03/2018

PFEIFER
SEIL- UND HEBETECHNIK
GMBH

DR.-KARL-LENZ-STRASSE 66
DE-87700 MEMMINGEN

Wire ropes – PHONE

FAX
+49 (0) 83 31-937-301
+49 (0) 83 31-937-123

Technical information E-MAIL wirerope@pfeifer.de

INTERNET www.wirerope.info
 Wire ropes –
Technical information
Moving means to set things in motion, to unfold
dynamics, to create things. For us in the PFEIFER
group, to move is very specific: it means that with our
products from Wire Rope Technology, Rope and Lifting
and Building Systems elevators, heavy loads on cranes,
sheet metal coils, workpieces and precast concrete
elements move. Our cable structure buildings are known
all over the world, and so is our extensive know­ledge
on the dynamics of wire rope in all applications.
Moving also means for us that we don't sit still, we study,
we learn, we apply and we invest. There is a reason
why the PFEIFER group is one of Europe´s leading
companies in Structures, Wire Rope Technology,
Rope and Lifting and Building Systems.
We get things going – special requests by customers,
efficient and practical solutions, technical expertise,
quality and dependable service – these are the benefits
for you as a partner.

Gerhard Pfeifer,
President of the PFEIFER group

The PFEIFER group is one of Europe´s

leading companies in Structures, Wire
Rope Technology, Rope and Lifting
and Building Systems. The head­
quarters are located in ­Memmingen,
Germany. Numerous service centres
and ­subsidiaries worldwide are
responsible for sales and distribution.

2
Wire ropes – Technical information 03/2018
 Content
Through the right choose of ropes and end termina- Wire ropes – a story of success . . . . . . . . . . . . . . . . . 4
tions in accordance with their operating conditions Technical aspects about wire ropes
you achieve the most economic lifetime, reduce
Components of wire ropes . . . . . . . . . . . . . . . . . . . 5
potential risks and avoid high downtime costs on
the basic of premature rope failure. Rope cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Well-know manufacturers of cranes and building Strand constructions . . . . . . . . . . . . . . . . . . . . . . . 6

equipment, as well as fleet operators and users, Rope types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
trust in PFEIFER know-how. Rely on our years of Surface treatment of wires . . . . . . . . . . . . . . . . . . . 8
experience!
Rope lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Explanation of important terms . . . . . . . . . . . . . . . 8
Rope selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Breaking force reduction caused
by rope end terminations . . . . . . . . . . . . . . . . . . . . . 15
Further products and services . . . . . . . . . . . . . . . . . 16
Correct handling of wire ropes . . . . . . . . . . . . . . . . . 20

Reduce every risk and trust in our

longtime experience of correct
rope selection!

us
Please let
!
advise you

 Further infomation can be found under

Products & Services at the PFEIFER web portal:
www.wirerope.info

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Wire ropes – Technical information 03/2018
 Wire ropes –
a story of success

Historical review
When Wilhelm Albert, an official of the German Board of Mines,
manufactured a steel wire rope in 1834, it was admittedly not
the first wire rope in the world, but the tools he used and the
level of wire production enabled him to produce ropes of accept-
able length and quality.
The ensuring rapid development of wire rope production and
its machinery and an ever increasing number of new rope
con­structions revealed, how urgently wire ropes were needed
by the emerging industrial revolution.
Since then the very simple Albert rope construction has deve­
loped – according to the ­various demands – into a vast and for
the uninformed somewhat daunting v­ ariety of rope constructions.
It was obvious from a very early stage that the structure of the
strand in particular has a great influence on the characteristics
of the rope. Over 100 years ago the Seale, Warrington, Filler wire
and the cross lay (formerly called standard) wire configuration
were already well known. Other c­ ommon strand formations,
e. g. Warrington-Seale and Warrington-Compound are merely
combinations of these basic constructions.

Wire and strand diameter of our wire ropes have been optimized
constantly by using computer technology. Thus bending proper-
ties and service life of the running ropes could be improved
considerably. By an absolutely equal load distribution to all wires
an early failure of any individual wire due to overloading will be
eliminated.

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Wire ropes – Technical information 03/2018
Technical aspects
about wire ropes

Components of wire ropes

Single wires 1 2 Strands
spinned to a strand (fig. 1) surrounding the core (fig. 2)

Rope cores
The inner part of a single layer rope surrounded by the outer
strands is normally filled by a rope core. Its main function is to
support the outer strands and, by using a steel core, also to
increase the load bearing metallic cross ­section.

