Please state ay local regulatios that eed to be adhered to 18. Causes of rope failure durig operatio 19. Notes: 54 Miig

55 TECHNICAL INFORMATION Summary Techical Iformatio (For guidace purposes oly) Brido supply a rage of Tiger High Performace steel wire ropes specifically desiged ad maufactured to meet the eeds of today s mie wider specificatios ad the demadig applicatios to which they are exposed. High performace ropes are ormally selected by customers whe they require the specific characteristics of improved performace, high stregth, low extesio or low rotatio. Torque Factor at 20% of MBF Rope Costructio Rope Modulus at 20% of MBF /mm 2 % Ordiary Lags TIGER 6R F 6 x 7 Class TIGER 6R F 6 x 19 Class TIGER 6R F 6 x 36 Class TIGER Dyform 6R F 6 x 7 Class TIGER Dyform 6R F 6 x 19 Class TIGER Dyform 6R F 6 x 36 Class TIGER 6T F 6 x 8 Class Sigle layer /a 13.4 TIGER 6T F 6 x 25 Class Compoud layer /a 13.4 TIGER 18M F 18 x 7 Class /a 6.6 TIGER 18M F 18 x 19 Class /a 6.6 TIGER Dyform x 7 Class /a 4.5 TIGER Dyform x 19 Class /a 4.5 TIGER 34M F 34 x 7 Class /a 5.1 TIGER 34M F 34 x 19 Class /a 5.1 TIGER 34LR 34 x 7 Class /a 2.3 TIGER 34LR 34 x 19 Class /a 2.3 TIGER Superflex 14 x /a 3.9 TIGER Superflex 17 x /a 2.6 TIGER Superflex 20 x /a 1.3 TIGER 6R CDR 6 x 19 Class /a 12.0 TIGER 6R CDR 6 x 25 Class /a 12.0 TIGER 6R CDR 6 x 31 Class /a 12.0 TIGER Dyform 6R CDR 6 x 19 Class /a 12.0 TIGER Dyform 6R CDR 6 x 26 Class /a 12.0 TIGER Dyform 6R CDR 6 x 31 Class /a 12.0 TIGER Zebra CDR 6 x /a 9.6 TIGER Zebra CDR 6 x /a 9.6 TIGER Zebra CDR 6 x /a 9.6 TIGER FL Hoist Class Variable TIGER FL Aerial Track Class Variable TIGER HL Guide Class Variable TIGER 24LS 67.2 /a 5.8 TIGER Dyform 24LS 77.6 /a 5.8 TIGER 34M SPI 40.7 /a 5.1 Miig 55

56 Guide to Examiatio The cotiued safe operatio of liftig equipmet, liftig accessories (e.g. sligs) ad other systems employig wire rope, depeds o the operatio of well programmed periodic rope examiatios ad the assessmet by the competet perso of the fitess of the rope for further service. Some of the More Commo Types of Wire Fractures Ca Iclude: A Severed by wear B Tesio C Fatigue D Corrosio fatigue Examiatio ad discard of ropes by the competet perso should be i accordace with the istructios give i the origial equipmet maufacturer s hadbook. I additio, accout should be take of ay local or applicatio specific Regulatios. The competet perso should also be familiar, as appropriate, with the latest versios of related Iteratioal, Europea or Natioal stadards such as ISO 4309 Craes - Wire ropes - code of practice for examiatio. Particular attetio must be paid to those sectios of rope which experiece has show to be liable to deterioratio. Excessive wear, broke wires, distortios ad corrosio are the more commo visible sigs of deterioratio. Note: This publicatio has bee prepared as a aid for rope examiatio ad should ot be regarded as a substitute for the competet perso. Wear is a ormal feature of rope service ad the use of the correct rope costructio esures that it remais a secodary aspect of deterioratio. Lubricatio may help to reduce wear. E Plastic wear F Martesite G Sheared ed Broke wires are a ormal feature of rope service towards the ed of the rope s life, resultig from bedig fatigue ad wear. The local break up of wires may idicate some mechaical fault i the equipmet. Correct lubricatio i service will icrease fatigue performace. Distortios are usually as a result of mechaical damage, ad if severe, ca cosiderably affect rope stregth. Visible rustig idicates a lack of suitable lubricatio, resultig i corrosio. Pittig of exteral wire surfaces becomes evidet i some circumstaces. Broke wires ultimately result. Iteral corrosio occurs i some eviromets whe lubricatio is iadequate or of a usuitable type. Reductio i rope diameter will frequetly guide the observer to this coditio. Cofirmatio ca oly be made by opeig the rope with clamps or the correct use of spike ad eedle to facilitate iteral ispectio. Note: No-destructive testig (NDT) usig electromagetic meas may also be used to detect broke wires ad/or loss i metallic area. This method complemets the visual examiatio but does ot replace it. Pictures courtesy of S.M.R.E. Crow Copyright 1966 Factors Affectig Rope Performace Multi-layer coilig of the rope o the drum ca result i severe distortio i the uderlyig layers. Bad coilig (due to excessive fleet agles or slack widig) ca result i mechaical damage, show as severe crushig, ad may cause shock loadig durig operatio. Small diameter sheaves ca result i permaet set of the rope, ad will certaily lead to early wire breaks due to fatigue. Oversize grooves offer isufficiet support to the rope leadig to icreased localised pressure, flatteig of the rope ad premature wire fractures. Grooves are deemed to be oversize whe the groove diameter exceeds the omial rope diameter by more tha 15% steel, 20% polyurethae liers. Udersize grooves i sheaves will crush ad deform the rope, ofte leadig to two clear patters of wear ad associated wire breaks. Excessive agle of fleet ca result i severe wear of the rope due to scrubbig agaist adjacet laps o the drum. Rope deterioratio at the termiatio may occur i the form of broke wires. A excessive agle of fleet ca also iduce rotatio causig torsioal imbalace. 56 Miig

57 TECHNICAL INFORMATION Troubleshootig Guide Typical examples of Wire Rope deterioratio 1 Mechaical damage due to rope 9 Typical wire fractures as a movemet over sharp edged result of bed fatigue. projectio whilst uder load. 2 Localised wear due to abrasio 10 Wire fractures at the strad, o supportig structure. or core iterface, as distict from crow fractures. 3 Narrow path of wear resultig 11 Break up of IWRC resultig i fatigue fractures, caused by from high stress applicatio. workig i a grossly oversize groove, or over small support rollers. 4 Two parallel paths of broke 12 Looped wires as a result of wires are idicative of bedig torsioal imbalace ad/or through a udersize groove i shock loadig. the sheave. 5 Severe wear, associated with 13 Typical example of localised high tread pressure. wear ad deformatio. 6 Severe wear i Lags Lay, 14 Multi-strad rope bird caged caused by abrasio. due to torsioal imbalace. 7 Severe corrosio. 15 Protrusio of rope cetre resultig from build up of tur. 8 Iteral corrosio whilst 16 Substatial wear ad severe exteral surface shows little iteral corrosio. evidece of deterioratio. Miig 57

58 Troubleshootig Guide The followig is a simplified guide to commo wire rope problems. More detailed advice ca be obtaied from ay Brido distributor. I the evet of o other stadard beig applicable, Brido recommeds that ropes are ispected/examied i accordace with ISO Problem Mechaical damage caused by the rope cotactig the structure of the istallatio o which it is operatig or a exteral structure - usually of a localised ature. Cause/Actio Geerally results from operatioal coditios. Check sheave guards ad support/guide sheaves to esure that the rope has ot jumped out of the iteded reevig system. Review operatig coditios. Opeig of strads i rotatio resistat, low rotatio ad parallel closed ropes - i extreme circumstaces the rope may develop a birdcage distortio or protrusio of ier strads. Note - rotatio resistat ad low rotatio ropes are desiged with a specific strad gap which may be apparet o delivery i a off tesio coditio. These gaps will close uder load ad will have o effect o the operatioal performace of the rope. Check sheave ad drum groove radii usig sheave gauge to esure that they are o smaller tha omial rope radius +5% - Brido recommeds that the sheave ad drum groove radii are checked prior to ay rope istallatio. Repair or replace drum/sheaves if ecessary. Check fleet agles i the reevig system - a fleet agle i excess of 1.5 degrees may cause distortio. Check istallatio method - tur iduced durig istallatio ca cause excessive rope rotatio resultig i distortio. Check if the rope has bee cut o site prior to istallatio or cut to remove a damaged portio from the ed of the rope. If so, was the correct cuttig procedure used? Icorrect cuttig of rotatio resistat, low rotatio ad parallel closed ropes ca cause distortio i operatio. Rope may have experieced a shock load. Broke wires or crushed or flatteed rope o lower layers at crossover poits i multi-layer coilig situatios. Wire breaks usually resultig from crushig or abrasio. Check tesio o uderlyig layers. Brido recommeds a istallatio tesio of betwee 2% ad 10% of the miimum breakig force of the wire rope. Care should be take to esure that tesio is retaied i service. Isufficiet tesio will result i these lower layers beig more proe to crushig damage. Review wire rope costructio. Dyform wire ropes are more resistat to crushig o uderlyig layers tha covetioal rope costructios. Do ot use more rope tha ecessary. Check drum diameter. Isufficiet bedig ratio icreases tread pressure. 58 Miig

