HIGH PERFORMANCE

OFFSHORE ROPES
APPLICATION HANDBOOK
2
SUCCSESS THROUGH PERFECTION 4
TECHNOLOGIES FOR YOUR BENEFIT 5
1. PRODUCT INFORMATION 7
1.1 MAIN HOIST ROPE, WHIP LINE EVOLUTION TK 16 7
1.2 BOOM HOIST ROPE QS 816 V (G) 8
1.3 MARINE RISER TENSIONER ROPE QS 814 VG (MRT) 9
1.4 MAIN HOIST ROPE, WHIP LINE EVOLUTION TK 18 10
2. PURCHASING RECOMMENDATIONS 12
3. REQUIRED INFORMATION WHEN ORDERING A ROPE 14
4. STORAGE, HANDLING & INSPECTION 15
4.1. CERTIFICATON AND MARKING 16
4.2 UNLOADING WIRE ROPES UPON RECEIPT 16
4.3 INSPECTING WIRE ROPES UPON RECEIPT 17
4.4 STORAGE 18
4.5 UNCOILING/UNWINDING 19
5. WIRE ROPE INSTALLATION 22
5.1 FIRST TIME INSTALLATION 23
5.2 REPLACEMENT INSTALLATION 23
5.3 CUTTING OF A ROPE 24
5.4 REEVING 25
5.5 CHOICE OF ROPE LAY DIRECTION IN MULTI-LAYER APPLICATION ON OFFSHORE 25
CRANES WITH PLAIN BARRELED DRUMS
5.6 MULTI-LAYER SPOOLING 27
5.7 RECOMMENDATION FOR OPTIMAL SPOOLING OF ROPES IN MULTI-LAYER
APPLICATION ON PLAIN BARRELED DRUMS 28
5.8 RECOMMENDATION: ROPE INSTALLATION ON MULTI-LAYER DRUMS FOR BOOM
HOIST ROPES ON OFFSHORE CRANES 29
5.9 AFTER FINISHING INSTALLATION 30
CONTENT
3
6. ROPES IN OPERATION 31
6.1 GENERAL 31
6.2 INSPECTING THE ROPE CONVEYING SYSTEM 31
6.3 SHEAVES AND DRUMS 32
6.4 ACTUAL ROPE DIAMETER 34
6.5 END TERMINATION 34
6.6 DOCUMENTATION 34
6.7 INSPECTION OF LEBUS GROOVED DRUMS FOR MULTI-LAYER SPOOLING 37
6.8 TWISTING OF SHEAVE BLOCK 38
6.9 UNTWISTING OF HOISTING ROPE 39
6.10 USING OF SWIVEL 39
7. WIRE ROPE MAINTENANCE (GENERAL) 40
7.1 CLEANING OF WIRE ROPES 40
7.2 WIRE ROPE LUBRICATION 40
7.3 RE-LUBRICATION 43
7.4 REMOVAL OF BROKEN WIRE ENDS 44
7.5 SLIP AND CUT (PROCESS) 44
7.6 ADDITIONAL TROUBLE-SHOOTING FOR ExPERIENCED STAFF 45
7.7 WARNINGS 46
8. DISCARD CRITERIA 48
9. CHECKLIST FOR OPTIMAL MULTI-LAYER SPOOLING 61
CONTENT

WARNING
The use of these products can be hazardous. Therefore, never use our products
for purposes other than those they were designed for. Customers must ensure that
all persons using these products are familiar with their correct use and the related
necessary safety precautions. Please bear in mind that any of these products can
cause harm, when they are used incorrectly or overstrained.
SUPERFI LL

and PLASTFI LL

are regi stered trademarks of TEUFELBERGER Ges.m.b.H.

TEUFELBERGER and are i nternati onal l y regi stered trademarksof TEUFELBERGER
Ges.m.b.H.Austri a.
4
TEUFELBERGER Seil Ges.m.b.H. ful l y concentrates on hi gh-performance steel wi re ropes
i n al l aspects of producti on, research & devel opment, marketi ng & sal es acti vi ti es: top qual i ty
products are the basi s of our success.
We care more for our customers thi s i s the mi ssi on of the TEUFELBERGER Sei l Ges.m.b.H.
Cl ose cooperati on wi th our suppl i ers, j oi nt devel opment work wi th OEMs and hi ghl y qual i fi ed
staff ensure that our products ful fi l l your requi rements 100%.
Two production sites wi th modern machi nery, an own research and devel opment department
al ong i n cl ose cooperati on wi th our subsi di ari es ensure that our know-how i s transferred
opti mal l y i nto your success. From the petrol eum i ndustry to harbors, from bui l di ng si tes and
forestry to ropeways for passengers and goods TEUFELBERGERs hi gh-performance steel
wi re ropes and systems for personal safety are perfectl y tai l ored to fi t your fi el d of appl i cati on.
The power of innovation and quality awareness for the benefit of our customers.
Long-term cooperati on wi th uni versi ti es and research i nsti tuti ons and wi th numerous key
users i n the aftermarket stands for our focus on customer requi rements. We gi ve research &
devel opment top pri ori ty, whi ch i s refl ected i n a decentral i zed company structure to expl oi t
synergi es. Our qual i ty awareness i s evi dent by ful fi l l i ng I SO 9001 as wel l as compl i ance wi th
i ndustry-speci fi c standards.
Service hotline
I n case of any urgent probl ems, you can reach TEUFELBERGER Wi re Rope as fol l ows:
24 h hotl i ne: +43 (0) 7242-615-388
SUCCSESS THROUGH
PERFECTION
PERFECT WORDWIDE SERVICE
24 hours 365 days avai l abi l i ty of servi ce engi neers
Speci fi c trai ni ng for mai ntenance peopl e, trai ni ng on the j ob (i .e. Sedco 702)
Joi nt i nstal l ati on for trai ni ng purposes
Free i nstal l ati on manual
5
Our know-how provi des essenti al advantages i n use and effecti ve cost savi ngs. Our hi gh-
performance steel wi re ropes achi eve an outstandi ng servi ce l i fe, provi de best possi bl e safety
for persons and devi ces and reduce mai ntenance, repl acement and organi zati on costs.

PLASTFILL INSERT
The l ubri cated steel core i s encl osed i n a ti ght syntheti c coat.
Advantages: l ong servi ce l i fe through permanent l ubri cati on, resi stance agai nst radi al pressure
and l ateral pressure, hi gher breaki ng forces through reduced stresses i n the rope.
The strands are embedded i n the syntheti c coat duri ng the cl osi ng process.
Advantages: exact strand posi ti on wi th consi stent cl earances for reduced i nternal abrasi on,
equal l oad shares at al l components due to opti mi zed constructi on.

SUPERFILL

COMPACTION TECHNOLOGY
Our compacti on method has been devel oped i n cl ose cooperati on wi th uni versi ti es and
i ndependent research i nsti tuti ons. Each rope strand i s compacted i n a speci fi c procedure wi th
the ai m of si gni fi cantl y i mprovi ng the ropes properti es:
up to 30% more breaki ng forces than non-compacted ropes
prol onged servi ce l i fe due to reduced i nternal stress
use of smal l er rope di ameters wi th the same breaki ng l oad (i mportant for new crane
constructi ons)
smooth rope surface resul ti ng i n reduced abrasi on on rope, sheaves and drums
a conti nuous constant wi re rope di ameter for l ong l engths

GALVANIZED STEEL WIRES
Our steel wi res are gal vani zed before they are drawn i n order to achi eve hi gh wi re preci si on.
Thi s ensures opti mal stabi l i ty and servi ce l i fe. Gal vani zati on i n combi nati on wi th our
PLASTFI LL
TM
technol ogy provi des for extreme resi stance agai nst corrosi on.
TECHNOLOGIES
FOR YOUR BENEFIT
6
ADVANTAGES OF TEUFELBERGER HIGH-PERFORMANCE ROPE DESIGN
The name TEUFELBERGER represents a sol i d corporate group wi th 3 strategi c busi ness
di vi si ons and more than 200 years of experi ence. The company i s fami l y-owned. More than 750
dedi cated empl oyees achi eve an export performance of more than 80% of total turnover per
year. TEUFELBERGER Seil Ges.m.b.H. concentrates excl usi vel y on the manufacturi ng,
research & devel opment, marketi ng and sal e of hi gh-performance steel wi re ropes.

KNOW-HOW AND EXPERIENCE IN THE INDUSTRY:
Manufacturi ng of steel wi re ropes for more than 80 years
Successful l ong term rel ati onshi ps wi th sati sfi ed key customers i n the offshore i ndustry
Devel opment of partnershi ps wi th wel l known crane manufactures for the offshore i ndustry,
e.g. Li ebherr, Seatrax, Nati onal Oi l wel l , Patri ot/TSC, Hui sman, I nterseas

ADVANCED RESEARCH AND DEVELOPMENT:
I nnovati ve rope desi gns matched to offshore appl i cati on needs
Hi gh and ongoi ng i nvestments i n our product devel opment and conti nuous i mprovement of
the manufacturi ng process i n order to provi de best materi al for the end user.
New ul tra-modern wi nch test stands and bendi ng fati que machi nes i n order to get
accurate and real i sti c test resul ts whi ch we use to devel op new desi gns.
R&D partnershi ps between the other strategi c busi ness di vi si ons promi se ongoi ng
devel opments i n the steel wi re rope sector.