Overview of material and construction:

3 4 5 6

Fibre core (FC) Steel core (WC) Independent wire rope core,
The core of the rope consists of There are two typical types of steel core ­plastic coated
natural (NFC) or synthetic fibre (SFC). 1. Wire strand core (WSC) The core consists of a plastic c­ oated
Fibre cores (fig. 1 and 3) store The core of a round strand rope consists of a strand (fig. 4). steel core (fig. 6 and 27).
lubricants, support the strands and
2. Independent wire rope core (IWRC)
dimish vibrations.
The core of the round strand rope consists of a stranded rope
(fig. 2 and 5).

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Wire ropes – Technical information 03/2018
 Strand constructions
Differentation of moving ropes 7 8
JJ  tandard stranding method (fig. 7)
S
Standard stranding methods cause wire crossings between the wire layers
within the strand resulting in high stress concentrations, where crossings
occur. Premature damage may be the consequence.
JJ Parallel
 stranding method (fig. 8)
All wires are arranged parallel in the strand structure thus a continous linear
contact is provided. The result is a reduction of compressive stress of the
wires. Therefore many of our special ropes for running service are made of
­parallel stranded strands.

Different lay type of outer wires in the strands

JJ right hand lay (abbreviated to z, fig. 9) 9 10 11 12
JJ left hand lay (abbreviated to s, fig. 10)

Different lay types of outer strands

JJ right hand lay (abbreviated to Z, fig. 11)
JJ left hand lay (abbreviated to S, fig. 12)

Different lay types

JJ  egular or Cross lay
R
The direction of lay of the wires in the outer strands will be in opposite
direction to the direction of lay of the outer strands in the rope itself.
Types of lay direction: 13 14 15 16
– sZ: right hand regular lay (fig. 13)
– zS: left hand regular lay (fig. 14)
Regular laid ropes are more pressure and deformation resistant.
JJ L ang lay
The direction of lay to the wires in the outer strands equals the direction
of lay of the outer strands in the rope. Types of lay direction:
– zZ: right hand lang lay (fig. 15)
– sS: left hand lang lay (fig. 16)
Lang lay ropes provide improved abrasion resistant properties when used
on multiple rope reeving.

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Wire ropes – Technical information 03/2018
Rope types
Single layer stranded ropes 17 18
Single layer round strand ropes (fig. 17) consists of several strands laid in
one layer around a fibre or steel core. They are applied in cranes, excavators,
winches, construction machinery, elevators or are used as sling ropes.

Rotation resistant ropes

Rotation resistant ropes designed to generate reduced levels of torque and
rotation when loaded (fig. 18). Rotation resistant ropes generally comprise an
assembly of at least two layers of strands laid helically around a core, the
direction of lay of the outer strands being opposite of that of the underlying
layer. To achieve an additional reduction of torque and rotation when loaded Seil-Nenn-Ø bis 12 mm
special rotation resistant ropes were designed and manufactured. Typical
application for these special ropes are hoisting ropes for cranes working 19 20
with only one fall and / or high lifting heights (fig. 19).

Parallel-closed stranded ropes

Parallel-closed stranded ropes (fig. 20) consist of at least two layers of
strands laid helically in one closing operation around a core. The diminished
gaps between the strands result in an enlarged metallic cross section and
thus in higher breaking load values. They are used e.g. for cranes, excava-
tors, c­ onstruction machinery.

Low-stress ropes
If all internal stresses in the wires resulting from the manufacturing process
have been completely or nearly eliminated the rope will be low-stressed. 21 22 23 24
If seizing is removed strands remain in position. Wire breakages occuring
during rope work do not protrude from the rope structure.

High performance compacted ropes

JJ  ompacted strand stranded rope (fig. 25)
C
Rope in which the strands, prior to closing of the rope, are subject to a 25 26
compacting process such as drawing, rolling or swaging. Fig. 21 and 22
shows the standard, fig. 23 and 24 the compacted strand.
JJ  ompacted (swaged) stranded rope (fig. 26)
C
After stranding the rope usually gets additionally compacted by swaging
or rolling.
The advantages of compacted ropes are: higher breaking load, better
­flexibility, smooth surface and a higher resistance to abrasion.

