Continuing Education: Technology

Steel Wire Ropes for Traction Elevators: Part Two

by Dr.-Ing. Wolfgang Scheunemann, Dr.-Ing. Wolfram Vogel and Dipl.-Ing. Thomas Barthel

able calculations in terms of such as

Learning Objectives traction capability. Today, the eight-
After reading this article, you strand rope with a natural fiber core
should: has made great inroads in the interna-
◆ Have realized that the simplest tional arena and can be considered
elevator rope is obtained by lay- the most frequently used elevator
ing six strands. rope today (Figures 16 and 17).
◆ Understand that the eight-strand In order to prolong the service life
rope with a natural fiber core of a rope, the contact pressure be-
can be considered the most fre- tween the rope and groove must be
quently used elevator rope today. restricted. This results in a minimum
◆ Have learned that depending on number of ropes and rope diameters.
the intended application, two The calculated contact pressure is
different core types are used in dependent upon the rope surface
elevator ropes: fiber cores made and independent of the breaking
of natural or synthetic fibers, and forces and, consequently, the rope
steel-wire cores. cross-section area. TRA 003[6] and
◆ Have realized that the most EN 81-1/1986[7] take into account a
commonly used suspension rope simplified form of pressure calcula-
diameters are 6-24 mm. tion. This is no longer in evidence in
◆ Have understood that the devel- EN 81-1/1998 and is intended to be
opment of small rope diameters addressed by a special calculation of
is being driven by the trend the rope safety factor according to
toward machine-room-less (MRL) Annex N.
elevators with small, fast-run- However, the factor of contact
ning drive machines and the move pressure should always be borne in
to reduce drive torque levels.
Value: 1 contact hour
mind. High minimum safety factors
◆ Have realized that a distinction (ratio of minimum breaking force to (0.1 CEU)
is made between detachable and operating load) of 12 (U.S. and Japan
permanent rope terminations. 10) require only a minimal metallic This article is part of ELEVATOR WORLD’s
cross-section in the rope. But precisely Continuing Education program. Elevator-industry
because of the adverse effects of personnel required to obtain continuing-education
Ropes and Rope Constructions
credits can receive one hour of credit by reading
The simplest elevator rope is pressure reducing the service life,
the article and completing the assessment exami-
obtained by laying six strands – for the rope diameter as a factor must
nation questions found on page 153.
example, using Warrington construc- be taken into account. This is why
For this article and more continuing-education
tion around a fiber core (Figure 15). the eight-strand rope with fiber core, opportunities, visit www.elevatorbooks.com
Until the 1950s, this was practically which adequately complies with the
the only kind of rope used. Since then, calculated requirements (relatively NATIONAL ASSOCIATION
OF ELEVATOR CONTRACTORS
®

Approved by NAEC for CET

the demands imposed on traction- low breaking force coupled with rel- CERTIFIED
ELEVATOR TECHNICIAN

EDUCATION PROGRAM

drive elevators in terms of speed, shaft atively high rope diameter) is in such
height, traffic flow, and expectations widespread use. Approved by NAEC for CAT
of ride quality have increased Further considerations to improve
tremendously. The changing ratio of the performance of ropes are:
Approved by NAESAI for QEI
elevator car weight to payload has ◆ Less permanent elongation (fewer
given rise, in some cases, to unfavor- rope shortening processes)
Continued

July 2009 | ELEVATOR WORLD | 63

 Continuing Education: Technology Continued

manufacturers wrongly assume tween the rope and sheave due to

that this type of rope is prohibited the unavoidable effect of slip. A high
in their countries simply because level of flexural stress calls for the
the only elevator standard appli- use of a large number of thin wires
cable in that country is one for in the outer strand layers. Under ex-
ropes with fiber cores. When using treme wear conditions, thick outer
ropes with a steel-wire core, it wires would be preferable; in other
should be made clear that the en- words, the rope and strand construc-
hanced benefits of longer service tion must be selected depending on
life and reduced rope elongation the predominant source of stress. If
can be considered an alternative exposed to high levels of flexural
for an installation being designed stress, preference would be given to
with a standard 8-X-19 fiber-core a Warrington rather than a Seale rope.
construction, and it can be oper- Added criteria when it comes to select-
Figure 9: Overview of full-steel elevator rope constructions ated using the same number of ing the right rope, however, include
ropes of the same thickness as a special country- and manufacturer-
◆ Less elastic elongation (car sus-
steel-wire core. However, if the specific factors and traditions.
pension, ride comfort and floor
increased minimum breaking force Rope selection is additionally in-
leveling accuracy)
of these ropes is used as a reason to fluenced by the restrictions in terms
◆ Less diameter reduction in opera-
reduce the number of ropes or the of diameter for certain types of rope
tion (service life)
rope diameter, a small part of their construction. Due to the extremely thin
◆ Longer rope service life due the
benefit will be “consumed.” filler wires, 8 X 25 filler construction
use of thinner wires in greater
Rotation-resistant rope construc- ropes (a rope with an extremely good
quantities
tions (Figure 10) should not be used fatigue bending life) are not produced
◆ The rope should be more rounded
in traction-drive elevators, as these in diameters less than 10 mm. A rope
than an eight-strand rope. The ac-
entail crossover of the outer and inner with 6 X 19 Seale construction cannot
tual contact pressure is reduced
strand layers and high-contact pres- be produced over 16 mm because
by the existence of more contact
sure levels. This leads to the danger the thick outer wires would result in
points between the rope and the
of unnoticed inner rope damage. excessive rope rigidity.
side of the groove.
Does the single ideal elevator This goes some way toward ex-
◆ The rope should remain round in
rope exist, or to take this possibility plaining the wide diversity of rope
operation and not adjust it shape –
even further, could there actually be constructions in existence. Added to
in particular, in hardened U-
one rope to cover all conceivable this is the wide variation in traction-
grooves, with a larger undercut.
applications? A rope used in traction- drive elevators. This diversity means
This long list of requirements can
drive elevators is exposed to a col- that a single rope construction would
be complied with use of full-steel
lection of stress factors comprising never be sufficient to achieve optimum
ropes, with the number of outer
flexure, tension, compression, and behavior. The bandwidth of different
strands being additionally increased
abrasion between the wires and be- elevators produced ranges from
to nine. Figure 9 illustrates examples
of full-steel ropes. Figure 19 illustrates
a proven elevator rope construction
with steel-wire core. Following the Seil
highly successful use of this type of
elevator rope in a number of com-
plex and demanding building projects,
it has been included in current inter- α=
national standards. 100°
Germany was for many years the
sole pioneer in the manufacture and B
application of elevator ropes with a
steel wire core. Its benefits and use
have since been adopted by other
countries. Even today, some elevator Figure 10: Rotation-resistant rope construction Figure 11: Rope and traction sheave, schematic view