MATERIAL REDUCED RISK OF CORROSION:
TEUFELBERGER excl usi vel y uses top-strength materi al s and hi ghl y modern producti on
processes i n order to ful fi l l customer requi rements.
Every rope whi ch wi l l be del i vered for the offshore i ndustry i s equi pped wi th hi gh-tensi l e,
drawn gal vani zed wi res.
Use of real hydrophobi c pol ypropyl ene PLASTFI LL
TM
materi al for best protecti on of the
core and provi di ng permanent l ubri cati on

TECHNOLOGIES:
A combi nati on of PLASTFI LL
TM
pl asti ci zed steel core, SUPERFI LL

strand compacted
ropes and DRAWN GALVANI ZED wi res provi des the best servi ce l i fe for our end user.
TECHNOLOGIES
FOR YOUR BENEFIT
7
1. PRODUCT INFORMATION
TEUFELBERGER ropes for the offshore industry provide
Hi ghest rel i abi l i ty
Hi ghest safety standards
Hi gh corrosi on resi stance
Reducti on of total cost of ownershi p through hi ghest possi bl e fati gue l i fe
Worl dwi de avai l abi l i ty (Si ngapore, Aberdeen, Perth, Houston, Norway, Dubai , ...)
1.1 MAIN HOIST ROPE, WHIP LINE EVOLUTION TK 16
Revol uti onary desi gn, hi gh-qual i ty materi al and opti mal producti on
processes - the new EVOLUTI ON TK 16 combi nes al l the features you
requi re for your appl i cati on: Hi ghest breaki ng l oads AND hi gh fl exi bi l i ty
i n combi nati on!
YOUR ADVANTAGE
Highest breaking loads worldwide!
A new rope structure and the SUPERFI LL

compacti on technol ogy together achi eve the

hi ghest breaki ng forces worl dwi de for strandcompacted ropes transl ati ng to more safety
duri ng operati on.
Minimum rotation with high torsion stability
The ropes superi or torque or turn characteri sti c ensures smooth and safe transportati on
of l oads.
Higher flexibility
Rope fl exi bi l i ty provi des very good spool i ng condi ti ons for mul ti l ayer wi ndi ng and a smooth
l i fti ng procedure under extreme condi ti ons. The rope addi ti onal l y absorbs hi gh dynami c l oad.
Longer service life, higher profitability
Ropes desi gned for l ong-term use - by further i mprovi ng producti on processes, the hi gh
qual i ty product of hoi st ropes has been i ncreased. The PLASTFI LL i nsert between the i nner
rope and outer strands provi des addi ti onal protecti on agai nst corrosi on. Your deci si on on
EVOLUTI ON TK 16 affi rms i ncreased producti vi ty, l ong-term cost reducti on and enhanced
competi ti veness.
8
SPECIFICATIONS

Ordi nary l ay (al so avai l abl e i n l ang s l ay), ri ght or l eft l ay
8 30 mm: 16 x K6 EPI WRC (K), RCN 23-1
32 42 mm: 16 x K7 EPI WRC (K), RCN 23-2
Rope grades: 1770 / 1960 / 2160
Number of wi res i n the outer strands: 96 (8 - 30 mm)
112 (32 42 mm)
MULTI -LAYER WI NDI NG
SUPERFI LL

PLASTFI LL
1. PRODUCT INFORMATION
YOUR ADVANTAGE
Reliability and safety duri ng operati on due to extremel y hi gh breaki ng l oads.
Cost reduction due to reduced rope abrasi on, l onger servi ce l i fe and reduced mai ntenance
i nterval s
Trouble-free operation resul ti ng from excel l ent absorpti on of bangs and vi brati ons
Long service life due to smoother rope surfaces
Outstanding winding characteristics resul ti ng from hi gh stabi l i ty agai nst l ateral pressure
Permanent lubrication due to PLASTFI LL
TM
i nsert
Extreme resi stance to negati ve external i nfl uences di sti ngui sh thi s rope
from others. TEUFELBERGER s SUPERFI LL

compacti on technol ogy

guarantees hi gh breaki ng forces, transl ati ng to hi ghest operati onal safety.
The desi gn of the i nner rope and the PLASTFI LL
TM
i nsert guarantee hi gh
stabi l i ty agai nst l ateral pressure.
1.2 BOOM HOIST ROPE QS 816 V(G)
9
1. PRODUCT INFORMATION
SPECIFICATIONS

QS 816 V ordi nary l ay, QS 816 V G l ang s l ay, l eft and ri ght l ay
10 - 42 mm: K26WS EPI WRC (K), RCN 9
42 - 50 mm: K31WS EPI WRC (K), RCN 11
Rope grades: 1770 / 1960 / 2160
Number of wi res i n the outer strands: 208 (10 - 42 mm)
248 (42 - 50 mm)
MULTI -LAYER WI NDI NG
SUPERFI LL

PLASTFI LL
Extreme bendi ng fati gue performance i s the strong poi nt of thi s rope.
The SUPERFI LL

-compacti on technol ogy devel oped by TEUFELBERGER

generates hi gh breaki ng forces and thus a hi gh safety l evel duri ng opera-
ti ons. The appl i cati on of thi s technol ogy to the steel core generates hi gh
resi stance agai nst radi al deformati on.
YOUR ADVANTAGE
Highest numbers on tonne-miles/cycles compared to 6 strand ropes
Reliability and safety duri ng operati on due to extremel y hi gh breaki ng forces
Cost savings through l ess abrasi on of the rope, l onger operati ng cycl es and mai ntenance
i nterval s
Excellent bending properties and hi gh fl exi bi l i ty due to 8-strand constructi on and hi gh
number of si ngl e wi res
Maximal resistance to corrosi on and strength due to the gal vani zati on of the wi res
Long fatigue life due to the smoother surface of the rope generated by SUPERFI LL

-
compacti on technol ogy
1.3 MARINE RISER TENSIONER ROPE QS 814 VG (MRT)
10
SPECIFICATIONS

Lang s l ay, l eft and ri ght l ay
44,5 - 63,5 mm, 1 3/4" - 2 1/2": 8 x K36WS - EPIWRC (K), RCN 13
Rope grades: 1770 / 1960
Number of wi res i n the outer strands: 288
SUPERFI LL

PLASTFI LL
MULTI -LAYER WI NDI NG
1. PRODUCT INFORMATION
1.4 MAIN HOIST ROPE, WHIP LINE, EVOLUTION TK 18
The EVOLUTI ON TK 18 i s our new hi gh-performance rope for l arge
cranes, e.g. i n the offshore and shi ppi ng i ndustry. EVOLUTI ON TK 18 has
been devel oped for cranes whi ch operate under hardest condi ti ons. Thi s
rope offers best i n cl ass breaki ng forces, a hi gh fl exi bi l i ty and i s the fi rst
choi ce for l arger di ameters between 44 and 70 mm.
YOUR ADVANTAGE
Optimal spooling results
Easier handling duri ng mounti ng
Smooth operations duri ng extremel y chal l engi ng l i fti ng operati ons
Longer service Life thi s hel ps cutti ng costs and i ncreasi ng profi tabi l i ty
Highest breaking forces i ncreases the safety factor
Lowest twist in its class ensures safe and effi ci ent handl i ng
Excellent suitability for heave compensati on-appl i cati on (onl y regul ar l ay ropes) due to
pro acti ve l ubri cati on
11
1. PRODUCT INFORMATION
SPECIFICATIONS
Ordi nary l ay (al so avai l abl e i n l ang s l ay), l eft or ri ght l ay
44 - 70 mm: 16 x K17F - EPI WRC (K), RCN 27
Rope grade: 1960
Number of wi res i n the outer strands: 272
Large offshore cranes
Subsea wi nches
"Heavy l i ft" cranes
FIELD OF APPLICATION
MULTI -LAYER WI NDI NG
SUPERFI LL

PLASTFI LL
12
Based on many years of experi ence, resul ti ng from cl ose co-operati on wi th l eadi ng crane
manufacturers and customers usi ng hi gh-performance wi re ropes, the fol l owi ng poi nts shoul d
be consi dered when sel ecti ng a wi re rope:
ALWAYS COMPARE APPLES WITH APPLES
Especi al l y consi der rope characteri sti cs l i ke breaki ng force, gal vani zati on, pl asti ci zed steel
core, expected l i feti me and general qual i ty factors whi ch i nfl uence the rope performance.
CONSIDER THE MINIMUM BREAKING FORCE AS THE KEY SELECTION CRITERION
The mi ni mum breaki ng force of a rope has to reach the l evel speci fi ed for a speci fi c crane as
shown i n the crane speci fi cati on document. The use of a rope wi th l ess than the speci fi ed
mi ni mum breaki ng force i s not al l owed and may have seri ous consequences!
LEFT OR RIGHT LAY
The l ay of a rope i s cruci al for the performance and the l i feti me of a wi re rope. The correct l ay
can al so be found i n the crane speci fi cati on document. I f you are not sure whi ch l ay i s needed,
you can al so contact our techni cal experts.
LANGS LAY OR ORDINARY LAY
Ordi nary l ay normal l y can be used for most appl i cati ons. To al l ow the use of a l angs l ay rope,
thi s must be speci fi ed i n the crane speci fi cati on document. Ropes i n l angs l ay can reach a
l onger servi ce l i fe under certai n ci rcumstances. Lang s l ay ropes must not be used i n si ngl e
l ayer spool i ng and/or j ust on pl asti c sl eaves.
CHECK CROSS REFERENCE
TEUFELBERGER can offer al ternati ve speci al wi re ropes for most rope types avai l abl e on the
market. To sel ect a proper rope type, pl ease speci fy the ori gi nal rope type. Our rope experts
wi l l then sel ect a rope that wi l l reach the performance of the menti oned rope i n any case.
CHECK METRICS (SIZE CONVERSION)
Be careful when converti ng the i mperi al i nto metri c si ze, especi al l y i n case you requi re e.g. a 1"
rope. We offer tai l or made ropes i n i mperi al si zes.
2. PURCHASING RECOMMENDATIONS
13
2. PURCHASING RECOMMENDATIONS
USE OF GALVANIZED ROPES
Gal vani zed ropes can be used i n any case and can al ways repl ace ungal vani zed (bri ght) ropes.
The opposi te way repl aci ng gal vani zed wi th ungal vani zed ropes i s not recommended and
may even be dangerous under certai n ci rcumstances, as the rope l oses the posi ti ve effect of
gal vani zati on (hi gher corrosi on resi stance l eadi ng to a l onger servi ce l i fe, especi al l y i n mari ti me
envi ronments).
CHECK ENVIRONMENTAL CONDITIONS
Factors l i ke humi di ty, sal t water, dust & di rt requi re a speci al protecti on of the i nner core.
Therefore, a pl asti ci zed steel core i s a maj or meri t i n rel ati on to servi ce & overal l l i feti me.
END TERMINATION
Pl ease check whi ch ki nd of end termi nati on, i f any, i s necessary for a speci fi c rope. Thi s
i nformati on has to be provi ded when pl aci ng an order. Pl ease consi der l oss of effi ci ency for
certai n end termi nati ons.

