®
TECHNICALDOCUMENTATION
2R. Verreet, Technical Documentation, 8/1997
INTRODUCTION AND TABLE OF CONTENTS
This manual about the technical properties of Casar Special Wire Ropes is intended
● to help the user of the ropes to find the best rope for his specific application,
● to help the designer to find the data he needs to build a safe, economic andgood machine, and
● to help the distributor of the ropes to give his customers even better assistance.
If you have a question which is not answered by this brochure, please do not hesitateto contact us. We will do our best to help you.
Introduction and table of contents ....................................................................... 2Computer aided rope design .............................................................................. 3What is...? .......................................................................................................... 4What is a compacted strand? ............................................................................. 5What is parallel lay rope? ................................................................................... 6What is a rotation-resistant rope? ....................................................................... 7What is the effect of the plastic layer? ................................................................ 8From wire to wire rope ........................................................................................ 9Breaking load ................................................................................................... 10Diagrams: Breaking load .................................................................................. 11Fill factors, weight factors, spin factors ............................................................. 12Bending fatigue................................................................................................. 13Diagrams: Bending fatigue ............................................................................... 14Which rope for which application? .................................................................... 16Rotation ............................................................................................................ 18Diagrams: Rotation ........................................................................................... 19Efficiency .......................................................................................................... 20Diagrams: Efficiency ......................................................................................... 21Left hand or right hand lay rope? ...................................................................... 22Elasticity and elongation ................................................................................... 23Diagrams: Elasticity and elongation .................................................................. 24Elongation curves ............................................................................................. 26Diagrams: General ........................................................................................... 28The drum .......................................................................................................... 30Conversion factors............................................................................................ 31
3R. Verreet, Technical Documentation, 8/1997
COMPUTER AIDED ROPE DESIGN
A steel wire rope is a complex machine part and consists ofa great number of wires and strands of different dimensions.It is subjected to a wide spectrum of mechanical stresses.
Based on a wide range of empirical data and test results,Casar Special Wire Ropes are adapted to the technicalrequirements and optimized with the help of a computer.
4R. Verreet, Technical Documentation, 8/1997
WHAT IS …?
LEFT HAND LAY
RIGHT HAND LAY
LANGS LAY
COMPACTED STRANDS
WIREWIRE
STRAND
ROPE
ORDINARY LAY
CONVENTIONAL STRANDS
5R. Verreet, Technical Documentation, 8/1997
WHAT IS A COMPACTED STRAND?
Some of the Casar Special Wire Ropesare made out of conventional strands,
some are made out of compacted strands.
In order to produce a compacted strand, a conventional strand made out of roundwires is drawn through a compacting tool. During this procedure, the wires areplastically deformed, the strand diameter is reduced and the surface is madesmooth. The contact conditions between the individual wires and the strand-to-strand contacts improve.
Ropes made out of compacted strands have a higher breaking load, a greaterflexibility and better rope- to- sheave contact conditions than comparable ropesmade out of conventional strands. Because of the larger outer wires and thesmaller exposed area they are more resistant to abrasion and corrosion.
compacted strandconventional strand
6R. Verreet, Technical Documentation, 8/1997
WHAT IS A PARALLEL LAY ROPE?
In a cross (non-parallel) lay strand all wires have differentlay lengths, and in a cross (non-parallel) lay rope allstrands have different lay lengths. The high stress con-centration at the crossover points leads to an earlyinternal failure.
parallel laystress distribution
cross (non-parallel) laystress concentration
In a parallel lay strand all wires have the same lay length,and in a parallel lay rope all strands have the same laylength. The linear contact leads to an optimal stressdistribution.
7R. Verreet, Technical Documentation, 8/1997
WHAT IS A ROTATION-RESISTANT ROPE?
In a conventional rope,an external load createsa moment which triesto untwist the rope andto rotate the load.
A rotation- resistantCasar Special Wire Ropehas a steel core which isan independent rope,closed in the opposite di-rection to the outerstrands. Under load, thecore tries to twist the ropein the one direction, theouter strands try to twist itin the opposite direction.
The geometrical designof a rotation-resistantCasar Special Wire Ropeis such that the momentsin the core and the outerstrands compensate eachother over a wide load-spectrum, so that evenwith great lifting heightsno rope twist occurs.
8R. Verreet, Technical Documentation, 8/1997
keeps out waterand abrasive elements
lowers the noise levelwhilst the rope working
preventsmetal-to-metal contact
acts as a cushionbetween the layers
prevents internalwire breaks
WHAT IS THE EFFECT OF THE PLASTIC LAYER?
The plastic layer ...
stabilizes the ropeduring the installation
seals in lubricant absorbs dynamic energy
prevents interstrand nicking stabilizes the rope structure
... solves rope problems !
greatly lowers,or even removes,
the incidence of birdcaging
9R. Verreet, Technical Documentation, 8/1997
FROM WIRE TO WIRE ROPE
entrance control
wire stock
qualitycontrol
qualitycontrol
stranding
spooling
compacting
spooling
qualitycontrol
qualitycontrol
stranding
spooling
compacting
spooling
qualitycontrol
qualitycontrol
stranding
spooling
compacting
spooling
qualitycontrol
qualitycontrol
stranding
spooling
compacting
spooling
qualitycontrol
qualitycontrol
stranding
spooling
compacting
spooling
closingof rope core
qualitycontrol
plastic extrusion
closingof rope
finalquality control
spooling
finishing
408 000
37 800
37 800
37 800
1 050
1 050
1 050
1 050
Length in m
for 1000 mof wire rope
using Casar Powerplast as an example
10R. Verreet, Technical Documentation, 8/1997
BREAKING LOAD
How do Casar Special Wire Ropesachieve their high breaking loads?
Conventional steel wire rope constructions can meet a requirementfor higher breaking loads only by increasing the tensile strength ofthe individual wires.
