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Top Tips on Caring for Wire RopesVIDEO ON THE TOPIC: Brunton Wolf Wire Ropes FZCO. - The leading manufacturer of wire ropes
The majority of wire rope problems occurring during operation actually begin during installation, when the rope is at its greatest risk of being damaged. Proper installation procedures are vital in the protection and performance of wire rope products. Until the rope is installed it should be stored on a rack, pallet or reel stand in a dry, well-ventilated storage shed or building.
Tightly sealed and unheated structures should be avoided as condensation between rope strands may occur and cause corrosion problems. If site conditions demand outside storage, cover the rope with waterproof material and place the reel or coil on a support platform to keep it from coming directly in contact with the ground.
While lubrication is applied during the manufacturing process, the wire rope must still be protected by additional lubrication once it is installed.
Lubricants will dry out over a period of time and corrosion from the elements will occur unless measures are taken to prevent this from happening. When the machine becomes idle for a period of time, apply a protective coating of lubricant to the wire rope. Moisture dew, rain, and snow trapped between strands and wires will create corrosion if the rope is unprotected. Also apply lubricant to each layer of wire rope on a drum because moisture trapped between layers will increase the likelihood of corrosion.
Always use the nominal diameter as specified by the equipment manufacturer. Using a smaller diameter rope will cause increased stresses on the rope and the probability of a critical failure is increased if the rated breaking strength does not match that of the specified diameter. Using a larger diameter rope leads to shorter service life as the rope is pinched in the sheave and drum grooves which were originally designed for a smaller diameter rope.
Just as using a different diameter rope can create performance problems, so can the use of an excessively undersized or oversized rope. If the rope is the wrong size or outside the recommended tolerance, return the rope to the wire rope supplier. It is never recommended nor permitted by federal standards to operate cranes with the incorrect rope diameter. Doing so will affect the safety factor or reduce service life and damage the sheaves and drum. Wire rope can be permanently damaged by improper unreeling or uncoiling practices.
The majority of wire rope performance problems start here. Improper unreeling practices lead to premature rope replacement, hoisting problems and rope failure. Place the payout reel as far away from the boom tip as is practical, moving away from the crane chassis. Never place the payout reel closer to the crane chassis than the boom point sheave. Doing so may introduce a reverse bend into the rope and cause spooling problems. Take care to determine whether the wire rope will wind over or under the drum before proceeding.
If the wire rope supplier secured the end of the rope to the reel by driving a nail through the strands, ask that in the future a U-bolt or other nondestructive tie-down method be used; nails used in this manner damage the rope. Take extra precaution when installing lang lay, rotation-resistant, flattened strand or compacted ropes. Loss of twist must be avoided to prevent the strands from becoming loosened, causing looped wire problems.
The end of the rope must be securely and evenly attached to the drum anchorage point by the method recommended by the equipment manufacturer. Locate the dead end rope anchorage point on the drum in relation to the direction of the lay of the rope. Do not use an anchorage point that does not correspond with the rope lay. Mismatching rope lay and anchorage point will cause the wraps to spread apart from each other and allow the rope to cross over on the drum.
Very gappy winding will occur resulting in crushing damage in multilayer applications. Regardless of the benefits of a grooved drum, tension must be applied to ensure proper spooling.
An improperly installed rope on a grooved drum will wear just as quickly as an improperly installed rope on a smooth drum. If a wire rope is poorly wound and as a result jumps the grooves, it will be crushed and cut under operating load conditions where it crosses the grooves.
Every wrap on the first or foundation layer must be installed very tightly and be without gaps. Careless winding results in poor spooling and will eventually lead to short service life. The following layers of rope must lay in the grooves formed between adjacent turns of the preceding layer of rope.
If any type of overwind or cross-winding occurs at this stage of installation and is not corrected immediately, poor spooling and crushing damage will occur. On a multilayer spooling drum be sure that the last layer remains at least two rope diameters below the drum flange top.
Do not use a longer length than is required because the excess wire rope will cause unnecessary crushing and may jump the flange. Loose wraps that occur at any time must be corrected immediately to prevent catastrophic rope failure. The use of a mallet is acceptable to ensure tight wraps, however a steel-faced mallet should be covered with plastic or rubber to prevent damage to the rope wires and strands. Rotation-resistant ropes of all constructions require extra care in handling to prevent rope damage during installation.
The lay length of a rotation-resistant rope must not be disturbed during the various stages of installation. By introducing twist or torque into the rope, core slippage may occur—the outer strands become shorter in length, the core slips and protrudes from the rope.
In this condition the outer strands become over- loaded because the core is no longer taking its designed share of the load.
Conversely, when torque is removed from a rotation-resistant rope core slippage can also occur. The outer strands become longer and the inner layers or core become overloaded, reducing service life and causing rope failure.
The plain end of a wire rope must be properly secured. The outer layer of the outside strands may also become overloaded as there is no complete core-to-strand support. It is imperative that the ends be held together tightly and uniformly throughout the entire installation procedure, including attaching the end through the wedge socket and the drum dead end wedge. When installing a new line, connect the old line to the new line by using a swivel-equipped cable snake or Chinese finger securely attached to the rope ends.
Welding ropes together or using a cable snake without the benefit of a swivel increases the likelihood of introducing torque into the new rope. A swivel-equipped cable snake is not as easy as welding the ropes, but this procedure can be mastered with a little patience and practice. Installation The majority of wire rope problems occurring during operation actually begin during installation, when the rope is at its greatest risk of being damaged.
