DIEPA Answers

8/17/2019 DIEPA Answers

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Index

1. The company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 „Drahtseilwerk Dietz“ – sole manufacturer of DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . 21.2 The DIEPA philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. What makes DIEPA Special Wire Ropes so special ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43. Basic information about ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1 Rope – strands - wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1.1 Structural design of a steel wire rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1.2 The outer strands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Basic terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84. Easy rope selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.1 Overview rotation resistant DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144.2 Selecting a rotation resistant DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.3 Overview non-rotation resistant DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.4 Selecting a non-rotation resistant DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . 175. Which direction of lay is appropriate – right- or left-handed ? . . . . . . . . . . . . . . . . . . . 185.1 General recommendations for DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.2 Simple method for the selection of optimum direction of lay of the rope . . . . . . . . . . . . . . . . . . 215.3 Right- and left-handed ropes working in pairs or multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.4 Coupling (joining) non-rotation resistant ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226. Single layer coiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.2 Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.3 The advantages of DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247. Multi-layer coiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257.2 How many outer strands ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267.3 Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277.4 The advantages of DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298. Grooves – their diameter and their radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309. The rope’s swivle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3110. Order data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3210.1 Use of a specified DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3210.2 Use of a DIEPA Special Wire Rope as an alternative to other specified rope . . . . . . . . . . . . . . 3211. Handling, inspection and in-service maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3311.1 Inspection on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

11.2 Transporting the rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3311.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3411.4 Cutting a DIEPA Secial Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3512. Installation and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3612.1 Inspection of the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3612.2 Unwinding from a reel or coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3612.3 Installing the rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3812.4 Installing the rope under load in a multy-layer coiling system . . . . . . . . . . . . . . . . . . . . . . . . . 4013. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4113.1 Re-lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4113.2 Shortening the rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4214. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4314.1 When is the rope to be inspected ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4314.2 What needs to be inspected ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

14.3 The most important discard criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4415. Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48


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1. The company

1.1 „Drahtseilwerk Dietz“ – sole manufacturer of DIEPA Special Wire Ropes

The company „Drahtseilwerk Dietz“ was founded in Germany in 1873, initiallyas a manufacturer of fibre ropes. Later on, as markets developed and require-ments changed, it decided to concentrate its efforts on the manufacture of steel

wire ropes. From the beginning, the earlier own-

ers recognised the need to develop new types of ropes for special applications and instituted theirown ‘in-house’ research and development pro-grams. The company „Drahtseilwerk Dietz“ wasgranted its first patent covering ropes producedin double parallel lay in 1936 and the brand nameDIEPA (= Dietz Patent) was born – nowadays asynonym for high performing steel wire ropes.

In 1943 the development of a new generation of rota-tion-resistant ropes began and in 1951 ropes incorporating a plastic insert wereintroduced to meet the ever-increasing performance requirements of machinerymanufacturers and end users.

Nowadays, DIEPA Special Wire Ropes are manufactured around the clock byapproximately 340 specialists operating in 15 production halls. With the con-tinuous modernisation and expansion of its machinery and facilities,„Drahtseilwerk Dietz“ is well placed to meet the ever-increasing demand for itsDIEPA Special Wire Rope products.

1.2 The DIEPA philosophy

Different applications place different demandson the rope, particularly as far as breaking force, abrasion, and in some cases, resistanceto rotation are concerned. A rope that meets allthe demands for every application rarelyexists. Indeed, the most appropriate rope is, inreality, a compromise of the different characte-

ristics that best meet the specific demands andexpectations for a given job. Figure 2 Simple bending machines

Figure 1 Aerial view of company


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It is important, therefore, for tests to be con-ducted that not only evaluate the rope forits breaking force and resistance to ben-ding, but also assess its resistance to abra-sion, rotational behaviour and structuralstability. These tests should be designed toevaluate the behavioural characteristics

throughout the rope's service life and thecompany „Drahtseilwerk Dietz“ has built,and operates, a large number and variety of testing facilities and equipment that aredevoted to this purpose.

Figure 3 Horizontal bending machine

Figure 4 Testing tower simulating actual working conditions


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2. What makes DIEPA Special Wire Ropes so special ?

Special design

Recognizing that many jobs require a unique design

of rope, the number of available rope designs in the

DIEPA manufacturing program is almost as varied as

the number of different types of lifting appliances.

Calculated with most up to date computer tech-

nology and based on decades of experience

New CAD and other computer software programs

provide the rope design specialist with the tools to calculate and determi-

ne the optimal dimensions of each single wire as it fits in the rope. To assist

in this process, account is also taken of the decades of manufacturing and

field experience.

High quality wire

A meal is only as good as the ingredients used in the recipe. The same prin-

cipals apply to rope-making. Only high quality wires are used in the manu-

facture of DIEPA Special Wire Ropes. Our proven and reliable suppliers

have continued to provide us, over the decades, with the best materials.

Lubricant

The lubricant is an important component of the rope that is often unde-

restimated. The use of a rope without sufficient lubricant, or, indeed, with

the wrong type of lubricant will inevitably lead to premature fatigue failu-

re and/or internal corrosion of the rope.

Figure 5Rotation resistant special wire rope


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Plastic insert

DIEPA uses only high quality polyamide-12, which has proven to be more mecha-

nically efficient and robust than other more common and cheaper lower grade

polymers.

Modern equipment and machinery

The manufacturing of a wide variety of ropes over a large size range requi-

res different types and sizes of machines. Our very own ‘in-house’ enginee-

ring department has the expertise and skills to design and build equip-

ment and machines that enables each DIEPA Special Wire Rope to be pro-

duced on the most appropriate machine. As an example, right-handed and

left-handed ropes of the same type are closed on mirror-imaged machines

in order to obtain identical quality.