Ropes with plastic coated steel core

The interior structure of some of our special ropes is plastic coated
(fig. 27). This structure is characterised by a number of improvements 27
JJ Reduced friction between rope core and outer strands
JJ High bending cycle strength
JJ High structural strength
JJ Excellent vibration-resistant properties
JJ Improved corrosion protection of the wire core

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Wire ropes – Technical information 03/2018
 Surface treatment of wires Rope lubrication
Wire surfaces Lubrication tasks
JJ bright (U) JJ F riction reduction
Uncoated ropes are marginally softer and more flexible than galvanized Lubrication of wires and strands reduces the destructive friction between
ropes and offer economical advantages for long lenghts. the single rope elements.
JJ galvanized (B) JJ  rotection against corrosion
P
Galvanized ropes are more insensitive against penetrating water and Special rope lubricants prevent an infiltration of humidity and pollution.
humidity than bright ropes. These ropes can be used in different applica- JJ E normous extension of the rope lifetime
tions and machinery. The single rope elements are protected by primary lubrication and regular
JJ Stainless steel relubrication, therefore the downtime costs will be reduced.
Ropes made of stainless steel are used if a high corrosion resistance
is necessary or if a high value is placed on the optics. These ropes can
be used for special requirements (e.g. hygiene regulations in the food
industry) as well.

Explanation of important terms

Nominal rope diameter Fill factor
The nominal rope diameter is a size which defines a rope in combination The fill factor is the relation of the metallic cross section of the rope to
with other characteristics. According to manufacturer or standard toler­ the area of its circumscribed circle.
ances, the permitted range for the rope diameter can be derivated from
the nominal rope diameter. Wire tensile strength grade
A level of requirement of tensile strength of a wire and its corresponding
Actual diameter range. It is designated by the value according to the lower limit of tensile
To measure the actual diameter (fig. 28) it is important to do it the correct strength and is used when specifying wire and when determining the
way. Only meassuring the surrounding diameter is correct. For this reason it calculated minimum aggregate breaking force a rope, expressed in N/mm².
is important to use caliper gauges with wide jaws. Common tensile strength grades are 1770 N/mm2, 1960 N/mm2 and
2160 N/mm2.
28
Rope strengths grade

7 The resulting tensile strenght of a rope is determined by the rope strenght

grade. This grade characterized the requirement levels of the breaking force
by a number (e.g. 1770, 1960, 2160)

Spinning loss factor

The spinning loss factor is a pragmatical value based on the breaking
load loss of the wires during the spinning process.

Minimum breaking load (Fmin)

The minimum breaking load of the rope is the product between nominal
aggregate breaking load and the spinning loss factor. Most of the end
­terminations decrease minimum breaking load of the rope. Detail in
“Rope end terminations”.

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Wire ropes – Technical information 03/2018
Rope selection

Various main applications

Wire ropes are divided into four main groups:
Slings Track ropes
… for load handling ropes. … are used in forest applications.

Structural cables Running ropes

… are ropes being anchored at two … are ropes running above sheaves,
fixed points and do not run over drums or traction sheaves, e.g.
sheaves or spool on a winch, hoist ropes, luffing ropes, e­ levator
e. g. guy and pendant ropes, ropes, haulage ropes etc.
­suspension ropes.

The most suitable rope for a given application is the one

best able to withstand the conditions the rope will encounter
in service. The correct choice for rope will not only decrease
the danger and hazards for personnel and machine but will
also help to prevent very expensive down time due to premature
failure of ropes etc.
Avoid any risk, trust in our experience and assign this task to us.
We are always ready to assist you in finding a solution or any
special rope problem you may have, just contact us.

us
Please let
!
advise you

9
Wire ropes – Technical information 03/2018
 Rotation resistant or non-rotation resistant rope?
Rotation resistant ropes 29
Rotation resistant ropes generate reduced levels of torque and rotation when
loaded.
1. R
 otation resistant ropes
These are rope constructions, e. g. 18 x 7, 17 x 7 (fig. 18), with two layers
of strands laid helically around a core, the direction of lay of the outer
strands being opposite to that of the underlying layer.
WARNING! Don’t use these ropes attached to a swivel or have
one or both ends rotate freely under load! If this is not observed
serious injury, considerable damage or death will occur!
Exception: Considering the recommendations of the rope
manufacturer and the consent of an expert person (construction
machinery manufacturer) a swivel is allowed to use.
2. H
 igh performance rotation resistant ropes (fig. 19)
We indicate the higher quality of these ropes through adding the term
“high performance”. The high performance resistant ropes have a steel
core which is an independent rope, closed in the opposite direction to the
outer strands. Today these ropes consist of 15 and more outer strands
(fig. 29). Due to that, under load the core tries to twist the rope in the one
direction, the outer strands try at the same time to twist the rope in the
opposite ­direction. The result is, that high performance rotation resistant
ropes almost compensate the torque over a particular load spectrum.
Because of these excellent rope properties the high performance rotation
restistant ropes are used with lifting heights and lifting unguided loads on
a single fall. Up to now these ropes were also called “non-rotation ropes”.
The high performance rotation ropes can be used with or without a swivel;
if possible, the use of a swivel is preferred.