CERTIFICATES
Pl ease check and speci fy when pl aci ng an order, whi ch certi fi cates are requi red.
TEUFELBERGER provi des ABS, DNV, LRS, GL etc.
14
3. REQUIRED INFORMATION WHEN ORDERING A ROPE
Customer (end user, ri g name)
Application
Nominal rope diameter (mm or i nch)
Diameter tolerance (i f appl i cabl e)
Nominal rope length (m or feet)
Length tolerance (i f appl i cabl e)
Construction (brand and name)
Type of core
Rope Grade
Finish ungal vani zed / gal vani zed
Type of lay
Type of lubrication
Required minimum breaking force
Rope standard
Manufacturing standard (I SO, EN, API )
Reel speci fi cati on (TK 18 onl y steel reel s)
Back tension required when spooling
onto winch?
Termination inner end
Termination outer end (TEUFELBERGER
Pul l -eye or tai l or made sol uti on)
Certification thi rd party authori ty
(i f requi red)
Gross weight (i ncl . termi nati on, reel etc.)
I D-number (i f requi red)
BASIC TECHNICAL INFORMATION
ADDITIONAL INFORMATION
Crane manufacturer crane type
Drum detai l s grooved: Yes or No
I f yes: Hel i cal or Lebus
Pi tch of groovi ng: Wi dth of drum (mm)
Sheave/drum to wi re rope di ameter
(D/d rati o)
Number of wraps per l ayer
Number of l ayers
Operati on cl i mate:
(hi gh/l ow temperatures)
I f subsea use: Yes or No
Operati on depth
Operati on pressure
Heave compensati on
Bold lettered informations are must information
15
4. STORAGE, HANDLING & INSPECTION

ATTENTION: Instructions and warnings (standard warning)
As a provi der of ropes wi th many years of experi ence, our rope recommendati ons are
nonbi ndi ng but based on experi ence. Pl ease note the speci al characteri sti cs of your system.
Contact us to fi nd the opti mal rope for you, based on the l atest experi ence. Typi ng and pri nti ng
errors excepted. Langs l ay ropes must be used for mul ti pl e l ayer wi ndi ng (on the drum) or
must be subj ected to regul ar, non-destructi ve i nspecti on.
Handl i ng & i nstal l ati on of the rope shoul d be carri ed out i n accordance wi th a detai l ed pl an and
shoul d be supervi sed by a competent person.


WARNING
Incorrectly supervised handling and installation procedures may result in serious injury
to persons in the working area of installation and as well as those persons directly
involved in the handling and installation.

General notes
The fol l owi ng notes and warni ngs are i ntended to ensure safe handl i ng. Non-compl i ance may
cause damage and hazard.
Warni ngs refer to potenti al hazards that may reduce the rope qual i ty, thus endangeri ng
personnel and damagi ng rope-rel ated equi pment.
16
4. STORAGE, HANDLING & INSPECTION
4.1 CERTIFICATON AND MARKING
Ensure that the correct rope has been suppl i ed by checki ng that the descri pti on on the
Certi fi cate i s i n accordance wi th that speci fi ed on the purchase order. Make sure that you take
the rel evant certi fi cate from the del i vered drum before usi ng the rope. (We refer to statutory
requi rements.)
Veri fy that the marki ng on the rope or i ts package matches the rel evant certi fi cate.
Retai n the certi fi cate i n a safe pl ace for i denti fi cati on of the rope when carryi ng out subsequent
peri odi c statutory exami nati ons i n servi ce. (We refer to statutory requi rements).

NOTE
The rating of a component of a machine or lifting accessory is within the responsibility
of the designer of the machine or accessory. Any re-rating of a lifting accessory must
be approved by a competent person. (See ISO 4309.)
4.2 UNLOADING WIRE ROPES UPON RECEIPT
Check the rope packagi ng for any transport damage.
Record any such damage on the del i very note.
When unl oadi ng, take appropri ate measures to avoi d damage to the rope.
I n parti cul ar, take care not to damage the rope wi th the forks of the l i ft truck.
To avoi d damage when l i fti ng coi l s or reel s, webbi ng sl i ngs are recommended.
Reel s are preferabl y l i fted by usi ng a shaft i nserted through the center hol e.
17
4. STORAGE, HANDLING & INSPECTION 4. STORAGE, HANDLING & INSPECTION
4.3 INSPECTING WIRE ROPES UPON RECEIPT
CHECK MARKING & CERTIFICATION
I f not properl y marked, coi l s or reel s must be l abel ed i mmedi atel y accordi ng to the del i very
note to avoi d subsequent confusi on. Accompanyi ng qual i ty certi fi cates must be checked
agai nst the purchase order speci fi cati ons and agai nst the marki ng on the reel . Make sure that
the certi fi cates are kept i n a safe dry pl ace.
CHECK ROPE PARAMETERS
Make sure that the rope del i vered meets the purchasi ng speci fi cati on, especi al l y i n terms of
Measuri ng rope di ameter -
correct
Measuri ng rope di ameter -
i ncorrect
To measure the rope di ameter, two di fferent
sets of measurements are taken, spaced at
a mi ni mum di stance of one meter, and i n
two di fferent pl anes perpendi cul ar to each
other. The measuri ng cal i pers (avai l abl e from
TEUFELBERGER) have to be suffi ci entl y wi de.
The rope di ameter i s the average of these
four measurements. (For measuri ng method
see DI N or CEN rope standards.) The wi re
rope di ameter shoul d be wi thi n the tol erance
speci fi ed i n the purchase order. I t has to be
checked i f there i s a di fferent tol erance i n the
rope handl i ng system manual .
rope di ameter
end termi nati on
l ay di recti on
ropes constructi on
MBF
I n general the di ameter
tol erances are +0 / +4%
of nomi nal di ameter for
TEUFELBERGER ropes
(i f i t i s not di fferent spe-
ci fi ed).
18
4.4 STORAGE
Wi re ropes shal l be protected agai nst humi di ty and weather condi ti ons.
They shoul d be stored i n dry, wel l venti l ated rooms at ambi ent temperature. Storage i n damp,
poorl y venti l ated condi ti ons may l ead to corrosi on.
I f ropes have to be stored i n the open ai r, make sure to:
1. avoi d that the rope i s i n di rect contact wi th the ground;
2. cover the rope compl etel y wi th water-proof sheets, thus preservi ng the ori gi nal l ubri cant.
Al l ow access of ai r to avoi d corrosi on beneath the cover.
Never store wi re ropes at el evated temperatures, nor expose them to dust, di rt or aci ds.
I f wi re ropes are l eft unused i n shut-down pl ants, renewed cl eani ng and l ubri cati on may be
requi red when operati on i s resumed (see 7.2 Wi re rope dressi ng).


CAUTION
If stored at elevated temperatures, or in damp, corrosive or dusty environments, or if
contaminated by soil or chemical contact, rope properties may suffer serious harm.
Stored ropes must be inspected at periodical intervals and, if necessary, re-lubricated
with grease compatible with the manufacturers instructions. Guidance on the right
dressing is given in chapter 7 and/or in the crane manufacturers maintenance
instructions.

CAUTION
Incompatible dressing may render the manufacturers lubricant ineffective, thus
critically lowering the rope quality. Wire ropes withdrawn from operation and stored
for later re-use require careful cleaning and lubrication prior to spooling. Store ropes
under same conditions as new ropes.
4. STORAGE, HANDLING & INSPECTION
19
4. STORAGE, HANDLING & INSPECTION 4. STORAGE, HANDLING & INSPECTION
4.5 UNCOILING/UNWINDING
Wire ropes must be uncoiled or unwound by trained personnel or under supervision.


CAUTION
Incorrect handling of wire ropes may be extremely dangerous. Critical damage to
ropes may seriously endanger both persons and the equipment. Wire ropes should
only be handled wearing protective clothing such as safety gloves and footwear, eye
protection and safety helmets.

CAUTION
The failure to wear suitable protective clothing may constitute a serious health
hazard and cause injuries: Skin problems resulting from excessive exposure to certain
lubricants; respiratory defects from inhaling gases when cutting ropes or embedding
them in sockets; eye injuries caused by sparks, wire fragments, wire and rope ends;
burns produced by sparks, molten lubricants or metals; and other injuries caused by a
backlash of wire and rope ends. Prior to first use, check if the wire rope corresponds
to the purchase order and the rope handling system manual or OEMs (original
equipment manufacturers) instructions.
Correspondence is ascertained by measuring the rope diameter and comparing the
rope construction given on the delivery note with the purchase order.
correct i ncorrect
20
4. STORAGE, HANDLING & INSPECTION

CAUTION
The use of wire ropes not corresponding to the OEMs instructions may cause serious
danger to personnel and rope conveying equipment.
Check the wire rope for defects caused by improper handling or storage.
Care must be taken when releasing the outboard end from the reel or the servings of
the coil. The wire rope will tend to fly in an abrupt and violent movement. Do not stand
in line with the outer end.

CAUTION
Uncontrolled release of the outboard end from the reel or uncontrolled opening of coil
servings may cause injury.
Ensure that the wire rope is not damaged during installation.
To maintain rope geometry, wire ropes must be uncoiled or unwound with maximum
care. The rope should not receive any twist or turn. Pulling over sharp edges or
through tight radii can seriously damage the rope and must be avoided. If the rope
must be drawn over fixed parts during installation, these must be covered by an
adequate device such as sheaves or wooden material if necessary. The rope should
never be pulled from coils sideways or over the flange of a reel to avoid turn causing
serious or even irreparable damage to the rope.
correct i ncorrect
21
4. STORAGE, HANDLING & INSPECTION 4. STORAGE, HANDLING & INSPECTION

CAUTION
In the absence of any uncoiling equipment, the rope must be unrolled flat on the
ground (see illustration page 20). WELCHE ILLUSTRATION GEHRT DAZU?
Uncoiling a rope from a drum also requires great care. The drum must be jacked up
on a frame using a rod inserted through the drums center hole. The rope is then
uncoiled from the drum under controlled tension to avoid the formation of loops. This
is achieved by applying a manual brake to the drum flange or using a special brake
device. Loops formed during uncoiling may seriously damage the rope. Under load,
loops contract and produce a kink which irreparably deforms the rope (see illustration
below).

CAUTION
A kink may significantly reduce the wire ropes breaking force and cause danger to
personnel and rope conveying equipment.
correct i ncorrect
22
5. WIRE ROPE INSTALLATION
Wi re ropes may onl y be i nstal l ed by techni cal experts or trai ned persons under competent
supervi si on.


CAUTION
Incorrect wire rope installation may be hazardous to those involved with installation
and subsequent operation. Make sure that the conveying equipment is safe for rope
installation and that it cannot be started accidentally. Refer to the system OEMs
operating instructions. Make sure to carefully plan the sequence of rope installation.
Follow the OEMs operating manual. Verify the availability of tools and auxiliary
equipment required for rope installation.
Instruct installation personnel accordingly. Installation should be performed with due
care and step by step under expert supervision.

