02_wire_rope_strand

e d p n o R a r e t S r i & W

SECTION 02

WIRE ROPE & STRAND

Wire Rope & Strand

& W i r S e t r R a o n d p e

GENERAL INFORMATION A. Noble & Son Ltd. has been stocking and distributing wire rope almost since the inception of the company in 1911.

Construction

The main components of a wire rope are shown below.

Apart from the distribution of wire rope Nobles personnel can supply guidance on correct usage and selection of wire rope. Nobles branches throughout Australia have swaging presses for terminating wire rope and NATA accredited tensile testing laboratories. The testing laboratories can be used for destruction testing and proof loading of wire ropes and wire rope assemblies. A. Noble & Son Ltd. represents a range of wire rope manufacturers from all over the world who each have their own specialities in mine winding, crane and general purpose ropes.

Description, Size & Construction A wire rope is made up of the basic components illustrated. The terms used to describe these component parts should be strictly adhered to, particularly when reporting on the conditions of ropes.

In the above example, each individual wire is arranged around a central wire to form a 7-wire strand. Six of these strands are formed around a central core to make a wire rope. The rope is specified as 6x7 (6/1) – i.e. six strands each of seven wires.

Describing wires as strands and strands as wire can be grossly misleading. For example, a report that a rope has a broken strand in most applications calls for immediate discarding of the rope, and subsequent cessation of operation, while a report that a rope has a broken wire in it should call for early inspection but seldom for discarding the rope.

The size and number of wires in each strand, as well as the size and number of strands in the rope greatly affect the characteristics of the rope. In general, a large number of smallsize wires and strands produce a flexible rope with good resistance to bending fatigue. The rope construction is also important for tensile loading (static, live or shock), abrasive wear, crushing, corrosion and rotation.

Core

Equal Laid Rope Strand

Wire Rope Wire

Composition Compositio n of Wire Rope

Wire Rope Description

The properties of a wire rope are derived from its size, construction, quality, lay and type of core. Size

Ropes are referred to by a diameter size. The correct way to measure wire rope is shown below.

Correct Method

Incorrect Method

22

Cross Laid Rope

Wire Rope & Strand


GENERAL INFORMATION A. Noble & Son Ltd. has been stocking and distributing wire rope almost since the inception of the company in 1911.

Construction

The main components of a wire rope are shown below.

Apart from the distribution of wire rope Nobles personnel can supply guidance on correct usage and selection of wire rope. Nobles branches throughout Australia have swaging presses for terminating wire rope and NATA accredited tensile testing laboratories. The testing laboratories can be used for destruction testing and proof loading of wire ropes and wire rope assemblies. A. Noble & Son Ltd. represents a range of wire rope manufacturers from all over the world who each have their own specialities in mine winding, crane and general purpose ropes.

Description, Size & Construction A wire rope is made up of the basic components illustrated. The terms used to describe these component parts should be strictly adhered to, particularly when reporting on the conditions of ropes.

In the above example, each individual wire is arranged around a central wire to form a 7-wire strand. Six of these strands are formed around a central core to make a wire rope. The rope is specified as 6x7 (6/1) – i.e. six strands each of seven wires.

Describing wires as strands and strands as wire can be grossly misleading. For example, a report that a rope has a broken strand in most applications calls for immediate discarding of the rope, and subsequent cessation of operation, while a report that a rope has a broken wire in it should call for early inspection but seldom for discarding the rope.

The size and number of wires in each strand, as well as the size and number of strands in the rope greatly affect the characteristics of the rope. In general, a large number of smallsize wires and strands produce a flexible rope with good resistance to bending fatigue. The rope construction is also important for tensile loading (static, live or shock), abrasive wear, crushing, corrosion and rotation.

Core

Equal Laid Rope Strand

Wire Rope Wire

Composition Compositio n of Wire Rope

Wire Rope Description

The properties of a wire rope are derived from its size, construction, quality, lay and type of core. Size

Ropes are referred to by a diameter size. The correct way to measure wire rope is shown below.

Correct Method

Incorrect Method

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Cross Laid Rope

Wire Rope & Strand GENERAL INFORMATION The conventional rotation resistant wire rope is composed of a number of strands that are laid up in opposite directions to produce a non-rotating effect. Rotation Resistant:

The 4 strand Mono Track is a complete departure from this convention and is created through theoretical analyses of the working torques. The wires are specially formed to produce a strand with a triangular section – this type of rope is only produced in Lang’s lay. This construction has improved wear and crush resistance and has wide application in winding and haulage systems. Triangular Strand: Multiple Operation

These are single strands of concentric layers of wires, some of which are cross laid to produce a non-rotating result. Galvanised Strand:

Single Operation

A strand with the outer layer composed of alternate shaped and round wires covering one or two layers of round wires laid in the opposite direction. Half Locked Coil:

A strand used as a rope and composed of one or two layers of Z-shaped wires laid over layers of half lock coil and/or layers of round wires. Full Locked Coil:

Rotation Resistant

A rope composed of flattened strands of six or eight wires contra laid over a triangular strand rope to produce a rotation resistant result. Rotation Resistant Mining Ropes:

Cores & Wire Tensile A number of core types are available and each gives specific properties to the rope: Triangular Strand

1. Fibre Core (FC) – sisal or polypropylene. 2. Wire Strand Core (WSC) – strand strand usually of the same construction as the outer strands. 3. Independent Wire Rope Core (IWRC) – a wire rope usually of 6x7 (6/1)/1x7(6/1) construction. Fibre Core (FC) in 6 x 7 rope

Galvanised Strand

A fibre core, generally sisal, provides a resilient foundation for the strands in the rope structure. Fibre cores are used for ropes that are not subjected to heavy loading and where flexibility in handling is required. Fibre cores are inadequate where wire rope is subjected to heavy loading, prolonged to outdoor exposure and crushing on small drums and sheaves.

Half Locked Coil

Wire Strand Core (WSC) in 6 x 7 Rope Rope Full Locked Coil

These cores are used chiefly for standing ropes (guys or rigging), and offer higher tensile strength and, owing to the larger wires in the core, greater resistance to corrosion failure.

Non-Rotating Mining

Individual strands are composed of successive layers of wire laid up at different lay lengths. This results in a cross laid rope. Multiple Operation:

This type of construction is now confined to a limited range of products such as ropes below 8mm diameter, and large sling and static ropes.

Independentt Wire Rope Core (IWRC) Independen in 6x25 FW Rope

In many instances it is recommended to use a wire rope with an independent wire rope core (I.W.R.C). Such a core is usually made up of 6 strands of 7 wires each plus centre strand.

All wires in the strand are laid up in the one manufacturing operation. This type of rope is standard production, providing an equal laid rope that eliminates internal cross-mating and forms a compact strand of high metallic content. There are three main types: 6x9/9/1, 6x25 FW and 6x36 SW. Single Operation:

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Wire Rope & Strand


GENERAL INFORMATION The independent wire rope core provides:

Preforming, Postforming & Lay

1. Permanent support and uniform spacing of the strands laid around it; it is not compressible and has greater wear resistance than fibre core.

Preforming

2. Permanent elastic stretch of the wire rope over a longer period of time.

Preforming can be applied to both Ordinary lay and Lang’s lay ropes and, unless specifically ordered otherwise, all standard ropes are supplied preformed.

A preformed rope is one in which the component strands are shaped to their final helical form before being laid into the rope.

3. Increased resistance to deterioration and deformation.

The advantages of preforming are mainly:

4. Delay of internal corrosion; the lubricant is not squeezed out of the core.

1. Reduction of internal stresses in the rope. This makes the rope easier to handle, install, reduces its tendency to kink and gives better spooling onto drums.

5. It increases the actual breaking load of the rope by at least 8% in the case of 6-strand ropes and about 25% in the case of 8-strand ropes.

2. Greatly improved resistance to bending fatigue particularly in operation over small drums and sheaves.

6. Better performance for operating in very high temperatures.

3. Greater stability and better resistance to shock loading and abrasion.

An independent wire rope core increases the weight of a 6-strand rope by about 10%, and that of an 8-strand rope by approx. 20%.

4. Improved rope life due to the better equalisation of loading between strands in the rope and reduction of internal stresses in the rope.

Although a new rope with I.W.R.C. may be somewhat less flexible than a new rope with fibre core, it retains its relative flexibility whereas a rope with fibre core gradually loses its flexibility during use. Having better resistance to deterioration and deformation, a rope with I.W.R.C. is less susceptible to damage when used on small sheaves and drums than a rope with fibre core, it will also last longer before deterioration and deformation set in when wound on a drum in multiple layers.

5. Greater safety in handling of ropes as broken wire ends do not protrude. This factor also reduces wear on equipment in contact with the rope. Postforming

Postforming is a manufacturing process applied to ropes to minimise stretch in service. It reduces the stretch caused by "bedding-in" the wires and strands onto their respective cores. In addition to controlling stretch, postforming produces results closely related to those achieved by preforming. Postforming is particularly useful in overcoming stretch in long lengths of rope and where take-up adjustment is restricted. It is commonly applied to ropes used in aerial ropeways, guying, chairlifts and control cables.

Tensile Strength Grades

Wire ropes are usually supplied in the following tensile ranges: Rope Grade

Range of wire tensile strength grades

1570

1370 to 1770

1770

1570 to 1960

1960

1770 to 2160

2160

1960 to 2160

N/mm2

Lay

This refers to the way the wires in the strands, and the strands in the rope are formed into the completed rope. The wire strands are essentially laid up in a planetary motion with controlled twist being imparted to produce a tightly formed rope.

Rope Grade Equivalents Rope Grade Designation

The term "lay" is used in three ways:

Equivalent Rope Grade

IPS

1770

EIPS

1960

EEIPS

2160

1. To describe the direction in which the strands are laid in the rope, right or left. In a Right Hand lay strands are laid around the rope core in a clockwise direction – see illustration. In a Left Hand lay, the strands are laid anti-clockwise – see illustration. Steel Wire Ropes are conventionally produced Right Hand lay unless special circumstances require Left Hand lay. 2. To describe the direction in which the wires are stranded in relation to the direction of the strands in the completed rope, e.g. Ordinary lay or Lang’s lay.

With the increasing use of heavy-duty and more compact equipment (e.g. power winches on mobile cranes and mine winding) there is a gradual upward trend in the required rope wire tensile range. However, as factors other than strength influence the life of wire rope, the specific application must be kept in mind when tensile strength of wire is selected.

Ordinary lay means the wires in a strand are laid in a direction opposite to the direction in which the strands are laid in the final rope. Lang’s lay is the reverse of Ordinary lay. That is, the wires are laid in the same direction as the strands in the rope.

Surface Finish

The most common are: Galvanised wire rope - Zinc coated Class B is denoted with B (formerly G).

Lang’s lay ropes have superior properties in resistance to wear, abrasion, fatigue and scuffing. This is illustrated on the following page, where it can be seen that wear on an outer wire is distributed over a far greater area than in Ordinary lay.

Galvanised wire rope - Zinc coated Class A is denoted with A (formerly G Class A).

3. "Lay" is also a measure of the pitch of a strand in a rope.

Uncoated or Bright wire rope (Black) - is denoted with U (formerly B).

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Wire Rope & Strand GENERAL INFORMATION Lay Directions & Types

Lay direction of strands for stranded ropes are right (z) or left (s) and correspond to the direction of lay of the outer wires in relation to the longitudinal axis of the strand.