64 | WWW.ELEVATOR-WORLD.COM | July 2009

traction-drive elevators with many
varied shaft heights, roped hydraulic
elevators and dumbwaiters with
widely different car suspensions and
counterweights, etc. Other contribu-
tory factors to the variety of construc-
tions are tensioned balance ropes on
high-speed installations and the ropes
used in overspeed governor devices.
In brief, it is impossible to address
all the different application require-
ments, cost and benefit expectations Figure 12: A six-strand rope with a 105° U-groove
with just a single rope construction.
The use of high-performance ropes
for a rarely used, slow-moving ele-
vator can be eliminated if only for
reasons of cost. Conversely, simple
rope constructions are out of place
in high-rise installations. In addition,
all the rope constructions illustrated
in Figure 9 are special ropes not
available from all manufacturers. It
is also essential to bear in mind that
differential force brought about as a
result of the different masses of the Figure 13: An eight-strand rope with a 105° U-groove
elevator car and counterweight has
to be transmitted through friction be-
tween the rope and sheave. This calls
for verification of what is known as
the traction capability, which falls
back on the model of the ideal round
rope illustrated in Figure 11.
This procedure has a proven suc-
cessful track record in this area.
However, the traction capability only
constitutes one side of the coin. The
actual installation conditions of the
rope in the groove naturally play a Figure 14: A nine-strand rope with a 105° U-groove

major influencing role in determining

The appendix to this article pro- The requirements, in summary, are:
the service life of the rope. This is
vides a simple aid for the selection of ◆ The smallest possible degree of
impressively demonstrated by the
suspension ropes, tensioned balance rope wear (thick wires, high wire
example of a full-steel rope with six,
ropes and governor ropes depending tensile strength)
eight and nine outer strands in un-
on the installation. It also explains ◆ A long rope life when running
dercut U-grooves with an extreme
which aspects resulted in the assign- over sheaves (thin wires)
undercut angle of ϕ = 105° (Figures
ment of a type of rope to an elevator ◆ Compatibility with the sheave
12-14). The illustration on the right
installation. (low wire tensile strength)
shows the rope with a rotated cross-
What is Required of Suspension ◆ The highest possible breaking
section relative to the illustration on
Ropes for Traction-Drive Elevators force (fewer or thinner ropes with
the left, but with a fixed rope center
The requirements imposed on ropes a high wire tensile strength)
point. In most cases, many strands
used in traction-drive elevators are ◆ Low rope elongation due to rope
and a dimensionally stable full-steel
contradictory and, in some, cases shortening processes and ride com-
rope constitute suitable construction.
even appear to be in competition. fort expectations (high metallic
Continued

July 2009 | ELEVATOR WORLD | 65

 Continuing Education: Technology Continued

Figure 15 Figure 16 Figure 17 Figure 18

cross-section and top-quality fiber i.e., the rope is less rigid and of- portant to ensure that the rope ter-
core) and fers better fatigue bending charac- mination (as for all elevator ropes) is
◆ A low price (steel and good core teristics. secured against rotation. When used
material cost money). ◆ A median price per meter for extreme shaft heights, the ropes
These requirements can clearly not all This construction is, internation- should untwist as little as possible
be fulfilled at once. Comprise is ally, the most frequently used eleva- during installation. The grooves of
called for, whereby it should be noted tor rope. However, the 8 X 19 War- the drive sheave should be inspected
at this point, the rope elongation fac- rington rope construction with when changing ropes, as these ropes
tor increasingly determines the choice natural fiber core (Figure 17) also will not adapt to a worn groove.
of rope with increasing shaft height. has a wide following due to its supe- The Drako 300 T nine-strand ele-
A six-strand rope with fiber core rior fatigue bending characteristics. vator rope was developed in 1955 as
(Figure 15) has the following benefits: It should be noted that the rope qual- probably the first elevator rope with
◆ A larger metallic cross-section, i.e., ity depends heavily upon the quality a steel-wire core (Figure 19). Its ben-
high breaking load relative to the of the fibers used to produce the efits are:
rope diameter fiber core. ◆ A very round cross-section with
◆ Relatively low permanent and An eight-strand rope with a steel- consequently low contact pres-
elastic elongation wire core offers most of the benefits sure between the rope and groove
◆ A favorable price per meter and very few of the drawbacks of ◆ A large number of thinner wires
This type of rope’s field of applica- eight-strand ropes with fiber core. with, consequently, very good fa-
tion should be in slow freight elevators Benefits include: tigue bending characteristics. In
and low-duty passenger elevators. ◆ Eight-strand ropes are rounder addition, a special arrangement of
The use of this type of rope should be than six-strand ropes. the wires in the strands and the
reconsidered for U-grooves with ◆ Eight-strand ropes with steel strands in the rope help to prevent
large undercuts or V-grooves. cores keep their round cross-sec- wire crossing and reduces the
An eight-strand rope with fiber core tion in operation and are conse- danger of internal wire breakage
(Figure 16) has the following benefits: quently suited for grooves with a invisible from the outside.
◆ Eight-strand ropes are rounder large undercut. ◆ Minimal permanent and elastic
than their six-strand counterparts, ◆ Eight-strand ropes of this type are elongation and consequently
creating more points of contact more flexible and offer good fa- good stop accuracy, even in high
between rope and groove and, tigue bending characteristics. shafts
consequently, ensuring more fa- ◆ Little or no permanent or elastic The nine-strand elevator rope is
vorable contact pressure condi- elongation the best solution as a suspension
tions. ◆ Low rope diameter reduction rope for all elevator installations with
◆ They have a slightly more de- under load and over time large shaft heights and for traction-
formable cross-section, i.e., the ◆ High breaking load relative to di- drive elevators with many deflection
rope adjusts more easily to ameter
sheaves. It is important to ensure
slightly worn grooves. The eight-strand rope offers an
that the rope termination is secured
◆ Eight-strand ropes have thinner easy maintenance solution for high-
against rotation. When used for ex-
wires than six-strand ropes of the duty elevators and is preferably used
treme shaft heights, the ropes should
same construction and diameter, for rope lengths of 50-100 m. It is im-
untwist as little as possible during