Duri ng assembl y, the reel shoul d be mounted at maxi mum di stance from the fi rst sheave or the
drum and wi thout defl ecti on, as defl ecti on may cause the rope to twi st (see Fi g. 1).
Rotati on-resi stant ropes, for exampl e, may even be damaged at fl eetangl es hi gher than 2.
When ropes are manufactured, ropes are wound on a reel , thus acqui ri ng a preferred bendi ng
di recti on. When mounti ng a rope, the rope shoul d retai n the same bend to avoi d damagi ng the
rope or reduci ng i ts servi ce l i fe (see Fi g. 2).
Fi g. 1 Fi g. 2
23
5. WIRE ROPE INSTALLATION 5. WIRE ROPE INSTALLATION
5.1 FIRST TIME INSTALLATION
When fi tti ng a new rope, turns shoul d not be put i nto or taken out of the rope. I f the rope i s not
i nstal l ed by usi ng the ol d rope, we recommend usi ng a texti l e auxi l i ary rope or a thi n, rotati on-
resi stant rope. Stranded ropes must have the same di recti on of l ay as the new rope.
Wi re rope socks must be suffi ci entl y l ong to prevent the ropes from sl i ppi ng out.
When usi ng an auxi l i ary rope to i nstal l the new rope, the rope sock must have an eyel et.
The auxi l i ary rope, whi ch may be a fi ber rope, must have suffi ci ent tensi l e strength.
I f the new rope i s i ntroduced usi ng the ol d rope, a rope sock open on both ends i s used.
I f the i nstal l ati on goes over l arge hei ghts, the wi re rope has to be prevented from rotati ng.
5.2 REPLACEMENT INSTALLATION
a) I f i nstal l i ng the new rope wi th the ai d of an ol d one, one method i s to fi t a wi re rope sock to
each of the rope ends. Al ways ensure that the open end of the sock i s securel y attached to the
rope by a servi ng or al ternati vel y by a cl i p. Connect the two ends vi a a l ength of fi ber rope or a
smal l ROTATI ON-RESI STANT rope of adequate strength i n order to avoi d turn bei ng transmi tted
from the ol d rope i nto the new rope.
I f the ol d rope i s used as pi l ot rope, make sure that no turn i s transmi tted to the new rope.
Do not wel d together ol d and new ropes. Though such j uncti on provi des a certai n amount of
tensi l e strength, the rope may break when passi ng over sheaves, thus creati ng a safety ri sk
and possi bl y damagi ng the new rope or the equi pment as a whol e. One way of j oi ni ng the ol d
and the new rope i s by usi ng a wi re rope sock fi tted over rope ends, whi ch must be secured
wi th tape or a cl i p (see i l l ustrati on bel ow).
Wi re rope sock
24
WIRE ROPE SOCK SEIZING
b) Al ternati vel y, a l ength of fi ber or steel rope of adequate strength may be used i n the system
as a pi l ot/ messenger l i ne.
Do not use a swi vel duri ng the i nstal l ati on of the rope i n such a case.
Moni tor the rope careful l y as i t i s bei ng pul l ed i nto the system and make sure that i t i s not
obstructed by any part of the structure or mechani sm whi ch may cause the rope to come free.
Fai l ure to moni tor duri ng thi s operati on coul d resul t i n i nj ury.
5.3 CUTTING OF A ROPE
I f i nstal l ati on requi res cutti ng a wi re rope, make sure to appl y proper servi ngs before cutti ng
ends, a mi ni mum of one servi ng to each si de (see i l l ustrati on bel ow). These servi ngs must be
equal to a mi ni mum of two rope di ameters i n l ength.
Speci al care has to be taken when appl yi ng servi ngs to rotati on-resi stant and mul ti -strand
ropes. Before cutti ng, the rope has to be secured and fi xed on both si des of the cutti ng secti on
so that both ends remai n i n the same posi ti on and do not unl ay. Wi re ropes are preferabl y cut
by usi ng an abrasi ve di sc cutter or hydraul i c rope cutter.

CAUTION
When using an abrasive disc cutter, sparks and separated
wire particles as well as toxic fumes may present a health
hazard.
5. WIRE ROPE INSTALLATION

CAUTION
If ropes will be delivered with becket loop / TEUFELBERGER Pull-eye / chainlink
for reeving purposes, please note that this connection can be only used while
installation procedure.
25
5. WIRE ROPE INSTALLATION 5. WIRE ROPE INSTALLATION
5.4 REEVING
Before i nstal l i ng a new rope, deci de whether to pul l the wi re rope through the enti re reevi ng,
or to wi nd i t on the rope drum as a fi rst step and pul l i t through the reevi ng as a second - an
excepti onal procedure requi ri ng suffi ci ent drum capaci ty. I f one i nner end of the new rope ends
i n a fi tti ng (e.g. a thi mbl e), the onl y possi bi l i ty i s to pul l the free end through the reevi ng.
When wi ndi ng a rope on a pl ai ned barrel ed drum, subsequent turns must be coi l ed ti ghtl y.
Suffi ci ent rope tensi on faci l i tates the operati on.

RECOMMENDATION
Avoid fleet angles higher than 2 degrees (rotation resistant ropes) and 4 degrees (non
rotation resistant ropes) during installation!
5.5 CHOICE OF ROPE LAY DIRECTION IN MULTI-LAYER
APPLICATON ON OFFSHORE CRANES WITH PLAIN BARRELED DRUMS
DEFINITION OF MULTI-LAYER SPOOLING:
The ropes are spool i ng i n mul ti l ayer appl i cati on i f more than one l ayer i s spool ed on the drum
MAIN LOAD LINE AND AUX LOAD LINE
These ropes shoul d be rotati on-resi stant ropes (non rotati ng) whi ch are torque bal anced. Due
to thi s behavi or rotati on resi stant rope wi l l bui l d a ti ght bottom l ayer, even on pl ai n drums
i ndependent of the posi ti on of the anchor poi nt of the drum and l ay di recti on. (as l ong as the
fl eet angl es are wi thi n the recommendati ons)
For main and aux line either right hand lay or left hand lay ropes can be used on the
plain barreled drum without influencing the spooling behavior.
26
BOOM HOIST ROPE
For thi s appl i cati on a non-rotati on resi stant rope (6 strand or 8 strand) shoul d be used. As thi s
constructi on i ntends to rotate i f l oadi ng wi l l be i ni ti ated the usual recommendati on (i .e. I SO
4308) for pl ai n barrel ed drums shal l be fol l owed.
For boom ropes the right hand lay should be installed on a drum with the anchor point
on the left side (overwind spooling) and vice versa.
See i l l ustrati on bel ow
.
5. WIRE ROPE INSTALLATION
27
5. WIRE ROPE INSTALLATION 5. WIRE ROPE INSTALLATION
5.6 MULTI-LAYER SPOOLING
I f mul ti -l ayer spool i ng i s requi red on the equi pments wi nch drum, ensure that the new wi re
rope i s under tensi on as i t i s coi l ed on the drum. Hi gh tensi on on the rope i ncreases i t s radi al
stabi l i ty (recommended tensi on = approx. 2,5 5% of MBF of rope), thus si gni fi cantl y reduci ng
wear i n the l ower rope l ayers on the drum.
Loose wi ndi ng may subsequentl y, when spool i ng under l oad, cause outer rope l ayers to cut
i nto l ayers bel ow, resul ti ng i n i rreparabl e rope damage. The outer l ayers may even be pul l ed i n
and trapped. The rope then has to be pul l ed out from l ayers bel ow by subsequent uncoi l i ng.
I n most cases i t wi l l be suffi ci ent to wi nd up the rope fi rst, then pul l i t compl etel y through the
reevi ng (to the dead wraps) and subsequentl y wi nd i t on the drum under mi nor back tensi on.
Some rope systems requi re drum wi ndi ng of the rope onto the drum under tensi on duri ng i ni ti al
i nstal l ati on. Rope tensi on shoul d be as hi gh as possi bl e, but not more than recommended
above of the mi ni mum breaki ng force. Such back tensi on can be achi eved by appl yi ng a brake
to the reel as the rope i s drawn off. Pl ease note that i t i s necessary to order conventi onal reel s
for the descri bed i nstal l ati on procedure. Cross reel s are unsui tabl e.
Brakes or tensi oni ng apparatus shal l not be appl i ed to the rope di rectl y to avoi d twi sti ng or
deformi ng the rope, causi ng i rreparabl e damage.

CAUTION
Loose or uneven spooling on the drum may cause excessive wear, crushing and
deformation of the rope.


For further assi stance i n rel ati on to correct choi ce of rope l ay di recti on i n the crane system,
pl ease contact
TEUFELBERGER Sei l Ges.m.b.H., T +43 7242 615-0, E wi rerope@teufel berger.com
28
5.7 RECOMMENDATION FOR OPTIMAL SPOOLING OF ROPES
IN MULTI-LAYER APPLICATION ON PLAIN BARRELLED DRUMS
INSTALLATION
Make sure that you use ful l y compacted ropes. These ropes are more resi stant agai nst radi al
deformati on.
I nstal l the ropes wi th proper tensi on and avoi d l oose l ayers (especi al l y on the fi rst wraps /
l ayer on the drum.
Rope entrance on the drum has to be smooth as the very fi rst rope wrap has to be very ti ght
on the drum fl ange. Avoi d sharp edges i n thi s area!
When upwi ndi ng the fi rst turn ensure a cl ose contact to the drum by the use of a pl asti c
hammer i n order to avoi d any damages on the rope.
I f fi rst l ayer i s ful l y spool ed onto the drum pl ease check i f there i s any remai ni ng gap be-
tween l ast wrap on the fi rst l ayer and drum fl ange. The gap shoul d not be l arger than of
the rope di ameter. I f gap i s l arger pl ease i nstal l a shi m pl ate accordi ng to crane manufactur-
ers recommendati on.
Pl ease note that the gap can vary because of the exi sti ng drum - and rope tol erances
Addi ti onal l y for boom hoi st ropes pl ease try to ti ghten the rope structure i n the safety wrap
area wi th the hel p of twi sti ng the end of the rope at the anchor poi nt si de (i nstructi ons are
avai l abl e at crane manufacturer or TEUFELBERGER).
Try to use j ust the number of turns that are necessary for the operati on of the crane and re-
gardi ng to safety wraps, fol l ow crane manufacturer s manual and appl i cabl e regul ati ons (API ).
Pl ease avoi d to use 1st rope l ayer as gui dance l ayer because of the ri sk of crushi ng.
Pl ease consi der a run i n ti me for a new i nstal l ed rope i n order to make wi re/strand setti ngs
happen fol l ow manufacurer s regul ati ons.
Avoi d sl ack rope i n the system because of the ri sk to get l oose wraps/l ayers wi th the resul t
of crushi ng.
Make sure that the rope i s permanent very wel l l ubri cated whi ch reduces fri cti on between
each wraps and l ayers of rope.
I n general usage of l ang s l ay compared to ordi nary l ay - constructi on provi de even more
fl exi bi l i ty and crushi ng resi stance and l ead to l onger l i feti me and better handl i ng of ropes.
5. WIRE ROPE INSTALLATION
29
5. WIRE ROPE INSTALLATION 5. WIRE ROPE INSTALLATION
5.8 RECOMMENDATION: ROPE INSTALLATION ON MULTI-LAYER DRUMS
FOR BOOM HOIST ROPES ON OFFSHORE CRANES
Exampl e of a dead end:
Two di fferent vi ews,
but one rope
Lay Type of rope:
ordi nary ri ght
FIXING THE ROPE AT THE ANCHOR POINT
OF THE DRUM:
Secure the rope at the posi ti on wi thi n the anchor
poi nt of the drum.