The direction of rope lay does not affect the Breaking Force of a rope. However, the combination of strand lay and rope lay will greatly affect the rope characteristics and this factor must be taken into consideration when choosing a rope. Although the lay length can slightly affect rope behaviour the dominant aspect that influences performance is the direction of lay and whether it is Lang’s lay or Ordinary lay. For example, the importance of rope lay is evident in a four-part highlift grab where rotation of the grab is prevented by the use of alternate right-hand and left-hand ropes. Characteristics of Lay:

Lay direction of ropes are right (Z) or left (S) and correspond to the direction of lay of the outer wires in a spiral rope, the outer strands in a stranded rope or the unit ropes in a cable-laid rope in relation to the longitudinal axis of the rope.

Lubrication, Specifications, Testing & Plastic Coating Lubrication

z (right lay)

When a rope is operated over a drum or sheave, the strands and wires move relative to one another. To reduce the resultant friction within the rope as well as the friction between the rope and drum or sheave, ropes are lubricated in manufacture. In addition this lubrication also retards corrosion and inhibits possible rotting of the fibre core. In special applications a combination of lubricants may be called for, e.g., the core and inner wires of the strands may be heavily lubricated while the lighter lubrication may be applied to outer wires and strands.

s (left lay)

Wire rope cores are normally heavily lubricated irrespective of the outer strand lubrication. Specifications

All standard ropes are produced to generally comply with the requirements of Australian Standards. However some of our more technically advanced wire ropes have special characteristics required to provide superior performance. Testing & Inspection of Wire Ropes

Ordinary lay RHOL / RHRL (sZ)

Nobles can offer special services for rope users to assist in their inspection of used ropes. Our personnel have in many cases had a lifetime in the industry during which considerable experience has been gained.

Lang’s lay

LHOL / LHRL (zS)

RHLL (zZ)

LHLL (sS)

The NATA accredited tensile laboratories in the various Nobles branches throughout Australia can provide tensile destruction testing services, while the company is also accredited by NATA to carry out non-destructive testing on wire ropes in situ.

Note: The first letter of the symbol denotes strand direction and the second letter denotes rope direction.

Right hand ordinary lay (sZ)

Plastic Coated Wire Ropes

Plastic coatings are extruded onto a range of rope and stranded products for applications requiring a high resistance to corrosion. Plastic coated ropes are available in the following rope size and construction range:

Right hand lang’s lay (zZ)

Left hand ordinary lay (zS)

6x7 and 7x7 up to 8mm galvanised 6x19 and 7x19 up to 12mm galvanised 6x24 up to 12mm galvanised

Left hand lang’s lay (sS)

Typical applications are rigging lines, handrails, steering lines and holding lines in the shipping, pearling and fishing industries. Plastic coated strands are also available in PVC and black polyethylene.

Right hand alternate lay (aZ)

One rope lay Standard Blue PVC Coating on 6 x 19 FC B 1570 Wire Rope

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Wire Rope & Strand


GENERAL INFORMATION Ordering The size, grade and construction of a rope must match the specific application and design factors.

Rope Core

The type of rope core must be specified because of the significant differences in properties of a wire rope core and fibre core.

Rope Length

Wire rope is manufactured to length tolerances as follows; Up to 400m = +5% - 0% 400 to 1000m = +20m Over 1000m = +2% - 0% When a closer length is required, this should be specified in the order. In calculating rope length requirements, it is advisable to consider the following practical points for economy in operation:

6 x 25 FW Fibre Core

Ordering for Special Applications

1. In most cases, mining regulations require a test length be cut at specified periods. Sufficient extra length to cater for such tests over the expected service life of the rope should be added to the necessary operating rope length, plus a minimum of 2 1/2 drum turns for anchorage.

To obtain the best rope recommended for particular equipment and operating conditions, information should be supplied on loading, sheave and drum diameters, speed of operation, corrosive conditions and fleet angles etc. A simple sketch of the rope rigging is a convenient means of showing this type of information.

2. It is also advisable to make allowance for "cropping" in service as a consequence of wear or accidental damage at the capel end.

All orders should contain information on the above factors. When purchasers are not sure of the exact requirements the following particulars should be submitted:-

3. In many rope applications, wear and other deterioration are concentrated in spots along the length of the rope. It is often possible to gain economies in the overall life of the rope by providing additional length to enable feeding through of the new rope from the drum to spread the area of wear. This practice is regularly used to advantage on cable-operated earthmoving equipment and oil-well drilling rigs.

(a) Length and size. (b) Load exclusive of mass of the rope. (c) Dimensions of drums and sheave. (d) Corrosive conditions. (e) Sketch of the application.

4. Short lengths of special rope constructions, if ordered in single units, can be costly to produce. Consideration of the number of such ropes in use and their probable service life can often make it more economical to order several such ropes at one time. As a rule, this helps to expedite production and lessens the possibility of delays in supply.

Special aspects of rope supply may be necessary

The following check list is suggested:(a) Special length considerations such as minimum length, exact length. (b) Special diameter tolerance. (c) Rope end preparation. (d) End attachments to inside or outside end. (e) Stretch considerations. (f) Special lubricant type and amount. (g) Special reel dimensions, strength, shaft sizes, anchorage details and lagging. (h) Despatch instructions.

On existing equipment the rope size is generally fixed by the grooving of the sheaves and drums. Larger ropes should never be used without modification of drum and sheave grooving to suit the new rope. It should be remembered that ropes 8mm and above are made to a diameter tolerance of minus 0% to plus 5% with the exception of 6x24 construction, which has a tolerance of plus 7%. Construction

EXAMPLE

The construction of a rope for any given application should be suited to the equipment and to the conditions under which it will operate. It is important to nominate the construction when ordering. For example, the rope illustrated is ordered as 6x25 Filler Wire.

A typical order for wire rope would read:

Rope Grade

Abbreviations

"500m 16mm 6x9/9/1 A, B or U 1770 Grade RHLL (zZ) IWRC."

Abbreviations, Prestretching & Seizing

The minimum tensile strength of the wire is expressed in megapascals.

The following abbreviations have been standardised for ordering and identification purposes.

Lay of Rope

Wire Qualities

1570 MPa

Lay affects behaviour and operating life of a wire rope. It is important therefore to quote (a) the direction of lay, and (b) the type of lay and details of the rope application and operating conditions. The illustration shows a right hand lang’s lay (zZ) or RHLL rope. Ropes are normally supplied right-hand lay.

1770 MPa 1960 MPa I.P.S. – Improved Plough Steel E.I.P.S. – Extra Improved Plough Steel

Right Hand Lang’s Lay

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Wire Rope & Strand


GENERAL INFORMATION Constructions & Lays

Short Seizing (for ropes below 26mm diameter)

RHOL LHOL RHLL LHLL RHAL Pref Post IWRC WSC FC FW TS W S SW SF D or d FS HLC FLC

1. Wrap the seizing wire around the rope eight or ten turns. 2. Twist the two ends of the seizing wire together approximately at the centre position of the seizing. Alternate tightening and twisting of the ends will draw the seizing up tight. 3. Cut the end of the twisted wires and knock down into a valley between strands.

Right Hand Ordinary Lay (sZ) Left Hand Ordinary Lay (zS) Right Hand Lang’s Lay (zZ) Left Hand Lang’s Lay (sS) Right Hand Alternate Lay (aZ) Preformed Postformed Independent Wire Rope Core Wire Strand Core Fibre Core Filler Wire Strand Construction Triangular Strand Construction Warrington Strand Construction Seale Strand Construction Seale Warrington Construction Seale Filler Construction Diameter (in millimetres) Flattened Strand Half Locked Coil Full Locked Coil

Short Seizing

Prestretching

The number of seizings required depends on the type and diameter of the rope. The following minimum number of seizings are recommended:-

Is the loading of a rope or strand from 33.3% to 50% of its breaking load to remove constructional stretch, and this allows for the more accurate setting of lengths for guying and suspension cables.

Preformed or Postformed ordinary lay – 1 seizing. Lang’s lay rope with wire rope core and rotation resistant ropes – 2 seizings.

The initial stretch cannot be accurately determined by theoretical means and will continue to take place until it has been completely removed.

Seizing Wire

Both soft annealed single wire and stranded seizing wires are used in the seizing of steel wire ropes. Suitable sizes are listed below:-

After this initial stretch (or constructional stretch) has been removed the strand will have a truly elastic measure where elongation is proportional to applied load. Seizing

List of Seizings Recommended For Standard Ropes

Either of the following methods of seizing will ensure that the rope will later perform its job satisfactorily. Long Seizing (for ropes over 26mm diameter)

1. Place one end of seizing wire in the valley between strands. 2. Take the long end of the wire and turn at right angles to itself and wind back over itself and the rope in a close tight seizing of the required length. 3. The amount of seizing should not be less than 6 to 8 times the rope diameter. 4. Twist the two ends of the wire together. Alternate tightening and twisting of the ends will draw the seizing up tight. 5. Cut the end of the twisted wires and knock down into a valley between two strands.

Rope Diameter (mm) 7 wire seizing strand

Single seizing wire

Up to 14

0.90

16 – 26

1.25

28 – 38

7/0.90

2.00

Over 38

7/1.25

2.75

Transport, Storage & Handling Transporting

Ropes are supplied on reels or in coil form. When transporting, care must be taken not to damage rope by contact with other goods. Reels and coils should be lifted rather than dropped, tipped or rolled, to avoid damage.

Long Seizing Seizing Mallet or Bat

Ropes should be uncovered as soon as they are received and checked for possible transit damage. Storage

Ropes, whether on reel or in coils, should be stored on blocks off the floor to prevent sweating and corrosion and under cover in dry conditions free from possible attack by corrosive agents, such as milldust, sulphur or acid fumes.

The above method is best applied using a seizing mallet or bat.

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Wire Rope & Strand


GENERAL INFORMATION If ropes are to be stored for any length of time in warm or hot conditions likely to cause the lubricant to drain to the lower side of the reel, the reels should be mounted on a horizontal shaft and turned over periodically to maintain uniform lubrication of the rope. Additional lubrication may be necessary.

WARNING • When releasing rope from coils or reels, care must be taken to retard the violent release of the rope end which could cause damage, serious injury or death.

Removed ropes awaiting further use, should be thoroughly cleaned, inspected, lubricated and stored under the same conditions as new ropes.

Installation

Handling

Rope Equipment Checking

Incorrect handling of rope from reels and coils can result in springing of wires and strands and kinking of the rope. This type of damage can seldom be entirely corrected and can greatly reduce the effective life of the rope.

Improved rope performance can be obtained by paying attention to the following areas: • Sheaves should be grooved to the nominal rope diameter plus an allowance of 7% to allow for rope manufacturing tolerances and should be re-machined when worn to nominal diameter plus 3%. Sheaves must also be free from score marks, run freely and be true. • Guides and rollers must be free from undersized grooving and broken flanges, and should run free and true. • Drum grooves should be checked for size and riser plates checked for effectiveness. • Displaced or damaged cheek plates in rope blocks or safety guards should be repaired. • Grabbing clutches and brakes should be repaired and adjusted to obviate impact loads on the rope. • End fittings, such as wedges, sockets and drums anchorages, should be inspected for excessive wear. The fleet angle has an important bearing on the winding of a rope from sheave to drum, particularly at high operation speeds. If winding is to take place smoothly, the fleet angles on both sides of the drum will have to be kept within acceptable limits. Excessive fleet angles can result in considerable abrasive damage to both sheave flanges and rope and considerably reduce the life of the rope and the equipment. Fleet angles normally range to a maximum of 1.5˚ for plain drums and to a maximum of 2.5˚ for grooved drums. Smaller angles are required for high speed haulage such as mine windings. Unless the head or guide sheave is centred with respect to the drum, there will be different values for the left and the right fleet angles.