Casar Special Wire Ropes are already designed for the highestbreaking loads by a combination of various technologies:
● A large number of strands increases the metallic area of the rope.
● Parallel lay leads to a more compact rope construction.
● A plastic layer reduces internal stresses.
● Compacting of the strands increases the fill factorof the rope elements.
● The tensile strength of the wires is chosen accordingto the requirements.
The high breaking loads of Casar Special WireRopes offer the user the following advantages:
● Design advantages by reducing the sheave and drum diametersand the size of motor and gearbox.
● Longer service life due to lower specific stress on the rope.
● Increased safety.
11R. Verreet, Technical Documentation, 8/1997
fill
fact
or
[ –
]
0.70
0.60
0.55
0.45
0.40
6 x
36 IW
RC
CA
SA
R S
trat
op
last
CA
SA
R T
urb
op
last
CA
SA
R S
up
erp
last
CA
SA
R S
trat
olif
t
CA
SA
R T
urb
olif
t
CA
SA
R S
up
erlif
t0.50
0.65
0.75
8 x
19 F
C
120
100
80
60
40
20brea
king
load
on
swiv
el [%
of m
inim
um b
reak
ing
load
]
6-st
rand
rope
18 x
7
CA
SA
R S
tarl
ift
CA
SA
R P
ow
erlif
t
CA
SA
R R
amm
bo
lift
CA
SA
R P
ow
erp
last
CA
SA
R Q
uad
rolif
t
CA
SA
R E
uro
lift
8-st
rand
rope
1
red
uct
ion
of
bre
akin
g lo
ad
[ %
]
2
4
6
8
10
10 20 30 40
2P
P P
2P
D/d [ – ]
18 x 76-strand rope8-strand rope
L
L
H
P
P
P
Pdyn = k • P
PdynPLHME
k = 1 + 1 + ( ) 2 • H • M • EP • L
======
dynamic loadstatic loadrope lengthheight; slackmetallic area ropemodulus of elasticity rope
220
180
160
120
100
80
600 100 200 300 400 500 600 700
temperature [ °C ]
ten
sile
str
eng
th [
kp
/mm
2 ]
140
200
200 400 600 800 1000 1200
fill
fact
or
[ –
]
0.75
0.70
0.60
0.55
0.45
0.40
36 x
7
18 x
7
CA
SA
R P
ow
erlif
t
CA
SA
R S
tarl
ift
CA
SA
R Q
uad
rolif
t
CA
SA
R P
ow
erp
last
0.50
0.65
CA
SA
R
Ram
mb
olif
t
CA
SA
R E
uro
lift
CA
SA
R
Mu
ltili
ft
CA
SA
R M
ult
ilift
F
90%
to 1
10%
90%
to 1
10%
90%
to 1
10%
90%
to 1
10%
90%
to 1
10%
90%
to 1
10%
60%
to 8
0%
40%
to 6
0%
40%
to 6
0%
[°F]
[°C]
DIAGRAMS: BREAKING LOAD
BREAKING LOAD 2: Comparison of the fill factors of rotation-resistant ropes. The fill factors of Casar Special Wire Ropes arein general considerably higher than the fill factors of conventionalropes.
BREAKING LOAD 4: Breaking loads of steel wire ropes whentested on sheaves, depending on the ratio sheave diameter/ropediameter. The factors of safety cover the reduction of the breakingloads.
BREAKING LOAD 1: Comparison of the fill factors of nonrotation-resistant ropes. The fill factors of Casar Special WireRopes are considerably higher than the fill factors of conventionalropes.
BREAKING LOAD 3: Breaking loads of steel wire ropes testedwith a swivel. The breaking loads of 6-strand and 8-strand ropesdecrease considerably, whereas the rotation-resistant CasarSpecial Wire Ropes achieve values in the range of their minimumbreaking loads.
BREAKING LOAD 6: Formula to determine the dynamic loadcaused by a falling weight. Dynamic loads are not covered by thesafety factor and should be avoided at all costs.
BREAKING LOAD 5: Tensile strength of steel wires as a functionof temperature (exposure time 10 min., cooled in air). Tempera-tures up to 300°C (~600°F) reduce residual stresses, highertemperatures reduce the tensile strength drastically.
12R. Verreet, Technical Documentation, 8/1997
FILL, WEIGHT AND SPIN FACTORS
rota
tion
resi
stan
tco
mpa
cted
str
ands
plas
tic la
yer
aver
age
fill f
acto
rav
erag
e w
eigh
t fac
tor
aver
age
spin
fact
or*
* rope diameters up to 40 mm, 1770 N/mm2
0,653
0,748
0,710
0,608
0,661
0,688
0,660
0,730
0,755
0,650
0,755
0,660
0,655
0,627
0,663
0,566
0,477
0,684
0,90
0,86
0,91
0,92
0,87
0,86
0,89
0,85
0,85
0,89
0,85
0,90
0,90
0,90
0,85
0,90
0,94
0,86
0,77
0,79
0,84
0,87
0,86
0,84
0,86
0,84
0,84
0,86
0,84
0,88
0,90
0,82
0,83
0,86
0,85
0,84
13R. Verreet, Technical Documentation, 8/1997
Why do Casar Special Wire Ropesattain the longest service lives?
Conventional rope designs often do not meet the requirements ofmodern reeving systems. Shorter service lives result. Casar SpecialWire Ropes offer various design advantages which lead to longerservice lives.
● A larger number of strands increases the number of contact areaswithin the rope and on sheaves and drums.
● Parallel lay prevents the crossover of strands and improvesthe contact conditions within the rope.
● A plastic layer reduces the danger of structural damageand internal wire breaks.
● Compaction of the strands improves the contact conditionswithin the rope and on sheaves and drums.
● A large number of strands with smooth surfaces increasesthe flexibility of the rope.