NOTE
One person of the team has to take care that
the twist does not turn back while fixing the
rope. After fixing the rope within the anchor
point, the twisting device must be removed from
the rope!
For boom hoi st ropes (l uffi ng) onl y:
Before fi xi ng the rope at the anchor poi nt, twi st the rope around i t s axl e i nto the "ti ght"
di recti on before wi th a sui tabl e twi sti ng devi ce. Make sure, that the twi st does not turn back,
whi l e fi xi ng the rope.
30
UP-WINDING UNDER TENSION
The fi rst l ayer must have an adequate tensi on of at
l east 2,5 5% of the mi ni mum breaki ng force or -
for heavy operati on - 10% of the rope tensi on of the
expected l oad.
Any l i mi t swi tch, i f fi tted, must be checked and re-adj usted, i f necessary, after the rope has
been i nstal l ed.
Record the fol l owi ng detai l s on the Certi fi cate after i nstal l ati on has been compl eted: type of
equi pment, l ocati on, pl ant reference number, date of i nstal l ati on and any re-rati ng i nformati on/
si gnature of competent person. Then safel y fi l e the Certi fi cate.
RUNNING-IN TIME
Run i n the new rope by operati ng the equi pment sl owl y a number of ti mes, preferabl y wi th a
l ow l oad of approx. 10% of the worki ng l oad l i mi t (WLL), for several cycl es. Thi s permi ts the
new rope to adj ust i tsel f gradual l y to worki ng condi ti ons.
Check that the new rope i s spool i ng correctl y on the drum and that no sl ack or cross l aps
devel op. I f necessary, appl y as much tensi on as possi bl e to ensure ti ght and even coi l i ng, es-
peci al l y on the fi rst l ayer. Ensure that the as-manufactured condi ti on of the rope i s mai ntai ned
throughout the whol e of the handl i ng and i nstal l ati on operati on.



NOTE
The rope should be in this condition before any proof test of the equipment or machin-
ery is carried out.
Proper spool i ng (no gap
between the strands)
5.9 AFTER FINISHING INSTALLATION
5. WIRE ROPE INSTALLATION
31
5. WIRE ROPE INSTALLATION
6. ROPES IN OPERATION
6.1 GENERAL
I nspecti on shoul d be performed acc. to the regul ar standards, exampl e I SO 4309 or API 2D or
other regul ati ons appl i cabl e i n the parti cul ar country.

Exampl e: see Compari son of di scard cri teri a I SO 4309 API 2D
6.2 INSPECTING THE ROPE CONVEYING SYSTEM
The rope conveyi ng system must be i nspected by a competent person or trai ned personnel
onl y.
The wi re ropes path through the equi pment shoul d be moni tored to check for any worn areas
produced by fri cti on of rope and other parts; take remedi al acti on i f necessary.

CAUTION
Failure to check the rope system may decrease rope service life and safety of
operation.

CAUTION
Defects in the rope conveying system may cause serious injury to personnel.
Each defect in rope pulleys or drums will damage the rope, thus shortening the ropes
service life at a much faster rate than through normal wear. Careful inspection of the
system is therefore required prior to installation. Before fitting the new rope, check the
condition of the entire system.
32
6.3 SHEAVES AND DRUMS
Check the groove di ameter and condi ti on of rope sheaves, defl ecti on sheaves and drums.
Grooves i n rope drums, rope and compensati on pul l eys must fi t rope di ameters. The groove
di ameter shoul d never be smal l er than the actual rope di ameter: i deal l y nomi nal di ameter +6%.
The groove di ameter i s checked wi th speci al groove gauges (see i l l ustrati on bel ow).
New wi re ropes may be l arger i n di ameter than ol d ropes, havi ng thi nned through use. When
i nstal l i ng a new wi re rope, i t may not fi t i nto the groove. Ropes runni ng i n narrow sheave
grooves wi l l present l ess endurance. For the groove base to compl y wi th I SO 4308 and API
2D, worn grooves may need to be mai ntai ned out pri or to rope i nstal l ati on. We recommend to
change the sheave. Further the condi ti ons have to be provi ded for the groovi ngs at the drum.
Sheaves shoul d rotate easi l y and the beari ngs must be i n good condi ti on. The sheaves must
be i n al i gnment wi th the rope travel l i ng di recti on and shoul d have no wobbl e and the sheaves
shoul d have no burrs. The drums must be checked for cracks and the rope guards and drum
wedges have to be i n perfect condi ti on.
Wi ndi ng drums and sheaves shal l be checked peri odi cal l y to ensure that al l these components
rotate correctl y i n thei r beari ngs. Sti ff or worn-out sheaves or rol l ers cause severe abrasi on of
the rope.
Ensure that every sheave rotates easi l y. Make a vi sual i nspecti on of the groove desi gn to see i f
there are any changes on the surface.
6. ROPES IN OPERATION
33
6. ROPES IN OPERATION
6. ROPES IN OPERATION
I neffecti ve compensati on of sheaves may gi ve ri se to unequal l oadi ng i n the rope reevi ng.
The radi us at the bottom of the groove i n al l sheaves shal l be adapted to the nomi nal di ameter
of the rope suppl i ed (see I SO 4308, EN 12385-3 or API 2C and API 9B for worn groove radi i at
sheaves).
I f the radi us has become too l arge or too smal l , the groove shoul d be refashi oned or the
sheave repl aced.
Exampl e how to fi gure out the actual groove di ameter wi th groove gauges.
-> Sheave for nomi nal rope di ameter 25.0 mm
26.5 mm whi ch corresponds to +6% of the nomi nal rope di ameter

The contour at the bottom of the grooves shoul d be ci rcul ar, and i t i s recommended that
the groove radi us, r, shoul d be wi thi n the range of 0.525 d to 0.550 d, wi th 0.5375 d as the
opti mum, whi ch i s equal to + 5% of the nomi nal rope di ameter = 26.25 mm mi ni mum.
Thi s al so appl i es to the pi tch of the drum.
Act. groove di ameter 25.0mm Worn-out sheave: si mul ated rope di ameter
-> too smal l

34
6.4 ACTUAL ROPE DIAMETER
The actual rope di ameter i s usual l y between + 0% and + 4% of nomi nal di ameter. Ropes that
are used i n mul ti l ayer spool i ng wi th several l ayers often requi re ti ghter tol erances i n order fi t
cl osel y to the pi tch at the drum. For correct measuri ng see page 18. We recommend usi ng
cal i pers wi th wi de j aws for measuri ng the actual di ameter i n order to get proper exact resul ts.
In order to find out the lay length measurements
I f actual di ameter vari es si gni fi cant to nomi nal di ameter and al l owed di ameter tol erances, there
coul d be a external twi st i n the rope. I n order to fi nd out l ay l ength, measurements can be
taken.
6.5 END TERMINATION
Rope anchorages and suspensi on devi ces must be i n perfect condi ti on. Check i f rope
termi nati on fi ts to the anchor poi nt. Make sure that anchor poi nt and fi tti ngs meets to the
OEMs operati ng i nstructi ons.
6.6 DOCUMENTATION
The accurate records of the exami ner can be used to predi ct the l i feti me of a parti cul ar type of
rope on a crane. Such i nformati on i s useful for regul ati ng mai ntenance procedures and al so for
control l i ng the repl acement of rope stock.
6. ROPES IN OPERATION
For further i nstructi ons pl ease contact
TEUFELBERGER Sei l Ges.m.b.H.
For mi ni mum al l owed actual di ameter (e.g. bel ow nomi nal di ameter), pl ease fol l ow di scard
cri teri a i nformati on API 2D / I SO 4309.
35
6. ROPES IN OPERATION
6. ROPES IN OPERATION
Wire rope inspection sheet ISO 4309:2010
Details see page 51 - 57
36
Wire rope inspection sheet API-2D
Details see page 59 - 60
6. ROPES IN OPERATION
37
6. ROPES IN OPERATION
6. ROPES IN OPERATION
INFLUENCES ON THE QUALITY OF MULTI-LAYER SPOOLING
Tol erance range of the actual rope di ameter
Number of outer strands / rope constructi on
Type of rope l ay (ordi nary / l ang s l ay)
Rope resi stance agai nst radi al deformati on
Li ne pul l
Drum geometry (pi tch, wi dth, etc.)
Fl eet angl e
Number of wraps i n one l ayer
Number of l ayers
Li ne speed
RELATION OF ACTUAL DRUM PITCH TO ACTUAL ROPE-
pl ay =act. pi tch act. rope- =
(0.005 to 0.015) x act. rope-
Recommended measuri ng of drum pi tch.
RELATION OF ACTUAL DRUM PITCH TO ACTUAL ROPE-
Resul ti ng i n severe wear
6.7 INSPECTION OF LEBUS GROOVED DRUMS FOR MULTI-LAYER SPOOLING
IMPORTANT:
A bi g factor of proper mul ti -l ayer spool i ng i s the correct rel ati on between actual di ameter and
actual drum pi tch (or drum wi dth on pl ai n barrel ed drums).
38
Danger of cutti ng i n
DRUM MEASUREMENT
Measurement tools
groove gauge
fi l l er gauge
pi tch cyl i nders
screwdri ver
cal i per
tape measure
rul er
cl eaner & cl eani ng cl oth
6.8 TWISTING OF SHEAVE BLOCK
Some rotati on may occur i n the i ni ti al cycl es of operati on. Thi s rotati on may resul t i n the
twi sti ng of the parts of rope formi ng the reevi ng or from the fol l owi ng features:
Turn i nduced duri ng i nstal l ati on of the rope.
Turn i nduced by the operati ng arrangements of reevi ng.
Turn i nduced by the drum.
6. ROPES IN OPERATION
Measurement tool s
39
6. ROPES IN OPERATION
6. ROPES IN OPERATION
6.9 UNTWISTING OF HOISTING ROPE
Untwi sti ng of the crane pul l ey bl ock wi th a rotati on-stabl e fi xed poi nt:
Determi nati on of di recti on of twi st
Bri ng the boom i nto hori zontal to i ts l owest posi ti on and the
pul l ey bl ock down to i ts l owest posi ti on. Then determi ne the
di recti on of twi st of the pul l ey bl ock from the crane cabi n.
I f the pul l ey bl ock twi sts counter-cl ockwi se, the rope has to
be twi sted cl ockwi se at the fi xed poi nt. (Reverse i f the pul l ey
bl ock twi sts cl ockwi se.)
6.10 USING OF SWIVEL
Swi vel s may onl y be used wi th rotati on-resi stant wi re ropes. Wi th 6- or 8-strand ropes as wel l
as l ow-rotati on ropes swi vel s are not al l owed. These types untwi st under l oad i f the ends of the
ropes are not fi xed. Thi s causes hi gh tensi on i n the wi res and therefore reduces fati gue l i fe.
Definition:
A steel wi re rope i s defi ned as rotati on-resi stant, i f a free l ength of
L = 1000 * d and a speci fi c l oad of S/d = 0 to 150 N/mm turns 360 maxi mum.
S.....l oad
d.....rope di ameter
(Ref.: Kl aus Feyrer; Drahtsei l e; Spri nger 1994; p.104, p.358)
40
7.1 CLEANING OF WIRE ROPES
Di rt must be removed from the rope before dressi ng.
When cl eani ng the rope wi th a cl oth, fi bers may get stuck on broken wi res or defecti ve parts
of the rope. Di rt can be removed usi ng a wi re brush. Use protecti ve goggl es when cl eani ng the
rope wi th a brush. Cabl e car ropes are cl eaned wi th speci al cl eani ng devi ces.
Wi re ropes must be mai ntai ned at regul ar i nterval s (e.g. DI N 15020/I SO 4309 or other l ocal
regul ati ons). Ensure that the rope conveyi ng equi pment cannot be started up by unauthori zed
persons duri ng mai ntenance operati ons.
7.2 WIRE ROPE LUBRICATION
Dependi ng on operati on, wi re ropes must be l ubri cated at regul ar i nterval s.
Use a l ubri cant that i s compati bl e wi th the manufacturers l ubri cant previ ousl y appl i ed. I f usi ng
a sol vent-based l ubri cant, i t shoul d be used spari ngl y because the sol vent may di ssol ve or
wash out the ori gi nal l ubri cant. Repeated l ubri cati on of wi re ropes enhances thei r endurance
and may reduce corrosi on.