66 | WWW.ELEVATOR-WORLD.COM | July 2009

 Figure 15: 6 X 19 Warrington with fiber core
Figure 16: 8 X 19 Seale with fiber core
Figure 17: 8 X 19 Warrington rope with nat-
ural fiber core
Figure 18: A Drako 250 T, 8 X 19 Warring-
ton rope with an independent wire-rope
core
Figure 19: A Drako 300 T, 9 X 25 rope with
an independent wire-rope core
Figure 20: A Drako 310 T, 10 X 19 Seale
wire with a parallel-laid core
Figure 21: A 6 X 36 Warrington/Seale non-
Figure 19 Figure 20 Figure 21 compacted rope with fiber core

installation. It is expedient for a work satisfactorily depends on the running and consistent rope lengths.
marking line to be provided on the experience of the respective rope These constructions are based on
rope as an aid for checking and, if manufacturer, and on the elevator the following requirements:
necessary, correcting rope align- installation itself. ◆ Improved lubrication
ment. The grooves of the drive Suspension Ropes for Roped ◆ An extremely round cross-section
sheave should be inspected when Hydraulic Elevators and consequently minimal contact
changing ropes, as these ropes will In the case of roped hydraulic eleva- pressure between the rope and
not adapt to a worn groove. tors, the suspension ropes only run groove
Parallel-Laid Ropes over deflection sheaves with round ◆ A large number of thin wires and,
In the rope constructions illus- grooves. The absence of a drive consequently, extremely good fa-
trated so far, the rope core and outer sheave means that, in this instance, tigue bending characteristics
strands are laid independently of liberally lubricated ropes can be ◆ The use of thicker and, conse-
each other in separate work used. Furthermore, the use of round quently, fewer ropes and tension-
processes. These ropes are durable grooves makes for higher specific ing sheaves
and relatively insensitive to loosen- rope tensile forces. The typically ◆ The use of thicker ropes with small
ing as a result of external effects due used rope constructions here are six- D/d = 30 and, consequently, the
to, for example, rope deflection. In a strand ropes with fiber cores that ability to select flexible multiple-
parallel-laid rope, the rope core and have been exposed to a particularly wire rope constructions (Figure 21)
strands are laid in a single work rigorous pre-stretching process (Fig- Rope rotation cannot be excluded,
process with the same length of lay, ure 15), and eight- and nine-strand as two tensioning sheaves are fre-
whereby the outer strands are placed ropes with a steel-wire core (Figures quently arranged side by side. This
in linear formation in a bed formed 18 and 19). The customary rope can be triggered initially by alignment
by two strands of the rope core (Fig- grade is 1770, and for ropes with a errors. Premature rope damage is
ure 20). These ropes demonstrate a steel-wire core, occasionally even possible – in particular, in the case of
high breakage force and, in some 1570 and 1570/1770. ropes with steel-wire cores. Ropes
cases, very high fatigue bending Compensating Ropes with a natural fiber core respond
characteristics in laboratory testing (Tensioned Balance Ropes) under typically low balance rope
with short rope lengths. However, For traction elevators with rated forces to changing humidity in the
they are sensitive to untwisting dur- speeds of more than 2.5 mps, ten- shaft (during construction, monsoon-
ing installation and/or due to rope sioned balance ropes are stipulated esqe climatic conditions, etc.) by
deflection, which is practically im- as a method of weight compensation marked changes in length. Artificial
possible to avoid in a 2:1 suspension and to limit compensating weight fiber cores have been shown to pro-
or in double-wrap installations. jump brought about by the safety vide a solution to the problem. Six-
The use of plastic deflection gear or the buffer. The suspension strand ropes with a high weight and
sheaves can also be highly critical and balance ropes differ fundamen- artificial fiber core are recommended
with this type of rope. Experience tally in terms of their application as balance ropes. For rope diameters
has shown that their use is unprob- conditions. The experience of past of 13-25 mm, for instance, 6 X 25
lematic for ropes of up to around 40 decades has culminated in special fillers and (for larger nominal rope
meters in length. To the extent of balance rope constructions permit- diameters) 6 X 36 Warrington/Seale
which rope lengths in excess of this ting greater rope service life, quieter constructions are used. Continued