The drawings show correct and incorrect methods of reeling a rope from the transport reel onto a drum or another reel. The transport reel should be firmly mounted and braked to prevent overrunning and give tight rewinding. A suitable stand for the reel is also shown.

Correct method

Incorrect method

Methods of removing rope from reels & coils

Turntables, preferably mounted on the floor, may be used for unwinding ropes from reels stored on their sides. Care must be taken to brake such turntables, as over-running could cause the rope to slacken, fall off and foul under the turntable. If a coil is too large to be handled manually it should be mounted on a turntable or suspended by a spindle from a swivel crane hook. When coiling ropes down by hand on the floor, an occasional coil wound “underhand” relieves torque and provides a more easily handled coil. Right Hand lay ropes should be coiled down clockwise, Left Hand lay ropes anti-clockwise.

Left Fleet Angle Sheave

Incorrect method: Don’t pull the rope from a stationary coil.

Right Fleet Angle Drum

Correct methods of taking ropes from coils: Roll the coil along the ground or use a turntable.

Rope End Preparation

Normally wire ropes are delivered with seized ends. As a rule, no further preparation is necessary, but in some cases where ropes must be reeved through restricted openings, such as drum anchorages and blocks systems, the rope can be supplied with welded tapered ends or with links welded on the ends. The latter enables the new rope to be installed by attaching it either to the old rope or a tow rope and drawing onto the equipment. Tensioning Rope

Wire rope for multi-layer drums must be installed under tension. It is imperative that the bottom layer is tight with the exact number of turns on the drum.

Correct methods of taking ropes from reels: When a large reel is used, it is recommended that a plank is used as a brake against the reel flange or on the shaft or side plate.

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Wire Rope & Strand


GENERAL INFORMATION Wire Rope Life The main factors, which affect rope life are:

2. Operating Environment:

– when corrosive conditions exist, regular rope inspection, particularly of the IWRC, is essential. The effects of corrosion can be partly offset by the use of galvanised wire rope. Temperature – excessively high operating temperatures can lead to deterioration of the wire rope core, and thereby cause rope fatigue. Corrosion

1. Basic design of equipment or installation :

Sheave size, drum design and drum diameter can directly affect wire rope life. For example, doubling the sheave size can produce up to four times the rope life. The minimum ratios in the following table should be adhered to:-

3. Rope Maintenance:

– in certain applications, e.g., drag ropes, it is possible to "end for end" the rope. This will give longer rope life due to the wear points being re-located. If additional rope can be accommodated on the drum, then progressive cutting back (cropping) will bring "new" rope into the system, and will re-locate wear points. Treatment of broken wires – broken wires affecting the life of adjacent wires should be removed. Discard practices - clear policies regarding discard should be formulated. Rope Maintenance Schedules, based on experience, should be drawn up to provide periodic inspections and removal cycles for each rope as well as inspections of individual components such as the sheaves. Regular maintenance ensures optimum rope life, minimises down time of plant and equipment and increases the efficiency of the operation.

Recommended Minimum Ratio of Drum & Sheave Diameter to Rope Diameter Rope Construction Ratio 6x7 43 6 x 19S (9/9.1) 32 6 x 21FW (10/5 + 5F/1) 30 6 x 19W (6 & 6/6/1) 30 6 x 25FW (12/6 + 6F/1) 23 6 x 36SW (14/7 & 7/7/1) 22 6 x 26WF (7 & 7/7/4/1) 22 6 x 24 (15/9/F) 22 6 x 29FW (14/7 + 7F/1) 22 6 x 41SW (16/8/8 & 8/8/1) 21 6 x 37 (18/12/6/1) 21 19 x 7 23 35 x 7 20 4 x 39 Mono Track 20 For Casar Ropes refer to A. Noble & Son Ltd.

End for ending and cropping

Broken Wires

General purpose ropes, crane ropes and hoist ropes should be discarded whenever any of the types of degradation exceed the limits given in the Table below. However, the rope life may be ended before these limits are reached. The table below allows for internal wire breaks and is valid for all constructions of rope. In 6-strand and in 8-strand ropes, wire breaks occur principally at the external surface. This does not apply to wire ropes having a number of layers of strands (typically multistrand constructions), where the majority of wire breaks occur internally and are therefore non-visible fractures.

Limit of Degradation for Discard of General Purpose Lifting Ropes, Crane Ropes & Hoist Ropes (see Notes 1 & 2) Limit of degradation for discard (see Note 4) Type of degradation

Construction (see Note 3)

Broken wires

Wear Loss of area

6 x 19 (12/6/1) 6 x 19 S (9/9/1) 6 x 26 SW (10/5 and 5/5/1) 6 x 25 FW (12/6 and 6/1) 6 x 29 FW (14/7/7/1) 6 x 24 (15/9/F) 8 x 19 S (9/9/1) 8 x 25 FW (12/6 and 6/1) 6 x 36 SW (14/7 and 7/7/1) 6 x 37 (18/12/6/1) 6 x 41 SW (16/8 and 8/8/1) 18 x 7 NR 34 x 7 NR 4 x 48 All types All types

Corrosion

All types

Maximum allowable number of broken wires over a length of 6 times the rope’s diameter

Maximum allowable number of broken wires over a length of 30 times the rope’s diameter

5 10 3 6 5 10 5 10 7 14 5 10 5 10 6 13 7 14 10 19 9 18 1 2 2 4 2 4 Outer wires are worn more than one third of their diameter The loss of metallic area due to visible combined wire wear and broken or cracked wires exceeds 10% Corrosion is marked by noticeable pitting or loosening of outer wires

NOTES: 1. The number of wire breaks before discard in the above table is quite high, and if wire breaks are concentrated in one strand, lower levels for discard are appropriate. If more than one third of the outer wires in a strand are broken over a length of six times the rope diameter, the rope shall be discarded. 2. Where ropes are used for lifts, AS 1735.2 applies, which is less stringent than the above table. The mining industry frequently requires more stringent discard criteria. 3. Rope of Lang’s lay construction other than rotation resistant ropes shall have no more than 50% of the above values. 4. Number of broken wires alone is not the only factor in discarding a wire rope.

For Casar and 4 x 39 Mono Track wire ropes refer to A. Noble & Son Ltd.

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Wire Rope & Strand


GENERAL INFORMATION Care & Maintenance

Deterioration

Breaking in

Typical examples of wire rope deterioration

A wire rope may be looked upon as a machine composed of a large number of moving parts. As such it should be broken in as soon as it is installed, by loading it very lightly for a few cycles and then gradually stepping up the load, to enable both wires and strands to ‘bed down’ into the working positions, with the load distributed as uniformly as possible.

1. Mechanical damage due to rope movement over sharp edges whilst under load

2. Localised wear due to abrasion on supporting structure.

With strand 6 and 8 stranded ropes, the torque can greatly diminish after breaking in by releasing the connection and allowing the torque to run out. This procedure may have to be repeated until the constructional stretch has been worked out of the rope and it has become neutral.

3. Narrow path of wire breaks caused by working in a grossly oversized groove or over small support rollers.

The use of ‘spinners’ or swivels should be avoided whenever possible. All ropes should be reeled onto winch drums as tightly and uniformly as possible during the initial installation. Inspection

4. Severe wear in Lang’s Lay, caused by abrasion at crossover points on multi-layer coiling application.

Wire rope is tough and durable, but nonetheless expendable and eventually reaches the end of its safe service life. Rope deterioration becomes noticeable through the presence of broken wires, surface wear, corrosion, wire or strand distortion due to mechanical abuse, or drastic reduction in diameter and lengthening of the lay. Also deterioration can be detected by the use of non-destructive testing techniques. Wire ropes should periodically be inspected for signs of deterioration.

5. Corrosion of severe degree caused by immersion of rope in water.

While Statutory Regulations govern the inspection and discarding of certain wire ropes, the same rules cannot be applied to all ropes. The proper frequency and degree of inspection depends largely on the possible risk to personnel and machinery in the event of rope failure. The determination of the point at which a rope should be discarded for reasons of safety requires judgment and experience in rope inspection in addition to knowledge of the performance of previous ropes used in the same application.

6. Typical wire fractures as a result of bend fatigue. 7. Wire fractures at the strand, or core interface, as distinct from ‘crown’ fractures caused by failure of core support.

Where the Statutory Regulations are laid down for the inspection and discarding of wire ropes and their attachments, wire rope users should become fully acquainted with the regulations and see that they are carried out.

8. Typical example of localised wear and deformation created at a previously kinked portion of rope.

Sufficient records should be kept to provide a reliable history of the ropes under their control. Inspection of both operated and discarded ropes frequently indicates equipment faults that have a large bearing on the service life and safety of the rope. It is therefore essential to inspect the equipment on which the rope is used as well as the rope itself.

9. Multi-strand rope ‘bird caged’ due to torsional unbalance. Typical of build-up seen at anchorage end of multi-fall crane application.

Non Destructive Testing

10. Protrusion of IWRC resulting from shock loading.

This method of inspection of wire ropes has become part of the mining industries standard requirements for over 20 years. An electromagnetic instrument is used to non-destructively examine the rope. It incorporates a sensor head that is able to induce a magnetic field in a section of rope that is located within the instrument. Changes in the metallic field enable a chart to be produced showing changes in metallic cross-sectional area and any wire breaks or other anomalies. Life of costly wire ropes may be extended by this sophisticated method. - METALLIC AREA LOSS CHART -

% REDUCTION

- LOCAL FAULT CHART -

30

Wire Rope & Strand GENERAL INFORMATION Stretch in Ropes When load is first applied to a new rope it stretches due to the individual wires settling down. This is referred to as the Initial or Manufacturing Stretch. Subsequently a gradual stretch takes place during the whole of the rope’s life; the amount depends on many variables such as length, type of construction, loading and the modulus of elasticity of the particular rope.

( 2aL E )

T = (2W + Lw) Where T W L w a E

= = = = = =

To forecast the amount of stretch accurately for a rope under a given set of conditions, calculations must be based on the result of a load/extension test on a sample from the particular rope. However, if the results of such a test are not available, an indication of the increase in length can be obtained from the formula.

Stretch in metres Load in kgs Length in metres Weight of rope in kgs/metre Cross sectional area of rope in millimetres 2 Modulus of Elasticity, kgs/mm 2

Approximate Modulus of Elasticity for New Ropes 6 x 7 FC

96 GPa

(0.0098 x 106 kgs/mm2)

7X7

117 GPa

(0.0119 x 106 kgs/mm2)

6 X 19 FC

89 GPa

(0.0091 x 106 kgs/mm2)

6 X 19 IWRC

110 GPa

(0.0112 x 106 kgs/mm2)

7 Wire Strand

145 GPa

(0.0148 x 106 kgs/mm2)

19 Wire Strand

125 GPa

(0.0127 x 106 kgs/mm2)

36 Wire Strand

110 GPa

(0.0012 x 106 kgs/mm2)

6 x 36 IWRC

82 GPa

(0.0084 x 106 kgs/mm2)

6 x 36 FC

82 GPa

(0.0084 x 106 kgs/mm2)

6 x 12/12/ Δ FC

96 GPa

(0.0098 x 106 kgs/mm2)

Locked Coil Winding Rope

125 GPa

(0.0127 x 106 kgs/mm2)

Locked Coil Guide Rope

138 GPa

(0.0141 x 106 kgs/mm2)

For used ropes 20% should be added to these figures.