The long service lives of Casar Special Wire Ropesoffer the user the following practical advantages:
● Reduced downtime due to fewer rope changes.
● Reduced costs for rope changes.
● Minimised rope costs.
● Optimum price/performance ratio.
BENDING FATIGUE
14R. Verreet, Technical Documentation, 8/1997
D/d = 20load proportional tominimum breaking load
on steel sheave on plastic sheave
300 000
200 000
100 000
0
CA
SA
RS
tarl
ift
CA
SA
R P
ow
erp
last
CA
SA
R S
tarl
ift
CA
SA
R P
ow
erp
last
18 x
7
A B C
A B
no
min
al r
op
e d
iam
eter
+ 6
%
groove diameter
gro
ove
dia
met
er =
C
max.
180 190 200 210 220 230 240
break
discard
CASAR Stratolift
tensile strength [ kp/mm2 ]
nu
mb
er o
f cy
cles
[
– ]
nu
mb
er o
f cy
cles
[
– ]
un
til d
isca
rd
300 000
200 000
100 000
0
D/d = 20load proportional tominimum breaking load
CA
SA
R T
urb
olif
t
CA
SA
R S
trat
olif
t
CA
SA
R T
urb
op
last
CA
SA
R S
trat
op
last
6 x
36 F
C
6 x
36 IW
RC
150 000
100 000
50 000
0
D/d = 20load proportional to minimum breaking load
CA
SA
RS
tarl
ift
18 x
7
CA
SA
R
Qu
adro
lift
CA
SA
RP
ow
erlif
t
CA
SA
RP
ow
erp
last
CA
SA
RE
uro
lift
400 000
100 000
200 000
0
300 000
CA
SA
R S
trat
olif
t (u
ng
alva
niz
ed)
CA
SA
R S
trat
olif
t (
gal
van
ized
)
optimum
nu
mb
er o
f cy
cles
[
– ]
un
til d
isca
rd a
nd
bre
ak
18 x
7
nu
mb
er o
f cy
cles
[
– ]
un
til d
isca
rd a
nd
bre
akn
um
ber
of
cycl
es
[ –
] u
nti
l dis
card
an
d b
reak
nu
mb
er o
f cy
cles
[
– ]
un
til d
isca
rd a
nd
bre
ak
DIAGRAMS: BENDING FATIGUE
BENDING FATIGUE 1: Comparison of numbers of cycles untildiscard and break for non rotation-resistant ropes. Under thesame test conditions, Casar Special Wire Ropes achieve muchhigher numbers of cycles than conventional ropes.
BENDING FATIGUE 2: Comparison of numbers of cycles forrotation-resistant ropes. Under the same test conditions, CasarSpecial Wire Ropes achieve much higher numbers of cycles thanconventional ropes.
BENDING FATIGUE 3: Comparison of numbers of cycles untildiscard and break for ungalvanized and galvanized ropes, inboth cases lubricated. Under the same test conditions, thegalvanized rope achieves higher numbers of cycles.
BENDING FATIGUE 4: Comparison of numbers of cycles untildiscard and break on steel sheaves and on plastic sheaves. Onplastic sheaves, the fatigue life is higher, but the residual life (%)between discard and break is lower.
BENDING FATIGUE 5: Comparison of numbers of cycles untildiscard and break for ropes of different tensile strength underconstant load.
BENDING FATIGUE 6: Rope life as a function of the groovediameter of the sheaves. The optimal groove diameter is nominalrope diameter plus 6% (B). For larger groove diameters, theservice life decreases steadily (C), for smaller groove diametersit decreases rapidly (A).
15R. Verreet, Technical Documentation, 8/1997
30
25
20
15
10
5
00 30.000 60.000 90.000 120.000
nu
mb
ers
of
bro
ken
wir
es 3
0 x
d
[–
]
tensile strength 180 kp/mm2
load 100 %
tensile strength 200 kp/mm2
load 111 %
number of cycles [ – ]
D/d = 20load proportional tominimum breaking load
5.000 10.000 20.000 50.000 100.000 200.000 500.000
100
50
20
10
5
2
1
Clog
. nu
mb
er o
f b
roke
n w
ires
[–
]
log. number of cycles [ – ]
BA
200
150
100
50
0
tension [ N / mm2 ]
nu
mb
er o
f cy
cles
[%
]
100 200 300 400 500
lubricated + relubricated
unlubricated
lubricated
100
~ 100%
breakdiscard
number of cycles [ % ]
actu
al b
reak
ing
load
[
% ]
00
rope diameter [ mm ]
nu
mb
er o
f cy
cles
[
–]
0
200 000
400 000
600 000
800 000
1 000 000
1 200 000
1 400 000
1 600 000
1 800 000
2 000 000
200 240 280 320 360 400400 440 480 520 560 6000
100 000
200 000
300 000
400 000
500 000
600 000
700 000
800 000
900 000
1 000 000
10 12 14 16 18 20 22 24 26 28 30sheave diameter [ mm ]
nu
mb
er o
f cy
cles
[
–]
DIAGRAMS: BENDING FATIGUE
BENDING FATIGUE 9: Breaking load of running steel wire ropesdepending on the number of cycles. Normally, the actual break-ing load increases during the first half of the service life. When thediscard criterion is reached, the rope can still achieve its mini-mum breaking load.
BENDING FATIGUE 10: Number of cycles until discard forunlubricated, lubricated (= 100%) and relubricated steel wireropes. Relubrication during service life considerably, increases,lack of lubrication reduces the service life drastically.
BENDING FATIGUE 8: Number of broken wires depending onthe number of cycles. Rope A: Casar Stratolift. Rope C: (compe-tition) fatigues too early. Rope B: (test rope) is dangerous,because the discard criterion is reached shortly after the first wireis broken.
BENDING FATIGUE 7: Number of visible broken wires depend-ing on the number of cycles in a bending fatigue test. The numberof wire ropes breaks increases steadily according to a power-function.