July 2009 | ELEVATOR WORLD | 67

 Continuing Education: Technology Continued

Overspeed Governor Ropes If ropes with fiber cores are used during operation result in fast rope-
Governor ropes are essential as governor ropes in particularly tall diameter shrinkage, as grease pressed
functional elements of the overspeed buildings, preference should be given out of the fiber core equates to a loss
controller, which engages the safety to ropes with synthetic-fiber cores. of volume in it.
device when an overspeed situation However, in this case, these should Artificial fibers such as polypropy-
is detected. The governor rope runs be subjected to rigorous pre-stretch- lene (PP), which is popularly used for
in the molded groove of the governor ing in order to limit their elongation crane ropes and cable-car ropes, are
wheel. When the safety device is in operation. This is particularly im- also used for elevator cables. Ropes
triggered, force is transmitted by fric- portant given that governor ropes with this type of core are frequently
tion between the rope and groove. must be pre-tensioned, and that the involved where groove wear takes
Consequently, the amount of rope tensioning path is limited. In the U.S., place on the sheave with a hardness
lubrication plays a significant role. In a certain proportion of governor of below 200 HB. Despite the many
recent years, increasingly stringent ropes of strength class IRON are still benefits, it must be borne in mind
demands have been made on break- encountered. The nominal tensile that fiber cores for elevator ropes
ing forces, which are increased as a strength stipulated for the outer wires with diameters of 7 mm and below
result of larger rope diameters, in these 700 N/mm2 ropes is due to made of natural fibers cannot always
higher rope grades or the use of full- the brass brake shoes used in some be manufactured to an adequate de-
steel constructions. speed governors. If steel ropes with gree of diameter accuracy, no matter
Generally, traditional six-strand higher rope grades were used in this how meticulously produced. How-
rope constructions with fiber cores case, there would presumably be a ever, fiber cores made of polypropy-
are used as governor ropes; in most risk of excessively fast wear of the lene offer the benefit of immunity to
cases, 6 X 19 Warrington ropes with gripping components. rotting in humid environments and
fiber cores (Figure 15). These are Rope Cores volume change caused by moisture
generally ropes with a diameter of 6 Depending on the intended appli- absorption. The drawbacks of the PP
mm or 6.5 mm in rope grades 1770 cation, two different core types are core are its high elastic elongation
and, in some cases, even 1960. How- used in elevator ropes: fiber cores and associated increased risk of rope
ever, EN 81 excludes rope grade 1960 made of natural or synthetic fibers, impressions created in sheaves.
for use in suspension ropes but allows and steel wire cores. In elevator ropes, For governor ropes and balance
it for governor ropes. With increas- fiber cores made of natural or synthetic ropes in installations involving long
ing shaft heights and, consequently, fibers are used. Natural fibers – gen- rope lengths – in particular in envi-
rope lengths, the degree of rope erally sisal – are the most widespread ronments with high levels of humid-
strength required also increases. for application in ropes. Due to their ity – chemical fiber cores would be
This results in the use of governor
flexibility, ropes with fiber cores are the preferred choice. Natural fibers
ropes with rope diameters between
able to adjust up to a certain extent absorb moisture, making the core
d = 8mm and 10 mm, and in some
to the relevant groove shape. The thicker and the rope shorter. Where
cases up to 13 mm with an 8 X 19
benefits of fiber cores are: longer governor-rope lengths are used,
Warrington or 8 X 19 Seale with in-
◆ Resistance to contact pressure the height at which the tensioning
dependent wire-rope core construc-
◆ Relatively low elastic rope elonga- pulley has to be fitted is not sufficient
tion (Figure 18).
tion to compensate for excessive rope
Some overspeed controllers do
◆ Low deformability stretch. Polyamide fibers have pro-
not decelerate the governor rope by
The drawbacks are: duced excellent results as fiber cores
blocking the governor wheel, but by
◆ Good yarn qualities (i.e., thin, even for ropes running in round grooves
means of closing brake shoes. The
yarns) are expensive and not easy due to their resistance to pressure.
governor rope required for this design
to come by. However, they come at a relatively
must not have excessively fine wires
◆ The material absorbs moisture from high price. Figure 22 provides a com-
or strands. Although most of the
the ambient air. parison of the various fiber materials
above-described rope constructions
◆ Rotting is a possibility. available for fiber cores in elevator
have proven successful on many dif-
Fiber core can store lubricant. Its ropes. Special controls are imposed
ferent overspeed governor designs,
ability to absorb high quantities of on the evenness of the core and
determining the correct type of rope
grease can become a drawback. amount of lubrication. The influence
construction to be used should lie
Storing too much lubricant during of the rope core on the service life of
with the overspeed governor manu-
manufacture and giving off too much ropes is frequently underestimated.
facturer.