Calculation of Cross Sectional Area of Wire Rope A = F x d2 A = Metallic area of rope with fibre core in mm 2 F = Compactness factor d = Nominal diameter of rope in millimetres For 6 strand rope with IWRC add 15%, with strand core add 20% For flattened strand rope with IWRC, add 10% For 8 strand rope with IWRC, add 20%

Factor F Rope Construction

Factor F

6x7

0.38

6 x 19/6 x 21

0.395

6 x 25 Filler Wire/6 x 36 Group

0.405

7 Wire Galvanised Guy Strand

0.596

19 Wire Galvanised Guy Strand

0.580

31


Wire Rope & Strand


GENERAL INFORMATION Tolerances on rope diameter Nominal Rope Diameter

Tolerance as percentage of nominal diameter

d mm

Ropes with strands that are exclusively of wire or incorporate solid polymer centres

Ropes with strands that incorporate fibre centres*

2 ≤ d < 4

+8 -0

-

4 ≤ d < 6

+7 -0

+9 -0

6 ≤ d < 8

+6 -0

+8 -0

≥8

+5 -0

+7 -0

* For example 6 x 24FC

Permissible differences between any two diameter measurements Nominal Rope Diameter

Tolerance as percentage of nominal diameter

d mm

Ropes with strands that are exclusively of wire or incorporate solid polymer centres

Ropes with strands that incorporate fibre centres*

2 ≤ d < 4

7

-

4 ≤ d < 6

6

8

6 ≤ d < 8

5

7

≥8

4

6

* For example 6 x 24FC

32

Wire Rope & Strand


BREAKING FORCE TABLES The following tables show rope mass in "kg per 100 metres" and breaking force in "kilonewtons" for the various rope groups.

All ropes are in millimeter diameter. Only preferred sizes have been included in the tables. Non preferred sizes should be the subject of special inquiry. Special non preferred sizes to suit existing deep mining and large excavator equipment are available although new equipment should use only preferred diameters.

It will be noted that the value varies from group to group since the various constructions contain different steel areas and variable losses are incurred as the result of the stranding of the wires.

The breaking force unit is the kilonewton, this being the force which, applied to a mass of one kilogram, produces an acceleration of one metre per second. The minimum rope breaking force required will depend on the factor of safety covered by the application and in the case of a single supporting rope where the rope mass is ignored will be equal to the gravitational force multiplied by the factor of safety. Minimum rope breaking force (kN) = Mass (tonnes) per rope part x factor of safety required x 9.81.

Wire quality has been nominated in 1570, 1770 and 1960 grade for the majority of wire ropes, the value 1570, 1770 etc. corresponds to the minimum tensile strength of the wire expressed in megapascals. Marine and General Purpose galvanised ropes have been nominated in 1570 grade and are confined to certain rope constructions. Other 6 strand constructions in galvanised rope should be ordered in 1770 grade. The breaking forces of rope of tensile grades other than 1770 can be calculated by multiplying the value of 1770 grade by the ratio of the grade number. The grade of 2070 is the preferred high tensile grade for 6 strand ropes but 1960 is preferred for 19x7, 35x7 and most Casar ropes.

To calculate approximate mass equivalent, at sea level, divide kilonewtons by 9.81 Example: 12mm 6 x 7 Fibre Core G1570 grade 75 = 7.65 tonnes 9.81 For most practical purposes, divide by 10 in lieu of 9.81 = 75 kN =

TYPICAL ROPE RECOMENDATIONS Applications

Rope Recommendations

Lay Preformed

Core

Log Skidder Yard Rope

13 - 28 32 - 36 13 - 28 16 - 20

19S 25FW 19S, 25FW 25FW, 29FW

RHOL RHOL RHOL RHOL

IWRC IWRC IWRC FC

PILING

Pile Driving Hammer Drop Hammer Pile Handling

16 - 32 16 - 32 13 - 24

36 25FW, 36SW, 4x39 25FW

RHOL RHOL RHOL

IWRC FC IWRC, FC

SLINGS

Slings - Standard Slings - High Tensile

9 - 32 9 - 28 32 - 104

24, 36SW 25FW, 36SW 36SW, 41SW

RHOL RHOL RHOL

FC, IWRC IWRC IWRC

CRANES

Tower - Hoist

20 - 42

Eurolift, 35x7, Powerlift, Starlift

RHOL or RHLL

Tower - Luffing Trolley Line Overhead

20 - 42 13 - 24 6 - 10

4x39, Stratoplast, Turboplast 25FW, 36SW 19x7, Starlift

RHLL RHOL

IWRC

1 - 3 Falls Overhead 4 Falls or more

12 - 18

35x7, Eurolift, 4x39 Stratoplast, Turboplast 25FW, 36SW, Betalift, Alphalift

RHOL RHOL or RHLL RHOL or RHLL

IWRC IWRC

Mobile - Hoist

Eurolift, Starlift, 19x7, 35x7,4x39 Eurolift, Starlift, 19x7, 35x7,4x39

Mobile - Luffing

11 - 20 22 - 32 13 - 26

25W, Stratoplast, Turboplast

RHOL or RHLL RHOL or RHLL RHLL

IWRC

Grab - Holding Closing

18 - 28 18 - 29

25FW, 36SW, 4x39 Stratoplast, Turboplast

RHOL or RHLL LHOL or LHLL

IWRC, FC

14 - 18

24, 4x39

LHOL, RHOL

FC

LOGGING

GRABS

Log Winch

Size Range Dia. (mm)

WATER DRILLING

Diamond

12 - 16 16 - 20

19x7, 4x39 35x7, 4x39

RHOL RHOL*

FC FC

SHIPPING

Mooring

16 - 26 26 - 40 32 - 56 12 - 32 10 - 32

24, 36SW 36SW, 41SW 36SW, 41SW 24 7x7, 7x19

RHOL RHOL RHOL RHOL RHOL

FC FC FC, IWRC FC IWRC

16 - 32 32 - 56

24, 36SW 36SW, 41SW

RHOL RHOL

FC FC, IWRC

5-8 8 - 28 32 - 64

19, 7x19 19S, 25FW, 36SW 25FW, 36SW, 41SW

RHOL RHOL RHOL

IWRC, FC IWRC IWRC

SLIPWAY

WINCHES

Trailer - Boat General Purpose

Note: 6 Strand ropes except where otherwise stated.

33

Logging Skylines………......……..3.5

AS 1666 - 1995………….......……5.0

For safety factors on cranes refer to AS 1418.1:2002

DRILLING

Towing Loading Gear - Lashing Rigging

Factors of Safety

……………………………...............….5.0

Wire Rope & Strand


GENERAL PURPOSE WIRE ROPES Galvanised Wire Ropes for Marine and General Purposes Round Strand 6 x 19

Galvanised Wire Ropes for Marine and General Purposes Round Strand 6 x 7

6 x 7 (6/1) Nominal Diameter

7 x 7 (6/1)

Approximate Mass

6 x 19 (12/6/1)

Minimum Breaking Force Grade 1570

Fibre Core FC

Wire Rope Core IWRC

Fibre Core FC

Wire Rope Core IWRC

mm

kg/100m

kg/100m

kN

kN

2

1.3

1.5

2.1

2.3

3

3.1

3.5

4.7

5.1

4

5.5

6.1

8.4

9.0

6 x 19S (9/9/1)

Nominal Diameter

Approximate Mass

6 x 19W (6 & 6/6/1) Minimum Breaking Force Grade 1570

Fibre Core FC

Wire Rope Core IWRC

Fibre Core FC

Wire Rope Core IWRC

mm

kg/100m

kg/100m

kN

kN

3.5

4.2

4.6

5.8

6.4

4

5.5

6.1

7.7

8.5

5

8.6

9.6

13.1

14.1

5

8.6

9.5

12

13.2

6

12.4

13.8

18.8

20.3

6

12.4

13.7

17.6

19.3

7

16.9

18.8

19.3

27.6

7

16.9

18.7

23.4

25.8

8

22.1

24.6

33.4

36.1

8

22.1

24.4

30.9

33.3

9

27.6

31.1

42.2

45.7

9

28

30.8

39.1

42.2

10

34.5

38.4

52.2

56.3

10

34.6

38.1

48.2

52.1

11

41.7

46.5

63.1

68.2

11

41.9

46.1

58.4

63.1

12

49.7

55.3

75

81.2

12

49.8

54.8

69.5

75

13

58.3

64.9

88.1

94.9

13

58.5

64.3

81.5

88.1

14

67.6

75.3

102

111

14

67.8

74.6

94.6

102

16

88.3

96.3

133

145

16

88.6

97.4

124

133

18

112

124

169

183

18

112

123

156

169

20

138

154

208

225

20

138

152

193

208

22

167

186

252

273

22

167

184

234

252

24

199

221

300

324

24

199

219

278

300

26

233

260

353

381

28

270

301

409

442

32

353

393

534

577

Galvanised Wire Ropes for Marine and General Purposes Round Strand 6 x 24 Fibre Core

Galvanised Wire Ropes (Higher Tensiles)

6 x 24 (15/9/F)

7 x 19 WSC

Nominal Diameter

6 x 19 S (9/9/1) Construction

mm

6 x 25 FW (12/6 & 6 F/1)

Approximate Mass Wi re Rope Core IWRC kg/100m

Minimum Breaking Force Grade 2070 Wire Rope Core IWRC kN

Nominal Diameter

Approximate Mass


mm

kg/100m

kN

8

20.1

28.7

9

25.4

36.4

10

31.4

44.9

11

38.0

54.3

12

45.2

64.0

13

53.1

75.9 88.0

4

7 x 19

6.1

11.9

14

61.5

5

7 x 19

9.5

18.7

16

80.4

115

6

7 x 19

13.7

27.3

18

102

145

6.3

7 x 19

15.1

33.4

20

126

180

8

6 x (9/9/1) S

24.4

47

22

152

217

10

7 x 19

38.1

68.6

24

181

259

11

6 x 25FW

50.6

89.4

26

212

304

16

6 x 25FW

107

188

28

246

352

32

322

460

34

Wire Rope & Strand


GENERAL PURPOSE WIRE ROPES General Purpose Wire Ropes

6 x 19 S (9/9/1)

6 x 21 FW (10/5 + 5 F/1)

6 x 25 FW (12/6 & 6 F/1)

6 x 26 WF (7 & 7/7/4/1)

6 x 29 FW (14/7 + 7 F/1)

6 x 36 SW (14/7 & 7/7/1)

8 - 44mm

8 - 60mm

8 - 60mm

9 - 16mm

10 - 44mm

9 - 60mm

Nominal Diameter

mm 8 9 10 11 12 13 14 16 18 20 22 24 26 28 32 36 40 44 48 52 56 58 60 64 70 75

6 x 41 SW 6 x 49 SFW (16/8 & 8/8/1) (16/16/8 + 8 F/1) 22 - 52mm

52 - 60mm


Approximate Mass 6 x 19 to 6 x 25 FC kg/100m 23 29.1 35.9 43.3 51.7 60.7 70.4 91.9 116 144 174 207 243 281 368 465 574 695 827 971 1130

6 x 19 to 6 x 25 IWRC kg/100m 25.6 32.4 40 48.4 57.6 67.6 78.4 102 130 160 194 230 270 314 410 518 640 774 922 1080 2250

6 x 26 to 6 x 49 FC kg/100m 23.5 29.7 36.7 44.4 52.8 62 71.9 94 119 147 178 211 248 288 376 476 587 711 846 992 1150