Figure 6 Non-rotation resistant special wire rope DIEPA PZ 371 with

plastic insert

Figure 7 New spinning machines ... Figure 8 ... in new manufacturing halls


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Qualified specialists

Many modern machines are computer controlled; but at DIEPA, rope-

making craft skills and experience are equally regarded as key require-

ments. Low fluctuations in the workforce at „Drahtseilwerk Dietz“ creates

the optimal mix of young dynamic enterprising forces and those having

long years of experience who are able to pass on their knowledge to the

younger generation.

Availability and punctual delivery

A wire and a rope warehouse, each storing several thousand tons of pro-

duct, facilitates punctual delivery and allows for timely responses to theneeds and wishes of our valued customers.

High quality certified in accordance with EN ISO 9001.

Figure 9 Wire warehouse Figure 10 Rope warehouse


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3. Basic information about ropes

3.1. Rope – strands – wires

3.1.1 Structural design of a steel wire rope

As the term ‘steel wire rope’ implies, the rope is made up of a large num-

ber of steel wires (1). These are twisted together to form strands (2a and

2b), following which some of these strands (2b) are used to form the core (3)of the rope. In the final manufacturing operation a layer of strands, known

as outer strands (2a), is closed over the core to complete the rope.

Some types of ropes also have a plastic insert (4). This is usually in the

form of a plastic coating applied to the core in a special process. Naturally,

lubricant is also applied to the interior of the rope.

Figure 11 Structural formation of a steel wire rope

(4) Plastic insert(1) Wires

(2b) Core strands

(2a) Outer strands

(3) Core


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3.1.2 The outer strands

The number of load-bearing wires in the outer strands is used to determi-

ne the individual discard criteria for visible broken wires. The so called ‘fil-

ler wires’ of a strand design such as 1-5-5F-10 or 1-6-6F-12 are not coun-

ted. As an example, a rope with 8 outer strands and each strand with a

design 1-6-6F-12 wires, i.e. 8x25F, is considered to have 152 load bearing

wires for the purposes of discard.

3.2 Basic terms and definitions

Direction of lay:

The direction of lay of the rope corresponds to

the direction of lay of the helix of the outer

strands. The direction of lay is either right-

handed, denoted ‘Z’ (figure 12) or left-handed,

denoted ‘S’ (figure 13). Strands also have a

direction of lay, denoted ‘z’ for right-handed lay

and ‘s’ for left-handed lay.

Figure 12Right-handed

Right-handedsZ

Left-handedzS

Figure 13Left-handed

Figure 14 Ordinary lay

Right-handedzZ

Left-handedsS

Figure 15 Lang lay


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Ordinary (regular) lay:

The direction of lay of the wires in the strands is opposite to that of the

strands in the rope (figure 14).

Lang lay:

The direction of lay of the wires in the strands is the same as that of the

strands in the rope (figure 15).

Rotation resistance:

A steel wire rope is rotation resi-

stant if the rope does not, or barely,

rotates around its longitudinal axis

while lifting an unguided load or if

its end termination does not turn or

turns very little. This characteristic

results from the fact that the direc-

tion of lay of the core is opposite to

the direction of lay of the rope itself. When a rotation resistant rope is

under load, the torque generated by the core is opposite to that generated

by the outer strands, thus creating an equalizing effect.

Tension free:

A steel wire rope is considered tension free if the wires do not, or barely,

jump out of their structural position when the rope is cut and is not served.

Low tension:

A steel wire rope is considered as low tension if the wires barely lose their

structural position when the rope is cut and is not served.

Free of twist:

A steel wire rope is regarded as being free of twist if it does not exhibit any

twist when it is laid out or when being installed. Every rope should be free

of twist. Being free of twist is sometimes confused with rotation resistance.

To ensure that every DIEPA Special Wire Rope is absolutely free of twist

Figure 16 Opposite torque moments in a rotation

resistant rope


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to allow for trouble-free handling during installation, every DIEPA Special

Wire Rope is laid out, prior to shipment, on a 100 metre long table.

Compacted strands A compacted strand is a strand of regular round wires with a diameter that isreduced – compacted – by passing the strand through a die or roller, or by swa-ging it. Before being compacted the strand has a larger diameter, requiring theuse of thicker wires. Therefore, size for size, a compacted strand has a higherfill factor, and hence, a higher breaking force than a conventional strand of round wires.

Round wire strand

before compacting

Figure 18 Compacted strand

Compacted strand Round wire strand with

same diameter

Figure 17 Bench for releasing twist


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Especially in a multi-layer coiling system,

the outer strands of a rope with conventio-

nal strands will interface with those of a

neighbouring layer (figure 19) and suffer

high abrasion of the surface. The smooth

cylindrical surface of a compacted strand

offers greater resistance to abrasion and

crushing forces than a conventional strand.

Compacted ropes

Compacted ropes are made of either regular

strands of round wires or of compacted

strands. After the rope is closed, its diame-

ter is reduced – compacted – by passing the

rope through a die or a roller, or by swaging

it. Such ropes have a particularly smooth,

cylindrical surface and are designed andproduced to perform especially well under

the extreme radial pressures to which a

rope is subjected in a multi-layer coiling

system.

A compacted rope has a higher metallic cross-sectional area than a con-

ventional rope, resulting in a particularly high breaking force.

Figure 19 Interference of round wirestrands

Figure 20 Contact between compactedstrands


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Figure 21 Interference of ropes with outerstrands of round wires

Figure 22 Contact between ropes with com-pacted outer strands


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4. Easy rope selection

The most important decision to make when selecting a wire rope is:

„Which type do I choose – a rotation resistant or a non-rotation

resistant rope?“

This decision must be made very carefully. There is no room for error.

Short rope life, changes to the structure of the rope, ab-

rupt and unexpected failure of the rope, etc., could result

from an incorrect choice.