CAUTION
Solvents can dissolve the manufacturers lubricant, causing large quantities of
lubricant to accumulate on the rope surface. This presents a hazard to rope conveying
equipment requiring a minimum of friction between rope and sheave.
7. WIRE ROPE MAINTENANCE (GENERAL)
41
7. WIRE ROPE MAINTENANCE (GENERAL)
7. WIRE ROPE MAINTENANCE (GENERAL)
I f the rope cannot be dressed for operati onal reasons, expect i t to be l ess durabl e and arrange
for shorter i nspecti on cycl es.




CAUTION
Ropes not dressed at the required intervals can have a significantly shorter life span
than ropes undergoing regular lubrication. Ropes are usually dressed by using a brush,
cloth or the like. There are also solvent-based lubricants that can be sprayed on.
Drip-feed lubricators or high-pressure lubricating machines are used in special cases.
High-pressure lubricators should only be handled by qualified personnel adhering to
manufacturers instructions.
42
7. WIRE ROPE MAINTENANCE (GENERAL)
TEUFELBERGER ropes are greased duri ng manufacture to reduce fri cti on wi thi n the rope and
prevent corrosi on. When ropes eventual l y turn dry by use and grease wears off, re-l ubri cate to
enhance durabi l i ty. Unol i t Oi l spray was devel oped for thi s purpose.
Application
TEUFELBERGER
High Performance
ropes in use
Type/Outer
Strands/
Plastification
Illustration
Interval
based on
Winch Oper-
ating hours
Intervals
based on
Service
Time*
Offshore
Cranes
Shi p Cranes
EVOLUTI ON TK 16
QS 816 V/G
EVOLUTI ON TK 18
SUPERFI LL

PLASTFI LL
TM
500 1 year
PERFECTI ON TK 15 250 0,5 years
Harbour
Cranes
EVOLUTI ON TK 16
QS 816 V/G
EVOLUTI ON Q8
SUPERFI LL

PLASTFI LL
TM
500 1 year
PERFECTI ON TK 15 250 0,5 years
* dependi ng on what occurs earl i er
SUPERFI LL

= compacted strands
PLASTFI LL
TM
= pl asti fi ed i nner-rope
Unol i t Oi l spray has been tai l ored to the ori gi nal l ubri cant used duri ng manufacture and can be
appl i ed qui ckl y and spari ngl y by usi ng the attached appl i cati on devi ce.
Thi s speci al grease covers a wi de temperature range between mi nus 40C and pl us 85C.
TEUFELBERGER recommend re-l ubri cati ng spari ngl y to preserve ori gi nal l ubri cant.
43
7. WIRE ROPE MAINTENANCE (GENERAL)
7. WIRE ROPE MAINTENANCE (GENERAL)
7.3 RE-LUBRICATION
I f the wi re rope has to be rel ubri cated, ask the rope manufacturer whi ch form, whi ch oi l or
grease manufacturer you can use for whi ch product. Lubri cants sel ected for i n-servi ce dressi ng
must be compati bl e wi th the rope manufacturers l ubri cant and shoul d be speci fi ed i n the
OEMs i nstructi on manual or other documents approved by the owner of the appl i ance. A dry
rope unaffected by corrosi on but subj ect to bend fati gue i s l i kel y to achi eve onl y 30% of that
normal l y attai ned by a l ubri cated rope.
CORRECT LUBRICATION
For a compati bi l i ty check of the l ubri cant you want to use, pl ease provi de a materi al & safety
data sheet for fi nal approval .
Do not carry out any i nspecti on or mai ntenance of the rope i f the appl i ance control s are
unattended, unl ess the surroundi ng area has been i sol ated, or suffi ci ent warni ng si gns have
been posted wi thi n the i mmedi ate vi ci ni ty.
I f the appl i ance control s are attended, the authori zed person must be abl e to communi cate
effecti vel y wi th the dri ver or control l er of the appl i ance duri ng the i nspecti on process.

NOTE
Do not carry out any inspection, examination, dressing/lubrication, adjustment or any
other maintenance of the rope whilst it is suspending a load, unless otherwise stated
in the OEMs instruction manual or other relevant documents.
Never clean the wire rope without recognizing the potential hazards associated with
working on a moving rope.
44
7. WIRE ROPE MAINTENANCE (GENERAL)
7.4 REMOVAL OF BROKEN WIRE ENDS
Protrudi ng wi re ends may damage nei ghbori ng wi res and affect the normal travel of the wi re
rope. They shoul d be removed. I t i s not advi sabl e to ni p ends off wi th pl i ers but to gri p them,
bendi ng them backwards and forwards unti l the wi re breaks i n the val l ey between two strands.
7.5 SLIP AND CUT (PROCESS)
I f wear mai nl y occurs when the rope i s reeved on the Lebus drum i n mul ti pl e l ayers, rope l i fe
may be i ncreased by cutti ng off one l ength accordi ng to 1/3 or 1/6 of drum ci rcumference.
Thi s procedure can be repeated up to three or si x ti mes per rope.


RECOMMENDATION
In order to guarantee maximum lifetime TEUFELBERGER recommends operating
always on the 1st layer, too. Safety wraps should be as less as possible, however, still
in accordance with international standards (ISO, API, etc.) plus 1 wrap additionally for
possible slip + cut process.
45
7. WIRE ROPE MAINTENANCE (GENERAL)
7. WIRE ROPE MAINTENANCE (GENERAL)
7.6 ADDITIONAL TROUBLESHOOTING FOR EXPERIENCED STAFF
CRUSHING OF BOOM HOIST ROPE ON DRUM - MAINLY ON THE FIRST LAYER:
Check the ti ghtness of the rope of each l ayer and wrap
Check how many wraps are remai ni ng on the drum whi l e the boom i s i n boom rest posi ti on
(Safety wraps shoul d be as l ess as possi bl e)
I f there i s on i ndi cati on of rope-crushi ng try to shi ft the cross over poi nt (crushed area) wi th
the hel p of sl i p & cut. (1/3 of drum ci rcumstance)
Rei nstal l the rope wi th tensi on. I n case of the boom rope ti ghten the rope structure wi th the
hel p of twi sti ng. (i nstructi ons avai l abl e at TEUFELBERGER or crane manufacturer)
Check D/d rati on (mi ni mum 1/18 acc to API -standard)
Check the ti ghtness of the rope structure (test wi th screw dri ver)
IRREGULAR SPOOLING ON BOOM AND LOAD LINES:
Check i f the fi rst l ayer i s ti ght. (shoul d be under tensi on and no gaps wi thi n the wraps)
Check i f the rope entrance i s smooth on the fl ange and there i s no gap between very 1st
wrap and fl ange. (no sharp edge al l owed)
Check actual rope di ameter whi ch has to be between +0/+4% of nomi nal rope di ameter
I f fi rst rope - l ayer i s ful l y spool ed pl ease check i f there i s any remai ni ng gap. Gap shoul d not
be bi gger than of the nomi nal rope di ameter. I f gap i s bi gger pl ease i nstal l a shi m pl ate
accordi ng crane manufacturers recommendati on
Check i f fl eet angl e are i n recommended range (not bi gger than 2 for non rotati ng rope and
for rotati ng rope not bi gger than 4)
Check i f the rope di recti on i s sui tabl e to the posi ti on of the anchor poi nt especi al l y on non
rotati on resi stant ropes (boom ropes).


ATTENTION
In order to solve these problems action should be taken by experienced personal.
Or for further questions please contact a rope expert of TEUFELBERGER
(Hotline number: +43 (0) 7242 615-388)
46
7. WIRE ROPE MAINTENANCE (GENERAL)
7.7 WARNINGS
Rope produced from carbon steel wi res i n the form shi pped i s not consi dered a heal th hazard.
Duri ng subsequent processi ng (e.g. cutti ng, wel di ng, gri ndi ng, cl eani ng) dust and fumes may
be produced contai ni ng el ements whi ch may affect exposed workers.
The products used i n the manufacture of steel wi re ropes for l ubri cati on and protecti on present
mi ni mal hazard to the user i n the form shi pped. The user must, however, take reasonabl e care
to mi ni mi ze ski n and eye contact and al so avoi d breathi ng thei r vapor and mi st.
After cutti ng, the rope cross-secti ons of non-preformed ropes, mul ti -l ayer ropes and paral l el
cl osed ropes must be wel ded, brazed or fused and tapered such that al l wi res and strands i n
the rope are compl etel y secured.
Fai l ure to correctl y secure the rope end i s l i kel y to l ead to sl ackness, di storti ons, premature
removal from servi ce and a reducti on i n the breaki ng force of the rope.
Ensure that any fi tti ngs such as cl amps or fi xtures are cl ean and undamaged before securi ng
rope ends.
Make sure that al l fi tti ngs are secure i n accordance wi th the OEMs i nstructi on manual or
manufacturers i nstructi ons, and take parti cul ar note of any speci fi c safety requi rements e.g.
torque val ues (and frequency of any re-appl i cati on of torque).
When termi nati ng a rope end wi th a wedge socket, ensure that the rope tai l cannot wi thdraw
through the socket by securi ng a cl amp to the tai l or by fol l owi ng the manufacturers
i nstructi ons.
The l oop back method uses a rope gri p, and the l oop shoul d be l ashed to the l i ve part of rope
by a soft wi re servi ng or tape to prevent fl exi ng of the rope i n servi ce.
The method of l oopi ng back shoul d not be used i f there i s a possi bi l i ty of i nterference of the
l oop wi th the mechani sm or structure.
47
7. WIRE ROPE MAINTENANCE (GENERAL)
7. WIRE ROPE MAINTENANCE (GENERAL)
Al ways i nspect a wi re rope for wear, damage or abuse before use.