1290

1440

1320

6 x 26 to 6 x 49 IWRC kg/100m 26.2 33.1 40.9 49.5 58.9 69.1 80.2 105 133 164 198 236 276 321 419 530 654 792 942 1110 1280 1390 1470 1730 2080 2360

FC

IWRC

kN 37.4 47.3 58.4 70.7 84.1 98.7 114 150 189 234 283 336 395 458 598 757 935 1130 1350 1580 1830

kN 40.3 51 63 76.2 90.7 106 124 161 204 252 305 363 426 494 645 817 1010 1220 1450 1700 1980 2200 2270 2691 3090 3622

Travelling Irrigator Galvanised Wire Ropes

6 x 7 (6/1) FC

7 x 7 WSC

Nominal Diameter

mm

Approximate Mass Polypropylene Core kg/100m

3.35


Wire Strand Core kg/100m

Polypropylene Core kN

Grade 2070 Wire Strand Core kN

Polypropylene Core kN

Wire Strand Core kN

16.1

17.1

18.8

24.6

4.4

8.5

5

8.6

9.6

6

12.4

13.8

21.2

22.9

7

16.9

18.8

21.8

31.1

37.1

8

22.1

24.6

37.6

40.7

47.4

9

27.6

31.1

47.6

51.5

60.2

10

34.5

38.4

58.8

63.5

74.1

35

27.1

Wire Rope & Strand


ROTATION RESISTANT WIRE ROPES 1960 Grade Wire Ropes are recommended as they still provide very high breaking loads but the slightly lower tensile ensures an excellent service life. 19 x 7 Construction Wire Ropes are not recommended in diameters above 18mm. 35 x 7 ropes should be used above 12mm diameter.

Rotation Resistant 35 x 7 L

Rotation Resistant 19 x 7 L Nominal Diameter

Approximate Mass

Minimum Breaking Force

Nominal Diameter

Approximate Mass

Grade 1960


mm

kg/100m

kN

mm

kg/100m

kN

6

15

25.9

14

87

162.4

8

27

44.8

16

114

212.2

9

34

56.8

18

144

268.0

10

42

70.7

19

160

298.9

12

60

101.6

20

178

331.8

13

70

119.6

22

215

401.5

14

82

138.5

24

256

477.3

16

107

180.3

26

300

560.0

18

135

229.2

28

348

649.7

30

399

745.3

32

455

848.9

34

513

957.5

36

575

1074.1

L = Langs Lay.

L = Langs Lay.

Rotation Resistant 35 x 7 L “Compacted” Nominal Diameter

Approximate Mass


mm

kg/100m

kN

14

100

182.3

16

131

238.1

18

165

301.9

19

184

335.8

20

204

371.7

22

247

450.4

24

294

536.1

26

345

628.7

28

400

729.4

30

459

837.0

32

522

952.6

34

590

1075.1

36

661

1205.6

L = Langs Lay.

36

Wire Rope & Strand


ROTATION RESISTANT WIRE ROPES a hazardous environment. To overcome this problem a 4-strand rope with a unique construction has been designed. These rotation resistant wire ropes are commonly used in the construction industry to minimise rotation in single and multi-part hoisting systems.

Rotation Resistant 4 x 39 (SES) Mono Track It is well known that wire ropes tend to spin or rotate under load. This can cause damage to the wire rope or load, work delays and

4 x 39 (SES)


Nominal Diameter

Approximate Mass

mm

kg/100m

H Grade kN

SH Grade kN

10

41

63.9

69.2

11.2

51

80.3

87

12

59

89

96.5

12.5

63

100

108.9

14

80

125.7

136.3

16

104

163.8

177.5

18

134

208.7

225.6

19

149

231.4

251.1

20

163

256

277.5

22.4

205

321.7

348.1

24

235

356

385.4

25

255

399.1

432.5

26

276

431.5

466.8

28

325

502.1

543.3

30

373

575.7

623.7

31.5

411

634.5

687.5

32

424

655.1

709

33.5

465

717.8

777.7

35.5

522

806.1

872.8

37.5

582

899.3

973.8

40

663

1000.3

1078.7

42.5

748

1127.8

1225.8

45

838

1255.3

1372.9

37

Wire Rope & Strand


CASAR SPECIAL WIRE ROPES

Hoist rope for tower cranes, mobile cranes, electrical hoists and other applications where rotation resistant ropes are required. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

mm

mm2

kg/100m

kN

kN

10 12 13 14 15 16 18 19 20 22 24 26 28 32 36 38 40 42

51.7 73.9 86.9 100.4 116.0 132.3 165.5 186.6 205.0 250.0 296.0 347.0 402.1 526.4 661.5 742.5 818.1 902.7

46.5 66.5 78.2 90.4 104.4 119.1 149.0 167.9 184.5 225.0 266.4 312.3 361.9 473.7 595.3 668.3 736.3 812.4

69.2 99.9 117.3 135.9 156.3 178.1 222.6 250.9 277.7 337.0 400.5 469.2 548.8 710.5 906.1 1005.5 1111.9 1234.1

76.6 110.7 129.8 150.5 173.0 197.2 246.5 277.8 307.5 373.2 443.5 519.5 607.7 786.7 1003.4 1113.5 1231.3 1366.6

• Is a rotation resistant, flexible hoist rope with a compacted steel core. • Is fully lubricated. • Has a high breaking load. • Has a core of special design avoiding crossovers between the strands of the core which reduces the danger of internal rope destruction. • Is known worldwide for its excellent service life. • Regular Lay or Langs Lay.

Hoist rope for mobile cranes, electrical hoists and other applications where rotation resistant ropes are required. Especially suitable for multiple layer spooling. Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 36 38 40 42

145.6 163.3 183.7 204.0 227.5 249.0 273.9 299.6 326.8 348.8 377.9 410.5 442.5 473.4 505.4 579.4 652.0 735.6 815.3 909.9 1000.8


Grade 1960

Grade 2160

kg/100m

kN

kN

kN

126.7 142.1 159.8 177.5 197.9 216.6 238.3 260.6 284.3 303.5 328.8 357.1 385.0 411.8 439.7 504.0 567.3 640.0 709.3 791.6 870.7

209.4 235.9 266.9 297.1 329.3 362.3 398.5 431.5 474.3 512.8 555.0 598.3 643.7 690.2 738.1 843.4 950.8 1070.0 1191.0 1360.0 1455.0

230.6 257.9 293.9 329.0 362.2 396.1 441.4 471.8 524.3 567.9 614.9 654.2 712.9 754.6 817.4 930.0 1045.0 1185.0 1319.0 1462.0 1611.2

249.1 280.6 317.5 352.8 391.7 430.9 472.0 513.2 564.1 609.4 657.4 711.7 765.6 821.0 877.9 1002.8 1130.9 1262.3 1412.2 1560.4 1667.4

• Is a rotation resistant, flexible hoist rope made out of compacted outer strands and a compacted steel core. • Is fully lubricated. • Has an extremely high breaking load and a very good resistance against drum crushing. • Has a core of special design avoiding crossovers between the strands of the core which reduces the danger of internal rope destruction. • Regular Lay or Langs Lay.

Other diameters are available on request

38

Wire Rope & Strand



Hoist rope for electrical hoists and lifting devices with multiple part reeving, twin hoist systems with left and right hand ropes, where rotation resistant ropes are not required. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

kg/100m

kN

kN

kN

4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 10 11 12 13 14 15 16

8.0 10.0 12.3 14.8 18.2 22.4 24.9 28.5 33.0 37.1 41.4 50.2 60.7 72.3 84.8 98.4 112.9 128.5

6.8 8.6 10.6 12.8 15.7 19.2 21.4 24.5 28.4 31.9 35.6 43.2 52.2 62.2 72.9 84.6 97.1 110.5

11.7 15.1 19.0 23.6 28.5 34.2 38.5 44.8 49.6 53.0 65.0 75.8 92.9 111.3 129.4 150.3 175.7 196.1

13.0 16.7 21.1 26.1 31.5 37.9 42.6 49.6 55.0 58.7 72.0 84.0 102.9 123.2 143.3 166.4 194.6 217.1

14.3 18.4 23.2 28.8 34.7 41.8 47.0 54.6 60.6 64.6 79.3 92.5 113.3 135.8 157.9 183.4 214.5 239.3

Grade 1770

Grade 1960

Grade 2160

• Is an 8 strand rope in parallel lay construction made out of conventional strands. • Is fully lubricated. • Is very flexible. • Has a high breaking load. • Alphalift should NOT be used with a swivel. • Regular Lay only.

Hoist rope for electrical hoists and lifting devices with multiple part reeving and twin hoist systems with left and right hand ropes, where rotation resistant ropes are not required. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

Grade 2160

mm

mm2

kg/100m

kN

kN

kN

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

36.9 47.3 57.3 68.6 83.7 97.4 113.2 130.0 147.7 167.7 187.3 206.9 233.8 254.3 275.9 302.9 333.5 362.3

31.4 40.2 48.7 58.3 71.2 82.8 96.2 110.5 125.6 142.5 159.2 175.8 198.7 216.2 234.5 257.5 283.5 307.9

56.1 71.8 87.9 106.9 126.5 148.7 172.3 197.9 226.3 253.4 286.4 318.5 351.6 390.1 426.3 465.2 507.3 549.1

62.1 79.5 97.3 118.4 140.1 164.6 190.8 219.1 250.6 280.5 317.1 352.7 389.4 432.0 472.0 515.2 561.8 608.0

68.4 87.6 107.2 130.5 154.4 181.4 210.3 241.5 276.2 309.2 349.5 388.6 429.1 476.1 520.2 567.7 619.1 670.1

• Is a 10 strand rope in parallel lay construction made out of compacted strands. • Is fully lubricated. • Is very flexible. • Has an extremely high breaking load. • Betalift should NOT be used with a swivel.


39

Wire Rope & Strand



Pendant rope for tower cranes, mobile cranes, grabs, suspended structures etc, when high breaking load is required. Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 38

147.2 166.1 185.3 207.5 229.6 251.1 278.4 304.2 330.5 357.3 391.6 424.1 452.1 486.5 519.5 560.0 593.4 634.1 666.8 747.4 836.5


Grade 1960

Grade 2160

kg/100m

kN

kN

kN

123.7 139.6 155.7 174.3 192.9 211.0 233.9 255.5 277.6 300.1 328.9 356.2 379.8 408.6 436.4 470.4 498.4 532.6 560.1 627.8 702.7

218.4 248.1 278.5 307.3 342.3 375.0 414.4 453.0 490.2 532.7 574.4 624.8 670.4 721.5 772.4 822.9 874.4 930.3 988.9 1101.7 1230.3

241.9 274.8 308.4 340.3 379.0 415.2 458.9 501.7 542.8 589.9 636.0 691.8 742.4 799.0 855.3 911.3 968.2 1030.2 1095.0 1220.0 1362.4

266.5 302.8 339.8 375.0 417.7 457.6 505.7 552.8 598.2 650.1 700.9 762.4 818.1 880.5 942.6 1004.3 1067.0 1135.3 1206.8 1344.5 1501.4

• Is an 8 strand rope in parallel lay construction made out of compacted strands. • Is fully lubricated. • Is very flexible. • Has an extremely high breaking load. • Turbolift should NOT be used with a swivel. • Regular Lay or Langs Lay.