59 TECHNICAL INFORMATION Troubleshootig Guide Problem Wires loopig from strads. Cause/Actio Isufficiet service dressig. Cosider alterative rope costructio. If wires are loopig out of the rope udereath a crossover poit, there may be isufficiet tesio o the lower wraps o the drum. Check for areas of rope crushig or distortio. Pigtail or severe spirallig i rope. Check that the sheave ad drum diameter is large eough - Brido recommeds a miimum ratio of rope/sheave to omial drum diameter depedig o the chose costructio, please cotact Brido for further referece. Idicates that the rope has ru over a small radius or sharp edge. Check to see if the rope has jumped off a sheave ad has ru over a shaft. Two sigle axial lies of broke wires ruig alog the legth of the rope approximately 120 degrees apart idicatig that the rope is beig ipped i a tight sheave. Check sheave ad drum groove radii usig sheave gauge to esure that they are o smaller tha omial rope radius + 5% - Brido would recommed that the sheave/drum groove radii are checked prior to ay rope istallatio. Repair or replace drum/sheaves if ecessary. Oe lie of broke wires ruig alog the legth of the rope idicatig isufficiet support for the rope, geerally caused by oversize sheave or drum groovig. Check to see if the groove diameter is o greater tha 15% greater tha the omial rope diameter. Repair or replace drum/sheaves if ecessary. Check for cotact damage. Short rope life resultig from evely/radomly distributed bed fatigue wire breaks caused by bedig through the reevig system. Fatigue iduced wire breaks are characterised by flat eds o the broke wires. Bedig fatigue is accelerated as the load icreases ad as the bedig radius decreases. Cosider whether either factor ca be improved. Check wire rope costructio - Dyform ropes are capable of doublig the bedig fatigue life of a covetioal steel wire rope. Cotiued o ext page Miig 59

60 Troubleshootig Guide Problem Short rope life resultig from localised bed fatigue wire breaks. Fatique iduced wire breaks are characterised by flat eds o the broke wires. Cause/Actio Bedig fatigue is accelerated as the load icreases ad as the bedig radius decreases. Cosider whether either factor ca be improved. Check wire rope costructio - Dyform ropes are capable of doublig the bedig fatigue life of a covetioal steel wire rope. Localised fatigue breaks idicate cotiuous repetitive beds over a short legth. Cosider whether it is ecoomic to periodically shorte the rope i order to move the rope through the system ad progressively expose fresh rope to the severe bedig zoe. I order to facilitate this procedure it may be ecessary to begi operatig with a slightly loger legth of rope. Broke rope - ropes are likely to break whe subjected to substatial overload or misuse particularly whe a rope has already bee subjected to mechaical damage. Review operatig coditios. Corrosio of the rope both iterally ad/or exterally ca also result i a sigificat loss i metallic area. The rope stregth is reduced to a level where it is uable to sustai the ormal workig load. Wave or corkscrew deformatios ormally associated with multistrad ropes. Check sheave ad drum groove radii usig sheave gauge to esure that they are o smaller tha omial rope radius +5% - Brido recommeds that the sheave/drum groove radii are checked prior to ay rope istallatio. Repair or replace drum/sheaves if ecessary. Check fleet agles i the reevig system - a fleet agle i excess of 1.5 degrees may cause distortio. Check that rope ed has bee secured i accordace with maufacturers istructios. Check operatig coditios for iduced tur. Good istallatio practices are vital to prevet torque build up i your ew rope. Istallatio at 90 degrees to the mai drum will add torque to all straded/multi-strad ropes. Rotatio of the load i a sigle fall system. Review rope selectio. Cosider use of rotatio resistat or low rotatio rope. Rotatio of the load i a multi - fall system resultig i cablig of the rope falls. Possibly due to iduced tur durig istallatio or operatio. Review rope selectio. Cosider use of rotatio resistat or low rotatio rope. Review istallatio procedure or operatig procedures. Core protrusio or broke core i sigle layer six or eight strad rope. Caused by repetitive shock loadig - review operatig coditios. 60 Miig

61 TECHNICAL INFORMATION Troubleshootig Guide Problem Rope accumulatig or stackig at drum flage - due to isufficiet fleet agle. Cause/Actio Review drum desig with origial equipmet maufacturer - cosider addig rope kicker, fleetig sheave etc. Suke wraps of rope o the drum ormally associated with isufficiet support from lower layers of rope or groovig. Check correct rope diameter. If grooved drum check groove pitch. Check tesio o uderlyig layers - Brido recommed a istallatio tesio of betwee 2% ad 10% of the miimum breakig force of the wire rope - Care should be take to esure that tesio is retaied i service. Isufficiet tesio will result i these lower layers beig more proe to crushig damage. Make sure that the correct rope legth is beig used. Too much rope (which may ot be ecessary) may aggravate the problem. Short rope life iduced by excessive wear ad abrasio. Check fleet agle to drum. Check geeral aligmet of sheaves i the reevig system. Check that all sheaves are free to rotate. Review rope selectio. The smooth surface of Dyform wire ropes gives better cotact with drum ad sheaves ad offers improved resistace to iterferece betwee adjacet laps of rope. Exteral corrosio. Cosider selectio of galvaised rope. Review level ad type of service dressig. Iteral corrosio. Cosider selectio of galvaised rope. Review frequecy amout ad type of service dressig. Cosider selectio of plastic impregated (PI) wire rope. Miig 61

62 Product Safety: Istructios & Warigs o the use of steel wire rope The followig Istructios ad Warigs combie to provide guidace o Product Safety ad are iteded for use by those already havig a workig kowledge of wire ropes, as well as the ew user. They should be read, followed ad passed o to others. Failure to read, uderstad ad follow these istructios could result i harmful ad damagig cosequeces. A Warig statemet idicates a potetial hazardous situatio which could result i a sigificat reductio i rope performace ad/or put at risk, either directly or idirectly, the safety or health of those persos withi the dager zoe of the rope ad its associated equipmet. Note: As a result of the creatio of the sigle Europea market ad the New Approach Directives which set out essetial requiremets (e.g. for safety); desigers, maufacturers, suppliers, specifiers ad users eed to keep themselves abreast of ay chages to the appropriate Regulatios ad atioal stadards. Esure that the rope does ot make ay direct cotact with the floor ad that there is a flow of air uder the reel. WARNING Failure to do so may result i the rope becomig cotamiated with foreig matter ad start the oset of corrosio before the rope is eve put to work. Support the reel o a simple A-frame or cradle, located o groud which is capable of supportig the total mass of rope ad reel. (See Fig. 2) Esure that the rope is stored where it is ot likely to be affected by chemical fumes, steam or other corrosive agets. 1. Storage 1.1 Uwrap the rope ad examie the rope immediately after delivery to check its idetificatio ad coditio ad verify that it is i accordace with the details o the Certificates ad/or other relevat documets. Note: The rope should ot be used for liftig purposes without the user havig a valid Certificate i his possessio. Check the rope diameter ad examie ay rope termiatios to esure that they are compatible with the equipmet or machiery to which they are to be fitted. (See Fig. 1) WARNING Fig 2 Failure to do so may seriously affect its coditio rederig it ufit for safe use. 1.3 Examie ropes i storage periodically ad, whe ecessary, apply a suitable dressig which is compatible with the maufacturig lubricat. Cotact the rope supplier, Brido or origial equipmet maufacturer s (OEM) maual for guidace o types of dressigs available, methods of applicatio ad equipmet for the various types of ropes ad applicatios. 1.2 Select a clea, well vetilated, dry, udercover locatio. Cover with waterproof material if the delivery site coditios preclude iside storage. Rotate the reel periodically durig log periods of storage, particularly i warm eviromets, to prevet migratio of the lubricat from the rope. WARNING Fig 1 Never store wire rope i areas subject to elevated temperatures as this may seriously affect its future performace. I extreme cases its origial asmaufactured stregth may be severely reduced rederig it ufit for safe use. Re-wrap the rope uless it is obvious that this will be detrimetal to rope preservatio. (Refer to the relevat Product Data sheets o rope dressigs for more detailed iformatio.) WARNING Failure to apply the correct dressig may reder the origial maufacturig lubricat ieffective ad rope performace may be sigificatly affected. Esure that the rope is stored ad protected i such a maer that it will ot be exposed to ay accidetal damage either durig the storage period or whe placig the rope i, or takig it out of storage. 62 Miig