68 | WWW.ELEVATOR-WORLD.COM | July 2009

Steel-Wire Cores
Fiber Material Absorption of Benefits Drawbacks
Steel-wire cores increase the
metallic cross-section and so reduce grease without
problems
tensile stress in individual wires.
Ropes with steel-wire cores are sub- Natural fiber Sisal up to 17% good grease absorption, damagable by
ject to lower elongation under the pressure resistant, low high air moisture
longitudinal elastic elongation
same load conditions as ropes with a
fiber core. The steel-wire core can Natural fiber Hemp up to 22% good grease absorption, lower diameter accuracy
take on widely different forms (Fig- good strand foundation, low than Sisal, damagable
ure 9) and be manufactured sepa- longitudinal elastic elongation by high air moisture
rately (independently) in a preceding
work step prior to being formed with Natural fiber Jute up to 20% only for ropes smaller
than 6 mm
the strands (Figures 18 and 19). An-
other variant is to produce the steel- Synthetic fiber up to 12% uniform thickness not very pressure
wire core and strands in a single Polypropylene resistant, ductile, melts
work step, i.e., in parallel (Figure 20). in high temperatures
The outer strands and the strands of
Synthetic fiber up to 8% very pressure resistant, low grease absorption,
the steel-wire core are placed simi-
Polyamide uniform expensive, high
larly to the wires in parallel-laid longitudinal elastic
ropes so that they make linear con- elongation, fusibel
tact with each other.
One factor that all ropes with steel Synthetic fiber low a fiber is as strong as steel, difficult handling,
cores have in common is that the Aramid, e.g. heat resistant up to 350° very expensive
ropes must not be permitted to rotate Figure 22: Rope core material comparisons
during installation. Although ropes
should always be laid with care, the vator rope subjected to frequent lem of excessive lubricant is extremely
negative influence of rope rotation in bending over sheaves over a service time consuming and cost intensive.
ropes with fiber cores is less pro- life of many years must be lubricated Due to the long service life of ropes
nounced than is the case in ropes well but to a precisely controlled de- in elevator installations, particular at-
with steel wire cores. While in ropes gree. It should be noted in this context tention is attached to re-lubrication.
with fiber cores, all the strands be- that the lubricant does not impair the Here, the same requirements apply
come evenly longer or shorter when necessary traction, which is determined as for initial lubrication, whereby
the rope rotates, in ropes with steel- not only by the geometry of the trac- steps must be taken to ensure that
wire cores, the outside and inside tion sheave, but also by the coordinate those used for initial and subsequent
strands loosen to a different degree. of friction between rope and sheave. lubrication are chemically compatible.
This can result in pronounced differ- Thought should also be given to the For application in traction elevators,
ences in terms of load-carrying ca- risk of contamination by grease or lubricants containing bitumen are
pacity and, consequently, serve to oil spun off under central force. not ideal, as they tend to form highly
shorten service life. Traction elevators differ consider- viscous adhesive encrustations on
Lubrication of Strands and Cores ably depending on their design in both sheaves and ropes. Friction-re-
Wires, strands and cores are impor- terms of traction reserve – in other ducing elements such as molybdenum
tant components of the rope; however, words, the difference between the sulfide or Teflon® particles should be
they are only able to interact ideally theoretically available traction and dispensed with, as their influence on
in the presence of lubrication between the traction used. Elevator ropes are traction can be very difficult to pre-
the wires. The only reason a rope is seldom produced specifically for one dict and they unnecessarily add to
able to bend so easily is because the installation. The rope manufacturer the cost of the application.
wires are capable of displacement must always base calculation on the Direction of Lay
relative to each other. Lubrication worst-case scenario and should only A distinction is made when con-
reduces friction between the wires. lubricate elevator ropes, as a rule, with sidering the direction of lay between
However, in the case of elevators, it relatively minimal quantity, with ex- right- and left-hand-lay ropes. As
is totally false to assume “the more treme care and as evenly as possible. rule, elevator ropes are right-hand-
the better.” On the contrary, an ele- Degreasing ropes to resolve the prob- lay ropes, i.e., the outer strands form
Continued

July 2009 | ELEVATOR WORLD | 69

 Continuing Education: Technology Continued

a right-hand helix. As a result of In round grooves, Lang-lay ropes takes place with the first load cycles
twist due to load, a torque created by achieve greater bending resistance after hanging, prior to commission-
the attempt of the elevator rope to than do ordinary-lay ropes. However, ing. This means that the permanent
reverse the laying status under tor- they are more sensitive to diagonal rope elongation (permanent rope
sional load, elevator installations pull and have more stringent demands stretch) that accompanies compaction
used to frequently be equipped with in terms of installation. Steps must of the rope structure is reduced, min-
right- and left-hand-lay ropes in be taken when hanging the ropes imizing the amount of work involved
pairs. This allowed compensation of freely in the shaft to prevent untwist- in shortening the ropes after only a
the forces acting on the guide rails of ing, as otherwise the wires will work short period of use.
the car and counterweight resulting loose and result in premature rope Experienced elevator rope manu-
from the twist due to load. However, damage. The degree to which Lang-lay facturers use suitable measures to
as these forces are only small rela- ropes are accepted differs widely achieve a pre-stretching effect dur-
tive to those generally absorbed by around the world. For example, while ing production by applying around
the guide rails, in modern elevator they are given equal status in the 30% of the rope breaking force. More
installations, priority is given to the U.K., in Germany, their use is subject intensive pre-stretching calls for a
requirement that all suspension ropes to certain provisos. separate work process. ISO 4344 re-
be as nearly identical as possible, Lang- or Regular-Lay Rope? stricts the maximum tensile force
i.e., should always originate from the An inferior-quality or carelessly applied during pre-stretching to 55%
same source of manufacture. The mounted Lang-lay rope entails a of the minimum breaking force.
mixed use of left- and right-hand-lay substantially greater hazard poten- The most notable effect is achieved
ropes, which can only be produced tial than an inferior-quality, ordi- when pre-stretching eight-strand
using separate manufacturing nary-lay rope. An elevator company ropes with natural fiber cores. Here,
processes, has generally been aban- aiming to change over to Lang-lay 0.2% permanent rope elongation can
doned. In drum-driven elevators, the ropes should ensure that it chooses a be achieved, as the strands become
drum pitch must be selected to design that has been thoroughly (permanently) more deeply embed-
match the direction of rope lay, i.e., tried and tested over a number of ded in the fiber core. In the case of
“right-lay rope – left-hand drum.” years. Also, close examination of the ropes with steel-wire cores, the effect
Regular (Ordinary) Lay and Lang Lay traction sheave grooves must take of pre-stretching on permanent
In the same way as the strands in place when considering the replace- elongation is relatively low. In addi-
the rope, the wires in the strands can ment of Lang-lay with ordinary-lay tion, the pre-stretching effect is par-
be laid in left- or right-lay wires. rope on an existing installation. The tially lost due to handling of pre-
Regular or ordinary lay is used to de- ordinary lay wires running in a differ- stretched full-steel ropes during the
scribe a different lay direction for the ent direction can wear the grooves if hanging process.
outer strands in the rope and the they have been imprinted by the Rope Diameter
wires in the outer strands. If the wires Lang-lay rope. Table 1 indicates the most com-
in the strand and the strands in the Preformed Ropes monly used rope diameters in Europe,
rope have the same lay direction, this is In preformed ropes, the inner ten- the USA and Japan (East Asia). For
described as Lang lay. In regular-lay sions of the wires used in the strands certain European countries, the most
ropes, the visible outer wires approxi- and the strands used in the rope are commonly used suspension-rope
mately follow the direction of the reduced, with the result that when diameters are additionally marked in
rope axis. In Lang-lay ropes, the vis- the rope binder is removed, pre-formed each case. Beyond this, 24-mm
ible outer wires are inclined at a ropes do not spring open. This sub- ropes are also used in the high-rise
steep angle to the rope axis. stantially simplifies the processes of sector. Although rope diameters
Ordinary-lay ropes are hard-wearing cutting to length and installing. Pre- smaller than 8 mm are not covered
and easy to mount. They have only a formed ropes are also known as by the current version of EN 81-1,
slight tendency to untwist when low-tension or low-twist ropes. Pre- elevator installations using 6.5- and
hanging freely in the shaft. Their elastic formed elevator ropes have become 6-mm ropes already exist. In the fu-
elongation is lower than it is in the the standard design in Europe. ture, it will be possible to use suspen-
case of Lang-lay ropes. These bene- Pre-Stretching sion ropes of just 5 mm and 4 mm
fits mean that the majority of eleva- Elevator ropes are pre-stretched (such as the Drako STX series) operated
tor manufacturers exclusively use in order to induce compaction of the on the basis of a separate approval
ordinary-lay ropes. rope structure, which otherwise only certificate from a Notified Body. The