Boom hoist rope for mobile cranes and grabs, hoist rope for container cranes, floating cranes etc. In multiple part reeving for smaller lifting height. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

mm

mm2

kg/100m

kN

kN

10 11 12 13 14 15 16 18 19 20 22 24 26 28 32 36 38 40 42 44 48

53.0 63.8 75.7 89.5 103.1 119.0 135.5 168.9 189.0 210.7 251.9 299.5 352.4 405.2 533.7 670.5 753.1 837.9 914.7 1010.7 1201.1

46.1 55.5 65.8 77.8 89.7 103.5 117.9 146.9 164.4 183.3 219.1 260.6 306.6 352.5 464.3 583.4 655.2 729.0 795.8 879.3 1044.9

80.2 97.1 115.1 136.6 157.9 183.1 207.2 260.2 292.1 321.0 391.7 464.5 548.9 629.6 828.0 1040.1 1163.0 1285.5 1422.0 1554.3 1858.8

88.7 107.5 127.4 151.3 174.8 202.7 229.4 288.2 323.5 355.5 433.7 514.3 607.8 697.3 911.0 1129.2 1262.6 1395.5 1543.8 1687.4 2018.0

• Is an 8 strand rope made out of compacted outer strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands giving the rope a high structural stability. The plastic layer also assists in avoiding internal rope destruction and protecting the core against corrosive environments. • Has a very high breaking load and good resistance against drum crushing. • Turboplast should NOT be used with a swivel. • Regular Lay or Langs Lay. Other diameters are available on request

40

Wire Rope & Strand



Hoist rope for container cranes, floating cranes, harbour cranes, portal cranes etc. In multiple reeving for smaller lifting heights. Holding rope and closing rope for grabs. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

mm

mm2

kg/100m

kN

kN

8 9 10 11 12 13 14 16 18 19 20 22 24 26 28 30 32 34 36 38 40 42 44

30.6 38.8 48.8 59.6 68.3 81.7 95.1 125.4 157.7 178.6 198.2 245.4 280.0 326.8 375.2 435.8 495.4 556.8 626.5 705.1 770.1 859.3 942.5

27.3 34.5 43.4 53.0 60.8 72.7 84.6 111.6 140.4 159.0 176.4 218.4 249.2 290.8 333.9 387.9 440.9 495.6 557.6 627.5 685.3 764.8 838.8

47.2 60.0 74.0 88.5 106.6 125.5 144.6 189.0 239.8 264.5 295.3 356.2 423.4 504.7 576.2 666.3 756.7 853.7 952.4 1071.1 1181.1 1308.5 1430.1

52.3 66.4 82.0 98.0 118.0 138.9 160.1 209.3 265.5 292.9 327.0 394.5 468.9 558.8 638.0 737.8 837.9 945.3 1054.7 1186.0 1307.9 1448.9 1583.7

• Is an 8 strand rope made out of conventional strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands giving the rope a high structural stability. The plastic layer also assists in avoiding internal rope destruction and protecting the core against corrosive environments. • Stratoplast should NOT be used with a swivel. • Regular Lay or Langs Lay.

Hoist rope for electrical hoists and lifting devices with multiple part reeving, where a rotation resistant rope is not needed due to great lifting heights, low number of falls or non guided loads. High breaking load. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

Grade 2160

mm

mm2

kg/100m

kN

kN

kN

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

19.0 26.3 34.8 44.1 54.2 65.7 79.6 92.6 107.1 123.1 139.4 158.5 176.4 198.3 220.1 240.4 264.8 299.8 325.7 353.1 383.9

16.1 22.4 29.6 37.4 46.1 55.9 67.6 78.7 91.1 104.6 118.5 134.7 150.0 168.6 187.1 204.3 225.1 254.8 276.9 300.1 326.3

29.5 41.0 54.2 68.6 84.5 102.4 123.9 144.2 166.9 191.7 217.1 246.8 274.8 308.9 342.9 374.5 412.5 467.0 507.3 550.0 598.0

32.7 45.4 60.0 76.0 93.5 113.4 137.2 159.7 184.8 212.3 240.4 273.3 304.3 342.0 379.7 414.7 456.8 517.1 561.8 609.0 662.2

35.2 48.9 64.6 81.8 100.7 122.1 147.8 172.0 199.0 228.6 258.9 294.4 327.7 368.4 408.9 446.6 491.9 556.9 605.0 655.9 713.1

41

• Is an 8 strand rope in parallel lay construction made out of compacted outer strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands. • Has a very high breaking load. • Paraplast should NOT be used with a swivel. • Regular Lay or Langs Lay.


Wire Rope & Strand



Hoist rope for deck cranes, offshore cranes and other applications in the marine environment, where rotation resistant ropes are required. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

mm

mm2

kg/100m

kN

kN

12 13 14 15 16 18 19 20 22 24 25 26 28 30 32 34 36 38 40 42

81.8 97.2 111.7 127.6 147.0 186.7 207.2 227.7 276.2 326.3 358.3 389.2 446.6 514.4 584.9 656.9 738.6 826.4 926.6 1013.4

72.0 85.6 98.3 112.3 129.4 164.3 182.4 200.4 243.0 287.2 315.3 342.5 393.0 452.7 514.7 578.1 650.0 727.3 815.4 891.8

118.2 139.0 161.7 184.5 209.4 266.9 297.1 329.3 398.5 474.3 512.8 555.0 643.7 738.1 843.4 950.8 1070.0 1191.0 1360.0 1455.0

130.8 152.7 179.1 204.0 230.6 293.9 329.0 362.2 441.4 524.3 567.9 614.9 712.9 817.4 930.0 1045.0 1185.0 1319.0 1462.0 1611.2

• Is a rotation resistant hoist rope made out of compacted strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands giving the rope a high structural stability. The plastic layer also assists in avoiding internal rope destruction and protecting the core against corrosive environments. • Has a high breaking load and good resistance against drum crushing. • Regular Lay or Langs Lay.

Boom hoist rope for mobile cranes and grabs, hoist rope for container cranes, floating cranes, portal cranes etc. In multiple part reeving for smaller lifting heights. Minimum Breaking Force

Nominal Diameter

Metallic Area

Approximate Mass

Grade 1770

Grade 1960

Grade 2160

mm

mm2

kg/100m

kN

kN

kN

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 38 40 42 44

137.0 156.6 176.0 194.0 215.4 237.7 260.0 286.4 312.2 336.5 363.7 390.7 420.3 445.8 480.5 509.3 560.3 585.1 630.2 704.1 774.3 861.9 949.8 1038.3

117.8 134.7 151.4 166.8 185.3 204.4 223.6 246.3 268.5 289.4 312.8 336.0 361.4 383.4 413.2 438.0 481.8 503.2 542.0 605.5 665.9 741.2 816.8 892.9

205.7 236.2 266.0 291.0 326.5 360.4 392.6 429.7 470.0 516.0 549.5 587.6 654.0 670.2 723.8 769.1 841.0 879.7 950.2 1065.1 1165.1 1298.3 1436.7 1567.8

226.5 260.0 292.8 320.4 359.4 396.8 432.2 473.0 517.4 585.0 604.9 646.8 720.0 737.8 796.8 846.7 925.9 968.4 1046.0 1172.5 1282.5 1429.3 1581.5 1725.8

248.1 284.8 320.8 351.0 393.8 434.7 473.5 518.2 566.9 613.4 662.7 708.6 822.0 808.3 872.9 927.5 1014.3 1060.9 1145.9 1284.5 1405.0 1565.8 1732.6 1890.7

• Is a 10 strand rope made out of compacted outer strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands giving the rope a high structural stability. The plastic layer also assists in avoiding internal rope destruction and protecting the core against corrosive environments. • Has a very high breaking load and good resistance against drum crushing. • Superplast 8 should NOT be used with a swivel. • Regular Lay or Langs Lay. Other diameters are available on request

42

Wire Rope & Strand


CASAR SPECIAL MINING WIRE ROPES Hoisting ropes in underground mining operations play a vital role in the production cycle, not only to hoist minerals but also to transport men and materials safely and efficiently. Winding ropes are therefore clearly safety critical throughout their operating life.

diameter. The increased capacity of the shaft will lead to increased profitability of the mine.

How to select the most suitable design This catalogue sets out a range of different mine hoisting applications that Casar ropes can be used for and identifies which rope construction should be used in particular circumstances.

Casar specialises in this technology and is a world leader in the manufacture of sophisticated wire rope products for a broad range of lifting applications. In Australia Casar has established a strong position in the mining industry.

In order to assist you in rope selection, tables that follow give factors that can be used to calculate for example the rope minimum breaking loads (MBL) and masses for a given rope diameter. This allows for automated rope diameter selection given basic winding system parameters. The detailed specifications of various Casar mining ropes are given in 1mm diameter increments, but with rope factors it is also possible to calculate the rope specifications for intermediate diameters, e.g. 42.5mm or 53.5mm, which Casar can manufacture on request.

Quality and high tech design Every effort is made to maintain and improve the quality of Casar wire rope products for the mining industry. Careful attention to quality and engineering design details ensures that a Casar rope will routinely outperform conventional six strand and rotation resistant ropes. Special features of Casar mining ropes include galvanising, compacted strands and a plastic layer between steel core and the outer strands. The internal plastic layer stabilises the construction and experience has shown that Casar winding ropes are less prone to torsional distortions like waviness and slack outer strands.

Tailor made rope construction Within a particular rope construction family Casar are able to deliver a wide range of fill factors and strength to mass ratios. An example of this is the comparison between Starplast M (with no compacted strands) and Starplast VM (with fully compacted strands). By varying the degree of strand compaction, Casar can manufacture ropes with every metallic cross sectional area, any breaking strength or any specific weight between the figures of Starplast M and Starplast VM. We are therefore able to adapt the rope specifications to the exact requirements of your shaft. This is the core competence of Casar.

Reliability and value for money Casar Special Mining Ropes offer benefits such as increased reliability of the hoisting system and reduced downtime due to less servicing and fewer rope changes. The higher breaking strengths of Casar Special Mining Ropes allow for an increase of payload for the same

Casar Mining Rope Factors Fill Factor

Spin Factor

Weight Factor

Wir Dia. Factor

FF

SF

WF

DF

Cross Section Factor CF

[-]

[-]

[-]

[-]

[-]

0.6590

0.68459

0.8700

0.0630

0.6517

0.8372

0.8700

0.6571

0.8415

0.6746 0.67238

MBL Factor

MBL Factor

Mass Factor

BLF 1960

MF

[-]

[-]

[-]

0.5176

0.7749

0.8581

0.00450

0.0748

0.5119

0.7585

0.8399

0.00445

0.8900

0.0546

0.5161

0.7441

0.8239

0.00459

0.8200

0.9100

0.0545

0.5298

0.7690

0.8515

0.00482

0.7938

0.8800

0.0500

0.5685

0.7987

0.8845

0.00500

BLF

1770

Caculating the MBL in kN for a given rope diameter and a given tensile strength MBL 1770 [kN] = 1.77 • FF • SF • II • (d[mm]) 2 / 4 or MBL 1770 [kN] = BLF 1770 • (d[mm]) 2 MBL 1960 [kN] = 1.96 • FF • SF • II • (d[mm]) 2 / 4 or MBL 1960 [kN] = BLF 1960 • (d[mm]) 2

Caculating a minimum rope diameter in mm for a given MBL and a given tensile strength dmin 1770 [mm] =

4 • MBL 1770 [kN] / (FF • SF • II • 1.77) or

dmin 1770 [mm] =

MBL 1770 [kN] / BLF 1770

dmin 1960 [mm] =

4 • MBL 1960 [kN] / (FF • SF • II • 1.96) or

dmin 1960 [mm] =

MBL 1960 [kN] / BLF 1960

Caculating the outer wire diameter of the rope for a given rope diameter = DF • d

Caculating the rope mass for a given rope diameter Rope mass [kg/m] = MF • d 2

43


Wire Rope & Strand TYPICAL MINE WINDERS

Ground mounted Koepe friction winder single rope

Tower mounted Koepe friction winder single-rope no deflection sheave

Ground mounted Koepe friction winder multi-rope

Koepe friction winders are either installed in a ground or tower mounted configuration. The number of head and tail rope pairs can vary between 1 and 10 depending on the hoisting duty of the winder. In general the combined unit mass of the head and tail ropes are equal to ensure balanced winding. Single layer rope constructions are widely used for shallower shaft Koepe

Tower mounted Koepe friction winder singlerope with deflection sheave

Tower mounted Koepe friction winder multi-rope no deflection sheaves

winders, but for depths exceeding 900 m it is critical that non-spin or rotation resistance constructions are used. For free looping tail ropes, non-spin ropes with swivels under both conveyances are recommended. For multi-rope winders, rope load balancing and equal driving sheave/drum circumferences are critical to ensure good rope life.

