Drawing Showing the Component Parts of a Standard Steel Wire Rope Core wire Rope wire Strand Steel wire rope Core of natural or synthetic fibre or steel * *) The strands are wrapped around a core of fibre or steel. If the rope has a fibre core it is marked +FC. if it has a braided steel strand as core it is marked +IWS and if it has a steel rope as core it is marked +IWR. 5:48
Technical Information Advice for Safe Use and Inspection Steel wire equipment - general Keep records for all equpiment in use. Lifting assembles must be marked with the following information: - Working Load Limit - Manufacturer - CE-marking - Year of manufacture Never exceed allowed WLL. Never use wire with kinks. Never knot the wire. Use edge protection to prevent sharp edges from damaging the wire. Do not stand or walk under suspended loads. Do not ride on the load. Steel wire rope must not be used in alkaline or acidic conditions. Do not use fi bre wire ropes in temperatures above +100 C without consulting the manufacturers instructions. Use the table for wire rope slings equipment to ensure that permitted WLL is not exceeded. Hooks 5 Never point load the hook - make sure the load is hanging correctly in the base of the hook. Do not side load the hook. To avoid crushing injuries, grip the hook by its sides with your fi ngertips only, never with your entire hand. Master links Always use the correct size link in the crane hook. The top link should be able to move freely in the hook. Protect the master link against bending over sharp edges. Inspection Provided heating to 400 C is not exceeded, the sling returns to normal working capacity after cooling fully. Slings must not be used above or beloew these temperatures, without reference to the manufacturer. Wire rope damaged by crushing, kinking or with damaged ferrules or end terminations must be discarded. Discard criteria for broken wires: 3 adjacent wires in any strand, maximum 6 within a length of 6 x rope diameter; 14 within a length of 30 x rope diameters. Note that steel wire rope should be opened up to expose the inner strands and core to inspection. 5:49
Strand Designs Standard constructions Round Strand All rope wires have the same diameter. Filler wires 1x25 (12/6F+6/1) The wires in the outer and inner layers have the same diameter. The space between the layers is fi lled up by wires with another diameter. Seale 1x19 (9/9/1) Every layer has a different wire diameter. All layers have the same amount of wires. Warrington - Seale 1x36 (14/7+7/7/1) This design is a combination of Warrington and Seale. Warrington 1x19 (6+6/6/6/1) The outer layer consists of wires with two different diameters. Example of rope sections Standard constructions 6x7 + FC 6X36 WS+FC 6x12 +7 FC 6x36 WS+IWRC 6x19 +FC 18x7 +WSC 6x19 +WSC 35x7 5:50
Technical Information Example of wire sections High performance constructions PYTHON Super 8 R PYTHON Ultra S PYTHON Super 8 S PYTHON Lift PYTHON Super 8 C PYTHON Hoist S 5 PYTHON Flameshield 8 PYTHON Hoist C PYTHON Power 9 R PYTHON Classic 35 PYTHON Power 9 S PYTHON Compac 35 5:51
Rope Spinning Methods Right hand Ordinary lay Left hand Ordinary lay Right hand Langs lay Left hand Langs lay Right-spinning is standard but left-spinning can be called for in some cases. e.g. when the lifting equipment requires ropes spun in both directions, e.g. on hoisting cranes where cargo rotation must be prevented. A transversely spun rope is more resistant to rough treatment than a longitudinally spun rope is. For example transversely spun ropes are usually suitable for construction work, which always call for a great caution. The contact surface of the outer wires of longitudinally spun ropes against pulleys is greater than that of transversely spun ropes. Transversely spun ropes are less prone to twisting in cases of freely suspended loads than longitudinally spun ropes are, a fact which suggests guiding in the latter case. Right- and left-spun ropes have the same technical properties. Right-spun ropes are usually available ex stock. 5:52
Technical Information Rope Wire Strength The tensile strength grade of the rope indicates the wire strength. The tensile grade indicated is the estimated minimum and also the basis for calculating the ultimate rope breaking load. The most common tensile grades are: 1570 N/mm² (160 Kp/mm²) 1770 N/mm² (180 Kp/mm²) 1960 N/mm² (200 Kp/mm²) 2160 N/mm² (220 Kp/mm²) The wire might be bright, zinc coated or stainless. Elongation of Steel Wire Rope There are no exact fi gures for different constructions, but the values in the table below can be used to give an idea of the extend of the elongation. Elongation in % of the ropes full length Load Safety factor Rope with fi bre core Rope with steel core Light load 8 0.25 0.125 Normal load 5 0.50 0.25 Heavy load 3 0.75 0.5 5 Cutting of Steel Wire Ropes Steel ropes are normally cut by grinding in special machines by the manufacturer. Thereby the wire ends become rounded. If a rope has to be cut on site, a hand-held cutter or shears can be used. The rope must be bound properly on both sides of the intended cut prior to cutting. Execution: Preformed ropes do not need more than one binding on each side of the cut while non-preformed ropes require two. The length of the binding must not be less than the diameter of the rope to be bound. The distance between bindings should be 6 times the rope diameter. Note: Anti-spin and some special constructions of steel wire rope should have at least four bindings on each side of the cut. 5:53
Handling Steel wire ropes are delivered on drums, wooden crosses or as bound coils. Safe handling Incorrect handling Do not lift rope reels or coils as shown in fi gure 1, as this may damage the rope. Use lifting slings or a bar or tube though the centre of the drum as shown in fi gure 2, 3 and 4. 5:54