Never use a wi re rope whi ch i s worn-out, damaged or abused. Never overl oad or shock l oad a
wi re rope.

I nform yoursel f: Read and understand the gui dance on product safety gi ven i n thi s brochure;
al so read and understand the machi nery manufacturers handbook.

Refer to appl i cabl e di recti ves, regul ati ons, standards and codes concerni ng i nspecti on,
exami nati on and rope removal cri teri a.

Protect yoursel f and others the fai l ure of a wi re rope may cause seri ous i nj ury or death!
I f the condi ti on of the rope i s not accordi ng the i nstal l ati on manual , pl ease stop worki ng
i mmedi atel y. Be sure to have al ways a spare rope on the ri g.

WARNING
Wire ropes will fail if worn-out, shock loaded, overloaded, misused, damaged,
improperly maintained or abused.

WARNING
All recommendations and advisory services provided for rope selection by
TEUFELBERGER staff is made to the best of our knowledge and is based on our long
standing experience. Your own specialised knowledge gained from security analysis
and your experience of use under varying conditions must not be ignored. Please note
our delivery conditions.

PLEASE NOTE
This manual is created in accordance with the experience and knowledge of
TEUFELBERGER. No guarantee will be accepted!
48
Each probl em you can see bel ow, di scard cri teri a rul es acc. to I SO 4309 and API 2D have to
be consi dered.

CORE PROTRUSION:
Cause / acti on
1. Shock l oadi ng - revi ew operati ng condi ti ons
2. Too l arge fl eet angl e - control reevi ng
3. Change rope i mmedi atel y
WAVINESS:
Cause / acti on
1. Too smal l groove radi us - check al l grooves
wi th gauges
2. Too l arge fl eet angl e - control reevi ng
3. Untwi sti ng duri ng i nstal l ati on
4. Check fl ange of the sheaves for damage areas
BASKET DEFORMATION:
Cause / acti on
1. Untwi sti ng duri ng ti me i n servi ce - mark the
rope and search for i nfl uences i n the reevi ng
2. Shock l oadi ng - revi ew operati ng condi ti ons
3. Too smal l groove radi us - check al l grooves
wi th gauges
EXTERNAL WEAR:
Cause / acti on
1. Too smal l groove radi us - check al l grooves
wi th gauges
2. Sl i di ng on edge(s) - search for abrasi on on the
crane
3. Check i f al l sheaves i n the reevi ng are free to
rotate
4. Heavy l i ne pul l - fati gue wear of a resul t of l ong ti me operati on
Source: I SO 4309
Source: I SO 4309
Source: I SO 4309
8. DISCARD CRITERIA
49
8. DISCARD CRITERIA
8. DISCARD CRITERIA
EXTERNAL CORROSION:
Cause / acti on
1. Consi der sel ecti on of gal vani zed rope
2. Revi ew frequency, amount and type of servi ce
dressi ng
CROWN WIRE BREAKS:
Cause / acti on
1. Too smal l groove radi us - check al l grooves
wi th gauges
2. Sl i di ng on edge(s) - search for abrasi on on the
crane
3. Check i f al l sheaves i n the reevi ng are free to
rotate
4. Revi ew operati ng condi ti ons
MECHANICAL DAMAGE:
Cause / acti on
1. General l y resul ts from operati ng condi ti ons
2. Check i f al l sheaves i n the reevi ng are free to
rotate
3. Revi ew operati ng condi ti ons
4. Check sheave guards and support rol l ers to
ensure that the rope does not j ump out of
i ntended reevi ng system
Source: I SO 4309
Source: I SO 4309
ROPE CRUSHING:
Cause / acti on
1. not i nstal l ed under tensi on
2. l ose structure whi l e i nstal l ati on
3. l ose fi rst l ayer / wraps on the drum
50
8. DISCARD CRITERIA
DISCARD CRITERIA FOR STEEL WIRE ROPES
NUMBER OF ALLOWABLE WI RE BREAKS TO I SO 4309:2010
TEUFELBERGER i s the speci al i st when i t comes to manufacturi ng hi gh-performance steel
wi re ropes for cranes, ropeways, and forestry appl i cati ons. I n connecti on wi th the use of our
products, your safety al ways fi gures as our number one pri ori ty. Consequentl y, the number
of wi re breaks of a rope represents one of several attri butes l ooked at when i nspecti ng your
products. Contrary to other di scard cri teri a, the al l owabl e number of wi re breaks i s desi gn-
dependent and therefore needs to be defi ned speci fi cal l y for each rope.

NUMBER OF ALLOWABLE WIRE BREAKS TO ISO 4309:2010 depending on:
si ngl e-l ayer or mul ti -l ayer wi ndi ng: for mul ti -l ayer wi ndi ng, a greater number of wi re breaks i s
al l owabl e. See Tabl e 3 and 4, page 53 - 54.
ordi nary l ay or l ang s l ay desi gn: contrary to the poi nt-l i ke contact i n the case of an ordi nary
l ay rope, l ang s l ay ropes are characteri zed by surface contact between the strands.
Thi s resul ts i n a reducti on of wi re breaks. See Tabl e 3 and 4, page 53 - 54.
dri ve mechani sm group: see DI N 15020, sheet 1 - 4.1.
maxi mum number of wi re breaks: 6 x rope di ameter or 30 x rope di ameter (the area where
the cri ti cal number occurs i s deci si ve). )
Rope Category Number (RCN): the cl assi fi cati on depends on the number of l oad-beari ng
wi res contai ned i n the outer strands of a rope. Fi l l er wi res do not count toward thi s number.

PLEASE NOTE
Marine Riser Tensioner ropes are recommended to use in langs lay. Due to its riser
system they are not operating in multi-layer spooling. So special attention to allowable
broken wires has to be taken! A seperate brochure "Maintenance of Marine Riser
Tensioner" is available!
51
8. DISCARD CRITERIA
8. DISCARD CRITERIA
ISO 4309: 2010(E)
Sti l l val i d si nce August 2010
INSPECTION CRITERIA:
1) Di ameter
2) Length of l ay
3) Number of broken wi res
4) Corrosi on
5) Ki nki ng, crushi ng, cutti ng
6) I mpropri ety
7) Heavy wear
8) Li mi ted areas
9) End connecti ons
10) Lubri cati on
DISCARD CRITERIA:
a) The nature and number of broken wi res
b) Local i zed groupi ng of wi re breaks
c) Val l ey wi re breaks
d) Wi res breaks at a termi nati on
e) The rate of i ncrease of wi re breaks
f) Decrease i n rope di ameter
g) Local decrease i n di ameter
h) The fracture of strands
i ) Corrosi on ( Extern, I nternal , Fretti ng)
j ) Wavi ness
k) Basket deformati on
l ) Core or strand protrusi on or di storti on
m) Protrudi ng wi res i n l oops
n) Local i ncrease i n rope di ameter
o) Fl attened porti on
p) Ki nk or ti ghtened l oop
q) Bend i n rope
r) Damage due to heat or el ectri c arci ng
The i ndi vi dual degrees of deteri orati on shoul d be assessed, and expressed as a percentage
of the parti cul ar di scard cri teri a. The cumul ati ve degree of deteri orati on at any gi ven posi ti on
i s determi ned by addi ng together the i ndi vi dual val ues that are recorded at that posi ti on i n the
rope. When the cumul ati ve val ue at any posi ti on reaches 100 %, the rope shoul d be di scarded.

52
8. DISCARD CRITERIA
VISIBLE BROKEN WIRES:
Di scard cri teri a for vi si bl e broken wi res
53
8. DISCARD CRITERIA
8. DISCARD CRITERIA
Single-layer and parallel-closed ropes
Number of wi re breaks, reached for exceeded, of vi si bl e broken wi res occurri ng i n
si ngl e-l ayer and paral l el -cl osed ropes, si gnal l i ng di scard of rope
Table 3
54
8. DISCARD CRITERIA
Rotation-resistant ropes
Number of wi re breaks, reached for exceeded, of vi si bl e broken wi res occurri ng i n
rotati on-resi stant ropes, si gnal l i ng di scard of rope
Table 4
55
8. DISCARD CRITERIA
8. DISCARD CRITERIA
DECREASE IN ROPE DIAMETER:

PLEASE NOTE
New ropes will normally have an actual diameter greater than the nominal diameter
Uniform decrease along the rope:
Uni form decrease i n di ameter si gnal l i ng di scard of rope - Rope spool i ng on a si ngl e-l ayer drum
and/or runni ng through a steel sheave
Calculation to determine actual uniform decrease and expression as percentage of
nominal rope diameter
Actual unform decrease i n di ameter expressed as per cent of nomi nal di ameter i s cal cul ated
usi ng Equati on (1):
56
8. DISCARD CRITERIA
LOCAL DECREASE
I f there i s an obvi ous l ocal decrease i n di ameter, such as that caused by fai l ure of a core or
rope centre, the rope shal l be di scarded (for an exampl e of a decrease associ ated wi th a
sunken strand.

LOCAL INCREASE IN ROPE DIAMETER
I f the rope di ameter i ncreases by 5 % or more for a rope wi th a steel core or 10 % or more
for a rope wi th a fi bre core duri ng servi ce, the reason for thi s shal l be i nvesti gated and
consi derati on gi ven to di scardi ng the rope.