Non-rotation resistant ropes

According to the rope properties “torque and rotation” non-resistant ropes
generate high levels of torque when loaded. That is why both rope ends must
be fixed when loaded to avoid rotation. Typical wire rope constructions are
ropes ropes with e.g. 6-, 8-, 9- or 10-outer strands. Non rotation resistant
ropes can be used, when the load is guided, in lifting systems where pairs of
the right and left hand ropes are working or when having a low lifting height
with more than one fall. Under these conditions the advantage of non-rotation
resistant ropes – compared with rotation-resitant ropes in the same applica-
tion – is, that these ropes achieve a higher service life.
WARNING! Don’t use these ropes attached to a swivel or have
one or both ends rotate freely under load! If this is not observed
serious injury, considerable damage or death will occur!

10
Wire ropes – Technical information 03/2018
Right-hand or left-hand lay rope?
For the installation of ropes on winches there is the basic rule:
30
JJ Right-hand lay rope for a left drum
JJ Left-hand lay rope for a right drum
For the correct running of the rope it is necessary that drum and reeving
will be of the same direction. If a rope runs from a right drum into a left
reeving or from a left drum into a right reeving only a test can prove
whether a left-hand or a right-hand lay rope must be installed.
By using multiple layer spooling systems we recommend to follow the
above mentioned basic rule.

Rope lay direction

How to determine the correct rope lay direction? 31 32
JJ F irst step: Check how the rope runs from the drum into the reeving.
There are two possibilities:
– overwound drum (fig. 31 and 33)
– underwound drum (fig. 32 and 34)
JJ Second step: Put your hand on the rope on the drum
– Index finger shows in the direction of the rope running into the reeving
– Thumb shows to the rope fix point on the drum
JJ Third step: Decision
– If you need your left hand to fulfill the requirements of the second 33 34
step, then you need a left-hand rope (fig. 31 and 32).
– If you need your right hand to fulfill the requirements of the second
step, then you need a right-hand rope (fig. 33 and 34).

11
Wire ropes – Technical information 03/2018
 Further information

Product safety
Our basic information in this brochure provides guidance on WARNING! Wire rope will fail if worn-out, shock loaded,
product safety. It is created for people already having knowledge ­over-loaded, misused, damaged, improperly maintained or
abused.
of wire ropes, as well as for new users. Please pass the basic
information on to others and take notice of our operation manual Always inspect wire rope before use for:
for stranded ropes. JJ wear
Read it carefully, understand and practice these instructions, JJ damages
also read and understand the machinery manufacturer’s manual. JJ deformations
If these are not observed serious injury, death or considerable JJ corrosion
damage can occur! Protect yourself and others!
Never use wire rope which is

!
JJ damaged
JJ worn-out
Further information can
JJ deformed
be found under "Correct JJ improperly maintained
handling of wire ropes" JJ not suitable
(page 20 and 21)
If in doubt about the wire rope, the wire rope application, the wire
rope end termination or anything else, regarding the wire rope,
please contact us or the machine maunfacturer.

Technical seminars for crane ropes

Target group
Contructors and persons responsible for cranes, crane drivers, crane
installers, mechanical engineers, customer service specialists at our
training centres, branches and on-site.

Seminar result
The seminar mediates important basics for the correct use and
surveillance of crane ropes.

Seminarinhalte
JJ Standards JJ Rope drive elements
JJ  rane rope types, terms,
C JJ Handling and assembly
rope constructions JJ Maintenance
JJ  erformance criteria for
P JJ Surveillance and discard
crane ropes
JJ Rope damages and its causes
JJ Correct rope selection

al
in technic
Interested se call us:
Plea
seminars? 1-937-301
33
+49 (0) 8

12
Wire ropes – Technical information 03/2018
Rope designations
1 Hoisting rope
2 Pendant rope 2
3 Luffing rope 2 2
1
4 Trolley rope
5 Closing rope
6 Winch rope
4 3
1

1 5
3

13
Wire ropes – Technical information 03/2018
 Steel wire rope end finishing
PFEIFER is expert in all kinds of rope assembly – from the high precision
manufacturing of the finest ropes for medical technology to the precise cutting
to length of crane hoisting ropes and the casting of ropes with the largest of
diameters.