70 | WWW.ELEVATOR-WORLD.COM | July 2009

development of rope diameters of
Rope Europe U.S. Japan
such small proportions is being
diameter Traction Roped hydraulic Governor Suspension Governor
driven by the trend toward machine- mm inch Susp. rope Susp. rope rope rope rope Tragseil
room-less elevators with small, fast-
running drive machines and the 6 x1) x
move to reduce drive torque levels. 6.5 x1) x2)
Rope diameter must be measured 8 x2) x x x
9 x x
within one layer and offset by 90°. If
3/18 (x) x
there is an even number of outer
10 x3) x x x7)
strands, measurement must take 11 7/16 x4) x x
place over two opposite strands. For 12 x x6)
an uneven number of strands, meas- 1/2 x5) x x
urement must take place over one 13 x2) x (x)
strand and the opposite gap between 14 x x
strands. The mean value must be 15 x
15.5 x
formed from the two diameters.
16 5/8 x x x
For elevator ropes (in particular,
11/16 x
for suspension ropes for traction ele- 18 x x
vators), the tolerance requirements 3/4 x
are more stringent than for other 20 x x
wire ropes in order to guarantee 13/16 x
low-wear transmission of forces be- 12 7/8 x x
1) 2) 3)
Small freight elevators most used in Germany most used in France 4) most used in U.K. 5) most used in
tween the sheave and rope. Accord-
U.S. 6) most used in Japan 7) officially minimum in Japan
ing to DIN EN 12385-5, the limiting
Table 1: The most commonly used rope diameters around the world
nominal diameter dimensions for
traction elevators are: 0 to +5 % for nations, of which only those illus- Aluminum Ferrule
suspension ropes with fiber core and trated in Figure 23 are regularly used An aluminum ferrule termination
0 to +2% for full-steel suspension in elevator construction. The termi- as specified in EN 13411, Part 3[12]
ropes. For suspension ropes used in nations comply with the conditions (formerly DIN 3093[11]) is very fre-
roped hydraulic elevators, the appli- of EN 81-1/1998, Section 9.2.3. quently used in Europe. It is mainly
cable tolerance window is 0 to +5%. A termination with wire-rope used in elevator construction in con-
For small rope diameters, in some grips in accordance with DIN junction with a thimble[14] and eye
cases, greater than 1% tolerance is 1142/EN 13411-5 is not listed nor bolt (Figure 23). This type of termina-
admissible. recommended for safety-relevant tion is frequently used in combination
A distinction is made between de- applications. The requirement for se- with a wedge socket at the other end
tachable and permanent rope termi- curing against untwisting (rotation) of the rope. Aluminum ferrule is pre-
after installation applies to all end assembled from the factory and can-
terminations. not be mounted during rope installa-
Figure 23: Rope termina-
Metal and Resin Socketing tion. It provides an extremely secure
tions used in elevator con-
struction: metal and resin In Germany, metal and resin sock- termination, which (apart from a few
socketing, aluminum ferrule eting is dying out as a method of end exceptions such as the U.S.) meets with
with thimble, swaged ter-
minal, symmetrical wedge termination for elevator ropes, while very broad acceptance. This makes it
socket EN 13411-7, asym- in the U.S.[9] and Far East, this type all the more regrettable that in cer-
metrical wedge socket and
rope eye with wire-rope of rope is still in frequent use. The tain countries, aluminum ferrule is
grips socketing deviates significantly from met with a certain degree of distrust.
EN 13411, Part 4[10] and can only be Swaged Termination
classed as safe in any respect in A swaged termination is a very
combination with small rope forces slim construction that permits a
in the elevator. The benefit of sock- wide range of different connection
eting is its relatively lean construc- possibilities. Swaged terminations
tion (Figure 23). Alternatively, plastic connect the steel sleeves and ropes
socketing can be used. permanently using the swaging
Continued
July 2009 | ELEVATOR WORLD | 71
 Continuing Education: Technology Continued