63 TECHNICAL INFORMATION Product Safety: Istructios & Warigs o the use of steel wire rope WARNING Failure to carry out or pay attetio to ay of the above could result i a loss of stregth ad/or a reductio i performace. I extreme cases the rope may be ufit for safe use. 2. Certificatio ad Markig Make sure that the relevat Certificate has bee obtaied before takig the rope ito use for a liftig operatio. (Refer to statutory requiremets) Check to verify that the markig o the rope or its package matches the relevat Certificate. Note: The ratig of a compoet part of a machie or liftig accessory is the resposibility of the desiger of the machie or accessory. Ay re-ratig of a liftig accessory must be approved by a competet perso. Retai the Certificate i a safe place for idetificatio of the rope whe carryig out subsequet periodic statutory examiatios i service. (Refer to statutory requiremets) 3. Hadlig ad Istallatio 3.1 Hadlig ad istallatio of the rope should be carried out i accordace with a detailed pla ad should be supervised by a competet perso. WARNING Icorrectly supervised hadlig ad istallatio procedures may result i serious ijury to persos i the viciity of the operatio as well as those persos directly ivolved i the hadlig ad istallatio. 3.2 Wear suitable protective clothig such as overalls, idustrial gloves, helmet, eye protectors ad safety footwear (ad respirator, particularly where the emissio of fumes due to heat is likely). WARNING Failure to wear suitable protective clothig ad equipmet may result i ski problems from over exposure to certai types of rope lubricats ad dressigs; burs from sparks, rope eds, molte lubricats ad metals whe cuttig ropes or preparig sockets for re-use; respiratory or other iteral problems from the ihalatio of fumes whe cuttig ropes or preparig sockets for re-use; eye ijuries from sparks whe cuttig ropes; laceratios to the body from wire ad rope eds; bruisig of the body ad damage to limbs due to rope recoil, backlash ad ay sudde deviatio from the lie of path of rope. 3.4 Check by measuremet that the omial diameter of the ew rope coforms to the omial size stated o the Certificate. For verificatio purposes, measure the diameter by usig a suitable rope verier fitted with jaws broad eough to cover ot less tha two adjacet strads. Take two sets of measuremets spaced at least 1 metre apart, esurig that they are take at the largest cross-sectioal dimesio of the rope. At each poit take measuremets at right agles to each other. The average of these four measuremets should be withi the toleraces specified i the appropriate Stadard or Specificatio. For a more geeral assessmet of rope diameter use a rope calliper. (See Fig 1) 3.5 Examie the rope visually to esure that o damage or obvious sigs of deterioratio have take place durig storage or trasportatio to the istallatio site. 3.6 Check the workig area aroud the equipmet for ay potetial hazards which may affect the safe istallatio of the rope. 3.7 Check the coditio of the rope-related equipmet i accordace with the OEM s istructios. Iclude the followig - Sheave ad Drum Sizes Regulatios throughout the world quote various miimum D:d ratios for differig rope costructios ad these must be cosidered whe selectig a suitable hoist rope. However as guidace the followig D:d ratios are recommeded. 6 Straded ropes 80:1 Multi Straded ropes 80:1 Locked coil ropes :1 depedig upo rope diameter. (I additio the drum to outer wire ratio should be betwee 1000 ad 1500:1) Factors such as speed ca ecessitate a icrease i the D:d ratio ad i certai circumstaces a D:d ratio below the recommeded value ca be tolerated but some reductio i rope life should be expected. BRIDON s Miig Divisio will be pleased to advise o this subject. Sheave Grooves Groove diameters should be such that they ca accommodate a ew rope takig ito accout the relevat oversize tolerace ad the fleet agles ivolved to provide adequate circumferetial support. 3.3 Esure that the correct rope has bee supplied by checkig to see that the descriptio o the Certificate is i accordace with that specified i the purchaser s order. Miig 63

64 Product Safety: Istructios & Warigs o the use of steel wire rope A groove diameter of 7.5% greater tha the omial rope diameter is ormally acceptable. However i certai cases experiece has show that clearaces betwee 10 ad 12.5% are required to obtai optimum performace. Before istallig a ew rope all sheave grooves should be checked to esure they provide the recommeded clearace. Drum Grooves O sigle layer drum hoists spiral groovig is recommeded. Where multi-layer coilig is ecessary the parallel grooves or oe of the pattered coilig systems should be used. I all cases correct pitch, clearace ad groove depth are essetial to obtai good rope performace. Whe a ew rope is fitted a variatio i size compared with the old wor rope will be apparet. The ew rope may ot fit correctly ito the previously wor groove profile ad uecessary wear ad rope distortio is likely to occur. This may be remedied by machiig out the grooves before the ew rope is istalled. Before carryig out such actio the sheaves or drum should be examied to esure that there will be sufficiet stregth remaiig i the uderlyig material to safely support the rope. The competet perso should be familiar with the requiremets of the appropriate applicatio/machiery stadard. Note: Geeral guidace to users is give i ISO 4309 Code of practice for the selectio, care ad maiteace of steel wire rope. Coils Trasfer the wire rope carefully from the storage area to the istallatio site. Place the coil o the groud ad roll it out straight esurig that it does ot become cotamiated with dust/grit, moisture or ay other harmful material. (See Fig. 5) Dimesios for groovig of drums Geeral recommedatios for straded ropes P = omial diameter + 5% R = omial radius + 7.5% A gap betwee the last tur o the bottom layer of rope o the drum ad the flage ca be corrected by fittig a packig (or false cheek) of suitable thickess o the iside of the flage. WARNING Failure to carry out ay of the above could result i usatisfactory ad usafe rope performace. Note: Grooves must have clearace for the rope ad provide adequate circumferetial support to allow for free movemet of the strads ad facilitate bedig. Whe grooves become wor ad the rope is piched at the sides, strad ad wire movemet is restricted ad the ability of the rope to bed is reduced. (See Fig. 4) If the coil is too large to physically hadle it may be placed o a swift turtable ad the outside ed of the rope pulled out allowig the coil to rotate. (See Fig. 5) WARNING Fig 5 Never pull a rope away from a statioary coil as this will iduce tur ito the rope ad kiks will form. These will adversely affect rope performace. (See Fig. 6) Fig 4 WRONG WRONG Fig 6 WRONG Note the kiks formig Sheave groove too arrow Sheave groove too wide RIGHT Sheave groove correctly supportig the rope for 33% of its circumferece 64 Miig

65 TECHNICAL INFORMATION Product Safety: Istructios & Warigs o the use of steel wire rope Reels Pass a shaft through the reel ad place the reel i a suitable stad which allows it to rotate ad be braked to avoid overru durig istallatio. Where multi-layer coilig is ivolved it may be ecessary for the reel to be placed i equipmet which has the capability of providig a back tesio i the rope as it is beig trasferred from reel to drum. This is to esure that the uderlyig (ad subsequet) laps are woud tightly o the drum. (See Fig. 7) Esure that the reel stad is mouted so as ot to create a reverse bed durig reevig (i.e. for a wich drum with a overlap rope, take the rope off the top of the reel). (See Fig. 7) 3.9 Esure that ay equipmet or machiery to be roped is correctly ad safely positioed ad isolated from ormal usage before istallatio commeces. Refer to the OEM s istructio maual ad the relevat Code of Practice Whe releasig the outboard ed of the rope from a reel or coil, esure that this is doe i a cotrolled maer. O release of the bidigs ad servigs used for packagig, the rope will wat to straighte itself from its previously bet positio. Uless cotrolled, this could be a violet actio. Stad clear. WARNING Fig 7 Failure to cotrol could result i ijury. Positio the reel ad stad such that the fleet agle durig istallatio is limited to 1.5 degrees. (See Fig. 8) ANGLE OF FLEET CENTRE LINE OF REEL CENTRE LINE OF SHEAVE Fig 8 If a loop forms i the rope esure that it does ot tighte to form a kik. WARNING A kik ca severely affect the stregth of a six strad rope ad ca result i distortio of a rotatio- resistat or low rotatio rope leadig to its immediate discard. Miig 65

66 Product Safety: Istructios & Warigs o the use of steel wire rope 3.11 Moitor the rope carefully as it is beig pulled ito the system ad make sure that it is ot obstructed by ay part of the structure or mechaism which may cause the rope to come free. Fig 10 WARNING Failure to moitor durig this operatio could result i ijury. This etire operatio should be carried out carefully ad slowly uder the supervisio of a competet perso Take particular care ad ote the maufacturer s istructios whe the rope is required to be cut. Apply secure servigs o both sides of the cut mark. (See Fig. 10 for typical method of applyig a servig to a multi-layer rope.) Esure that the legth of servig is at least equal to two rope diameters. (Note: Special servigs are required for spiral ropes, i.e. spiral strad ad locked coil.) Legth of servig for locked coil widig ropes ad half locked coil guide ropes The legth of rope to be served depeds o the object of the servig ad o the size ad type of the rope. If the servig is to restrai the cut ed of a rope it must be loger tha oe iteded to restrai the ed of a short sample to be cut from a rope. A rope of the straded type exerts oly a moderate burstig force o a servig but a large locked coil rope exerts a cosiderable burstig force ad, should the servig burst, the rope will ulay itself violetly over a log legth. Thus, for the cut ed of a straded rope, two servigs each of a legth at least six times the rope diameter should be used ad kept i place util the rope ed is otherwise secured. For the cut ed of a large locked coil rope a servig or servigs of each legth of twety times the rope diameter is advisable, (FLCWR s to be served with tied aealed sigle wire servig, the secured by solderig these wires together, refer to Brido for further techical iformatio). The buried wire with multi-strad servig wire should ot be used with rotatio resistat ropes. These servigs should be backed up by a miimum of six two-bolt clamps set clear of the served legth util the rope ed is otherwise secured. Servigs should be left permaetly o locked coil widig ropes so that there is oe about 0.6m (2ft) clear of the capel to allow proper examiatio of the rope at this poit ad aother betwee the capel ad the earest pulley or drivig sheave i the head frame. This is to localise ay ulayig of the rope ed, or of broke wires, i the evet of a icidet. Oe servig either side of the cut is ormally sufficiet for preformed ropes. For o-preformed ropes, multi-layer (i.e. rotatio-resistat ad low rotatio ropes) ad parallel closed ropes (i.e. DSC ropes) a miimum of two servigs each side of the cut will be ecessary (See Fig. 10). Arrage ad positio the rope i such a maer that at the completio of the cuttig operatio the rope eds will remai i positio, thus avoidig ay backlash or ay other udesirable movemet. Cut the rope with a high speed abrasive disc cutter. Other suitable mechaical or hydraulic shearig equipmet may be used although ot recommeded whe a rope ed is required to be welded or brazed. For servig istructios for FL ad HL ropes refer to Brido. 66 Miig