Cutting to length
JJ  re-stressing
P
To achieve exact rope lengths under specified working conditions, it is
necessary to pre-stress ropes with a deteremined load. A pre-stressing
machine with a capacity rating of 3500 kN (in high precision class 1)
and a length of 215 meters, enable us to do various elongation-, tensile-
and breaking tests.

!
Ways of rope end finishing
JJ  ope ends without end terminations
R
– Rope end seizing
Standard or tailor-made –
Seizing of rope ends avoids loosening of the rope structure. Firm through our own development
seizing is absolutely necessary for rotation resistant ropes as they
and production every rope
are not preformed.
– Fusing recieves the optimal connection.
We can taper and fuse rope ends up to a rope diameter of 40 mm. Larger
diameters, the rope ends will be welded. Such end treatment simplifies
the mounting of ropes on winches or in open wedge sockets.
– Welding
To protect ropes with large diameters against untwisting, the rope end is
professionally welded by our experienced workers.
– Splicing
We are masters of traditional rope making and can splice eyes, Flemish
eyes etc. for you.
JJ Installation of end terminations on rope ends

– Swaging
Aluminium ferrules or steel fittings are cold bonded to the wire rope under
extremely high pressure. Two presses, with a pressing force of 4000 t
each, enable us to swage steel wire ropes up to 97 mm diameter. Swaging
reduces the minimum breaking load of ropes.
– Casting
Socketing with zinc alloy or synthetic resin means that the minimum
breaking force is not reduced. Two socketing towers with five socketing
boxes each, allow short processing time with a large number of ropes.
In our plant ropes up to 140 mm diameter are casted with sockets.
PFEIFER is very e­ xperienced in casting rope fittings either in our facilities
or on site.
– Rolling
Rolled end terminations are pressed on the rope by a rolling motion.
Due to the slim design the resulting connection can be used in different
applications.

14
Wire ropes – Technical information 03/2018
Breaking force reduction caused
by rope end terminations

Most rope end terminations reduce

the breaking force of the rope system
significantly. As a approximate value,
we give you the remaining value of
the minimum breaking force as a
Cast open spelter socket 100 % 100 % Cast cylindrical socket
percentage of the minimum breaking
force of the rope according to the
following table.

Flemish eye 90 % 90 % Swaged thread fitting**

WARNING:
These data define the ideal case.
That means that the in rope system
Swaged eye 90 % 90 % Swaged clamp with thread**
used rope end terminations (especially
casting sockets, fittings and open
wedge sockets) must fit in design and
material quality regarding the used rope
type (construction, nominal strength,
compacted / uncompacted). If in doubt,
Swaged thimble 90 % 90 % Closed swaged fitting**
the system breaking force needs to be
determined by type testing through
tensile testing.

Swaged solid thimble 90 % 90 % Open swaged fitting**

Swaged fork end thimble 90 %

Rope clamp acc. EN 13411-5*** 80 %

Spliced eye 80 % 80 % Open wedge socket symmetric

Spliced thimble 80 %* 80 % Open wedge socket asymmetric

* With spliced terminations in some cases, a reduction of the tensile strength of up to 40 %

may occur. This depends on the rope construction and the rope diameter.
** These terminations are only for use with full steel wire ropes (with steel core).
*** The use of wire clamps with compacted wire ropes is not described by the standard and
should therefore be avoided! 15
Wire ropes – Technical information 03/2018
 Further products
and services

Rope accessories
Connecting links Swivels
For fast and simple connection To avoid the rope torque being
and fastening options of steel transmitted to the load and thus
wire ropes causing great damage
Available in various versions