Tower mounted Koepe friction winder multi-rope with deflection sheaves

Double drum winder

Double drum and BMR winders are almost always ground mounted. For these winders, single layer rope constructions can be used even in very deep shafts in even in excess of 3000 m. However, in such cases the lay length changes from the manufactured state would be significant. Rope load balancing and accurate drum spooling between rope pairs are critical on BMR winders. Ropes which offer high drum crushing

Blair mult-rope (BMR) winder

resistance are preferred for these applications as the ropes normally deteriorate first at the _ turn and layer crossovers on parrellel grooved drums. In cases where the ropes are free to rotate during the winding cycle (e.g. kibble winders) or where the shaft uses rope guides, non-spin or rotation resistant constructions are used.

44

Wire Rope & Strand


MINING WIRE ROPES

• Is an 8 strand rope made out of compacted outer strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands giving the rope a high structural stability. The plastic layer also assists in avoiding internal rope destruction and protecting the core against corrosive environments. • Has a very high breaking load and good resistance against drum crushing. • Turboplast should NOT be used with a swivel. • Regular Lay or Langs Lay. Minimum Breaking Force Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

kg/100m

Grade 1770 kN

Grade 1960 kN

32

530.0

461

793.5

878.7

33

563.7

490

843.9

934.5

34

598.3

521

895.8

992.0

36

670.8

584

1004.3

1112.1

38

747.4

650

1119.0

1239.1

40

828.1

720

1239.9

1373.0

42

913.0

794

1367.0

1513.7

44

1002.1

872

1500.3

1661.3

46

1095.2

953

1639.8

1815.8

48

1192.5

1038

1785.5

1977.1

50

1294.0

1126

1937.3

2145.3

52

1399.6

1218

2095.4

2320.4

54

1509.3

1313

2259.7

2502.3

56

1623.2

1412

2430.2

2691.1

58

1741.2

1515

2606.9

2886.7

• Is an 8-strand rope made out of compacted outer strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands, giving the rope a high structural stability, avoiding internal rope destruction and protecting the core against corrosive environments. • Has a very high breaking load and a good resistance against drum crushing. • Duroplast should NOT be used with a swivel. • Regular Lay or Langs Lay. Minimum Breaking Force Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

28

401.3

30

kg/100m

Grade 1770 kN

Grade 1960 kN

349

594.7

658.5

460.7

401

682.6

755.9

32

524.1

456

776.7

860.1

34

591.7

515

876.8

970.9

36

663.4

577

983.0

1088.5

38

739.1

643

1095.3

1212.8

40

819.0

712

1213.6

1343.9

42

902.9

786

1338.0

1481.6

44

990.9

862

1468.4

1626.1

46

1083.1

942

1605.0

1777.3

48

1179.3

1026

1747.6

1935.2

50

1279.6

1113

1896.2

2099.8 Other diameters are available on request

45

Wire Rope & Strand


MINING WIRE ROPES

• Is a rotation resistant hoist rope made out of compacted outer strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands, giving the rope a high structural stability, avoiding internal rope destruction and protecting the core against corrosive environments. • Has a high breaking load and good resistance against drum crushing. • Regular Lay or Langs Lay. Minimum Breaking Force Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

kg/100m

Grade 1770 kN

Grade 1960 kN

30

464.5

413

669.7

741.5

32

528.5

470

761.9

843.7

34

596.6

531

860.1

952.5

36

668.9

595

964.3

1067.8

38

745.3

663

1074.4

1189.8

40

825.8

735

1190.5

1318.3

42

910.4

810

1312.5

1453.4

44

999.2

889

1440.5

1595.1

46

1092.1

972

1574.4

1743.5

48

1189.1

1058

1714.3

1898.4

50

1290.3

1148

1860.2

2059.8

52

1395.6

1242

2012.0

2227.9

54

1505.0

1339

2169.7

2402.6

• Is a rotation resistant hoist rope made out of compacted strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands, giving the rope a high structural stability, avoiding internal rope destruction and protecting the core against corrosive environments. • Has a high breaking load and good resistance against drum crushing. • Regular Lay or Langs Lay. Minimum Breaking Force Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

kg/100m

Grade 1770 kN

Grade 1960 kN

30

476.8

434

692.1

766.4

32

542.5

494

787.5

872.0

34

612.5

557

889.0

984.4

36

686.7

625

996.6

1103.6

38

765.1

696

1110.4

1229.6

40

847.7

771

1230.4

1362.5

42

934.6

851

1356.5

1502.1

44

1025.8

933

1488.8

1648.6

46

1121.1

1020

1627.2

1801.9

48

1220.7

1111

1771.8

1962.0

50

1324.6

1205

1922.5

2128.9

52

1432.7

1304

2079.4

2302.6

54

1545.0

1406

2242.4


46

Wire Rope & Strand


MINING WIRE ROPES

• Is a rotation resistant hoist rope made out of compacted strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands giving the rope a high structural stability. The plastic layer also assists in avoiding internal rope destruction and protecting the core against corrosive environments. • Has a high breaking load and good resistance against drum crushing. • Regular Lay or Langs Lay. Minimum Breaking Force Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

kg/100m

Grade 1770 kN

Grade 1960 kN

20

227.4

200

319.5

353.8

22

275.1

242

386.6

428.1

24

327.4

288

460.1

509.4

25

355.3

313

499.2

552.8

26

384.3

338

539.9

597.9

28

445.7

392

626.2

693.4

30

511.6

450

718.8

796.0

32

582.1

512

817.9

905.7

34

657.2

578

923.3

1022.4

36

736.7

648

1035.1

1146.3

38

820.9

722

1153.3

1277.2

40

909.6

800

1277.9

1415.1

42

1002.8

882

1408.9

1560.2

• Is a 12 strand rope made out of compacted strands. • Is fully lubricated. • Has a plastic layer between the steel core and the outer strands, giving the rope a high structural stability, avoiding internal rope destruction and protecting the core against corrosive environments. • Has a high breaking load and good resistance against drum crushing. • Langs Lay only. Minimum Breaking Force Nominal Diameter

Metallic Area

Approximate Mass

mm

mm2

kg/100m

Grade 1770 kN

Grade 1960 kN

30

465.1

414

683.3

756.6

32

529.2

471

777.4

860.9

34

597.4

532

877.7

971.9

36

669.8

596

983.9

1089.6

38

746.3

664

1096.3

1214.0

40

826.9

736

1214.8

1345.1

42

921.1

811

1371.0

1500.9

44

1000.5

891

1469.8

1627.6

46

1093.5

973

1606.5

1779.0

48

1190.7

1060

1749.2

1937.0

50

1292.0

1150

1898.0

2101.8

52

1397.4

1244

2052.9

2273.3

54

1507.0

1341

2213.9


47

Wire Rope & Strand


MINING WIRE ROPES Full Locked Coil Winding Ropes Nominal Diameter

Approximate Mass

mm 32 33 35 37 38 40 41 43 44 46 48 49 51 53 54 56 57 59 61 62 64

Half Locked Coil Guide Ropes Nominal Diameter

Approximate Mass

kgs/m

Nominal Breaking Load kgs

mm

kgs/m

Nominal Breaking Load kgs

5.78 6.14 6.91 7.72 8.14 9.02 9.48 10.4 10.9 11.9 13 13.5 14.7 15.8 16.4 17.7 18.3 19.6 21 21.7 23.1

88,800 94,400 106,000 119,000 125,000 139,000 146,000 160,000 168,000 184,000 200,000 208,000 226,000 244,000 253,000 272,000 282,000 298,000 319,000 329,000 351,000

29 32 35 38 41 45 48 51

4.63 5.63 6.74 7.94 9.25 11.1 12.7 14.3

42,900 52,200 62,500 73,900 85,700 103,000 117,000 133,000

Nominal Breaking Load x 1.082 = Aggregate Breaking Load These ropes conform to N.C.B. Spec 388

Full Locked Coil

Half Locked Coil

Up to 57mm Nominal B.L. x 1.197 = Aggregate B.L. Over 57mm Nominal B.L. x 1.212 = Aggregate B.L. These ropes conform to N.C.B. Spec. 186

Triangular Strand 6x8 to 17 6 x 19 6 x 22 6 x 23 6 x 25 6 x 27 or 28

Outer Wires - Fibre Core (8/10/Δ) (9/12/Δ) (10/12/Δ) (12/12/Δ) (14 OR 15/Δ)

Nominal Diameter

Approximate Mass 6 x 27 to 6 x 28 kg/100m

Minimum Breaking Force Grade 1770 kN

mm

6 x 19 to 6 x 25 kg/100m

16 18

105 132

164 206

20

164

255

22

200

312

24

237

369

26

276

432

28

320

500

32

420

655

36

530

825

40

653

637

1020

44

800

782

1250

48

945

923

1475

52

1080

1730

56

1250

2000

60

1440

2300

48

6 x 12/12/3TS

6 x 10/12/3TS

6 x 15/12/9TS

Wire Rope & Strand


AMERICAN WIRE ROPES Hoist and Luffing Ropes for Lattice Boom Cranes (American Manufacture)

Alternate Lay for Luffing Ropes

Right Hand Ordinary Lay for Hoist Ropes

6 x 25 FW or 6 x 31 WS IWRC Nominal Diameter

Approximate Mass

Nominal Strength in kN

Inches

mm

kg/100m

Extra Extra Improved Plough Steel

Extra Improved Plough Steel

5/8

15.9

107

202

183

3/4

19.1

155

288

262

7/8

22.2

211

390

354

1

25.4

275

506

460

1 1/8

28.6

348

636

578

1 1/4

31.8

430

782

711

Nominal Strength is an American term. Minimum Breaking Force is 2 1/2 % lower than the Nominal Strength.