67 TECHNICAL INFORMATION Product Safety: Istructios & Warigs o the use of steel wire rope WARNING Whe usig a disc cutter be aware of the dager from sparks, disc fragmetatio ad fumes. (Refer 3.2.) Esure adequate vetilatio to avoid ay build-up of fumes from the rope ad its costituet parts icludig ay fibre core (atural or sythetic) ay rope lubricat(s) ad ay sythetic fillig ad/or coverig material. Whe termiatig a rope ed with a wedge socket, esure that the rope tail caot withdraw through the socket by securig a clamp to the tail or by followig the maufacturer s istructios. (See Fig. 11 for two recommeded methods of securig the rope tail of a wedge socket termiatio). WARNING Some special ropes cotai sythetic material which, whe heated to a temperature higher tha ormal productio processig temperatures, will decompose ad may give off toxic fumes. WARNING Rope produced from carbo steel wires i the form shipped is ot cosidered a health hazard. Durig subsequet processig (e.g. cuttig, weldig, gridig, cleaig) dust ad fumes may be produced which cotai elemets which may affect exposed workers. The products used i the maufacture of steel wire ropes for lubricatio ad protectio preset miimal hazard to the user i the form shipped. The user must however, take reasoable care to miimise ski ad eye cotact ad also avoid breathig their vapour ad mist. After cuttig, the rope cross-sectios of opreformed ropes, multi-layer ropes ad parallel closed ropes must be welded, brazed or fused ad tapered such that all wires ad strads i the rope are completely secured. WARNING Failure to correctly secure the rope ed is likely to lead to slackess, distortios, premature removal from service ad a reductio i the breakig force of the rope. Fig 11 The loop back method uses a rope grip ad the loop should be lashed to the live part of rope by a soft wire servig or tape to prevet flexig of the rope i service. The method of loopig back should ot be used if there is a possibility of iterferece of the loop with the mechaism or structure. WARNING Failure to secure i accordace with istructios could lead to loss of the rope ad/or ijury Esure that ay fittigs such as clamps or fixtures are clea ad udamaged before securig rope eds. Make sure that all fittigs are secure i accordace with the OEM s istructio maual or maufacturer s istructios ad take particular ote of ay specific safety requiremets e.g. torque values (ad frequecy of ay re-applicatio of torque) Whe coilig a rope o a plai (or smooth) barrel drum esure that each lap lies tightly agaist the precedig lap. The applicatio of tesio i the rope greatly assists i the coilig of the rope. Miig 67

68 Product Safety: Istructios & Warigs o the use of steel wire rope WARNING Ay looseess or ueve widig will result i excessive wear, crushig ad distortio of the rope. With plai barrel drums it is difficult to achieve satisfactory multi-layer coilig beyod three layers. The directio of coilig of the rope o the drum is importat, particularly whe usig plai barrel drums, ad should be related to the directio of lay of the rope i order to iduce close coilig. (See Fig. 12 for proper method of locatig rope achorage poit o a plai drum.) Proper method of locatig rope achorage poit o a plai drum start rope at left flage right had left had left had right had lay ropeuderwid right had lay ropeoverwid left had lay ropeuderwid left had lay ropeoverwid Note: Thumb idicates side of rope achorage Fig 12 Whe multi-layer coilig has to be used it should be realised that after the first layer is woud o a drum, the rope has to cross the uderlyig rope i order to advace across the drum i the secod layer. The poits at which the turs i the upper layer cross those of the lower layer are kow as the cross-over poits ad the rope i these areas is susceptible to icreased abrasio ad crushig. Care should be take whe istallig a rope o a drum ad whe operatig a machie to esure that the rope is coiled ad layered correctly. fitted i accordace with the OEM s istructio maual or maufacturer s istructios. Whe re-usig a socket ad depedig o its type ad dimesios, the existig coe should be pressed out. Otherwise, heat may be ecessary. WARNING Whe meltig out sockets which have previously bee filled with hot metal, the emissio of toxic fumes is likely. Note that white metal cotais a high proportio of lead. Correctly locate ad secure ay coectio pis ad fittigs whe assemblig ed termiatios to fixtures. Refer to maufacturer s istructios. WARNING Failure to pay attetio to ay of the above could result i usafe operatio ad potetial ijury Limit switches, if fitted, must be checked ad re-adjusted, if ecessary, after the rope has bee istalled Record the followig details o the Certificate after istallatio has bee completed: type of equipmet, locatio, plat referece umber, duty ad date of istallatio ad ay reratig iformatio/sigature of competet perso. The safely file the Certificate Ru i the ew rope by operatig the equipmet slowly, preferably with a low load, for several cycles. This permits the ew rope to adjust itself gradually to workig coditios. Note: Uless otherwise required by a certifyig authority, the rope should be i this coditio before ay proof test of the equipmet or machiery is carried out. Check that the ew rope is spoolig correctly o the drum ad that o slack or cross laps develop. If ecessary, apply as much tesio as possible to esure tight ad eve coilig, especially o the first layer. Where multi-layer coilig is uavoidable, succeedig layers should coil evely o the precedig layers of rope Check the state of re-usable rope ed termiatios for size, stregth, defects ad clealiess before use. No-destructive testig may be required depedig o the material ad circumstaces of use. Esure that the termiatio is 68 Miig

69 TECHNICAL INFORMATION Product Safety: Istructios & Warigs o the use of steel wire rope WARNING Irregular coilig usually results i severe surface wear ad rope malformatio, which i tur is likely to cause premature rope failure Esure that the as-maufactured coditio of the rope is maitaied throughout the whole of the hadlig ad istallatio operatio If samples are required to be take from the rope for subsequet testig ad/or evaluatio, it is essetial that the coditio of the rope is ot disturbed. Refer to the istructios give i 3.12 ad, depedig o the rope type ad costructio, ay other special maufacturer s istructios. 4. I Service 4.1 Ispect the rope ad related equipmet at the begiig of every work period ad particularly followig ay icidet which could have damaged the rope or istallatio. The etire legth of rope should be ispected ad particular attetio paid to those sectios that experiece has prove to be the mai areas of deterioratio. Excessive wear, broke wires, distortio ad corrosio are the usual sigs of deterioratio. For a more detailed examiatio special tools are ecessary (see Fig. 13) which will also facilitate iteral ispectio (see Fig. 14.) Fig 13 Note: Shorteig the rope re-positios the areas of maximum deterioratio i the system. Where coditios permit, begi operatig with a rope which has a slightly loger legth tha ecessary i order to allow for periodic shorteig. Whe a o-preformed rope, multi-layer rope or parallel closed rope is used with a wedge socket ad is required to be shorteed, it is essetial that the ed of the rope is secured by weldig or brazig before the rope is pulled through the mai body of the socket to its ew positio. Slacke the wedge i the socket. Pass the rope through the socket by a amout equivalet to the crop legth or sample required. Note that the origial bet portio of the rope must ot be retaied withi the wedge socket. Replace the wedge ad pull up the socket. Prepare ad cut i accordace with sectio Esure that the rope tail caot withdraw through the socket, see sectio WARNING Failure to observe this istructio will result i a sigificat deterioratio i the performace of the rope ad could reder the rope completely ufit for further service. I cases where severe rope wear takes place at oe ed of a wire rope, the life of the rope may be exteded by chagig roud the drum ed with the load ed, i.e. turig the rope ed for ed before deterioratio becomes excessive. 4.2 Remove broke wires as they occur by bedig backwards ad forwards usig a pair of pliers util they break deep i the valley betwee two outer strads (see Fig. 15). Wear protective clothig such as overalls, idustrial gloves, helmet, eye protectors ad safety footwear durig this operatio. Fig 15 Fig 14 I the case of ropes workig over drums or sheaves it is particularly ecessary to examie those areas eterig or leavig the grooves whe maximum loads (i.e. shock loads) are experieced, or those areas which remai for log periods i exposed places such as over a head gear pulleys. O some ruig ropes, but particularly relevat to stadig ropes (e.g. guide ropes) the areas adjacet to termiatios should be give special attetio (see Fig. 14). WARNING Do ot shear off the eds of broke wires with pliers as this will leave a exposed jagged edge which is likely to damage other wires i the rope ad lead to premature removal of the rope from service. Failure to wear adequate protective clothig could result i ijury. Miig 69

70 Product Safety: Istructios & Warigs o the use of steel wire rope Note: Broke wires are a ormal feature of service, more so towards the ed of the rope s life, resultig from bedig fatigue ad wear. The local break up of wires may idicate some mechaical fault i the equipmet. Record the umber ad positio i the rope of ay removed broke wires. 4.3 Do ot operate a appliace if for ay reaso (e.g. rope diameter, certified breakig force, rope costructio, legth or stregth ad type of rope termiatio) the wire rope ad its termiatio is cosidered usuitable for the required duty. 4.4 Do ot operate a appliace if the wire rope fitted has become distorted, bee damaged or has deteriorated to a level such that discard criteria has bee reached or is likely to be reached prior to ormal expected life based o historical performace data. WARNING Rope distortio is usually a result of mechaical damage ad ca sigificatly reduce rope stre gth. 4.5 A authorised competet perso must examie the rope i accordace with the appropriate Regulatios. 4.6 Do ot carry out ay ispectio, examiatio, dressig/ lubricatio, adjustmet or ay other maiteace of the rope whilst it is suspedig a load, uless otherwise stated i the OEM s istructio maual or other relevat documets. Do ot carry out ay ispectio or maiteace of the rope if the appliace cotrols are uatteded uless the surroudig area has bee isolated or sufficiet warig sigs have bee posted withi the immediate viciity. If the appliace cotrols are atteded, the authorised perso must be able to commuicate effectively with the driver or cotroller of the appliace durig the ispectio process. 4.7 Never clea the wire rope without recogisig the potetial hazards associated with workig o a movig rope. WARNING Failure to pay attetio or take adequate precautio could result i ijury. If cleaig by cloth/waste, the material ca be sagged o damaged surfaces ad/or broke wires. If cleaig by brush, eye protectors must be wor. If usig fluids it should be recogised that some products are highly iflammable. A respirator should be wor if cleaig by a pressurised spray system. WARNING Failure to take adequate precautio could result i ijury or damage to health. Oly use compatible cleaig fluids which will ot impair the origial rope lubricat or affect the rope associated equipmet. WARNING The use of cleaig fluids (particularly solvet based) is likely to cut back the existig rope lubricat leadig to a greater quatity of lubricat accumulatig o the surface of the rope. This may create a hazard i appliaces ad machiery which rely o frictio betwee the rope ad the drive sheave (e.g. lifts, frictio widers ad cableways). 4.8 Lubricats selected for i-service dressig must be compatible with the rope maufacturig lubricat ad should be refereced i the OEM s istructio maual or other documets approved by the ower of the appliace. If i doubt cotact the rope supplier or Brido. 4.9 Take particular care whe applyig ay i-service lubricat/ dressig. Applicatio systems which ivolve pressure should oly be operated by traied ad authorised persos ad the operatio carried out strictly i accordace with the maufacturer s istructios. Most wire ropes should be lubricated as soo as they are put ito service ad at regular itervals thereafter (icludig cleaig) i order to exted safe performace. WARNING A dry rope uaffected by corrosio but subject to bed fatigue, is likely to achieve oly 30% of that ormally attaied by a lubricated rope. Do ot dress/lubricate the rope if the applicatio required it to remai dry. (Refer OEM s istructio maual.) Reduce the period betwee examiatios whe ropes are ot subjected to ay i-service dressig ad whe they must remai dry. Note: The authorised perso carryig out a rope ispectio must be capable of recogisig the potetial loss of safe performace of such a rope i compariso with lubricated rope. Clea the rope before applyig a fresh dressig/lubricat if it is heavily loaded with foreig matter e.g. sad, dust. 70 Miig