methods of pressing or rolling. The drop out. The dead rope end has to – Safety Part 5: Stranded Ropes for Lifts
[3] ISO 4344 (published 2004), Steel Wire Ropes
neatness of the finished connection be secured with a rope grip in com- for Lifts – Minimum Requirements
makes this type of termination a fa- pliance with EN 13411-5 (formerly [4] DIN 50150, Conversion Table for Vickers
Hardness, Brinell Hardness, Rockwell Hard-
vored option in open-design applica- DIN 1142). It is not admissible for
ness and Tensile Strength, December 1976,
tions such as hotels. They are also both ends of the rope (end under Beuth Verlag GmbH, Berlin
popular where space is at a premium load and dead end) to be terminated [5] EN 81-1/1998, Safety Rules for the Con-
struction and Installation of Lifts – Part 1:
– for instance, car arrangements together with this type of socket. Electric Lifts
with piggyback suspension. Swaged Wire-Rope Grips [6] TRA 003, Technical Rules for Elevators –
Calculation of Traction Sheaves, September
terminations generally have to be European Lift Standard DIN EN 1981, Verein der Technischen
secured against rotation. The insert 81 permits the termination of ropes Überwachungsvereine e. V., Essen
[7] DIN EN 81, Safety Rules for the Construction
depth of the rope in swaged termina- with “three suitable” wire-rope grips. and Installation of Lifts – Particular Applica-
tions (and, consequently, the swag- The use of wire-rope grips should be tions for Passenger and Goods Passenger
ing length) is decisive to functional rejected for use in applications of Lifts Part 1: Electric Lifts, October 1986
[8] EN 12385 – Part 1 (published 2003), Steel
safety. By looking through the in- such high safety relevance as lifts. In Wire Ropes. Safety – Part 1: General Re-
spection hole provided at the end of this regard, EN 81-1 urgently requires quirements
[9] ASME A17.1 Safety Code for Elevators and
the insert path, a check can be made revision. The fact that the U.K. (the Escalators. The American Society of Mechani-
to ensure that the end of the rope is only country in which this type of cal Engineers, New York
inserted sufficiently far enough into end termination is still in widespread [10] EN 13411 – Part 4 (2002), Terminations for
Steel Wire Ropes. Safety – Part 4: Metal and
the sleeve. use for elevators) has prohibited its Resin Sockets.
For terminations of this kind not use in new installations makes the [11] DIN 3093, Wrought Aluminium Alloy Fer-
rules; Parts 1 and 2, December 1988, Beuth
specified by a standard, a type ap- urgent need for revision all the more Verlag GmbH, Berlin
proval certificate issued by a Notified evident. Even more telling is the re- [12] EN 13411 – Part 3 (2003), Terminations for
Body is required in accordance with quirement according to DIN 1142/EN Steel Wire Ropes. Safety – Part 3: Ferrules
and Ferrule-Securing
EN 81 for a specific elevator applica- 13411, Part 5 that the rope diameters [14] EN 13411 – Part 1 (2002), Terminations for
tion to verify that the system offers of interest to elevator constructors Steel Wire Ropes. Safety – Part 1: Thimbles
for Steel Wire Rope Slings
the same degree of safety in combi- must be fitted with at least four grips. [15] DIN 15315, Wire Rope Grips for Elevators,
nation with the designated ropes as The main problem inherent in ter- May 1983, Beuth Verlag GmbH, Berlin
one of the regulated types of end ter- [16] EN 13411 – Part 7 (2004), Terminations for
mination using wire-rope grips is the
Steel Wire Ropes. Safety – Part 7: Symmetric
mination. necessity for regular retightening of Wedge Socket
Wedge Sockets the clamping screws. In addition, it is [17] DIN 1142, Wire Rope Grips for Rope Termi-
nations, January 1982, Beuth Verlag GmbH,
The symmetrical wedge socket not possible to exclude the possibil- Berlin
described by EN 13411, Part 7[16] ity that extreme rope vibrations [18] EN 13411 – Part 5 (2003), Terminations for
Steel Wire Ropes. Safety – Part 5: U-bolt
(formerly DIN 15315[15]) is com- could cause concealed rope damage
Wire Rope Grips
monly seen in Germany, the U.K., at the first rope grip adjacent to the [19] EN 13411 – Part 6 (2003), Terminations for
Italy and Japan (Figure 23). To secure free rope length. Temporarily short- Steel Wire Ropes. Safety – Part 6: Asymmet-
ric Wedge Socket
the dead end of the ropes, only a grip ening a rope using a wire rope grip is [20] Czitary, E., Seilschwebebahnen [Cable pul-
in compliance with EN 13411, Part an extremely hazardous exercise leys], Springer Verlag, Vienna, 1951
[21] Wyss, Th., Stahldrahtseile der Transport-
5[18] (formerly DIN 1142[17]) may be that should be avoided without fail:
und Förderanlagen (Steel Wire Ropes in
used. as the parts of the rope at which a Transport and Conveyor Systems)
The asymmetrical wedge socket, wire grip has previously been located Schweizer Druck- und Verlagshaus AG,
Zürich 1956
in compliance with EN 13411, Part subsequently run over sheaves, there [22] TRA 102, Technische Regeln für Aufzüge –
6[19] (Figure 23) offers advantages in is a high likelihood of the rope frac- Prüfung von Aufzugsanlagen, (Technical
Rules Governing Lifts – Inspection of Lift
terms of rope guidance but has the turing prematurely at these points.
Systems) April 1981, Verein der Technis-
drawback of a relatively bulky de- Even if rope grips are fixed onto the chen Überwachungsvereine e. V., Essen
sign. This can generally be compen- rope as an aid to installation, this [23] DIN 15020, Principles Relating to Rope Dri-
ves Sheet 2, Monitoring of Rope Installa-
sated through the use of long eye should only be done at areas of the tions, April 1974, Beuth Verlag GmbH,
bolts in staggered formation. Cau- rope that do not later run over rope Berlin
[24] ISO 4309, Wire Ropes for Lifting Appli-
tion is called for in situations where sheaves. ances – Code of Practice for Examination
slack is created. Unlike the symmet- Bibliography: and Discard, 1990
[1] EN 10016, Non-Alloy Steel Rods for Draw- [25] EN 12385 – 3 (2003), Steel Wire Ropes –
rical wedge socket, with this socket ing and/or Cold Rolling Safety – Part 3: Information for Use and
type, it is possible for the wedge to [2] EN 12385 – Part 5 (2003), Steel Wire Ropes Maintenance