BENDING FATIGUE 11: Number of cycles until discard (lowercurve) and break (upper curve) depending on the nominal ropediameter. For every combination of sheave diameter and line pullthere is an optimum rope diameter.
BENDING FATIGUE 12: Number of cycles until discard (lowercurve) and break (upper curve) depending on the sheave dia-meter. The service life of a wire rope increases with increasingsheave diameter.
16R. Verreet, Technical Documentation, 8/1997
CASAR DRAHTSEIL-WERK SAAR GMBH
Casarstraße 1 • 66459 KirkelPostfach 187 • 66454 Kirkel Telefon: (0 68 41) 80 91- 0
Teletex: 68 41 972 CasarTelefax: (0 68 41) 86 94
®
Tower crane
Tower crane
Tower crane
Tower crane
Tower crane
Mobile crane
Mobile crane
Mobile crane
Deck crane
Deck crane
Offshore crane
Offshore crane
Grabbing crane
Grabbing crane
Grabbing crane
Bulk handling rope
Bulk handling rope
Elevator
Container crane
Container crane
Floating crane
Floating crane
Electrical hoist
Ladle crane
Floating grab
Floating grab
Shovel
Shovel
Shovel
Dragline
Dragline
Dragline
Cable crane
Cable crane
Scraper
Scraper
Hoist rope
Boom hoist rope
Trolley rope
Installation rope
Pendant rope
Hoist rope
Boom hoist rope
Pendant rope
Hoist rope
Boom hoist rope
Hoist rope
Boom hoist rope
Holding- and closing rope
Pendant crane
Boom hoist rope
Hoist-, closing-, grab rope
Trolley- and compensation rope
Hoist rope
Hoist rope
Boom hoist rope
Hoist rope
Boom hoist rope
Hoist rope
Hoist rope
Holding- and closing rope
Pendant rope
Hoist rope
Crowd line
Boom line
Hoist rope
Drag rope
Boom hoist rope
Hoist rope
Trolley rope
Traction and haulback rope
Boom hoist rope
WHICH ROPE FOR WHICH APPLICATION?
17R. Verreet, Technical Documentation, 8/1997
18R. Verreet, Technical Documentation, 8/1997
ROTATION
Why are Casar Special Wire Ropesso rotation-resistant?
Conventional wire ropes try to untwist under load. Stability can oftenonly be achieved by overloading the core of the ropes.
Rotation-resistant Casar Special Wire Ropes are stabilized againstrotation by various technologies.
● A wire rope core, closed in the opposite direction of the outerstrands, creates a stabilizing moment.
● A compacted core increases the rotational stability.
● A favourable ratio of the metallic areas leads to stability withoutoverloading the core.
The high rotational stability of Casar Special WireRopes offers the user the following advantages:
● No block rotation even with great lifting heights.
● Long service life because of an untwisted rope structure.
● Great safety in crane operations.
19R. Verreet, Technical Documentation, 8/1997
torq
ue
fact
or
[–
]
0.12
0.08
0.04
0
-0.04
-0.080
CASAR Stratoplast
spec. rope twist [ deg mm/m ]500 500 10001000
op
enin
g m
om
ent
clo
sin
g m
om
entto
rqu
e fa
cto
r [
–]
untwisted closed
CASAR Powerlift
0.16
0.14
0.12
0.10
0.08
0.06
0.040 20 40 60 80 100 120 140
load [ kn ]
torq
ue
fact
or
[–
]
untwisted
-40°/m
-20°/m-10°/m
10°/m
20°/m
40°/m
0°/m
CASAR Stratoplastø 19/180
twisted
load [ kn ]
torq
ue
fact
or
[–
]
0 20 40 60 80 100 120 140
0.10
0.08
0.06
0.04
0.02
0
0.02
0.04
0.06
0.08
0.10
twisted
untwisted
10°/m
20°/m
40°/m
-10°/m
-20°/m
-40°/m
0 10 20 30 40 50 60 70
40 000
30 000
20 000
10 000
0
load [ % of minimum breaking load ]
spec
. ro
pe
twis
t [
deg
mm
/ m
]
8 x 36 IWRC
Stratoplast
Superplast
Quadrolift
Powerlift
Starlift
Powerplast
Eurolift
D
e
d
h
k Dedh
=====
torque factorrope spacing at blockrope spacing at topnominal rope diameterlength of fall
k < D • e4,8 • h • d
h >> D
CASAR Starliftø19/180
0.06
0.04
0.02
0
0.10
0.08
CA
SA
R S
up
erp
last
CA
SA
R T
urb
op
last
CA
SA
R S
up
erlif
t r
CA
SA
R T
urb
olif
t r
CA
SA
R S
trat
olif
t r
CA
SA
R S
trat
op
last
CA
SA
R S
tarl
ift
CA
SA
R A
lph
alif
t r
CA
SA
R Q
uad
rolif
t
CA
SA
R M
ult
ilift
F
CA
SA
R M
ult
ilift
0.12
DIAGRAMS: ROTATION
ROTATION 1: Torque factors for different Casar Special WireRopes. The torque factor is defined as the moment of the ropeunder a given load, divided by the load and the rope diameter.
ROTATION 2: Torque factors of Casar Stratoplast and CasarPowerlift against the rope twist (forcible twist). The high torque ofCasar Powerlift under forcible twist guarantees a high resistanceagainst rotation of the load.
ROTATION 3: Torque factor of Casar Stratoplast depending onthe load for different levels of rotation. For higher loads, theforcible twist does not influence the torque factor very much.
ROTATION 4: Torque factor of Casar Starlift as a function of theload for different levels of rotation. The forcible twist influences thetorque factor of the rope considerably. Any rotation of the loadcreates a high moment in the opposite direction, stabilizing thesystem.