71 TECHNICAL INFORMATION Product Safety: Istructios & Warigs o the use of steel wire rope 4.10 The authorised perso resposible for carryig out wire rope maiteace must esure that the eds of the rope are secure. At the drum ed this will ivolve checkig the itegrity of the achorage ad esurig that there are at least two ad a half dead laps tightly coiled. At the outboard ed the itegrity of the termiatio must be checked to esure that it is i accordace with the OEM s maual or other documets approved by the ower of the appliace Adjust the legths of ropes i multi-rope systems i order that equal forces (withi approved limits) are evidet. If a wire rope eeds cuttig refer to Whe securig rope eds refer to Whe re-usable ed termiatios are used refer to Whe re-coectig ay ed termiatios to fixtures refer to WARNING Damage to, or removal of compoet parts (mechaical or structural) caused by abormal cotact with wire rope ca be hazardous to the safety of the appliace ad/or the performace of the rope (e.g. damage to the drum groovig, such that coilig is erratic ad/or the rope is pulled dow ito uderlyig layers, which might cause a dagerous coditio or, alteratively, cause localised rope damage at cross-over positios, which might the radically affect performace; loss/removal of wear plates protectig the structure leadig to major structural damage by cuttig ad/or failure of the wire rope due to mechaical severace) Followig ay periodic statutory examiatio or routie or special ispectio where ay corrective actio is take the Certificate should be updated ad a record made of the defects foud, the extet of the chages ad the coditio of the rope Apply the followig procedures for the selectio ad preparatio of samples, from ew ad used legths of rope, for the purpose of examiatio ad testig to destructio. Check that the rope ed, from which the sample will be take, is secured by weldig or brazig. If ot, select the sample legth further away from the rope ed ad prepare ew servigs (see 3.12). (see Fig. 10) ad apply a rope clamp or grip as close to the cut mark as practically possible. Do ot use solder to secure the servigs. Esure that the sample is kept straight throughout the whole procedure ad esure that the miimum sample legth is 3 metres for ropes up to ad icludig 40mm diameter ad 12 metres for larger diameter ropes. The rope should be cut with a high speed abrasive disc cutter or a oxyacetylee torch. Weld the rope eds of the sample as described i sectio 3.12, after which the clamp or grip ca be removed. The idetificatio of the rope must be established ad the sample suitably marked ad packed. It is recommeded that the 3 metre sample is retaied straight ad secured to a wood batte for trasportatio. For a 12 metre sample, coil to a diameter as large as practically possible ad ever less tha 2 metres. Note: Samples take for destructio testig are required to be termiated i accordace with a recogised resi socketig stadard (e.g. BS EN or ISO 7596). WARNING Failure to comply with these procedures will result i measured breakig force values which are ot truly represetative of the actual stregth of the rope. 5. Wire Rope Discard 5.1 Discard the wire rope i accordace with curret Regulatios ad i accordace with the OEM s istructio maual. 5.2 If a wire rope is removed from service at a level of performace substatially differet to historically established performace data ad without ay obvious reaso(s), cotact Brido or Brido s distributor for further guidace. 5.3 Oly qualified ad experieced persoel, takig the appropriate safety precautios ad wearig the appropriate protective clothig, should be resposible for removig the wire rope. WARNING Take particular care whe removig ropes with mechaical damage as they may fail abruptly durig the chage-out procedure. Hadle the rope i accordace with the istructios give i sectio 3. Serve the rope, usig the buried wire techique Miig 71

72 Product Safety: Istructios & Warigs o the use of steel wire rope Take the utmost care whe removig exhausted/failed ropes from drums ad sheaves as they may be grossly distorted, lively ad tightly coiled. WARNING Failure to take adequate precautios could result i ijury. WARNING Wire rope which beds aroud sheaves, rollers or drums will deteriorate through bedig fatigue. Reverse bedig ad high speed will accelerate the process. Therefore, uder such coditios select a rope with high bedig fatigue resistace. Refer to Product Data Iformatio, ad if i doubt ask for advice. 5.4 Store discarded rope i a safe ad secure locatio or compoud ad esure that it is suitably marked to idetify it as rope which has bee removed from service ad ot to be used agai. WARNING Discarded rope ca be a dager (e.g. protrudig broke wires, excessive grease/lubricat ad rope mass) to persoel ad equipmet if ot hadled correctly ad safely durig disposal. 5.5 Record the date ad reaso for discard o the Certificate before filig for future referece. 5.6 Pay attetio to ay Regulatios affectig the safe disposal of steel wire rope. 6. Rope Selectio Criteria Esure that the correct type of wire rope is selected for the equipmet by referrig to the OEM s istructio maual or other relevat documets. If i doubt cotact Brido or Brido s distributor for guidace. 6.1 Rope Stregth If ecessary, refer to the appropriate Regulatios ad/or applicatio stadards ad calculate the maximum force to which the rope will be subjected. The calculatio may take ito accout the mass to be lifted or moved, ay shock loadig, effects of high speed, acceleratio, ay sudde starts or stops, frequecy of operatio ad sheave bearig frictio. By applyig the relevat coefficiet of utilisatio (safety factor) ad, where applicable, the efficiecy of the rope termiatio, the required miimum breakig load or force of the rope will be determied, the values of which are available from the relevat Natioal, Europea or Iteratioal stadards or from specific Product Data literature. If i doubt ask for advice from Brido or Brido s distributor. 6.2 Bedig fatigue 6.3 Abrasio Wire rope which is subject to abrasio will become progressively weaker as a result of: Exterally - draggig it through overburde, sad or other abrasive materials ad passig aroud a sheave, roller or drum. Iterally - beig loaded or bet. WARNING Abrasio weakes the rope by removig metal from both the ier ad outer wires. Therefore, a rope with large outer wires should ormally be selected. 6.4 Vibratio Vibratio i wire rope will cause deterioratio. This may become apparet i the form of wire fractures where the vibratio is absorbed. WARNING These fractures may be iteral oly ad will ot be visually idetified. 6.5 Distortio Wire rope ca be distorted due to high pressure agaist a sheave, improperly sized grooves or as a result of multi-layer coilig o a drum. Rope with a steel core is more resistat to crushig ad distortio. 6.6 Corrosio Rope with a large umber of small wires is more susceptible to corrosio tha rope with a small umber of large wires. Therefore, if corrosio is expected to have a sigificat effect o rope performace select a galvaised rope with as large a outer wire size as possible bearig i mid the other coditios (e.g. bedig ad abrasio) uder which the rope will be operatig. The size ad umber of sheaves i the system will ifluece the performace of the rope. 72 Miig

73 TECHNICAL INFORMATION Product Safety: Istructios & Warigs o the use of steel wire rope 6.7 Coectig Ropes I the evet that it is ecessary to coect oe rope to aother (i series) it is essetial that they have the required stregth, are of the same type ad both have the same lay directio (i.e. coect right lay to right lay). WARNING Failure to heed this warig could result i catastrophic failure particularly at a termiatio which is capable of beig pulled apart (i.e. splice) due to ulayig. 6.8 Rope Legth Rope legth ad /or differece i legth betwee two or more ropes used i a set may be a critical factor ad must be cosidered alog with rope selectio. WARNING WARNING Failure to observe this geeral guidace could result i failure of the ropes to support the load. For temperatures over 400 C, other materials such as stailess steel or other special alloys should be cosidered. WARNING Rope lubricats ad ay sythetic fillig ad/or coverig materials may become ieffective at certai low or high operatig temperature levels. Certai types of rope ed termiatios also have limitig operatig temperatures ad the maufacturer or Brido should be cosulted where there is ay doubt. Ropes with alumiium ferrules must ot be used at temperatures i excess of 150 C. Wire rope will elogate uder load. Other factors such as temperature, rope rotatio ad iteral wear will also have a effect. These factors should also be cosidered durig rope selectio. 6.9 Preformed ad No-preformed Ropes Sigle layer roud strad rope is ormally supplied preformed. However, if a o-preformed rope is selected the persoel resposible for its istallatio ad/or maiteace eed to take particular care whe hadlig such rope, especially whe cuttig. For the purposes of this istructio, multi-layer, parallel closed ad spiral ropes should be regarded as o-preformed ropes Operatig Temperatures Wire rope with a steel core should be selected if there is ay evidece to suggest that a fibre core will ot provide adequate support to the outer strads ad/or if the temperature of the workig eviromet may be expected to exceed 100 C. For operatig temperatures above 100 C de-ratig of the miimum breakig force of the rope is ecessary (e.g. betwee 100 C ad 200 C reduce by 10%; betwee 200 C ad 300 C reduce by 25%; betwee 300 C ad 400 C reduce by 35%). Do ot use ropes with high carbo wires above 400 C. Miig 73