A rotation resistant rope must be selected when:

Lifting an unguided load on a single fall

Lifting an unguided load on several falls at a great

lifting height

see page 14 – „Selecting a rotation resistant DIEPA Special Wire Rope“

Rotation resistant ropes can work with or without a swivel.

A non-rotation resistant rope must be selected when

Lifting a guided load

Lifting an unguided load on several falls at a small lif-

ting height (e.g. Electric Overhead Travelling Cranes)

Lifting loads with right-handed and left-handed ropes

operating in pairs

see page 16 – „Selecting a non-rotation resistant DIEPA Special

Wire Rope“

Non-rotation resistant ropes must not be used with a swivel

13

Figure 24 Non-rotationresistant rope

Figure 23 Rotation resistant

rope


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4.1 Overview rotation resistant DIEPA Special Wire Ropes

non-compacted outer Strands

DIEPA D 1315 Ordinary lay

DIEPA D 1315 C Lang lay

compacted outer Strands – high breaking force

DIEPA D 1315 Z Ordinary lay

DIEPA D 1315 CZ Lang lay

DIEPA D 1315 ZP Ordinary laywith plastic insert

DIEPA D 1315 CZP Lang lay

with plastic insert

compacted outer Strands – very high breaking force

DIEPA B 60 Ordinary lay

DIEPA B 63 Ordinary lay

with plastic insert

DIEPA B 65 Lang lay

DIEPA B 68 Lang lay

with plastic insert

DIEPA D 915 CZ Lang lay

for tower cranes

Figure 25 DIEPA D 1315 C

Figure 26 DIEPA D 1315 CZ

Figure 27 DIEPA B 65

Figure 28 DIEPA D 915 CZ


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4.2 Selecting a rotation resistant DIEPA Special Wire Rope

All DIEPA Special Wire Ropes listed in page 14 can be used

universally and therefore can be employed in many different types of lif-

ting appliances requiring a rotation resistant rope. It simplifies selec-

ting the rope.

Examples: Hoisting rope for mobile cranes, telescopic cranes, crawlers, off-shore cranes, EOTs with a single fall, ship deck cranes, etc..

The final decision in selecting a rope from one from the above three groupsshall be made based on the required breaking force.

For single-layer coiling DIEPA D 1315

on the drum: DIEPA D 1315 Z

DIEPA B 60

For multi-layer coiling Every rotation resistant rope listed in

on the drum: page 14, whereby ropes in Lang layand/or with compacted outer

strands have a longer service life

For tower cranes: DIEPA D 915 CZ

DIEPA D 1315 CZ

DIEPA B 65

For specific application DIEPA Super 3

(if necessary contact us): DIEPA Super 4

DIEPA D 1200 Z

DIEPA D 1318 Z

DIEPA D 1318 CZ

DIEPA D 1318 ZP

DIEPA D 1318 CZP


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4.3 Overview non-rotation resistant DIEPA Special Wire Ropes

non-compacted outer strands

DIEPA P 825 Ordinary lay

with plastic insert

DIEPA S 321 Ordinary layin hot environments

compacted outer strands – high breaking force

DIEPA PZ 371 Ordinary lay

with plastic insert

DIEPA SKZ 8 Ordinary lay

DIEPA SKZ 8P Ordinary lay

with plastic insert

compacted outer strands – very high breaking force

DIEPA H 50 Ordinary lay

DIEPA H 53 Ordinary lay

with plastic insert

Every non-rotation resistant rope can also be manufactured in Lang lay.

Please contact us.

Figure 29 DIEPA P 825

Figure 30 DIEPA PZ 371

Figure 31 DIEPA H 50


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4.4 Selecting a non-rotation resistant DIEPA Special Wire Rope

All non-rotation resistant DIEPA Special Wire Ropes listed in page 16 can

be used universally and therefore can be employed in many different

types of lifting appliances which require a non-rotation resistant rope. It

simplifies selecting the rope.

The final decision in selection the rope in one of the above two groups shall

be made based on the required breaking force.

For single-layer coiling DIEPA P 825

on the drum: DIEPA S 321 (in hot environments)

DIEPA PZ 371

Examples: Indoor cranes, overhead DIEPA SKZ 8P

travel cranes, floating dredges,

mill’s work cranes, etc.

For multi-layer coiling : DIEPA PZ 371

DIEPA SKZ 8

DIEPA H 50

Example: Boom hoist rope DIEPA H 53

For specific applications DIEPA K 114

(if necessary contact us): DIEPA PZ 299

DIEPA S 417

DIEPA ZV 831

DIEPA SKZ 12


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5. Which direction of lay is appropriate – right or left handed ?

5.1 General recommendations for DIEPA Special Wire Ropes

During coiling onto the drum the rope is bent and receives a slight twist.

A drum whose grooves are pitched to the right will induce twist into a

left-handed lay rope. A right-handed lay rope will be untwisted by the

same drum grooving. When the rope exits the drum the added twistor untwist is not always fully released from the rope and as the number

of lifts increases a certain amount of twist remains and builds up in the

rope.

Non-rotation resistant DIEPA Special Wire Ropes are specially designed

and manufactured to resist the additional twist so that at the end there is

usually no, or very little, residual twist. The amount of residual twist, if any,

is so small that it has no adverse influence on the performance of the rope.

DIEPA Special Wire Ropes with a plastic insert will usually resist the

un-twist expected when the rope used is of the wrong direction of lay as

dictated by the direction of the pitch of the drum.

A small amount of twist can be sufficient to negatively influence the struc-

ture of a rotation resistant rope. Such ropes are more sensitive to any

type of twist because the direction of lay of the core is laid in the opposite

direction to that of the outer strands. For this reason it is not advisable to

use a rope with the same direction of lay as the pitch of the drum whensingle layer coiling.