ROTATION 5: Specific rope twist as a function of the load. Whentested on a swivel, 6-strand and 8-strand ropes untwisted undervery low loads. Casar Powerlift, Casar Starlift and Casar Power-plast only started untwisting at high loads.
ROTATION 6: Formula to determine the stability of a block. If theconditions of the formula are met, the block will be stable (staticsituation). The formula can also be used to determine the mini-mum rope spacing or the greatest stable length of fall.
20R. Verreet, Technical Documentation, 8/1997
EFFICIENCY
Why are Casar Special Wire Ropesso flexible?
● Modern machines demand flexible wire ropes.
Casar Special Wire Ropes are designed to provide maximum flex-ibility. The high flexibility is achieved by a combination of differenttechnologies.
● A larger number of wires and strands allows easier bending.
● Intensive lubrication in all stages of production reducesthe internal friction.
● The smooth surfaces of the compacted strands preventindentations and allow easier relative motion of the elements.
● Cold-resistant lubricants and cold-elastic plastics guaranteegood flexibility at low temperatures.
The high flexibility of Casar Special Wire Ropesoffers the user the following advantages:
● Improved running properties due to lower friction losses.
● Reduction of motor capacity.
● Easy handling during installation.
● Excellent spooling on the drum.
21R. Verreet, Technical Documentation, 8/1997
DIAGRAMS: EFFICIENCY
EFFICIENCY 1: Efficiencies of rotation-resistant steel wire ropeson sheaves with roller bearings for low loads. Casar Special WireRopes show higher efficiencies than conventional steel wireropes. D/d = 20
EFFICIENCY 2: Efficiencies of rotation-resistant steel wire ropeson sheaves with roller bearings for low loads. Most rotation-resistant wire ropes show lower efficiencies than non rotation-resistant wire ropes.
EFFICIENCY 3: Efficiencies of rotation-resistant steel wire ropeson sheaves with roller bearings for high loads. Casar Special WireRopes show higher efficiencies than conventional steel wireropes. D/d = 20
EFFICIENCY 4: Efficiency of a steel wire rope on sheaves withroller bearings against load for different sheave diameters. Theefficiency decreases considerably with decreasing sheave di-ameter.
EFFICIENCY 5: Efficiencies of steel wire ropes on sheaves withroller bearings against load for different temperatures. The influ-ence of low temperatures is minimized by the use of speciallubricants and plastics. D/d = 20
EFFICIENCY 6: Efficiencies of galvanized and ungalvanizedsteel wire ropes on sheaves with roller bearings for low loads.Galvanized ropes show lower efficiencies. D/d = 20
0 0.5 1.0 1.5 2.0
CASAR Stratoplast r
CASAR Stratolift r
CASAR Turbolift r
6 x 37 + Fe
load [ % of minimum breaking load ]
effi
cien
cy [
% ]
100
700 0.5 1.0 1.5 2.0
80
90
CASAR Starlift ungalvanized
30 x d20 x d
10 x d
load [ % of minimum breaking load ]
effi
cien
cy [
% ]
100.0
98.50 10 20 30 40
99.0
99.5CASAR Powerlift
18 x 7
CASAR Starlift
load [ % of minimum breaking load ]
effi
cien
cy [
% ]
100
98
96
94
92
900 0.5 1.0 1.5 2.0
CASAR Powerlift -40°C (-40°F)
CASAR Powerplast 20°C (70°F)
CASAR Powerplast -40°C (-40°F)
load [ % of minimum breaking load ]
effi
cien
cy [
% ]
100
700 0.5 1.0 1.5 2.0
80
90
CASAR Starlift galvanized
CASAR Starlift ungalvanized
load [ % of minimum breaking load ]
effi
cien
cy [
% ]
100
98
96
94
92
90
100
98
96
94
92
900 0.5 1.0 1.5 2.0
CASAR Powerplast
CASAR Quadrolift
CASAR Powerlift
load [ % of minimum breaking load ]
effi
cien
cy [
% ]
CASAR EuroliftCASAR Starlift
CASAR Starlift 20°C (70°F)
22R. Verreet, Technical Documentation, 8/1997
LEFT HAND OR RIGHT HAND LAY ROPE?
The choice of the correct direction of lay is essential for the proper functioning of a reevingsystem. A wrong direction of lay leads to torque build-up, to spooling problems and to structuraldamage to the rope.
One layer spoolingFor drums with one layer, the direction of lay has to be chosen according to the followingrule:
right hand drum - left hand lay ropeleft hand drum - right hand lay rope
Multiple layer spoolingWith multiple layer spooling, the direction of the spooling changes from layer to layer. So thedirection of lay of the rope would also have to be changed from layer to layer. Here the directionof lay should be chosen for the layer which is working the most.
right hand layer - left hand lay ropeleft hand layer - right hand lay rope
Multiple-part reevingIn a multiple part reeving system very often the influence of the fleet angles between the sheavesis greater than the influence of the drum. In this case, the direction of lay of the rope should bechosen depending on the direction of the reeving.
right hand reeving - left hand lay ropeleft hand reeving - right hand lay rope
And here is how you determine the direction of the winding of the drum or reeving system:Place yourself at the fix point ( ⊗) of the rope on the drum (at the reeving system) and follow theturns of the rope with your finger.
☞
☞ ☞
☞ ⊗⊗⊗⊗
⊗⊗⊗⊗
right hand drum - left hand lay rope left hand drum - right hand lay rope
If you move your finger counterclockwise, thedrum (reeving system) is left hand, and needsa right hand lay rope.
If you move your finger clockwise, the drum(reeving system) is right hand, and needs aleft hand lay rope.
☞ ☞
☞☞
23R. Verreet, Technical Documentation, 8/1997
ELASTICITY AND ELONGATION
What gives Casar Special Wire Ropesthe best stress-strain behaviour?
Conventional steel wire ropes often have insufficient modulus ofelasticity and too high permanent elongations.