74 Product Safety: Istructios & Warigs o the use of steel wire rope WARNING CAUTIONARY NOTICE RESTRICTIONS ON THE USE OF LARGE DIAMETER MULTI-STRAND ROPES. All wire ropes are proe to damage if they are ot properly supported whe used at high loads. Larger Multi-strad ropes are particularly susceptible to this form of abuse, due to their rigid costructio ad the relatively fie wire sizes ivolved i their maufacture/costructio. Istaces have bee recorded of ropes beig heavily worked over plai drums ad failig prematurely, despite the omial tesio beig beig i the regio of half the breakig stregth of the rope. The best way of prevetig difficulties of this sort is to avoid coditios that are likely to geerate damagigly high cotact stresses. A simple method of assessig the severity of the cotact coditios is to firstly calculate the tread pressure based o the projected omial area ad the apply a factor (of say 10*) to allow for the highly localised ad itermittet ature of the actual wire cotacts, as idicated below :- Type of cotact Close-fittig U-groove Oversize U-groove Plai drum Level of support Good Fair Poor Tread path width 100% of rope dia. 50% of rope dia. 20% of rope dia. Tread pressure = 2T/Dd 4T/Dd 10T/Dd Cotact stress = 20T/Dd 40T/Dd 100T/Dd Note: Cotact stresses which exceed 10% of the wire UTS should be cosidered a cause for cocer, especially if the rope is operatig at a low factor of safety. [* This is because the true cotact area is very much less tha the projected omial area.] Worked example: Cosider case of a 50mm Multi-strad rope (MBL=2100) operatig at a 3:1 factor of safety. The, for the Cotact stress < 200 Mpa say, the followig miimum bedig diameters are idicated: Close-fittig groove 1400mm Oversize U-groove mm U-grooved drum mm 74 Miig

75 TECHNICAL INFORMATION Material Safety Data Itroductio Steel wire rope is a composite material ad depedet upo its type may cotai a umber of discrete materials. The followig provides full details of all the idividual materials which may form part of the fiished wire rope. The descriptio ad/or desigatio of the wire rope stated o the delivery ote ad/or ivoice (or certificate, whe applicable) will eable idetificatio of the compoet parts. The mai compoet of a steel wire rope is the wire, which may be carbo steel, coated (zic or Z95/A15) steel or stailess steel. The other three compoets are (i) the core, which may be of steel of the same type as used i the mai strads or alteratively fibre (either atural or sythetic), (ii) the rope lubricat ad, where applicable, (iii) ay iteral fillig or exteral coverig. No Occupatioal Exposure Limits (OEL s) exist for steel wire rope ad the values provided i this publicatio relate to compoet elemets ad compouds. The actual figures quoted i relatio to the compoet parts are take from the latest editio of EH40. Rope produced from carbo, coated or stailess steel wires i the as-supplied coditio is ot cosidered a health hazard. However durig ay subsequet processig such as cuttig, weldig, gridig ad cleaig, dust ad fumes may be produced which cotai elemets that may affect exposed workers. The followig idicates the order i which specific iformatio is provided:- Carbo steel wire, Coated steel wire, Stailess steel wire, Maufacturig rope lubricats, Fibre cores, Fillig ad coverig materials, Geeral iformatio Carbo Steel Wire - Hazardous Igrediets Compoet % Weight (Max) Log term exposure limit (8-hour TWA referece period) mg/m 3 Short term exposure limit (10-miute referece period) mg/m 3 BASE METAL Alumiium Carbo Chromium Cobalt Copper Iro Magaese Molybdeum Nickel Phosphorus Silico Sulphur Vaadium Boro Titaium Nitroge Lead Arseic Zircoium COATED Sodium Calcium Boro Phosphorus Iro Zic Oil may be applied Balace Noe Listed Noe Listed Noe Listed Physical Data Specific Gravity: Meltig Poit: o C Appearace & Odour: Solid. Odourless Metal Solubility i water: Isoluble Flash Poit: Noe Vapour Pressure: N/A Vapour Desity: N/A Evaporatio: N/A % Volatiles: N/A Boilig Poit: > 2800 o C Miig 75

76 Material Safety Data Coated (Zic ad ZN95/A 15) Steel Wire - Hazardous Igrediets Compoet % Weight (Max) Log term exposure limit (8-hour TWA referece period) mg/m 3 Short term exposure limit (10-miute referece period) mg/m 3 BASE METAL Alumiium Carbo Chromium Cobalt Copper Iro Magaese Molybdeum Nickel Phosphorus Silico Sulphur Vaadium Boro Titaium Nitroge Lead Arseic Zircoium COATED Zic Alumiium Iro Sodium Calcium Boro Phosphorus Sulphur Oil may be applied Wax may be applied Balace Noe Listed Noe Listed Noe Listed Noe Listed Physical Data Specific Gravity: Meltig Poit: o C Appearace & Odour: Solid. Odourless Metal Solubility i water: Isoluble Flash Poit: Noe Vapour Pressure: N/A Vapour Desity: N/A Evaporatio: N/A % Volatiles: N/A Boilig Poit: > 2800 o C 76 Miig

77 TECHNICAL INFORMATION Material Safety Data Maufacturig Rope Lubricats The products used i the maufacture of steel wire ropes for lubricatio ad protectio preset miimal hazard to the user i the as-supplied coditio. The user must, however, take reasoable care to miimise ski ad eye cotact ad also avoid breathig their vapours ad mists. A wide rage of compouds is used as lubricats i the maufacture of steel wire rope. These products, i the mai, cosist of mixtures of oils, waxes, bitumes, resis, gellig agets ad fillers with mior cocetratios of corrosio ihibitors, oxidatio stabilizers ad tackiess additives. Most of them are solid at ambiet temperatures ad provided ski cotact with the fluid types is avoided, oe preset a hazard i ormal rope usage. However, to assist i the assessmet of the hazard caused by these products, the followig table cotais all the compoets which may be icorporated ito a wire rope lubricat ad which may be cosidered hazardous to health. Hazardous Igrediets: Compoet Oil mist Paraffi wax fume Bitume Silica, fused Total ihalable dust Respirable dust Alumiium flake Zic oxide, fume Butae Log term exposure limit (8-hour TWA referece period) mg/m 3 There are o other kow costituets of ay wire rope lubricat used that are classified as hazardous i the curret editio of EH Short term exposure limit (10-miute referece period) mg/m The worker should ot: 1) put oily rags or tools ito pockets, especially trousers, 2) use dirty or spoiled rags for wipig oil from the ski, 3) wear oil soaked clothig, 4) use solvets such as paraffi, petrol etc., to remove oil from the ski. Cocetratios of oil mists, fumes ad vapours i the workig atmosphere must be kept as low as is reasoably practicable. Levels quoted i the curret editio of HSE Guidace Note EH40 Occupatioal Exposure Limits must ot be exceeded. Health Hazards Ihalatio of oil mists or fumes from heated rope lubricats i high cocetratios may result i dizziess, headache, respiratory irritatio or ucosciousess. Eye cotact may produce mild trasiet irritatio to some users. Fumes from heated rope lubricats i high cocetratios may cause eye irritatio. If heated rope lubricats cotacts ski, severe burs may result. Prologed or repeated ski cotact may cause irritatio, dermatitis or more serious ski disorders. Fibre Cores Beig i the cetre of a steel wire rope, the materials (atural or sythetic) from which fibre cores are produced do ot preset a health hazard durig ormal rope hadlig. Eve whe the outer core strads are removed (for example whe the rope is required to be socketed) the core materials preset virtually o hazard to the users, except, maybe, i the case of a used rope where, i the absece of ay service dressig or as a result of heavy workig causig iteral abrasive wear of the core, the core may have decomposed ito a fibre dust which might be ihaled, although this is cosidered extremely ulikely. The pricipal area of hazard is through the ihalatio of fumes geerated by heat, for example whe the rope is beig cut by a disc cutter. Geeral advice o hadlig ropes with lubricats To avoid the possibility of ski disorders, repeated or prologed cotact with mieral or sythetic hydrocarbos must be avoided ad it is essetial that all persos who come ito cotact with such products maitai high stadards of persoal hygiee. The worker should: 1) use oil impermeable gloves, or if ot available, suitable oil repellet type barrier creams, 2) avoid uecessary cotact with oil usig protective clothig, 3) obtai first aid treatmet for ay ijury, however slight, 4) wash hads thoroughly before meals, before usig the toilet ad after work, 5) use coditioig creams after washig, where provided. Miig 77