Provide Proper Storage Until the rope is installed it should be stored on a rack, pallet or reel stand in a dry, well-ventilated storage shed or building.
Use Proper Unreeling Procedures Wire rope can be permanently damaged by improper unreeling or uncoiling practices. Keep Wraps Tight The end of the rope must be securely and evenly attached to the drum anchorage point by the method recommended by the equipment manufacturer. Treat Rotation-Resistant Ropes with Extra Care Rotation-resistant ropes of all constructions require extra care in handling to prevent rope damage during installation.
It is imperative that the ends be held together tightly and uniformly throughout the entire installation procedure, including attaching the end through the wedge socket and the drum dead end wedge Use a Cable Snake When installing a new line, connect the old line to the new line by using a swivel-equipped cable snake or Chinese finger securely attached to the rope ends.
Information about wire rope unloading, storage, handling, installation, operation, lubrication, inspection, maintenance and possible causes for rope faults is given in this article to get best service from it. Whenever handling wire rope, take care not to drop reels or coils. This can damage wire rope and collapse the reel, making removal of the wire rope extremely difficult. Rope in a coil is unprotected and may be seriously damaged by dropping. Wire ropes should be stored in a well ventilated, dry building or shed and shall not be in contact with the floor.
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We need to take proper care of our tools and equipment to ensure their longevity and endurance. Their safe and prolonged use is dependent upon the upkeep that they receive. A wire rope is one of the most essential equipment in several industries. Since it is a consumable item, it comes with a shelf life. It is, typically, used in heavy industries and due to the nature of the work it serves its properties are bound to change when in use. On reaching its maximum potential, however, the strength starts to deteriorate rapidly. This difference in the strength of the rope is brought about by factors such as changes in the structure of the rope, wire breaks, corrosions and abrasions.
Steel Wire Rope/Steel Cable for Offshore Rigging
Wire ropes specialists for more than 90 years, the Lemmens Company has gradually extended its activity to all lifting, handling, lashing and anti-fall safety equipments. At the same time, it has developed another sector with tarpaulins. Its major advantage is its know-how and experience splicing, grommets, cable-lays, etc. In addition, its team of experienced professionals can provide first-rate technical assistance. Brand name items All of our brands. Your safety depends on the materials you use.
Every steel wire rope, which is subject to corrosion, abrasion, and fatigue, will fail one day if it is not discarded in time. Steel wire rope flaw detector INTROS enables simultaneously accurate measurement of loss of metallic area LMA and detection of outer and inner localized flaws LF , such as broken wires, strands, pitting corrosion. Operation of the instrument is based on magnetic flux leakage MFL principle, so the instrument uses strong permanent magnets to magnetically saturate the rope under inspection. Only in case of magnetic saturation, it is possible to obtain high accuracy and sensitivity of the instrument. Software Wintros RTV for on-line indication of traces, that is very convenient for some specific applications. Certificates Booklet. Basic unit is battery operated and connected to magnetic head by special cable. Currently explosive proof design is not available. The basic unit enables to display traces immediately after inspection.
Inspection and Maintenance
Material: Galvanised, ungalvanised or stainless steel, etc. Application: Elevator, crane lifting, hanging basket. Steel wire rope is used across a wide spectrum of industries for many applications.
The following Instructions and Warnings combine to provide guidance on Product Safety and are intended for use by those already having a working knowledge of wire ropes, as well as the new user. They should be read, followed and passed on to others. Failure to read, understand and follow these instructions could result in harmful and damaging consequences. If in doubt, contact Bridon for guidance. The calculation may take into account the mass to be lifted or moved, any shock loading, effects of high speed, acceleration, any sudden starts or stops, frequency of operation and sheave bearing friction. By applying the relevant design factor and, where applicable, the efficiency of the rope termination, the required minimum breaking load or force of the rope will be determined, the values of which are available from the relevant National or International standards or from specific Product Data literature. If in doubt, ask for advice from Bridon. Reverse bending and high speed will accelerate theprocess.
Steel Wire Rope/Steel Cable for Ship Loading and Unloading
Follow Us Facebook Instagram Linkedin. Search for: Search:. Home Wire Ropes. Wire ropes need to be treated with a lot of attention during their storage, as well as during their installation. In opposite cases, if any part of the surface of the wire rope is damaged, it may not be discovered until much later and that will affect its working time life! Steel wire ropes should be stored in a clean, cool, dry place indoors.
Wire Rope Installation & Storage
Proper lubrication of your wire rope, chain and cable can safely extend its operational life regardless of application. Cranes, elevators, shovels, drilling rigs, suspension bridges and draglines are some of the many applications that use wire rope, chain or cable to perform work such as pulling, dragging or hoisting. These applications often are exposed to harsh environmental conditions, including extreme weather. Lubrication Engineers can help your wire rope, chain and cable last longer and operate safely by implementing a lubricant reliability program and recommending the right lubricants for the job. Most wire ropes are lubricated during the manufacturing process, but this lubricant will not last the entire life of the rope. When looking for a lubricant to relubricate your wire rope, choose one that contains no acids or alkalis, possesses the adhesive strength to stay on the rope, can penetrate between wires and strands, has high fluid film strength, resists oxidation and remains pliable. It is important to remember that most wire ropes fail from the inside out.
Wire Rope Sheaves
Introduction 2. Lubrication 3.
The steel wire rope must be lubricated regularly. Friction is also thereby reduced between the steel wire rope and the surfaces with which it comes into contact. The lubricant used must be free of acids and must not have a destructive effect on the steel wires, the fibre core and the environment.
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