Just as when the rope is wound onto the drum the rope also suffers

bending when threaded. If the direction of the pitch of the drum differs

from that in which the rope will be threaded, the direction of the pitch

of the drum determines the direction of lay of the rope. The reason is that

the drum usually has the greater influence on the rope. In certain

circumstances one selects a rope with a direction of lay better suited for

the threading rather than be suitable for the direction of the pitch of thedrum.


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Thus the following is imperative:

For a grooved drum having a right-handed pitch a left-handed lay rope is

recommended. Consequently, for a grooved drum having a left-handed pitch a

right-handed lay rope should be used, as stated in DIN 15 020, part 1, para 5.6

„Direction of lay“ and ISO 4308, Annex C.

Coiling on a single layer with a rotation resistant DIEPA Special WireRope:

The above recommendati-

on must be strictly adhe-

red to. Failure to do so

could result in permanent

changes to the structure of

the rope, such as the for-

mation of a birdcage, prot-

rusion of the core between

the outer strands, etc.

Coiling on a single layer with a non-rotation resistant DIEPA Special

Wire Rope:

DIEPA Special Wire Ropes with an internal plastic insert have an exceptionally

high degree of compactness and robustness. This special property of DIEPA Spe-cial Wire Ropes allows, on certain occasions, the use of a rope with the apparent

‘wrong’ direction of lay according to the general recommendations, such as when a

rope with the specified or proper direction of lay may not be readily available.

Multi-layer coiling:

The direction of coiling at the drum changes from layer to layer. A drum

with left-handed pitch grooves wraps the first layer of the rope with a pitch

to the left and the second layer with a pitch to the right. Therefore, it isgenerally not possible to select a rope with an optimum direction of lay.

Figure 32 Single layer coiling


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For rotation resistant and non-rotation resistant DIEPA Special Wire

Ropes it is recommended that the direction of lay be determined by the

pitch of the grooves in the drum (i.e. the first layer). The reason for this is

that the rope will fit better and form a better base and support for the over-

lying layers. Experience has shown that if a rope with the proper direction

of lay is not readily available, one can, on certain occasions, deviate from

this rule.

In some cases it is even advantageous to select a rope with a direction of

lay required by that layer of rope that is more often wound ‘onto’ and ‘off’

the drum.

Twin lifting appliances:

When both ends of the rope have to be affixed to

the drum, one of the ends will be „wrong“ according

to the recommendations relating to the optimaldirection of lay. Thus it makes no difference which

direction of lay applies to the rope.

In twin lifting appliances up to a limited lifting

height, it is possible to employ a non-rotation

resistant DIEPA Special Wire Rope. At higher

heights, the bottom block is likely to twist and the

rope falls tangle. This is sometime referred to as

‘cabling’.

Figure 33 Multi-layer coiling

Figure 34 Double drum lifting appliance


23/5221

Rotation resistant ropes cannot be used because of the possibility of struc-tural deformation due to both ends of the rope being coiled and fixed. Inthis case one must select a rope specifically designed for such applicationssuch as the DIEPA Super 4. This type of rope, however, has a lower resi-stance to bending than a rotation resistant rope. Please contact DIEPA when selecting a rope for this type of application.

5.2 Simple method for the selection of optimum direction of lay of the rope

One stands in front of the drum andpoints with the thumb towards the flan-ge of the drum in which the rope is affi-xed while the index finger points in thedirection that the rope exits the drum.

If done with the right hand then aright-handed rope is recommended.See figure 35. In this case the pitchof the drum grooving is left-handed.

If done with the left hand then aleft-handed rope is recommended.See figure 36. In this case the pitchof the grooving is right-handed.

5.3 Right- and left-handed ropes wor-king in pairs or multiples

When two or more ropes work simultaneous-ly, in pairs, in parallel, on a lifting applian-ce, both right- and left-handed ropes must beused. The build up of torque within eachrope is balanced out as they oppose eachother in opposite directions. This prevents

rope tangle (i.e. twisting or cabling of thefalls of rope).

Figure 35 Right hand = right-handed ropePitch of the drum’s grooves = left-handed

Figure 36 Left Hand = left-handed ropePitch of the drum’s grooves = right-handed

L R

L R

L R

L R

Figure 37 Ropes used in pairs

right-handed

rope

left-handed

rope


24/5222

The lifting height has no significance when DIEPA Special Wire Ropes are

used, because right- and left-handed ropes will have the same equalizing

amount of torque. One must make sure that the ropes used are of the same

type.

5.4 Coupling (joining) non-rotation resistant ropes

Only ropes of the same type and diameter may be coupled (joined) together,otherwise one rope will untwist (unlay) the other.

Only ropes of the same direction and type of lay may be coupled (joined)

together, otherwise the torque generated when the ropes are loaded will

result in serious untwisting/unlaying of both ropes where the ropes are

joined, leading to structural deformation (such as birdcaging) of the rope

and a significant loss in breaking force, etc.

Figure 38 Coupling (joining) non-rotation resistant ropes

right-handed

rope

left-handed

rope

right-handed

rope

left-handed

rope

right-handed

rope

left-handed

rope

left-handed

rope

right-handed

rope


25/5223

6. Single layer coiling

6.1 General

The principal demand placed on a rope by drive systems with single-layer

coiling, is resistance to reverse bending .

Additionally, and from a safety standpoint, it is preferable that the ropeexhibits deterioration on the outside of the rope as opposed to hidden inter-

nal deterioration that might otherwise go unnoticed.

That is why every DIEPA Special Wire Rope designed for this type of operati-

on has a high performance core, in some cases optimized with a plastic insert.

6.2 Test results

DIEPA Special Wire Ropes are designed and manufactured to outperformconventional ropes. Although they cost more to produce, they will prove

to be more cost effective overall when taking everything into account,

such as downtime and cost of replacement.