Technical Information Handling Correct methods of unwinding rope. 5 Incorrect methods of unwinding rope. 5:55
Kinking and its effects 1. A seemingly harmless loop has formed as a result of incorrect unwinding. 2. Here the loop has tightened. 3. An attempt to straighten the loop by uncoiling and hammering has dislocated the rope wires. 4. After a period of using the rope, a concentrated point of wire breakage develops. 5:56
Technical Information Coiling Different types of rope drums The correct way of coiling up right-spun rope. Left-spun Right-spun From left to right From right to left Left-spun Right-spun 5 The correct way of coiling up left-spun rope. Right-spun Left-spun From left to right From right to left 5:57
Pulleys A general rule: LARGE PULLEY-DIAMETER = LONG ROPE LIFE The table below shows the minimum recommended bending ratio for various rope designs Bending ratio D d D = the pulley diameter d = the rope diameter Rope design Minimum 6x7 42 6x24 Seale + FC 26 6x19 Seale 32 6x36 Warrington Seale 21 18x7 eller 19x7 Anti-spin 34 Python Classic 35 20 Python Super 8 R - S - C 20 Python Flameshield 8 20 Python Power 9 R - S 26 Python Ultra S 26 Python Lift / Hoist 20 Groove Shape The adjacent fi gure shows the importance of using pulleys with the correct groove shape. Too big a groove can fl atten the rope and can result in groove wear (see dotted line). When a new rope with the correct diameter is installed, the sharp edges at the bottom of the groove may create fractural impressions that reduce rope life. Too thick a rope for the groove. The rope is fl attened sideways, resulting in dislocation of the rope wires. This also shortens rope-life. The correct groove shape whose diameter is 1.05-1.10 times the rope diameter. The contact surface of the rope against the groove becomes more than 2/3 of the circumference, resulting in the longest rope life. 5:58
Technical Information Lubrication - Supplementary Lubrication The lubrication applied to steel wire ropes during production protects the rope during storage and the initial period of use. Thereafter, steel wire ropes should be re-lubricated regularly. Good lubrication is important to rope-life as it not only protects against corrosion but also reduces friction between the wires and strands of the rope. The lubricant should be liquid enough to penetrate the rope well. The rope should be cleaned before re-lubrication. For best effect, the lubricant should be applied where the rope opens up, e.g. on the entry side of a pulley or hoisting drum. 5 Running-In of Steel Wire Rope When the steel rope is correctly installed and running easily across all the pulleys the running-in phase can begin. The rope should run with a light load, about 10% of the max. load, for about 15-20 minutes at low speed. This running-in phase allows the rope and its components to adapt to the intended working conditions. The amount of time spent on running-in will pay off as increased rope life many times over. 5:59
Wire Grease Dinitrol Lubricating rust protection grease Characteristics Wire grease is a very effective rust protection grease and also a good lubricant. Its adhesion to steel surfaces is good. The protective fi lm which is amber and greasy is also very pliable. Applications Wire grease is mainly intended for situations where, in addition to rust protection, lubricant is also required. It is well suited to rust protection of machine parts requiring good lubrication and rust protection during varying climatic conditions, e.g. on board ships. Wire grease is a perfect lubricant for running steel ropes and an excellent rust protector of various steel objects stored or transported in corrosive conditions. Before treating a rusty steel rope, Dinitrol 41 (see below) should fi rst be applied to improve the penetration of Wire grease. Wire Oil Dinitrol 41 Thin-bodied, penetrating rust protection liquid Characteristics Dinitrol 41 is a rust protection liquid with a good ability to penetrate gaps and joints. Dinitrol 41 also penetrates rust and dirt and prevents further corrosion. After the solvent has evaporated, an amber, greasy protection fi lm remains, offering very good rust protection indoors or during cold storage. In combination with additional rust protection agents, reliable protection outdoors is achieved. Applications Dinitrol 41 is mainly intended for rust protection of structures, machines and machine parts which cannot be properly cleaned or where rust has already formed. Dinitrol 41 effectively prevents further corrosion and is therefore perfect for protecting steel structures. Dinitrol 41 is also very well-suited to the protection of cleaned and dry steel surfaces where a less durable protection fi lm is required. In addition, Dinitrol 41 can be used for transport and storage protection of fi nished and semi-fi nished products. Physical and chemical properties Wire Grease Dinitrol Color Amber Type of fi lm Greasy Density at 23 C 915 kgs/m3 DAM 4:1 Recommended fi lm thickness (dry fi lm) 75-100 µm Drying time 1 h Min. storage temp. -20 C Consumption 0.07 kgs/m2 Liqueifying temp. 55 Durability - Indoor storage 1-3 years - Outdoors, under cover 1-2 years Wire Oil Dinitrol Color Amber Type of fi lm Greasy Density at 23 C 846 kgs/m3 DAM 4:1 Viscosity 23 C. DIN2 55 s DAM 5:1 Solvent White spirit Dry contents 45% (by weight) DAM 2:1 Flash point 40 C DAM 4:1 Flammability classifi cation 2b Work-environmental air volume requirement 900 m3/l Recommended fi lm thickness 8 µm Drying time 1-2 h Min. storage temp. -30 C SAE J400 Effect on varnish None SS186011 Consumption 0.02 l/m2 Durability - Indoors 9-15 months 5:60