78 Material Safety Data Uder these coditios, atural fibres are likely to yield carbo dioxide, water ad ash, whereas sythetic materials are likely to yield toxic fumes. The treatmet of atural fibres, such as rotproofig, may also produce toxic fumes o burig. The cocetratios of toxic fumes from the cores, however, will be almost egligible compared with the products geerated by heatig from the other primary materials, e.g. wire ad maufacturig lubricat i the rope. The most commo sythetic core material is polypropylee, although other polymers such as polyethylee ad ylo may occasioally be used. Fillig ad Coverig Materials Fillig ad coverig materials do ot preset a health hazard durig hadlig of the rope i its as-supplied coditio. The pricipal area of hazard is by the ihalatio of fumes geerated by heat, for example whe the rope is beig cut by a disc cutter. Uder these coditios, filligs ad coverigs, which are geerally polypropylee, polyethylee ad polyamide (but i some cases may be of atural fibre) are likely to produce toxic fumes. Geeral Iformatio Occupatioal protective measures 1) Respiratory protectio - Use geeral ad local exhaust vetilatio to keep airbore dust or fumes below established occupatioal exposure stadards (OES s). Operators should wear approved dust ad fume respirators if OES s are exceeded. (The OES for total dust is 10mg/m3 ad for respirable dust is 5mg/m 3 ). 2) Protective equipmet - Protective equipmet should be wor durig operatios creatig eye hazards. A weldig hood should be wor whe weldig or burig. Use gloves ad other protective equipmet whe required. 3) Other - Priciples of good persoal hygiee should be followed prior to chagig ito street clothig or eatig. Food should ot be cosumed i the workig eviromet. Emergecy medical procedures 1) Ihalatio - Remove to fresh air; get medical attetio. 2) Ski - Wash areas well with soap ad water. 3) Eyes - Flush well with ruig water to remove particulate; get medical attetio. 4) Igestio - I the ulikely evet that quatities of rope or ay of its compoets are igested, get medical attetio. Safety Iformatio 1) Fire ad explosio - I the solid state, steel compoets of the rope preset o fire or explosio hazard. the orgaic elemets preset, i.e. lubricats, atural ad sythetic fibres ad other atural or sythetic fillig ad coverig materials are capable of supportig fire. 2) Reactivity - Stable uder ormal coditios. Spill or leak procedures 1) Spill or leak - Not applicable to steel i the solid form. 2) Disposal - Dispose of i accordace with local Regulatios. Rope Termiology Wires Outer wires: All wires positioed i the outer layer of wires i a spiral rope or i the outer layer of wires i the outer strads of a straded rope. Ier wires: All wires of itermediate layers positioed betwee the cetre wire ad outer layer of wires i a spiral rope or all other wires except cetre, filler, core ad outer wires of a straded rope. Core wires: All wires of the core of a straded rope. Cetre wires: Wires positioed either at the cetre of a spiral rope or at the cetres of strads of a straded rope. Layer of wires: A assembly of wires havig oe pitch circle diameter. The exceptio is Warrigto layer comprisig alterately laid large ad small wires where the smaller wires are positioed o a larger pitch circle diameter tha the larger wires. The first layer is that which is laid immediately over the strad cetre. Note: Filler wires do ot costitute a separate layer. Tesile stregth grade of wires: A level of requiremet of tesile stregth of a wire ad its correspodig tesile stregth rage. It is desigated by the value accordig to the lower limit of tesile stregth ad is used whe specifyig wire ad whe determiig the calculated miimum breakig force or calculated miimum aggregate breakig force of a rope. Wire fiish: The coditio of the surface fiish of a wire, e.g. bright, zic coated. 78 Miig

79 TECHNICAL INFORMATION Rope Termiology Strads Strad: A elemet of rope usually cosistig of a assembly of wires of appropriate shape ad dimesios laid helically i the same directio i oe or more layers aroud a cetre. Note: Strads cotaiig three or four wires i the first layer or certai shaped (e.g. ribbo) strads may ot have a cetre. Roud strad: A strad with a cross-sectio which is approximately the shape of a circle. Triagular strad: A strad with a cross-sectio which is approximately the shape of a triagle. Note: Triagular strads may have built-up cetres (i.e. more tha oe wire formig a triagle). Oval strad: A strad with a cross-sectio which is approximately the shape of a oval Flat ribbo strad: A strad without a cetre wire with a crosssectio which is approximately the shape of a rectagle. Compacted strad: A strad which has bee subjected to a compactig process such as drawig, rollig or swagig whereby the metallic cross-sectioal area of the wires remais ualtered ad the shape of the wires ad the dimesios of the strad are modified. Note: Brido s brads of Dyform rope cotai strads which have bee compacted. Sigle lay strad: Strad which cotais oly oe layer of wires, e.g Parallel lay strad: Strad which cotais at least two layers of wires, all of which are laid i oe operatio (i the same directio), e.g ; 12-6F-6-1; Each layer of wires lies i the iterstices of the uderlyig layer such that they are parallel to oe aother, resultig i liear cotact. Note: This is also referred to as equal lay. The lay legth of all the wire layers are equal. Seale: Parallel lay strad costructio with the same umber of wires i each wire layer, each wire layer cotaiig wires of the same size, e.g ; 8-8-1; Warrigto: Parallel lay strad costructio havig a outer layer of wires cotaiig alterately large ad small wires, the umber of wires i the outer layer beig twice that i the uderlyig layer of wires, e.g ; Filler: Parallel lay strad costructio havig a outer layer of wires cotaiig twice the umber of wires tha i the ier layer with filler wires laid i the iterstices wires of the uderlyig layer of wires, e.g. 12-6F-6-1; 14-7F-7-1. Multiple operatio lay strad: Strad costructio cotaiig at least two layers of wires, at least oe of which is laid i a separate operatio. All of the wires are laid i the same directio. Cross-lay: Multiple operatio strad costructio i which the wires of superimposed wire layers cross over oe aother ad make poit cotact, e.g. 12/6-1. Compoud lay: Multiple operatio strad which cotais a miimum of three layers of wires, the outer layer of which is laid over a parallel lay cetre, e.g. 16/ Ropes Spiral Rope: A assembly of two or more layers of shaped ad/or roud wires laid helically over a cetre, usually a sigle roud wire. There are three categories of spiral rope, viz. spiral strad, halflocked coil ad full-locked coil. Spiral Strad: A assembly of two or more layers of roud wires laid helically over a cetre, usually a sigle roud wire. Half-locked Coil Rope: A spiral rope type havig a outer layer of wires cotaiig alterate half lock ad roud wires. Full-locked Coil Rope: A spiral rope type havig a outer layer of full lock wires. Straded Rope: A assembly of several strads laid helically i oe or more layers aroud a core or cetre. There are three categories of straded rope, viz. sigle layer, multi-layer ad parallel-closed. Sigle Layer Rope: Straded rope cosistig of oe layer of strads laid helically over a core. Note: Straded ropes cosistig of three or four outer strads may, or may ot, have a core. Some three ad four strad sigle layer ropes are desiged to geerate torque levels equivalet to those geerated by rotatio-resistat ad low rotatio ropes. Rotatio-resistat Rope: Straded rope havig o less tha te outer strads ad comprisig a assembly of at least two layers of strads laid over a cetre, the directio of lay of the outer strads beig opposite (i.e. cotra - lay) to that of the uderlyig layer of strads. Low Rotatio Rope: Rotatio resistat rope havig at least fiftee outer strads ad comprisig a assembly of at least three layers of strads laid over a cetre i two operatios. Note: this category of rotatio resistat rope is costructed i such a maer that it displays little or o tedecy to rotate, or if guided, geerates little or o torque whe loaded. Combied parallel lay: Parallel lay strad costructio havig three or more layers of wires, e.g ; ; F-7-1; F+8-1. Note: The first two examples above are also referred to as Warrigto-Seale costructio. The latter two examples are also referred to as Seale-Filler costructio. Miig 79

80 Rope Termiology Compacted Strad Rope: Rope i which the outer strads, prior to closig of the rope, are subjected to a compactig process such as drawig, rollig or swagig. Note: Brido s products cotaiig compacted strads are idetified by Dyform. Compacted Rope: Rope which is subjected to a compactig process after closig, thus reducig its diameter. Solid Polymer Filled Rope: Rope i which the free iteral spaces are filled with a solid polymer. The polymer exteds to, or slightly beyod, the outer circumferece of the rope. Cushioed Rope: Straded rope i which the ier layers, ier strads or core strads are covered with solid polymers or fibres to form a cushio betwee adjacet strads or layers of strads. Cushio Core Rope: Straded rope i which the core is covered (coated) or filled ad covered (coated) with a solid polymer. Solid Polymer Covered Rope: Rope which is covered (coated) with a solid polymer. Solid Polymer Covered ad Filled Rope: Rope which is covered (coated) ad filled with a solid polymer. Rope Grade (Rr): A umber correspodig to a wire tesile stregth grade o which the miimum breakig force of a rope is calculated. Note: It does ot imply that the actual tesile stregth grades of the wires i a rope are ecessarily the same as the rope grade. Preformed Rope: Straded rope i which the wires i the strads ad the strads i the rope have their iteral stresses reduced resultig i a rope i which, after removal of ay servig, the wires ad the strads will ot sprig out of the rope formatio. Note: Multi-layer straded ropes should be regarded as o-preformed rope eve though the strads may have bee partially (lightly) preformed durig the closig process. Rope Class: A groupig of rope costructios where the umber of outer strads ad the umber of wires ad how they are laid up are withi defied limits, resultig i ropes withi the class havig similar stregth ad rotatioal properties. Rope Costructio: System which deotes the arragemet of the strads ad wires withi a rope, e.g. 6x36WS, 6x19S. Strad ad Rope Lays Lay directio of strad: The directio right (z) or left (s) correspodig to the directio of lay of the outer layer of wires i relatio to the logitudial axis of the strad. Lay directio of rope: The directio right (Z) or left (S) correspodig to the directio of lay of the outer strads i relatio to the logitudial axis of a straded rope or the directio of lay of the outer wires i relatio to the logitudial axis of a spiral rope. Ordiary lay: Straded rope i which the directio of lay of the wires i the outer strads is i the opposite directio to the lay of the outer strads i the rope. Right had ordiary lay is desigated sz ad left had ordiary lay is desigated zs. Note: This type of lay is sometimes referred to as regular lay. Lag s lay: Straded rope i which the directio of lay of the wires i the outer strads is the same as that of the outer strads i the rope. Right had Lag s lay is desigated zz ad left had Lag s lay is desigated ss. Alterate lay: Straded rope i which the lay of the outer strads is alteratively Lag s lay ad ordiary lay. Right had alterate lay is desigated AZ ad left had alterate lay is desigated AS. Cotra-lay: Rope i which at least oe ier layer of wires i a spiral rope or oe layer of strads i a straded rope is laid i the opposite directio to the other layer(s) of wires or strads respectively. Note: Cotra-lay is oly possible i spiral ropes havig more tha oe layer of wires ad i multi-layer straded ropes. Rope lay legth (Straded Rope): That distace parallel to the axis of the rope i which the outer strads make oe complete tur (or helix) about the axis of the rope. Cores Core: Cetral elemet, usually of fibre or steel, of a sigle layer straded rope, aroud which are laid helically the outer strads of a straded rope or the outer uit ropes of a cable-laid rope. Fibre core: Core made from atural fibres(e.g. hemp, sisal) ad desigated by its diameter ad ruage. Fibre Film Core: Core made from sythetic fibres (e.g. polypropylee) ad desigated by its diameter ad ruage. Note: K deotes compacted strads. Cable-laid Rope: A assembly of several (usually six) sigle layer straded ropes (referred to as uit ropes) laid helically over a core (usually a seveth sigle layer straded rope). Braided Rope: A assembly of several roud strads braided i pairs. Electro-mechaical Rope: A straded or spiral rope cotaiig electrical coductors. 80 Miig