Bolts
For fast and stable securing
in the most diverse areas of
application

Manual strand ropes Detailed manual for the proper use of your strand ropes with
useful tips to extend the rope lifetime
Further languages on request
Included in each Rope Service Starter Kit and the measurement
equipment cases 75/150 or available as PDF in the PFEIFER
download centre at:

 www.pfeifer.info/manual-strand-ropes

16
Wire ropes – Technical information 03/2018
Rope service and rope handling
Rope lubrication Maintain your wire ropes with the proper re-lubricant and extend
the lifetime.
RL-S & RL-B
Save costs for new ropes and rope changes by extended lifetime.
Product Part.-No.
We can offer re-lubricating large rope lengths using a special
12 x Spray 600 ml 245066
re-lubrication device. Our service team comes to you worldwide
Bucket 10 l 212406
and saves you cost intensive trips with your crane.
Bucket 30 l 212405

Rope measurement Use our special measurement devices from the rope specialist
to reduce costs by extending the lifetime.
• Groove gauges
Based on our long-term practical experience of rope drive
• Caliper gauges
inspection, we created a measurement devices program.
• Sets These measurement devices are used by our rope experts
for each inspection and thereby approved for general use.

Tools for working So that you can also easily carry out minor work on ropes,
PFEIFER offers you a selection of different tools for working
on ropes on ropes.
• Crimping pliers
• Wire rope cutter

Rope assembly aids PFEIFER rope assembly aids assist you reliably in the attachment
and replacement of your steel ropes.
• Winding blocks
• Rope tensioning clamps
• Cable grips

Innovative PFEIFER-reels and PFEIFER-stands for reels –

the perfect combination for your ropes:
packaging solutions
• Optimized packaging sizes
• Reels
• Simplified transport – to be taken by forklift
• Stand for reels
• Stands for reels are gently for reels and ropes
• Prevention of transport mistakes and resulting damages
• Heat treatment according to ISPM 15
17
Wire ropes – Technical information 03/2018
 Rope services
Rope assembly Rope application
PFEIFER is expert in all kinds consultancy
of rope assembly – from the Through the correct selection
high-precision manufacturing of ropes and end connections
of the finest ropes for medical to suit the conditions of use
technology to the precise cut- you can achieve the most
ting to length of crane hoisting economical lifetime, reduce
ropes and the casting of ropes possible dangers and avoid
with the largest of diameters. high failure costs.

End connection Repair service

design Steel wire ropes are subject
Standard or tailor-made – to wear in tough continuous
through our own development use and can be damaged by
and production every rope external influences. PFEIFER
receives the optimal connec- offers you a rope repair in
tion. original rope quality at your
premises.

Rope stocking PFEIFER guarantees fast availability in one of the industry's

largest stock assortments and a capacity of well over 4000
tonnes in a fully automatic rope warehouse in Memmingen
and in further warehouses all over the world. High-performance
logistics partners guarantee fast delivery. Thanks to optimised
packaging, every reel reaches its destination worldwide well
protected.

Rope inspection After the delivery of the optimum rope we support our customers
and are happy to assist with all questions regarding the rope
application.
We analyse optimization potentials at rope winches and drives,
check ropes for damages and abrasion to extend the lifetime
and reduce rope change and down time costs.
We do this job on a daily basis – worldwide.

Technical rope Using discarded products or disregarding basics of proper

application by the use of wire ropes can cause enormous
seminar danger for humans and material.
Interested in a seminar Trained employees increase safety in your company, avoid
at your premisis? accidents and reduce costs.
We would be pleased In our established technical seminars, our competent and
to provide you with an experienced instructors train your staff in latest standards
individual offer. and in all theoretical and practical issues.
18
Wire ropes – Technical information 03/2018
Rope services
Rope analysis Test Facility for Determining
Bending Fatigue
PFEIFER analyses with extensive tests in the central Rope and
Material Test Centre all properties of wire ropes and applied
materials at the headquarter in Memmingen as well as at
further machines at PFEIFER DRAKO in Mülheim/Ruhr. Also
necessary tests can be done locally in our global subsidiaries.
Aware that not only the usual catalog values such as
weight per meter and minimum breaking force decide on
the performance of wire ropes, all properties of the ropes
are determined at PFEIFER in extensive tests.
Equipped with this knowledge, we will choose the right wire
rope for your application and so we optimize the lifetime of
your equipment.

Spectral Analysis

Multi Layer Spooling Test Tower

Magnaflux Test Rope Efficiency Test Facility

Further Offers:
Test Facility for Lateral Pressure
Resistance
Coat Thickness Measuring
Pull Test Facility
Ultrasonic
800 kN Tension Fatigue Test Facility
Torsion Test Facility
Microscopic Analysis
Elongation and Pull Test Facility
Hardness Test
Notch Impact Test
Dye Penetrate Test

Pull Test Facility 19

6,000 kN
Wire ropes – Technical information 03/2018
 Correct handling of
wire ropes

Spooling of wire ropes

Correct
Lay wire rope rings on clean
ground. Please consider the
preferred bending direction
when rewinding the rope.