FRACTURE OF STRANDS
I f a compl ete strand fracture occurs, the rope shal l be i mmedi atel y di scarded.
CORROSION:
Di scard cri teri a for corrosi on and i ntermedi ate severi ty rati ngs
57
8. DISCARD CRITERIA
8. DISCARD CRITERIA
DEFORMATION AND DAMAGE:
Waviness
The rope shal l be di scarded i f, under any condi ti on, ei ther of the fol l owi ng condi ti ons exi sts

a) on a strai ght porti on of rope, whi ch never runs through or around a sheave or spool s on to
the drum, the gap between a strai ghtedge and the undersi de of the hel i x i s 1/3 d or greater;

b) on a porti on of rope, whi ch runs through a sheave or spool s on to the drum, the gap
between a strai ghtedge and the undersi de of the hel i x i s 1/10 d or greater.
Key
d nomi nal rope di ameter
g gap
58
8. DISCARD CRITERIA
RCN OF TEUFELBERGER HIGH-PERFORMANCE WIRE ROPES
Design type Diameter range RCN
612 W 7 - 10 04
PS 610 F 26 - 40 04
QS 610 V 10 - 16 06
Q 812 F 15 - 46 06
EVOLUTION Q8 24 - 48 06
QS 814 VG 44 - 64 13
QS 816 V(G) 10 - 50 09
QS 808 S 10 03
BS 909 S 11 05
O
R
D
I
N
A
R
Y

R
O
P
E
S
Design type Diameter range RCN
PERFECTION TK 15 08 - 22 23-2
EVOLUTION TK 16 08 - 30 23-1
EVOLUTION TK 16 31 - 42 23-2
EVOLUTION TK 17 08 - 30 23-1
EVOLUTION TK 17 31 - 42 23-2
EVOLUTION TK 18 42 - 70 27 N
O
N
-
R
O
T
A
T
I
N
G

R
O
P
E
S
59
8. DISCARD CRITERIA
8. DISCARD CRITERIA
INSPECTION CRITERIA:
1) Di ameter
2) Length of l ay
3) Number of broken wi res
4) Corrosi on
5) Ki nki ng, crushi ng, cutti ng
6) I mpropri ety
7) Heavy wear
8) Li mi ted areas
9) End connecti ons
API 2D fifth edition
Sti l l val i d si nce June 2003
DISCARD CRITERIA:
a) Broken wi res (l ay l ength, strand, end
connecti ons)
b) Val l ey wi re breaks
c) Ori gi nal di ameter of outsi de wi re of the
strand i s worn
d) Rope constructi on has been di storted
e) Heat damage
f) Reducti on of rope di ameter
g) I ncrease i n the l ength of an i ndi vi dual
rope l ay
h) Extensi ve external and/or i nternal
corrosi on
API 2D FIFTH EDITION
60
8. DISCARD CRITERIA
COMPARISON REGARDING BROKEN WIRES OF RUNNING ROPES:
API 2D FIFTH EDITION
1) Runni ng ropes used i n the boom hoi st:
a. Si x (6) randoml y di stri buted broken wi res wi thi n one (1) l ay l ength.
b. Three (3) broken wi res i n one strand wi thi n one (1) l ay l ength.
2) Runni ng ropes of rotati on-resi stant constructi on used i n the mai n or auxi l i ary hoi st:
a. Four (4) randoml y di stri buted broken wi res wi thi n one (1) l ay l ength.
b. Two (2) broken wi res i n one strand wi thi n one (1) l ay l ength.
3) Standi ng ropes such as boom pendants:
a. Three (3) broken wi res wi thi n one (1) l ay l ength.
b. Two (2) broken wi res at the end connecti on.
4) One (1) val l ey break may i ndi cate i nternal rope damage requi ri ng cl ose i nspecti on
of thi s secti on of the rope.
a. When two (2) or more val l ey breaks are found i n one (1) l ay l ength the rope
shoul d be reti red.

NOTE
Valley breaks are more detrimental than surface broken wires.
COMPARISON REGARDING THE DIAMETER () OF RUNNING ROPES:
REDUCTION OF ROPE DIAMETER
Reducti ons of the rope di ameter i n a nonworki ng area (an area away from the sheaves)
compared to the l owest di ameter of the rope measured i n three (3) worki ng areas (areas where
the rope regul arl y goes over a sheave) of more than the fol l owi ng i s observed:
3/64 (.047) i nch for di ameters up to and i ncl udi ng i nch
1/16 (.062) i nch for di ameters of 7/8 through 11/8 i nch
3/32 (.093) i nch for a di ameter of 11/2 i nch
See Fi gure G.6 for proper method of measuri ng rope di ameters.
More than one-thi rd of the ori gi nal di ameter of the outsi de wi res of the strand are worn.
61
9. CHECKLIST FOR OPTIMAL MULTI-LAYER SPOOLING
RECOMMENDATION FOR OPTIMAL SPOOLING OF WIRE ROPES IN
MULTI-LAYER APPLICATION ON PLAIN BARRELLED DRUMS
Before starti ng to change the wi re ropes or i n case of i nvesti gati on for i rregul ar spool i ng,
check the condi ti on at the rope sheaves, speci al l y the groove di ameters, whi ch must fi t the
rope di ameter.
The groove di ameter shoul d never be smal l er than the actual rope di ameter.
ISO 4309:2010(E) Chapter 4.4: For opti mal performance, the effecti ve sheave groove di am-
eter shoul d be l arger than the nomi nal rope di ameter by about 5 % to 10 %, and i deal l y, at
l east 1 % greater than the actual di ameter of the new rope.
The groove di ameter i s checked wi th speci al groove gauges, avai l abl e at TEUFELBERGER.
See page 32 - 33
Rope entrance on the drum has to be smooth as
the very fi rst rope wrap has to be very ti ght on
the drum fl ange. Avoi d sharp edges i n thi s area.
Use gri nder careful l y.
For boom hoist ropes (luffing) only:
Before fi xi ng the rope at the anchor poi nt, twi st the rope around i t's axl e i nto the "ti ght"
di recti on before wi th a sui tabl e twi sti ng devi ce.Make sure, that the twi st does not turn back,
whi l e fi xi ng the rope. See page 29
I nstal l the rope wi th proper tensi on and avoi d l oose wraps (especi al l y at the fi rst l ayer on the
drum)! See page 21
The fi rst l ayer must have an adequate tensi on of at l east 2,5 5% of the mi ni mum breaki ng
force.
When upwi ndi ng the fi rst l ayer, ensure a cl ose contact to the drum's fl ange by the use of a
non-steel hammer (copper, brass or pl asti c i n order to avoi d damages on the rope).
Avoi d any ki nd of gaps between rope wraps!
Rope
Entrance
8. DISCARD CRITERIA
62
9. CHECKLIST FOR OPTIMAL MULTI-LAYER SPOOLING
When fi rst l ayer i s ful l y spool ed onto the drum,
pl ease check next to the rope entrance, i f there
i s any remai ni ng gap between l ast wrap and
drum fl ange. The gap shoul d not be l arger than
hal f of the rope di ameter.
I f gap i s l arger, than hal f of the rope di ameter,
pl ease i nstal l a shi m-pl ate to cl ose that di stance.
I f gap i s smal l er than hal f of the rope di ameter,
i nstal l shi m-pl ate onl y i n case of spool i ng prob-
l ems. Take under consi derati on, that the rope
di ameter wi l l decrease duri ng operati on!
Cal cul ati on of rough shi m-pl ate si ze can be done
by TEUFELBERGER.
The usage of of shi m-pl ate wi l l i nfl uence the
fl eet-angl e (fl eet angl e gets reduced)!
Pl ease note, that the gap can vary because of the
exi sti ng drum - and rope tol erances.So tack the
shi m-pl ates onl y i nstead sol i d wel di ng.
Pl ease avoi d to use the 1st l ayer j ust as gui dance
l ayer because of the ri sk of crushi ng. If necces-
sary to do so unspool every 100 worki ng hours
unti l the safety-wraps and respool under tensi on
as menti oned above.
shim plate
drum
flange
rope
entrance
GAP
drum inside
rope wraps
gap for the
remaining last wrap
proper spooling
63
If the l ast wrap at any l ayer does not fi t the whol e
way al l around the drum because of a narrati on
of the gap, the rope wi l l confi gures a hi l l to ri se
above thi s narrati on, whi ch causes di stracti ons at
the next l ayer's spool i ng.
Gri nd-off the drum's wal l at the parti al l y l ocati on
of the narrati on.
Make sure, not to i nj ure the wi re rope's suface
wi th the gri nder or mi l l i ng tool .
Cover the surface of the wi re at the drum i n order
to avoi d pol l uti on by the gri ndi ng or mi l l i ng chi ps.
If the desi ng of the crane generates too smal l
fl eet-angl es at the drum i n di recti on to the fi rst
sheave, the rope may cl i mb up the drum's wal l
before i t col l apses upon i tsel f i nto an unsystemati c
confi gurati on wi th gaps between the wraps, - the
basement for i rregul ar spool i ng of the next l ayer.
A rope-ki cker wi l l support the wi re-rope fi ndi ng i t's
way i nto the val l ey of the pri or l ayer ri ght i n ti me
i nstead cl i mbi ng up the drum's wal l .
Pl ease consi der a run i n ti me for a new i nstal l ed rope i n order to make wi res and strands set-
ti ngs happen.
Fol l ow manufacturer's regul ati ons.
Avoi d sl ack rope i n the system because of the ri sk to get l oose wraps and l ayers wi th the
resul t of crushi ng.
Make sure that the rope i s permanent very wel l l ubri cated, whi ch reduces fri cti on between
each wraps and l ayers of rope.
For correct i nspecti on adequat measuri ng tool s are requi red. TEUFELBERGER offers al l speci al
groove gauges, fi l l er gauges, wi de j aws verni er cal i pers to ensure proper wi re-rope di ameter
measurement on request.
9. CHECKLIST FOR OPTIMAL MULTI-LAYER SPOOLING
9. CHECKLIST FOR OPTIMAL MULTI-LAYER SPOOLING
coiling-up
the drums wall
TEUFELBERGER Seil Ges.m.b.H.
Bhmerwaldstrae 20
4600 Wels, Austria
T +43 7242 615-0
F +43 7242 60501
E wirerope@teufelberger.com
www.teufelberger.com
YOUR BENEFIT WITH TEUFELBERGER:
EXPERTISE
Our special steel wire ropes are designed for fulfilling the requirements of your
application in an optimal way.
HIGHEST QUALITY
Only high-strength material and state-of-the-art production processes are used
for our products.
SERVICE AROUND THE CLOCK
Our 24-hour hotline and top service team ensure that our experts are available within
the shortest time possible wherever required. 24-hour hotline: +43 (0) 7242-615-388
EXPERT CONSULTANCY
TEUFELBERGERs network of consultants ensures that expert support is close to you.
Our staff is especially trained for your application which translates into cooperative
development of the most useful answer to any problems which may occur.
DELIVERY RELIABILITY
TEUFELBERGERs management of orders ensures optimal processing in production
and logistics.
RESEARCH AND DEVELOPMENT
Our R&D deparment provides permanent product improvement in terms of safety,
reliability and service life.
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