Casar Special Wire Ropes are optimized with regard to their stress-strain properties by various features:
● The full steel construction provides a high modulus of elasticity.
● The compact rope structure guarantees minimal permanentelongations in the working range.
● The homogeneous load distribution on all rope elements createshigh elongations at break.
● The plastic layer absorbs dynamic energy.
The balanced stress-strain propertiesof Casar Special Wire Ropes
offer the user the following advantages:
● High rigidity of suspended structures.
● Less retentioning for suspended structures and positioningmachines.
● High safety against dynamic failure.
24R. Verreet, Technical Documentation, 8/1997
1.3
1.2
1.1
1.0
0.9
0.8
CA
SA
R S
trat
op
last
CA
SA
R T
urb
op
last
CA
SA
R S
up
erlif
t
CA
SA
R T
urb
olif
t
CA
SA
R S
trat
olif
t
CA
SA
R S
up
erp
last
CA
SA
R T
ech
no
lift
CA
SA
R A
lph
alif
t
mo
du
lus
of
elas
tici
ty
[ x
105
N/m
m2
]
3.0
4.5
4.0
3.5
CA
SA
R T
urb
olif
t
1.2
1.0
0.8
0.6
0.4
0.2 0 20 40 60 80 100
previous load [ % of minimum breaking load ]
8 x 19 FE
CASAR Stratolift
0 10 20 30 40 50
0.75
0.50
0.25
0
CASAR Stratolift
8 x 19 FE
3.0
4.5
4.0
3.5
CA
SA
RS
tarl
ift
CA
SA
RP
ow
erlif
t
CA
SA
R P
ow
erp
last
CA
SA
R R
amm
bo
lift
CA
SA
RQ
uad
rolif
t
4.72
elo
ng
atio
n a
t b
reak
[%
]
CA
SA
R E
uro
lift
1.3
1.2
1.1
1.0
0.9
0.8
CA
SA
R S
tarl
ift
CA
SA
R
Po
wer
lift
CA
SA
RP
ow
erp
last
CA
SA
R
Eu
rolif
t
CA
SA
R Q
uad
rolif
t
CA
SA
RR
amm
bo
lift
CA
SA
R
CA
SA
R T
urb
op
last
CA
SA
R
CA
SA
R
CA
SA
R
CA
SA
R A
lph
alif
t
Tec
hn
olif
t
Str
ato
pla
st
Su
per
pla
st
Su
per
lift
CA
SA
R S
trat
olif
t
4.65
mo
du
lus
of
elas
tici
ty
[ x
105
N/m
m2
]
elo
ng
atio
n a
t b
reak
[%
]
previous load [ % of minimum breaking load ]
per
man
ent
elo
ng
atio
n [
% ]
mo
du
lus
of
elas
tici
ty
[ x
105
N/m
m2
]
DIAGRAMS: ELASTICITY AND ELONGATION
ELASTICITY 1: Moduli of elasticity for non rotation-resistantCasar Special Wire Ropes. The modulus of elasticity of a steelwire rope is about half the modulus of plain steel. (Average valuesfrom a great number of tests)
ELASTICITY 2: Moduli of elasticity for rotation-resistant CasarSpecial Wire Ropes. The modulus of elasticity of a steel wire ropeis about half the modulus of plain steel. (Average values from agreat number of tests)
ELASTICITY 4: Elongation at break for rotation-resistant CasarSpecial Wire Ropes. The elongations at break range from 3.1 to4.7 percent. (Average values from a great number of tests)
ELASTICITY 6: Permanent elongation depending on the previ-ous load for Casar Stratolift and a conventional rope fibre core.The permanent elongation increases with increasing load. CasarStratolift shows a much lower elongation.
ELASTICITY 3: Elongation at break for non rotation-resistantCasar Special Wire Ropes. The elongations at break range from3.2 to 4.7 percent. (Average values from a great number of tests)
ELASTICITY 5: Modulus of elasticity depending on the previousload for Casar Stratolift and a conventional rope with fibre core.The modulus increases with increasing load. Casar Stratoliftshows a much higher modulus.
25R. Verreet, Technical Documentation, 8/1997
DIAGRAMS: ELASTICITY AND ELONGATION
ELASTICITY 7: Load-elongation diagram (Casar Powerplast).During the test, the computer determines the increase of themodulus of elasticity, the total and permanent elongation, theenergy absorption, the elongation at break, the diameter changeand other required data.
ELASTICITY 11: Specific energy of Casar Special Wire Ropes. ELASTICITY 12: Comparison of the stress-elongation- curves ofsteel, rope wire, strand and wire rope.
ELASTICITY 9: Rope diameter of a new rope depending on theload in a break test. During service, the rope diameter is of causereduced by additional factors, e. g., abrasion.
ELASTICITY 10: Absorbed energy at 80% of the minimumbreaking load for Casar Special Wire Ropes. Langs lay ropeshave a higher energy absorption than regular lay ropes, ropeswith an internal plastic layer have a higher energy absorption thanfull steel ropes.
ELASTICITY 8: Permanent elongation after unloading depend-ing on the time. The effect prestressing disappears to a greatextend with increasing time. Here 6-strand rope as an example.