Correct
Place reel on a suitable frame
or spike, draw-off straight.
Make absolutely sure that
the rope is not fouled.

Correct
When winding on a rope drum, pay
attention to the direction of rotation
and the right distance between reel
and drum. A too small distance can
cause torsional damage in the rope
during later operation.

Wrong
Drawing-off the rope of a ring or
over the flange of the reel as well
as counterwise spooling cause
“twist” for each winding in the
rope. Loops may occur, which
may result in bends under tension.

Detailed handling constructions

you will find in our operating
manual for stranded ropes in the
PFEIFER download centre at:
 www.pfeifer.info/
manual-strand-ropes

20
Wire ropes – Technical information 03/2018
Storage and transport of wire ropes
Correct
Store wire ropes dry and cool.
Avoid ground contact, so that
humidity can not taper the rope.
Take off air and water tight trans-
port packing. Humidity causes
oxidation.

Correct
Protect the rope of crushes and
kinks.

Wrong
Improper transportation of wire
rope reels and rings will cause
irreparable damage to wires,
strands or the rope structure.

Instructions for use

With the use of wedge sockets the Detailed handling constructions
rope is introduced on the balanced you will find in our operating
side so that under load the center manual for wedge sockets in the
line of the rope is in-line with the PFEIFER download centre at:
OHQJWK bolt hole. The dead end is passed  www.pfeifer.info/
RIWKH through the asymmetric side and manual-wedge-socket
GHDGHQG is secured with a rope clip.
The length of the dead-end should
be 10 x the nominal rope diameter,
at least 150 mm. The rope clip must
be applied only to the loose,
unloaded rope end, never on both
Instruction strands. The maximum operating
When a rope is to be re-terminated with a wedge socket assembly temperature for wedge sockets is
this can only be achieved by shortening the rope. No part of any 200 °C / 400 F.
previous flattening and/or damaged rope should be on the standing
part of the rope or within the clamping area between either side of
the socket body and the wedge.
21
Wire ropes – Technical information 03/2018
 Installation of wire ropes
Wire ropes can easily be damaged and must therefore be handled with The end termination of non-rotation resistant and rotation resistant ropes has
utmost care during transport and unloading. to be fixed on both end terminations against rotation.
Only the installation of an untwisted an undamaged rope will guarantee a It is NOT allowed to use non-rotation resistant or rotation resistant ropes
trouble-free operation. Ropes must always be uncoiled from the reel or the with a turnable fixed point (e. g. swivel).
ring in the direction of winding. Lateral uncoiling of the rope causes twisting
If the lower layers on the drum are hardly or seldom used the pretension
and can lead to destruction by kink formation. It is recommended to use a
of the entire rope has to be renewed from time to time. To renew the
frame-mounted reel for coiling the rope onto the drum. Coiling in the direction
pretension in the hoist ropes the complete rope has to be spooled off and
of bend gives an excellent fit on the drum and avoids that any additional
wound up again with tension of approximately 2 % of the minimum
tension is built-up in the rope. Never drag ropes over soil or dirt.
breaking force or 10 % of the maximum line pull force in operation.
For installing the new rope it has to be fixed to the still mounted old one or Ropes work most efficient if is always used the entire rope length.
an auxiliary rope. Connection between the two ropes can be achieved either
If the rope areas are used unequal the rope can be turned after a certain
by a cable grip or two welded pad eyes connected with a swivel.
time. In multi-layer spooling the lifetime of the rope can be significantly
Any transmission of torsion to the new rope from either the old one or the
extended by cutting away the length of half the drum diameter from the
auxiliary rope must be definitively avoided. Nonrotating ropes must be
rope at the fastening point of the drum. Through this procedure the
protected from torsion by insertion of a swivel.
predamaged rope areas are relocated from the climbing zones on the
Multi-layer operation requires that even the lower layers must be tightly drum into the parallel zones. The shortening procedure can be carried out,
coiled with a pretension of 1 – 2 % of the minimum breaking load of the at most, two times.
rope. It is attained by braking the reel.