72 | WWW.ELEVATOR-WORLD.COM | July 2009

[26] Wire Rope Users Manual, American Iron
and Steel Institute, Washington Dr.-Ing. Wolfgang Scheunemann is technical director and head of the Technical Competence Center
[27] Babel, H., Metallische und nichtmetallis- at Pfeifer Drako Drahtseilwerk GmbH & Co. KG.
che Futterwerkstoffe für Aufzugscheiben
(Metallic and Non-Metallic Filler Materials
Dr.-Ing. Wolfram Vogel is head of R&D at Pfeifer Drako Drahtseilwerk.
for Elevator Sheaves), Dissertation Univer-
sity of Karlsruhe, 1979
[28] Hafenbautechnische Gesellschaft e. V., Dipl.-Ing. Thomas Barthel is head of Testing for Elevator Technology at Pfeifer Drako Drahtseilwerk.
Hinweis für den Einsatz von Seiltrieben mit
Kunststoff-Seilrollen in Kranen, fördern
und heben 33 (1983) (Notes on the Use of Learning-Reinforcement Questions
Rope Traction Systems with Plastic Sheaves
in Cranes, Transport and Lifting), No. 1, p. 33 Use the below learning-reinforcement questions to study for the
[29] DIN 15063, Lifting Appliances; Sheaves, Continuing Education Assessment Exam available online at
Technical Conditions, see explanations on www.elevatorbooks.com or on page 153 of this issue.
5.4 December 1977, Beuth Verlag GmbH,
Berlin
◆ When is a six-strand rope with a fiber core used?
[30] Hymans, F./Hellbronn, A. V., Der
neuzeitliche Aufzug mit Treib- ◆ When is a nine-strand rope with a steel-wire core used?
scheibenantrieb (The Modern Lift with ◆ What are parallel-laid ropes?
Traction Drive), Springer Verlag ◆ What are compensating ropes?
[31] SR Kunststoffrollen, Sicherheitstechnische
Richtlinien für Aufzüge – Seilrollen aus
◆ What are overspeed governor ropes?
Kunststoff (SR Plastic Sheaves, Safety ◆ What is a fiber core?
Guidelines for Lifts – Plastic Sheaves], De- ◆ What is a steel-wire core?
cember 1984, Carl Heymanns Verlag KG,
◆ What do regular lay and Lang lay mean?
Köln, Berlin
[32] Molkow, Michael, Stahlseile und neuartige ◆ Why are ropes pre-stretched?
Tragmittel (Steel Ropes and New Means of ◆ Which rope diameter tolerances are admissible?
Suspension), Lift Report 27. Year of publica-
◆ What’s the main difference between a swaged terminal and a wedge socket?
tion (2001), Volume 5, p. 6-12

July 2009 | ELEVATOR WORLD | 73

Continuing Education: Technology

ELEVATOR WORLD Continuing Education

Assessment Examination Questions
Instructions:
◆ Read the article “Steel Wire Ropes for Traction Elevators: Part Two” (page
63) and study the learning-reinforcement questions.
◆ To receive one hour (0.1 CEU) of continuing-education credit, answer the
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◆ Approved for Continuing Education by NAEC for CET® and CAT® and
NAESAI for QEI.

1. How many strands does the simplest elevator rope 6. What are overspeed governor ropes, in addition to
have? being triggers for the safety device?
a. Three. a. Mostly traditional six-strand rope constructions
b. Four. with fiber cores.
c. Five. b. Ropes for which no lubrication is required.
d. Six. c. Very fast-running ropes.
d. All of the above.
2. How many strands does the most frequently used ele-
vator rope have today? 7. What are typical fiber-core materials?
a. Three. a. Sisal.
b. Six. b. Polypropylene.
c. Eight. c. Polyamide.
d. Nine. d. All of the above.

3. Which requirements can not be complied with when 8. What is particularly important when installing steel-
using full-steel ropes? core ropes?
a. Less permanent elongation. a. Preventing rope rotation.
b. Less elastic elongation. b. Saving ropes from heat.
c. Better sound. c. Keeping ropes from touching each other.
d. Longer rope service life. d. Removing ropes from magnetic fields.

4. What is the application field of six-strand elevator 9. How do the visible outer wires lie in a regular-lay rope?
ropes? a. Approximately vertical to the rope axis.
a. High-duty elevators. b. In a steep angle to the rope axis.
b. Low-duty elevators. c. Approximately in line with the rope axis.
c. Slow freight elevators. d. In several directions.
d. A and b.
e. B and c. 10. Which rope terminations are detachable?
a. Metal socketing.
5. What is the application field of eight-strand elevator b. Aluminum ferrule.
ropes with steel-wire cores? c. Swaged terminal.
a. High-duty elevators. d. Symmetric wedge socket.
b. Elevators with rope lengths between 50 m and
100 m.
c. A and b.
d. None of the above.

July 2009 | ELEVATOR WORLD | 153

 Continuing Education: Technology Continued

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