elongation [ % ]0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
500
450
400
350
300
250
200
150
100
50
00
1.00
0.75
0.50
0.25
01 min 5 min 30 min 60 min 24 h
load 80 % of minimum breaking load
load 40 % of minimum breaking load
load 20 % of minimum breaking load
elo
ng
atio
n a
fter
un
load
ing
[
% ]
time after unloading
0
50
100
150
200
undrawnsteel
rope wire strand wire rope
elongation [ % ]
str
ess
[ k
p/m
m2 ]
load [ % of minimum breaking load ]0 20 40 60 80
0
2
4
6
8
10
12
spec
ific
en
erg
y [
Nm
/( m
• m
m2
) ]
A
B
C
A: energy input
B: energy output
C: energy converted into permanent deformation and heat
CASAR Dragplast
CASAR Stratoplast l
rop
e d
iam
eter
[ %
of
actu
al r
op
e d
iam
eter
]
load [ % of minimum breaking load ]0 10 20 30 40 50 60
100
99
98
97
Superlift
Starlift
StratoliftTurboplast rStratoplast lTurbolift r
Stratoplast r
Powerlift
6 WKP
Eurolift
load
[ k
N ]
abso
rbed
sp
ecif
ic e
ner
gy
[ N
m/(
m m
m2 )
]at
80%
of
min
imu
m b
reak
ing
load
0
2
4
6
8
10
12
CA
SA
R Q
uad
rolif
t
CA
SA
R P
ow
erlif
t
CA
SA
R S
tarl
ift
CA
SA
R T
ech
no
lift
CA
SA
R S
trat
olif
t
CA
SA
R T
urb
op
last
Kr
CA
SA
R T
urb
olif
t K
r/L
CA
SA
R D
rag
pla
st L
CA
SA
R T
urb
op
last
L
CA
SA
R R
amm
bo
lift
CA
SA
R P
ow
erp
last
CA
SA
R E
uro
lift
CA
SA
R S
trat
op
last
26R. Verreet, Technical Documentation, 8/1997
ELONGATION CURVES
The knowledge of the elongation properties of asteel wire rope can be of great importance to theequipment manufacturer or user. Therefore wepresent the load-elongation diagrams of the mostimportant Casar Special Wire Ropes, here.
The upper curves show the total elongationsdepending on the load. The lower curves showthe permanent elongations remaining in the ropeafter unloading depending on the previous load.
The diagrams show the average values of agreat number of cyclical loading and unloadingtests performed with ropes of different diametersand tensile strength. The diagrams are inde-pendent of the rope diameter. The influence ofthe tensile strength is negligible.
Please note: setting in the end fitting can causeadditional elongation.
R = Regular Lay; L = Langs Lay
0 20 40 60 80
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
elo
ng
atio
n [
% ]
CASAR Powerlift
CASAR Starlift
CASAR Powerlift
CASAR Starlift
load [ % of minimum breaking load ]
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0800 20 40 60
CASAR Stratolift R
CASAR Turbolift R
CASARStratolift R
CASAR Turbolift R
elo
ng
atio
n [
% ]
load [ % of minimum breaking load ]
elongation curves 1
elongation curves 3elongation curves 2
0 20 40 60 80
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
CASAR Powerplast
CASAR Eurolift
CASAR Powerplast
CASAR Eurolift
elo
ng
atio
n [
% ]
load [ % of minimum breaking load ]
27R. Verreet, Technical Documentation, 8/1997
ELONGATION CURVES
elongation curves 5
elongation curves 7elongation curves 6
0 20 40 60 80
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
CASAR Turboplast R/L
CASAR Stratoplast R/L
CASAR Turboplast L
CASAR Turboplast R
CASAR Stratoplast R/L
0 20 40 60 80
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
CASAR Superplast R
CASAR Superplast L
CASAR Superplast R
CASAR Superplast L
elo
ng
atio
n [
% ]
load [ % of minimum breaking load ]
0 20 40 60 80
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
elo
ng
atio
n [
% ]
load [ % of minimum breaking load ]
0 20 40 60 80
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
CASAR Superlift R
CASAR Superlift R
elo
ng
atio
n [
% ]
load [ % of minimum breaking load ]
CASAR Quadrolift
CASAR Quadrolift
elo
ng
atio
n [
% ]
load [ % of minimum breaking load ]
elongation curves 4
CASAR Technolift
CASAR Douzeplast
CASAR Technolift
CASAR Douzeplast
28R. Verreet, Technical Documentation, 8/1997
24
22
20
18
16
14
12
106 7 8 9 10 11 12
ang
le o
f la
y [
deg
]
lay length factor [ – ]
161210
8
6
100
80
60
40
20
03 6 9 12 15 18
number of outer wires [ – ]
per
cen
tag
e o
f m
etal
lic a
rea
[ %
]
outer layer
inner wires
1.0
0.9
0.8
0.7
0.6
0.50 10 20 30 40
fill
fact
or
[ –
]
number of wires [ – ]
π
1615
10
5
03 6 9 12 15 18
number of outer wires [ – ]
spec
ific
su
rfac
e [
mm
2 / m
m •
mm
]
total surface of all elements
outer surface
surface of steel bar
650
600
550
500
450
400160 180 200 220 240 260
tensile strength [ kp/mm 2 ]
Bri
nel
l har
dn
ess
HB
30
[ k
p/m
m2
]
1/3/3 1/4/4 1/5/5 1/6/6 1/7/7
1/8/8 1/9/9 1/10/10 1/11/11 1/12/12
1/13/13 1/14/14 1/15/15 1/16/16 1/17/17
DIAGRAMS: GENERAL
GENERAL 1: Brinell hardness HB 30 of the wire surface depend-ing on the tensile strength of the wire.
GENERAL 2: Surface of a seale strand, divided by the stranddiameter and the strand length, depending on the number ofouter wires. The outer (exposed) surface is only slightly largerthan the surface of a steel bar, the total surface is much larger.
GENERAL 4: Percentage of the total metallic area for the outerand inner wires of a seale strand depending on the number of thecore increases steadily, and the percentage of the outer wiresdecreases steadily with increasing number of outer wires.
GENERAL 5: Seale strand 1+N+N, for N=3 to N=16. Withincreasing N, the diameter of the center wire is increasing whilethe diameter of the outer wires is decreasing.
GENERAL 3: Fill factor of a seale strand depending on the totalnumber of wires. The fill factor increases steadily with the numberof wires.
GENERAL 6: Angle of lay depending on the lay length factor for6-, 10-, 12-, and 16-strand ropes.