Figure 39 Service life of the rope up to the discard criteria

DIEPA P 825 8x19F+SE 6x36+SE


26/5224

The longer the length of rope required or the more complex is the application,

the better DIEPA Special Wire Ropes compare. The diagram (figure 39)

clearly demonstrates their improved performance characteristics.

6.3 The advantages of DIEPA Special Wire Ropes

When used in single-layer coiling, DIEPA Special Wire Ropes offer the fol-

lowing advantages:

High resistance to bending

Smooth surface to protect sheaves and drum

Less elongation – every DIEPA Special Wire Rope is pre-stretched

Higher structural stability to counter the effects of the larger fleet

angles

Special lubricant

Extended ‘safe’ service life resulting from high performance core con-

taining a large number of single wires


27/5225

7. Multi-layer coiling

7.1 General

The different coiling systems are not discussed here in any detail, regardless

of whether they have regular grooves (figure 40) or Lebus grooves (figure 41).

Experience shows that a rope will achieve a longer service life on a multi-layer

coiling system using a drum fitted with Lebus system.

Of special significance for optimum coiling, leading to an increased service

life, is the relationship between the diameter of the rope and the width

(pitch) of the grooves in the drum. The width of the groove is obtained by

measuring the distance occupied by ten grooves and dividing the result by

ten. (Ten grooves are measured in order to reduce or eliminate the possi-bility of an erroneous measurement of one width.)

Figure 42 Determining the pitch of the grooves

pitch

distance 10 grooves

Figure 40Drum with regular(helical) grooving

Figure 41Drum withLebus-grooving


28/5226

7.2 How many outer strands ?

The more outer strands there are in the

rope the thinner each of them will be.

Figure 43 shows a rope with 18 outer

strands having smaller strands than one

with 15. Thinner strands of the same

strand construction contain thinner indi-

vidual wires, which makes the rope more

flexible and provide a higher resistance to

reverse bending. At first glance, these

characteristics appear to be advantage-

ous as a hoisting rope is bent by sheavesmany times during its life. A flexible rope

is also more easily attached and detached

An optimum situation occurs when the actual rope diameter is approxima-

tely 1% smaller than the width of the grooves, thus promoting compact

(close) coiling. The diameter of the rope should never be larger than the

width of the grooves, otherwise the rope would not sit correctly in the groo-

ves, resulting in irregularities of the coil, especially along the flange of the

drum where the rope climbs from the first to the second layer.

When selecting a rope, attention should be paid to ensuring that the actual dia-

meter of the rope is within strict limits and will remain so when the rope is

under load. The diameter of the rope should reduce in size very little as the ser-

vice life progresses and it is clear that a rope should be selected that is capable

of resisting the intense crushing forces asso-

ciated with multi-layer coiling and avoid

any tendency to become oval-shaped in cross

section. DIEPA Special Wire Ropes with a

specially constructed core and having com-pacted outer strands are most advantageous

under these extreme operating conditions.

Figure 43 Comparison – 15 outer strands to18 outer strands

18outer

strands

15

outer

strands


29/5227

from a wedge socket and coils with fewer problems onto and off a winch drum.

Thicker outer strands of the same design, however, allow for the use of

thicker individual wires that will significantly increase the ropes’ resi-

stance to abrasion, wear, mechanical damage, corrosion and the crushing

forces at the drum inherent in a multi-layer coiling system.

Rope selection is often a compromise. Only through the optimum tuning of

each and all of the different design characteristics of the crane is it possi-

ble to employ a rotation resistant rope in a multi-layer coiling system that

will result in improvements to service life.

For this reason DIEPA manufactures rotation resistant ropes with 15 outer

strands (e.g. DIEPA D 1315 CZ) that possess all of the above mentioned

characteristics. The specially designed core provides for very high flexibili-

ty and resistance to bending fatigue. An indicator of the high flexibility is

the large number of individual wires used (e.g. DIEPA D 1315 CZ has 328

single wires).

When subject to multi-layer coiling, rotation resistant ropes with 15 outer

strands, for example, have fewer points of contact between adjacent coils

in the same layer and at the cross over points on the drum than a rope with

18 outer strands; but testing and field experience have repeatedly demon-

strated that this is more than compensated for by the use of ropes contai-ning the thicker wires.

7.3 Test results

When ropes of different design are compared with one another on a multi-

layer coiling system it has been shown that by changing from ‘ordinary’ to

‘Lang lay and using ‘compacted’ instead of ‘regular’ strands of round wires,

the service life can be significantly improved.


30/5228

The Lang lay arrangement results in a more flexible rope, facilitating rope

installation and fitting of the rope termination. In addition, coiling at the

drum is optimised.

Compacted strands, having a smoother surface than conventional strands

of round wires, offer a greater resistance to abrasion and crushing forces.

By combining these two characteristics, additional increases in service lifecan be achieved. Indeed, test results clearly show that DIEPA D 1315 CZ

with its Lang lay, compacted strands, is truly a high performance rotation

resistant „special rope“.

Figure 44 Test results in a multi-layer coiling system

Ordinary lay

outer strandsnot compacted

DIEPA D 1315

Lang lay

outer strandsnot compacted

DIEPA D 1315 C

Ordinary lay

outer strandscompacted

DIEPA D 1315 Z

Lang lay

outer strandscompacted

DIEPA D 1315 CZ


31/52


32/5230

Figure 45 Measuring the diameter of the grooves

8. Grooves – their diameter and their radius

The grooves in the drum and in the sheaves are required to provide ade-

quate support for the rope during operation. Therefore, during their calcu-

lation or control the following must be taken into consideration:

DIEPA Special Wire Ropes in new condition have a real diameter 3 to 4 %

larger than the nominal diameter, unless otherwise agreed. In a groove

having a radius size 0.53 d (where d = nominal rope diameter), one can

expect the longest service life of a rope. If the radius of the groove is smal-

ler, or even narrower then the diameter of the rope, then one can expect

such changes to the rope’s structure as birdcaging, corkscrew, etc. If the

radius of the groove is larger, then insufficient support is provided. A groo-

ve radius of 0.55 d can result in a 20 % reduction in the service life of the

rope.