Discarding time for wire ropes according to ISO 4309

Discarding time for wire ropes according to ISO 4309
Exemplary for single layer and parallel-closed ropes
Number of visible wire breaks, reached or exceeded, occurring in single-layer
and parallel-closed ropes, signalling discard of rope
RCN Total number of Number of visible outer wire breaks
b
Detailed handling constructions
load-bearing Sections of rope, running over steel shea- Sections of wire you will find in our operating
wires in the ves and/or spooled on a single layer drum rope spooled onto a manual for stranded ropes in the
outer layer of (random distribution of wire breaks) multilayer drum
c
PFEIFER download centre at:
strands in the d
Classes M1 to M4 or calss unknown All Classes
 www.pfeifer.info/
a
rope
Ordinary lay Langs lay Ordinary and
n
langs lay
manual-strand-ropes
over a length of
e e e e e e
6d 30d 6d 30d 6d 30d
01 n ≤ 50 2 4 1 2 4 8
02 51 ≤ n ≤ 75 3 6 2 3 6 12
03 76 ≤ n ≤ 100 4 8 2 4 8 16
04 101 ≤ n ≤ 120 5 10 2 5 10 20
05 121 ≤ n ≤ 140 6 11 3 6 12 22
06 141 ≤ n ≤ 160 6 13 3 6 12 26
07 161 ≤ n ≤ 180 7 14 4 7 14 28
08 181 ≤ n ≤ 200 8 16 4 8 16 32
09 201 ≤ n ≤ 220 9 18 4 9 18 36
10 221 ≤ n ≤ 240 10 19 5 10 20 38
11 241 ≤ n ≤ 260 10 21 5 10 20 42
12 261 ≤ n ≤ 280 11 22 6 11 22 44
13 281 ≤ n ≤ 300 12 24 6 12 24 48
n > 300 0,04 × n 0,08 × n 0,02 × n 0,04 × n 0,08 × n 0,16 × n
NOTE Ropes having outer strands of Seale construction where the number of wires in each strand
is 19 or less (e. g. 6 × 19 Seale) are placed in this table two rows above that row in which the
construction would normally be placed based on the number of load bearing wires in the outer layer
of strands.
RCN = Rope category number
a
For the purpose of this International Standard, filler wires are not regarded as load-bearing wires
and are not included in the values of n.
b
A broken wire has two ends (counted as one wire).
c
The values apply to deterioration that occurs at the cross-over zones and interference between
wraps due to fleet angle effects (and not to those sections of rope which only work in sheaves
and do not spool on the drum).

22 Twice the number of broken wires listed may be applied to ropes on mechanisms whose classifi-
d

cation is known to be M5 to M8.

e
d = nominal rope diameter
Wire ropes – Technical information 03/2018
Discard
Warning: Considering security ropes should be taken off Looping on a wire rope
operation in time, if one of the following criterias apply:
3
J Broken strand
J Local concentration of wire breaks
J Achievement of type and number of wire breaks according to the tablets
J Corkscrew deformation (fig. 1)
J Corkscrew (fig. 2)
J Hairpin like escape of wires (fig. 3)
J Decrease of diameter – regarding the nominal rope diameter
J Local increase of diameter
J Heavy corrosion: The surface of the wires is strongly affected or
rosty dust comes out of the rope
Through corrosion and wear heavy loose strand
J Loose rope structure (fig. 4)
J Constriction (fig. 5) 4
J Kinks or flattened areas(fig. 6 + 8)
J Bends or other deformations (fig 7)
J bluish discoloration, broken or fused wires due to heat effects or
electric arc
If several of the above mentioned criterias apply, they need to be considered
in their entirety. Therefore ropes need to discarded, if none of the criteria are
completely but some partially fulfilled. For example: Light Corkscrew with
some broken wires.
The above criteria are an excerpt from the ISO 4309 maintenance and care,
Constriction due to a broken rope core
inspection and storage. Consequently, these criteria do not replace the
instructions and requirements for inspection and maintenance of wire ropes 5
as written in the standard. For evaluation of the discard criteria please refer
to our original operating manual for strand ropes!
If in doubt on the estimation of the cable damage, the rope must be
discarded or your rope specialist needs to be contacted:
wirerope@pfeifer.de or via phone +49 (0) 83 31-937-301.

Flattened wire rope caused by over-ride

Corkscrew deformation Basket deformation Bend caused by a pinched Kind caused by mechanical impact
rope sling

1 2 7 8

23
Wire ropes – Technical information 03/2018
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