29R. Verreet, Technical Documentation, 8/1997
DIAGRAMS: GENERAL
GENERAL 7: Reduction of the metallic area by abrasion. Re-maining metallic area of the outer wire depending on the ratio ofthe width of the abrasion ellipse s vs. the wire diameter d.
GENERAL 8: Reduction of the metallic area by abrasion. Re-maining metallic area of the outer wire depending on the ratio ofthe remaining height of the wire h vs. the wire diameter d.
GENERAL 9: Quality control for rope wire according to DIN 2078.Number of required bends in a bending test depending on thewire diameter. R = radius of bend. Tensile strength 1770 N/mm2.
GENERAL 10: Quality control for rope wire according to DIN2078. Number of required torsions in a torsion test depending onthe wire diameter. Tensile strength 1770 N/mm2.
GENERAL 11: Quality control for rope wire according to DIN2078. Required weight of the zinc coating per surface unit andthickness of the coating for drawn galvanized and heavy galva-nized wires depending on the wire diameter.
0
100
90
80
70
60
50
40
30
20
10
rem
ain
ing
met
allic
are
a [
% ]
ratio h/d [ – ]0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
dh
0
100
90
80
70
60
50
40
30
20
10
ratio s/d [ – ]0 0.2 0.4 0.6 0.8 1.0 0.8 0.6 0.4 0.2 0
d
s
b
bDaDidL
Da
=====
reel wideflange diameterbarrel diameterrope diameterrope length
< L < ( Da2 - Di2 ) b
4 d2
. .
..( Da2 - Di2 ) b
4 d2
. .
.
Di
π π 2
18
16
14
12
10
8
6
4
2
00 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
wire diameter [ mm ]
nu
mb
er o
f re
qu
ired
ben
ds
[ –
]
R =
1.7
5
R =
2.5
R =
3.7
5
R =
5
R =
7.5
R =
10
R =
15
wire diameter [ mm ]
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
30
20
10
0
nu
mb
er o
f re
qu
ired
to
rsio
ns
[ –
]
0 1.0 2.0 3.0 4.0
0.035
0.030
0.025
0.020
0.015
0.01
0.005
260
240
220
200
180
160
140
120
100
80
60
40
20
0
heavy galvanized
drawn galvanized
wire diameter[ mm ]
wei
gh
t o
f th
e zi
nc
coat
ing
per
su
rfac
e u
nit
[
g/m
2 ]
thik
nes
s o
fzi
nc
coat
ing
[
mm
]
rem
ain
ing
met
allic
are
a [
% ]
GENERAL 12: Formula to calculate the rope length on a reel.
30R. Verreet, Technical Documentation, 8/1997
THE DRUM
The drum is an important element of a hoisting system. We distinguish betweengrooved and ungrooved drums, and between single and multiple layer drums. Inorder to guarantee good spooling on the drum, the following rules should beconsidered:
Single layer drum● The direction of layer of the rope has to be chosen opposite to the direction
of winding on the drum.
Multiple layer spooling● Wedges should be provided to help the rope to climb into the second
and third layer.
● The first layers must be installed under tension.
● The direction of lay of the rope should be chosen according to the rules(see page 22).
In the second and higher layers, adjacent wraps are no longer separated by thewalls on the drum, so that the wraps can form indentations. In order to avoidpremature rope destruction, the following rules should be observed in selecting thecorrect type of rope:
● In Langs lay rope, indentations between outer wires do not occur. So Langs layrope should be preferred to regular lay rope.
● In rope with compacted outer strands, indentations between outer wires do notoccur. So rope with compacted outer strands should be preferred to conven-tional rope (see page 31).
● Eight strand rope should be preferred to six strand rope (see page 31),because it has a more closely circular cross- section.
Under the pressure of the overwinding layers, the rope of the lower layers is subjectto high radial forces which might cause structural damage.
● Ropes with an internal plastic layer show excellent results because of their highstructural stability.
31R. Verreet, Technical Documentation, 8/1997
1 m = 1000 mm = 3,28 ft = 39,37 inch
1 kN = 101,97 kp = 0,10197 t metric-f = 224,8 lbs-f
1 N/mm2 = 0,10197 kp/mm2 = 145,04 p.s.i. = 10 bar
1 mm2 = 0,00155 sq.inch
1 metric t = 1000 kg = 1,102 short t = 0,9842 long t= 2204,6 lbs
1 kg/m = 0,672 lbs/ft.
CONVERSION FACTORS
Conventional outer strands:
Between conventional outer strands of adja-cent rope wraps, there is danger of mutualindentations of the outer wires. The indenta-tions can lead to severe external damage tothe ropes.
Compacted outer strands:
The outer wires of compacted outer strandscannot form indentations. This is why ropeswith compacted outer strands are so suitablefor multiple layer spooling.
Eight strand and ten strand ropes:
Eight strand and ten strand ropes do not formdeep indentations, because their cross- sec-tion is very round. This is why eight strandropes and ten strand ropes are so suitable formultiple layer spooling.
Six strand ropes:
Six strand ropes can form deep indentations,because they have deep valleys between theouter strands. The indentations can lead tosevere external damage to the ropes.
© Copyright 1991/1997 CASAR Drahtseilwerk Saar GmbH, content subject to alterations.Technical author: Roland Verreet, WRTA Wire Rope Technology Aachen.
Realisation, Layout and Typesetting: PR Werbeagentur u. Verlag GmbH, Aachen.
Length
Force
Tensile Strength
Cross Section
Weight
Weight per Length Unit
®
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CASAR DRAHTSEILWERK SAAR GMBHCasarstraße 1 • D-66 459 KirkelPostfach 187 • D-66 454 Kirkel
Phone ++ 49-68 41/80 91-0Fax ++ 49-68 41/86 94
Sales Dept.Phone ++ 49-68 41/80 91-39/44Fax ++ 49-68 41/80 91-29
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