Sheaves of synthetic material must have a groove radius of a least 0.55 d.

Sheaves of synthetic material work similar to brakes and can block the

rope from sliding into the sheave, especially when the rope runs at an

angle. Sheaves of synthetic material are used primarily in cranes with a

multi-layer coiling. However, the reduction in resistance to reverse ben-

ding caused by the larger size of the groove will be of less significance as

the service life of the rope is largely affected by the more intense wear and

tear experienced in the multi-layer coiling at the drum.

The shape and size of the grooves in the drum and sheaves aresubject to wear and their exact size can be determined by the use of

gauges.


33/5231

9. The rope’s swivel

Basically, all rotation resistant DIEPA Special Wire

Ropes can be employed with or without a swivel. On cer-

tain cranes or for certain applications (lifts of great

heights, long periods of continuous work) the use of a

swivel (figure 46) is recommended. Rotation resistant

ropes could develop a twist (due to elongation or by theguiding system) during operation. If the ends of a rotati-

on resistant rope are permanently fixed without being

connected to a swivel, the rope cannot release this twist.

On reeving systems with multiple falls this twist can

lead to a turning of the bottom hook block or result in the

formation of a ‘birdcage’ in the rope.

Attention: Only rotation resistant ropes may be used in conjunction with a

swivel. Semi-rotation resistant and non-rotation resistant ropes untwistunder load when used with a swivel, resulting in a permanent change to

the structure of the rope. Furthermore, the breaking force of the rope may

be substantially reduced (figure 47).

Figure 46Rope swivel

Figure 47 Remaining breaking forceafter test to destruction whenusing a swivel

DIEPA D 1315 CZrotation resistant

6-strandnon-rotation resistant

normal rope

19 x 7semi-rotation resistant

normal rope


34/5232

10. Order data

10.1 Use of a specified DIEPA Special Wire Rope

Number and length of the ropes (5 x 200 m, etc.)

Type of rope (DIEPA D 1315 CZ, DIEPA 321, etc.)

Nominal diameter of the rope (20 mm, etc.) Direction of lay (right- or left-handed)

Nominal tensile strength – grade – of the wires (1770 N/mm2, etc.)

Surface finish of the wires (bright, galvanized, etc.)

Lubrication (with or without lubricant)

Type of rope end or termination (plain, fused, solid thimble, etc.)

10.2 Use of a DIEPA Special Wire Rope as an alternative to other specified rope

If a DIEPA Special Wire Rope is being selected for the first time and is to

be used as an alternative to an existing rope with a view to improving rope

performance, no exact designation of the rope is needed (e.g. DIEPA S 321,

etc.). Instead the following information is necessary:

Type of rope used until now and its designation (e.g. DIN 3064

6 x 36 + SE, DIN EN 12385, etc.)

Double check if according to page 13, a rotation resistant rope or a non-rotation resistant rope is required.

State whether the system is single- or multi-layer coiling

State the required minimum breaking force

With this information we will be able to recommend a DIEPA Special Wire

Rope or offer you one from our warehouse.


35/5233

11. Handling, inspection and in-service maintenance

11.1 Inspection on delivery

The condition of the rope and/or its packing should be inspected on the deli-

very truck or when down loaded. Any mechanical damage to the rope or

damage caused during transportation can then be recorded on the delivery

document.

11.2 Transporting the rope

Damage to the rope can result from incorrect or careless hand-

ling techniques. Contact with sharp objects or the edges of the

arms of a forklift invariably result in damage to the rope (figures 48

and 49).

A better means of transport is through

the use of a bar through the middle hole

or axle of the reel (figure 50). The reel can

then be lifted with a forklift or directly

with a sling attached to a crane (figure

51).

Figure 48 + Figure 49 Transportation damage caused by forklifts

Figure 50 Proper method – with the help of a bar


36/5234

If the arms of the forklift are long enough it is

possible to lift the reel directly with the forklift by

placing the arms underneath both flanges of the

reel (figure 52).

Textile slings can be used effectively when lifting

coils (figure 53).

11.3 Storage

Ropes should be stored in dry, dust free and, if possible, slightlyheated rooms and protected against any potential mechanical damage.

Any wet packing material must be removed. The identification markings of

the rope should not be misplaced. They assist the management in quality

control.

Storage in the open for short periods of time is possible under certain con-

ditions. Direct contact with the ground should be prevented, e.g. by using

a pallet. Covering with a plastic foil requires continuous control and regu-

lar inspections of the foil for ruptures, which could allow water to penetra-te or lead to a build up of condensation.

Figure 51 Proper method – with the helpof a sling

Figure 53 Proper method – with thehelp of a textile slingFigure 52 Proper method – with the help of long arms


37/5235

It is possible for a film of rust to develop on the rope surface after a

rope has been stored for a long period of time in a hot or humid area.

The rust will normally be limited to the outer layer, and more often

than not, will only be an indication of a red pigmentation of the

lubricant. Scratching the surface of the rope with a fingernail will

show if the wires have been affected. If the surface of the wires

are not scarred by the rust, the rope can than be used withoutrestrictions. This optical feature can easily be eliminated by the

use of regular oils and grease or commercially available rope care pro-

ducts.

11.4 Cutting a DIEPA Special Wire Rope

When cutting a DIEPA Special Wire Rope, the following points must be

adhered to in order to prevent damage or changes to the structure of the

rope:

All non-rotation resistant DIEPA Special Wire Ropes are specially pre-

formed. Thus, for ropes with smaller diameter it is sufficient to wrap with

tape the area where the cut will take place; for rope of larger diameter this

should be done as shown in figure 54.