81 TECHNICAL INFORMATION Steel core: Core produced either as a idepedet wire rope (IWRC)(e.g. 7x7) or wire strad (WSC)(e.g. 1x7). Solid polymer core: Core produced as a sigle elemet of solid polymer havig a roud or grooved shape. It may also cotai iteral elemets of wire or fibre. Isert: Elemet of fibre or solid polymer so positioed as to separate adjacet strads or wires i the same or overlyig layers ad fill, or partly fill, some of the iterstices i the rope. (see Zebra) Rope Characteristics ad Properties Calculated Miimum aggregate Breakig Force: Value of miimum aggregate breakig force is obtaied by calculatio from the sum of the products of the cross-sectioal area (based o omial wire diameter) ad tesile stregth grade of each wire i the rope, as give i the maufacturer s rope desig. Calculated Miimum breakig Force: Value of miimum breakig force based o the omial wire sizes, wire tesile stregth grades ad spiig loss factor for the rope class or costructio as give i the maufacturer s rope desig. Fill factor: The ratio betwee the sum of the omial crosssectioal areas of all the load bearig wires i the rope ad the circumscribed area of the rope based o its omial diameter. Spiig loss factor (k): The ratio betwee the calculated miimum breakig force of the rope ad the calculated miimum aggregate breakig force of the rope. Breakig force factor (K): A empirical factor used i the determiatio of miimum breakig force of a rope ad obtaied from the product of fill factor for the rope class or costructio, spiig loss factor for the rope class or costructio ad the costat π/4. Miimum breakig force (Fmi): Specified value, i, below which the measured breakig force is ot allowed to fall i a prescribed test ad, for ropes havig a grade, obtaied by calculatio from the product of the square of the omial diameter, the rope grade ad the breakig force factor. Miimum aggregate breakig force (Fe,mi): Specified value, i, below which the measured aggregate breakig force is ot allowed to fall i a prescribed test ad, for ropes havig a grade, obtaied from the product of the square of the omial rope diameter (d), the metallic cross-sectioal area factor (C) ad the rope grade (Rr). Nomial legth mass: The omial mass values are for the fully lubricated ropes. For frictio wider ropes, the values should be reduced by 2%. The omial legth mass values are subject to a tolerace of plus 2% to mius 5%. Rope torque: Value, usually expressed i N.m, resultig from either test or calculatio, relatig to the torque geerated whe both eds of the rope are fixed ad the rope is subjected to tesile loadig. Rope tur: Value, usually expressed i degrees per metre, resultig from either test or calculatio, relatig to the amout of rotatio whe oe ed of the rope is free to rotate ad the rope is subjected to tesile loadig. Iitial extesio: Amout of extesio which is attributed to the iitial beddig dow of the wires withi the strads ad the strads withi the rope due to tesile loadig. Note: This is sometimes referred to as costructioal stretch. Elastic extesio: Amout of extesio which follows Hooke s Law withi certai limits due to applicatio of a tesile load. Permaet rope extesio: No-elastic extesio. Miig 81

82 Coversio Factors S.I. Uits Force 1 = Mp 1 UK tof = N 1 N = kgf 1 lbf = N 1 kgf = N 1 lbf = kgf 1 kgf = 1 kp 1 UK tof = toe 1 N = x 10-4 UK tof 1 UK tof = N = lbf 1 UK tof = 2240 lbf 1 kgf = lbf 1 short tof 1 t = UK tof (USA) = 2000 lbf 1 = UK tof 1 kip (USA) = 1000 lbf 1 kip = kgf Pressure/Stress 1 N/mm 2 = kgf/mm 2 1 kgf/mm 2 = N/mm 2 1 N/mm 2 = 1 MPa 1 kgf/mm 2 = lbf/i 2 1 lbf/i 2 = x 10-4 kgf/mm 2 1 kgf/mm 2 = tof/i 2 1 tof/i 2 = kgf/mm 2 1 N/m 2 = x 10-4 lbf/i 2 1 lbf/i 2 = N/m 2 1 N/m 2 = 1 x 10-6 N/mm 2 1 tof/i 2 = x 10 8 dy/cm 2 1 bar = lbf/i 2 1 hectobar = 10 N/mm 2 1 hectobar = 1 x 10 7 N/m 2 Mass 1 kg = lb 1 lb = kg 1 toe (t) = UK to 1 UK to = toes (t) 1 kg/m = lb/ft 1 lb/ft = kg/m 1 kg = 1000 g 1 kip (USA) = 1000 lb 1 Mp = 1 x 10 6 gf 1 toe (t) = Legth 1 m = ft 1 ft = m 1 km = miles 1 mile = km Area 1 mm 2 = i 2 1 i 2 = mm 2 1 m 2 = ft 2 1 ft 2 = m 2 Volume 1 cm 3 = i 3 1 i 3 = cm 3 1 litre (1) = i 3 1 i 3 = x 10 4 ml 1 m 3 = x 10 4 i 3 1 yd 3 = m 3 82 Miig

83 TECHNICAL INFORMATION BRIDON MANUFACTURING AND SALES LOCATIONS UNITED KINGDOM Docaster Balby Carr Bak, Docaster, South Yorkshire, DN4 5JQ Uited Kigdom Phoe: +44(0) Fax: +44(0) Aberdee Brido Iteratioal Ltd 1 Berry Street Aberdee, AB25 1HF sales@brido.com Phoe: NORTH AMERICA Brido America C280 New Commerce Blvd. Wilkes Barre, PA USA miig@bridoamerica.com Phoe: Fax: GERMANY Brido Iteratioal GmbH Magdeburger Straße 14a D-45881, Gelsekirche Germay miig@brido.com Phoe: +49(0) Fax: +49(0) POLAND Brido Iteratioal Ltd ul. Ge.W.Sikorskiego 20 Cuprum Area, Pozium +4 Biuro r 1.6, Lubi Polad salespolad@brido.com Phoe: Fax: RUSSIA Brido Iteratioal Moscow Prospect Mira 101 Moscow , Russia ifo@brido.ru Phoe: Fax: INDONESIA PT Brido Jl. Raya Bekasi Km. 43, Cibitug, Bekasi brido@cb.et.id Phoe: Fax: SOUTH AFRICA Brido Iteratioal Limited C/O Shutterlock (Pty) Ltd, The Corer of Harred ad Fiat Street, Aureus Idustrial Site, Radfotei, South Africa baileyk@brido.com Phoe: +27 (0) ext. 204 Fax: +27 (0) MIDDLE EAST Brido Middle East PO Box Dubai Uited Arab Emirates bridome@emirates.et.ae Phoe: Fax: BRAZIL Brido do Brasil Aveida Rio Braco, 89, Ed. Mahatta Tower, 26 adar, Cetro Rio de Jaeiro RJ, CEP: Brasil leitej@bridoamerica.com Phoe: Fax: Mobile: Brido do Brasil Warehouse & Service Ceter Aveida Nacif Salim Sele, 365 Codomiio Idustrial Cabiúas Cabiúas - Macaé - RJ CEP: brazilsalesteam@bridoamerica.com Oil & Gas: Miig & Craes: Sales & Ispectios: SINGAPORE Brido Sigapore (Pte) Ltd. 27D Loyag Crescet Sigapore, bluestrad@brido.com.sg Phoe: Fax: CHINA Brido Hog Kog Ltd. Uit B G/F Roxy Idustrial Cetre Tai Li Pai Road Kwai Chug, New Territories Hog Kog sales@brido.com.hk Phoe: Fax: Brido Hagzhou 57 Yoghua Street Xiacheg District Hagzhou City, Zhejiag Provice P.R.Chia sales@bridohagzhou.com Phoe: Fax: AUSTRALIA Brisbae 123 Eagle Street, Brisbae, Queeslad, 4000, Australia salesaustralia@brido.com Phoe: Perth 221 St Georges Terrace, Perth 6000, Australia salesaustralia@brido.com Phoe: NEW ZEALAND Brido New Zealad 6-10 Greemout Drive East Tamaki, Aucklad PO Box Pamure New Zealad sales@brido.com Phoe: Fax: Miig 83

84 Groud Floor Ico Buildig, First Poit Balby Carr Bak, Docaster South Yorkshire DN4 5JQ, Uited Kigdom Phoe: +44(0) Fax: +44(0) Magdeburger Straße 14a D-45881, Gelsekirche, Germay Phoe: +49(0) Fax: +49(0) miig@brido.com C280 New Commerce Blvd. Wilkes Barre, PA 18706, USA Phoe: Fax: brido@bridoamerica.com 09/2015 Editio 7