OIL INDUSTRY WIRE ROPES Drilling Lines 6 x 19 SEALE

Right Hand Ordinary Lay, Ungalvanised IWRC to API Spec 9A Nominal Diameter


Approximate Mass

IPS Grade

EIPS Grade

Inches

mm

kg/100m

lb/ft

kN

1000 lb

kN

1000 lb

7/8

22

211

1.42

308

69.2

354

76.6

89.8

460

103.4

1

26

275

1.85

399

1 1/8

29

348

2.34

503

113

578

130

1 1/4

32

430

2.89

617

138.8

711

159.8

1 3/8

35

521

3.5

743

167

854

192

1 1/2

38

619

4.16

880

197.8

1014

228

1 5/8

42

726

4.88

1023

230

1174

264

1 3/4

45

844

5.67

1183

266

1361

306

49

Wire Rope & Strand


ONESTEEL FISHING WIRE ROPES The OneSteel range of fishing ropes are characterised by the very high levels of galvanising achieved in the high strength 1770 MPa grade wire. Galvanising levels at 25% above Class A (now Class W10Z to AS/NZS 4534) are targeted in manufacture.

base lubricant with extreme pressure additives and corrosion inhibitors. In accord with occupational health and environmental principles the use of bitumastic based lubricants has been discontinued.

OneSteel refer to these as marine grade galvanised wire products. This along with the special treatment that ropes receive in manufacture to prevent nicking and marking the zinc ensures a product that is highly resistant to corrosion. The product is popular for warps and bridles in trawling.

Note:

Rope cores are lubricated laid polypropylene for best results. Also the rope strands are lubricated in manufacture using a wax

• Information on other rope sizes, constructions and compak fishing ropes are available on request. • There is a limit to the wire size available with the marine grade levels of galvanising in high strength 1770 MPa grade. In larger sizes these may need to be of 1570 grade tensile wire to obtain the same high levels of galvanising.

Galvanised - 6x9/9/1 Fibrillated Poly Core RHOL

Galvanised - 6x9/9/1 Wire Rope Core RHOL

Nominal Diameter mm

Approximate Mass kgs/100m

Minimum Breaking Load 1770 kN

Nominal Diameter mm



12

54.5

84.3

20

163.8

252.0

14

70.7

113.7

22

198.3

305.0

24

240.9

363.0

16

92.9

149.1

18

119.5

189.0

20

144.8

234.5

22

173.2

283.0

1770 Grade Wire is standard, 1570 may be available upon request.

KISWIRE FISHING WIRE ROPES Kiswire fishing ropes are available in both A & B galvanising and ALUMAR. ALUMAR fishing ropes have 5% aluminium in the zinc galvanising mix with the inclusion of the aluminium ensuring superior resistance to corrosion and a longer working life.

These test indicate that ALUMAR technology improves corrosion resistance by approximately 3 times. ALUMAR fishing ropes are the end product of many years of testing in regard to the correct level of aluminium to be included in the zinc mix. The level of 5% provides the optimum balance of corrosion resistance, durability and working life.

ALUMAR ropes have performed extremely well in laboratory Salt Spray (NaCI) and SO2 Atmosphere humidity tests.

Galvanised - 6x9/9/1 Wire Rope Core RHOL

Galvanised - 6x9/9/1 Poly Core RHOL Nominal Diameter mm



Nominal Diameter mm



8

24.4

37.4

10

41.8

63.1

9

30.8

47.3

11

50.6

76.3

10

38.0

58.4

12

60.2

90.8

11

46.0

70.7

14

82.0

124.0

12

54.7

84.1

16

107.0

161.0

14

74.5

114.0

18

135.0

204.0

16

97.3

149.0

20

167.0

252.0

18

123.0

189.0

20

152.0

234.0

1770 Grade Wire is standard, 1570 may be available upon request. AB Galvanised fishing ropes also available upon requests.

50

Wire Rope & Strand WIRE ROPE LUBRICANTS Lubrication impregnated into a wire rope during manufacture is not sufficient to last the life of the rope. Additional lubrication should be added to the rope during service.

Lanotec Where environmental considerations are paramount Nobles recommends the use of Lanotec environmentally friendly sealants and lubricants. Nobles are a leading stockist and distributor of Lanotec and like Nobles Lanotec is a 100% Australian-owned and operated company manufacturing a range of naturally based products that are suitable for use on wire rope and in general industry. By using Lanotec’s naturally based products Nobles can provide lubrication, corrosion protection and degreasing solutions that are both environmentally friendly and user safe.

The frequency of lubrication in the field is determined by the operating conditions of the rope e.g. high-speed heavy duty operation calls for more frequent lubrication, as do wet and/or corrosive conditions. Nobles offer two main options for the lubrication of wire rope.

Nobles Wire Rope Lubricant Nobles standard wire rope lubricant offers the benefits of; • Better rope life • Cleaner operation – no fling off • Easier application of lubricant • Cost savings

Naturally-based Products

Lanotec products comprise a range of lanolin based surface coatings in both liquid and grease forms; and a citrus based cleaner/degreaser (Citra-Force). Commitment to Testing

The Lanotec range is manufactured to strict quality standards and independent application testing using NATA certified laboratories ensures Lanotec products are tested and proven. Heavy Duty (HD) Lanolin

Wire rope with Nobles Wire Rope Lubricant (applied with a pressure lubricator). Note: smooth regular all-over coating.

HD Lanolin is recommended for wire rope and is particularly well suited to industrial lifting, rigging and marine applications. HD Lanolin is suitable for harder working, harder wearing areas. • Non conductive to 70 Kv • Ideal for harsh and highly corrosive environments • Lubricates, protects and extends the life of wire rope, chain and associated fittings • Provides excellent corrosion protection for stainless steel rigging and balustrading • Suitable for high speed and load bearing chains • Battery terminals and connectors such as electric fork trucks and the like • Assembly lube for rubber hoses and multi pin plugs • Component preservation and internal protection of motors and bearings • Outside storage protection

Rope after application through same pressure lubricator using Bitumen Rope Oil. Note: poor uneven coverage with some strands not coated.

51



Wire Rope & Strand STAINLESS STEEL WIRE ROPE There are three common constructions of stainless steel wire rope used in fixed rigging applications. Nobles are stocking stainless steel wire rope mainly in 316 grade but some 304 grade product is available.

7 x 19 7x19 is the most common and versatile construction of stainless steel wire rope. It consists of 7 strands each with 19 wires and is the most flexible and the easiest construction to work with particularly where the rope needs to turn corners, change directions or where ferrule secured thimble eyes and wire rope grips are used. 7x19 can be used in either fixed rigging or for limited working rope applications such as on a boat winch.

7x7 7x7 consists of 7 strands each with 7 wires and is not as flexible as 7x19. 7x7 is an excellent choice for fixed rigging applications such as balustrading and safety barrier rails. Although 7x7 is stiffer than 7x19 it is still capable of limited angles and can be used with thimble eyes or swage fittings. 7x7 has very limited applications as a running or working rope.

1 x 19 1x19 consists of a single strand with 19 wires. 1x19 is very stiff and is suitable for fixed "straight line" rigging only such as mast stays, guy ropes and structural applications. It cannot be used with thimble eyes and is best utilised and looks very effective with machine swaged end fittings.

52

Wire Rope & Strand


STAINLESS STEEL WIRE ROPE

Stock Code

Grade & Construction

Nominal Diameter mm

Approximate Mass kg/100m

Minimum Breaking Load kg

AS0201196

2

1.98

340

AS0301196

3

4.46

756

AS0401196

4

7.93

1,345

AS0501196

5

12.4

2,100

AS0601196

6

17.8

3,030

AS0801196

8

31.7

5,380

AS1001196

10

49.5

8,400

AS0207076

2

1.57

232

AS0307076

3

3.54

520

4

6.29

1,000

AS0507076

5

9.83

1,520

AS0607076

6

14.2

2,060

AS0207194

2

1.7

295

AS0307194

3

3.42

540

AS0407076

AS0407194

316 Grade 1x19

316 Grade 7x7

4

6.09

1,089

AS0507194

5

9.52

1,820

AS0607194

6

13.8

2,480

AS0807194

8

24.3

4,082

AS0207196

2

1.7

212

AS0307196

3

3.42

478

AS0407196

4

6.09

850

5

9.52

1,490

AS0607196

6

13.8

1,912

AS0807196

8

24.3

3,400

AS1007196

10

38.1

5,310

AS0507196

304 Grade 7x19

316 Grade 7x19

• 316 Grade ropes are preferred but 304 Grade is also usually available. Please nominate grade required at time of order. • White is the standard colour for PVC covered ropes but other colours may be available. • Reels are available in 305m, 500m or 1000m lengths. • Other constructions and sizes available on request.

53

Wire Rope & Strand


GALVANISED STRAND Galvanised Strand is commonly used for guys on communication towers, broadcasting towers, power poles and as load carrying members in building structures.

1 x 37 Galvanised Strand

Characteristics

Galvanised Strand is less flexible than wire rope, it is stronger and has a higher modulus of elasticity. It is furnished with Class A galvanised finish.

Galvanised Strand for General Purpose Applications

1x7

1 x 19

Nominal Diameter mm

Construction (abbreviated form)

4.2

1x3

5.7

1x3

2.5

1x7

1.4

3

1x7

3.5

Minimum Breaking Force, kN 820 1320 Grade Grade

Nominal Mass kg/100m

Nominal Area mm 2

11.7

7.6

9.43

21.4

13.4

17.17

3

3.2

3.97

2

4.3

4.4

5.56

1x7

2.8

6.2

9.9

6.3

7.92

4

1x7

3.5

7.6

12.2

8.7

10.8

5

1x7

5.4

11.7

18.8

12.8

15.9

6

1x7

7.9

17

27.4

17.7

26.6

7

1x7

10.7

23.1

37.2

25.5

31.7

8

1x7

14.6

30.2

48.6

32.3

40.1

9

1x7

17.8

38.4

61.8

39.8

49.5

10

1x7

21.9

47.3

76.1

51.2

63.6

11

1x7

26.6

57.4

92.4

60.6

75.3

12

1x7

31.6

68.2

109

75.4

88

10

1 x 19

46

74

50.4

60.3

12

1 x 19

63.2

101

72.6

87.2

14

1 x 19

86

137

98.8

119

16

1 x 19

182

129

144

380 Grade

54

Wire Rope & Strand


GALVANISED STRAND TO AS 2841

Galvanised Strand for Guying Purposes

1 x 19 Nominal diameter

1 x 37

Construction* (abbreviated form)

mm

1 x 61


Nominal Mass

Nominal Area

Young Modulus**

kN

kg/100m

mm2

GPa

10

1 x 19

88

50.4

60.3

166

12

1 x 19

126

72.6

87.2

166

14

1 x 19

172

98.8

119

166

16

1 x 19

210

129

145

166

18

1 x 19

265

163

183

166

20

1 x 19

368

212

254

166

22

1 x 19

442

255

305

166

24

1 x 19

518

299

357

166

26

1 x 37

580

348

400

166

28

1 x 37

713

427

491

166

32

1 x 37

897

538

618

166

36

1 x 61

1150

687

789

166

40

1 x 61

1420

848

975

166

44

1 x 61

1800

1080

1240

166

48

1 x 91

2050

1260

1450

166

52

1 x 91

2400

1480

1700

166

54

1 x 91

2610

1610

1850

166

58

1 x 127

2850

1760

2020

158

64

1 x 127

3640

2250

2580

158

70

1 x 169

4450

2750

3150

158

76

1 x 169

4850

2990

3430

158

82

1 x 217

5560

3520

4050

158

86

1 x 217

6040

3830

4400

158

90

1 x 271

6940

4400

5050

158

95

1 x 271

7550

4790

5500

158

102

1 x 271

8850

5610

6440

158

* For strand 70mm diameter and greater, the number of wires may vary from that shown in the table provided that the other physical properties are in accordance with those shown in the table. ** The values shown are indicative of values obtained after removal of constructional stretch. If a precise value is required, it should be determined by experiment.

55

02_wire_rope_strand

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