Rotation resistant DIEPA Special Wire Ropes must be prepared for cut-

ting as shown in figure 54.

Figure 54 Serving the area where a DIEPA Special Wire Rope will be cut.

Point of cut

Length of serving =5 x nominal diameter of rope


38/5236

12. Installation and operation

12.1 Inspection of the drive system

It is recommend that the various components of the drive system are ins-

pected before installing the rope. Special attention must be given to the

condition of the sheaves and the drum, which should be within normally

accepted limits. (See chapter 8. Grooves – their diameter and their radius)

12.2 Unwinding from a reel or coil

Every length of DIEPA Special Wire Rope is laid out prior to being shipped

(figure 17). This ensures that they are supplied completely free of twist and

do not need to be laid out again prior to installation. The following steps

must be followed on site:

a) Unwinding from a reel

To prevent the formation of kinks the supply reel should be set up asshown in figure 55. The rope shall never be pulled from a reel which is

laying on its side (figure 56).

Wooden boards should be used on one or both sides of the reel flange(s)

(figure 57) for use as a brake(s) (figure 58) to prevent the rope from

running loose and forming loops on the reel, which could become

damaged (figure 59) or displaced over the flange of the reel.

Figure 55 Reel supported by stands Figure 56 Wrong uncoiling from reel


39/52


40/5238

12.3 Installing the rope

When the rope is unwound from a reel it is advantageous to maintain the

direction of bending as it leaves the reel, thus avoiding any reverse bending

of the rope (figure 63 and 64).

There are two ways to change a rope: either the old rope is removed and

the new rope is fed on by hand; or, the old one is used as a lead rope to pull

the new one through the reeving system.

In the latter case it is necessary to ensure that there is a good connection

between both ropes.

Figure 61 Uncoiling on the floor Figure 62 Wrong uncoiling of wraps

Figure 63 Wrong direction of bending Figure 64 Right direction of bending

DrumReel

Drum

Reel


41/52

The connection should not be rigid, otherwise any twist present in the old

rope will be transferred to the new one. Connecting both ropes with a

Chinese finger (figure 65) is, therefore, preferable. When using a Chinese

finger ensure that it is firmly secured and unable to slide. Remove any

restrictions, such as rope guards, that might affect the smooth passage of

the rope through the system before installing the new rope.

For lead ropes use only rotation resistant ropes (semi-rotation resistant

ropes) or ropes with the same direction of lay as the rope being installed.

If welded attachments (figure 66) are fitted to facilitate installation, they

should be attached to a thinner strand or rope of sufficient strength to with-stand the forces that will be induced during installation. The distance bet-

ween the two ropes should be long enough in order for the connecting strand

or rope to take up any twist that might be present.

39

Figure 65 Chinese finger

Figure 66 Welded link ‘becket’


42/5240

12.4 Installing the rope under load in a multi-layer coiling system

The installation of a rope on a multiple-layer coiling system must be car-

ried out very carefully. The high flexibility of DIEPA Special Wire Ropes,

due to their large number of wires, can only be advantageous. Particular

attention must be paid to ensure that the rope sits properly in the bottom

of the grooves immediately after leaving the flange or barrel of the drum.

This area presents a special problem in that it is where the rope switchesfrom the second to the third layer. If the rope does not sit properly it will

suffer an over proportional amount of fatigue in this area.

The rope should be installed under as much load (back-tension) as

possible, the required amount being approximately 2% of the minimum

breaking force of the rope. If the site conditions do not permit this kind of

value then the supply reel or mounting reel should receive as much

braking as physically possible (figure 57).

It is also advantageous to thread the rope through the bottom hook block

as many times as possible so that the rope can be driven out as far as the

last couple of coils. Afterwards, several lifts should be carried out alterna-

tively with loads and without loads attached to the bottom hook block. This

will help the rope adjust to the reeving system, to the bends in the guiding

system and especially to the spooling arrangement at the drum.


43/5241

13. Service

13.1 Re-lubrication

DIEPA Special Wire Ropes are originally delivered lubricated with a special

corrosion preventing lubricant that is highly adhesive and has good film coa-

ting characteristics. The lubricant does not only cover the outer surface of

the rope, it also fills every space within the rope. This simplifies the servi-cing of DIEPA Special Wire Rope.

Under certain conditions, blank spots may appear on the surface

of the rope. In this case, the rope needs to be lubricated again.

A timely re-lubrication can have positive effects on the service life of the

rope.

Re-lubrication can be done with commercially available rope lubricants

or with regular oils and greases.

Lubricants used in re-lubrication barely

penetrate the interior of the rope (figure 67

and 68); therefore, excessive application

should be avoided. Excessive amounts of

lubricant remaining on the surface of the rope

make detection of wire breaks more difficult.

A fallacy is widely held that galvanized ropesare not required to be re-lubricated or, even

more bizarre, that they are manufactured

without a lubricant. This is totally untrue.

Where metal slides on metal (the wires slide

against each other each time the rope bends

over a sheave) a lubricant is necessary to redu-

ce friction. Nobody would contemplate the

idea of galvanizing the pistons of the engine of

a car and then drive away without any engineoil. The same applies to steel wire ropes.

Figure 67 + Figure 68Re-lubricating with extreme amounts does not solvethe corrosion problems in the interior of the rope


44/5242

13.2 Shortening the rope

Sometimes, very long lengths of rope in a single layer coiling

system suffer must of the wear and tear in areas associated with rope

that most often bends over the guiding sheaves and/or at the drum.

By shortening the rope at the rope anchorage (not at the end in the

drum) in a timely manner, the affected areas will be re-positioned,

thus promoting a longer service life for the rope.

In a multi-layer coiling system, the rope

wears out mainly at the so-called crossover

zones (‘S’ shaped form assumed by the rope).

To offset this wear it is sometimes possible to

shorten the rope at the drum end. It is

recommended that a length equivalent to

approximately one third of the circumference

of the drum is cut off. This will have the effect

of displacing the concentrated areas of wear at

the cross over zones, significantly improving

the service life of the rope. Depending on the

rope length, it may be possible to repeat this

action a second time. A longer rope life is the

reward for this action.

Figure 69 Wear area –crossover zones

Wear area


45/5243

14. Inspection

14.1 When is the rope to be inspected ?

Wire ropes do wear out and must be inspected at regular intervals by

qualified (competent) personnel. The intervals between inspections should

be scheduled so as to allow for timely identification of deterioration and

damage. A daily visual inspection is recommended. Be aware that brokenwires will not necessarily increase at a rate proportional to the time in

service.

For example: a rope that shows five broken wires after 100 days in service

may have many more than ten broken wires after 200 days in service.

14.2 What needs to be inspected ?

When ropes operate in single layer coiling systems, special attention

should be given to those portions of the rope that are bent the most by the

sheaves and/or the drum. Another critical area of the rope is that portionthat is bent in the sheaves and/or drum when the load is picked-up.

Figure 70 Development of wire breaks

Time in service

W i r e b r e a k s


46/5244

On multi-layer coiling systems the areas of rope that require greater

attention are those that come into contact with the flanges of the drum

and the cross-over areas (figure 69) where the top layer crosses over the

underlying layer.

The inspection procedures should be conducted in accordance with

DIN 15 020, part 2, or ISO 4309 : 2004.

14.3 The most important discard criteria

Following is a condensed description of the most important discard

criteria

Wire breaks

This is the most commonly used discard criteria.

DIN 15 020, part 2, and ISO 4309 : 2004 list the number of breaks in

the load bearing wires in outer strands needed to determine the discard

criteria. This information is also included in our catalogue for each dif-

ferent type of rope. According to DIN EN 12385-2, the ropes description

is to be taken from the works certificate, which also includes other

information relating to the rope.

The number of visible broken wires are to be counted in that area

of the rope where most of them are present. The length of the

area has been determined to be 6d (= 6 x nominal rope diameter) and

30d.The rope must be discarded whenever the number of broken wires coun-

ted, in 6d or 30d, is equal to, or greater than, those listed in the stan-

dards. A qualified person can determine whether the rope can remain

in operation until the end of the shift.

Many tests conducted by the company DIEPA, as well as decades of

practical experience, show that the number of wire breaks listed in the

standard for some types of ropes are very conservative, giving away pre-

cious service life. The principal mode of deterioration for a rope in a

multi-layer system occurs through abrasion of its surface. The core of


47/5245

the rope does not have „the chance“ to wear out. Still, according to the

standards, the rope must be discarded.

Broken strand

When a strand breaks, the rope must be immediately dis-

carded.

Reduction of the rope’s diameter (interior wear)When the real diameter of the rope is reduced by 15 % from the

nominal diameter as result of internal wear, then the rope has

reached discard criteria. DIEPA Special Wire Ropes have a very high

metallic cross-sectional area and, therefore, their diameter is very

stable. Thus, this criteria is not very relevant to DIEPA Special Wire

Ropes.

Abrasion (outer wear)

The rope has reached discard criteria when its diameter has reduced by

10 % from the nominal diameter due to abrasion of the surface of the

rope. Just as in the case with the above criteria „reduction of the rope’s

diameter“, the discard criteria for abrasion seldom needs to be applied

to DIEPA Special Wire Ropes.

Deformation of the rope

DIEPA Special Wire Ropes are structurally very stable; hence, the

criteria described below seldom needs to be applied:

Corkscrew

When the amount of deformation „x“ as shown in the picture is, or

exceeds, one third of the nominal diameter of the rope, the ropemust be discarded.

X

Figure 71 Corkscrew


48/5246

Bird-caging

The rope must be discarded whenever a bird-cage develops.

Looped wires

Extreme deformation of the rope in the form of looped wires is a

reason for discard.

Flattening of the circumference, mechanical damage, and kinks

Flattening of the circumference and/or mechanical damage are

permanent deformations caused by crushing and depending upon

the extent, may be a reason for discard.

Figure 72 Bird-caging

Figure 73 Looped wires

Figure 74 Flattening


49/5247

Kinks will occur when a rope forming a loop is pulled

tight.

Bend

Bends are angular deformations of the rope caused by external

influence.

Every inspection of the rope should be documented. An example of this

record is included in page 48.

Figure 75 Kink

Figure 76 Bend


50/5248

15. Enclosure

Simple example of an Inspection Record

Type of crane / Crane number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of rope: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Length of rope [m]: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rope nominal-Ø [mm]: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actual-Ø of the rope in new condition [mm]: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of lay / Direction of lay: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nominal tensile strength [N/mm2]: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of wire surface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date rope was installed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating hours / Number of lifts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Max. allowable number of broken wires in 6 x d in 30 x d

. . . . . . . . . . . . . . . . . . . . . . . .

Location on Number of broken wire: Ropes actual-Ø Additional observations

the rope: 6 x d 30 x d

Discard criteria met: Date / Signature

YES / NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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AUGUS T RICH. DIE TZ & S

OHN

Drah t- und Han fseil werk

GmbH & Co. KG

D-96 456 Neus tad t bei Cob

urg

R

DIEPA

Drahtseilwerk Dietz

GmbH & Co. KG

Damaschkestraße 30D-96465 Neustadt bei Coburg

Postfach 1167D-96456 Neustadt bei Coburg

Phone +49 (0) 9568 924-0Fax +49 (0) 9568 924-101

E-mail [email protected]

Rev. 02/07

Documents

DIEPA Answers