08/2013

PFEIFER
SEIL- UND HEBETECHNIK
GMBH

DR.-KARL-LENZ-STRASSE 66
D-87700 MEMMINGEN
Wire Ropes TELEPHONE +49 (0) 83 31-937-267
TELEFAX +49 (0) 83 31-937-341

Technical Information E-MAIL wireropes@[Link]

INTERNET [Link]
 Giving you a peace of mind!
Proficiency and
expert knowledge
PFEIFER is your specialist for the
application-oriented rope selection
and the delivery of customized wire
ropes. Cutting to length, prestressing,
splicing, endless laying, swaging
and hot metal socketing this is our
business.
PFEIFER has been dealing with ropes
for generations. Leading crane and
elevator manufacturers, the port, A good feeling
construction and automobile industry
Throughout manufacturing, with us,
as well as rope users from many
you are on the safe side. We hold all
different industries are our customers.
necessary licences and qualifications.
They all trust in PFEIFERs worldwide
Additional proof of our high quality
renown efficient service.
standard is the certification for the
quality assurance system according
to DIN EN ISO 9001.

Highest quality level Efficient production,

Wire ropes have a central function Exact testing
wherever they are applied: lifting, Our manufacturing and test equipment
transporting, pulling, staying or conforms to the latest requirements.
handling. All this involves a high In the coiling alley with a 4000 t
degree of responsibility; we are well wire rope storage capacity ropes are
aware of this fact. The highly qualified cut to length to close tolerances in all
competent staff, the latest production required lengths and diameters.
equipment and strict quality control
measures are a guarantee for the We provide large swaging presses
quality standard of PFEIFER products. with a pressing force of 3000 t. Ropes
with a diameter up to 80 mm can be
fitted with various types of end termi-
nations.
Two socketing towers with a capa-
city of 10 socketing boxes allow for
connection of sockets and rope.
In the 240 m pre-stressing tunnel
wire ropes up to 160 mm dia. can
be dynamically prestressed to exact
length. Our hydraulic prestressing
machine has a capacity rating of
6000 kN, therefore elongation-, tensile
and pull tests of ropes in high
precision class 1 are possible.

2
Wire Ropes Technical Information 08/2013
The PFEIFER group Rope application technology
Only a rope manufactured to appro-
PFEIFER is one of the leading European companies for rope, anchoring and
priate specifications will be able to
lifting systems. The group consists of many companies both in Germany and
fulfil a given task. As a specialist in the
abroad. PFEIFER headquarters are located in Memmingen, Germany.
use of steel wire ropes, we can supply
Business fields the right rope for your job. Wire rope
The business fields of the PFEIFER group are: manufacturing takes place at our
group company PFEIFER DRAKO
Drahtseilerei Gustav Kocks GmbH &
Co. in Mlheim, Germany.

Cable structures Mining and industry ropes

Architects can use cable structures PFEIFER DRAKO in Mlheim, Germany
to transform space into vast areas of located in the heart of the german
lightness and transparency. Impres- coal mining area has been producing
sive examples of the aesthetics and ropes of high quality for the past
elegance of PFEIFER cable structures 150 years. Other parts of the product
can be found all over the world. range include special steel wire ropes
for steel mills, different industrial
applications and deep sea research.

Lifting technology Elevator products

Safely lifting heavy loads our PFEIFER DRAKO elevator ropes are
development engineers have acquired used in skyscrapers worldwide.
a great deal of expertise in this field. With the surge of highrise buildings
We are your global partner when it and highspeed elevators demands
comes to the technological and safety for increased performance are met
challenges involved in the integrated through continuous development.
lifting and moving of heavy loads.

Attachment and lashing equipment Inspection service,

With our experienced staff and technical seminars
our extensive product program we We completely service all your lifting
meet our customers permanently devices in your factory. We teach
changing needs we inspect we maintain we repair.

Connecting and lifting systems Protection systems

We are the market leaders in the fields against natural hazards
of lifting anchors, fixing systems and PFEIFER ISOFER, Switzerland is
infrastructure technology. We have a pioneer in the development,
developed products of the highest manufacturing and installation
standards and believe we can offer of protection systems against
the most comprehensive and com- natural hazards or rock and slope
petitive systems for the construction stabilization.
industry today.

3
Wire Ropes Technical Information 08/2013
 Table of content
Technical aspects about wire rope 58
Rope cores (C)
Strand constructions
The strand direction of lay
The stranded rope direction and type of lay
Rope types
Surface treatment of wires / rope lubrication
Explanation of important terms

Rope selection 9 10
Rotation resistant ropes
Non-rotation resistant ropes
Right-hand or left-hand lay rope?
How to determine the correct rope lay direction?

Product safety 10

Rope designations 11

Steel wire rope end finishing 12

Breaking force reduction caused by rope end terminations 13

Correct handling of wire ropes 14 15

Spooling of wire ropes
Storage and transport of wire ropes
Applying of pretension in the multiplayer spooling

Discard 16

Approved rope quality 17

Measurement devices 18

Wire rope accessories 19

4
Wire Ropes Technical Information 08/2013
Technical Aspects about Wire Rope
History 1 3

When Wilhelm Albert, an official of the

German Board of Mines, manufactured
a wire rope in 1834, it was admittedly,
not the first wire rope in the world, but
the tools he used and the level of steel
wire production enabled him to produce
ropes of acceptable 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 emerg-
ing industrial revolution. Since then the
very simple Albert rope construction
has developed according to the
various demands into a vast and for
the uninformed somewhat daunting
variety of rope constructions.

Common types of ropes

Standard ropes
Rotation resistant ropes
Compacted ropes Fibre core (FC) (fig. 1 and 2)
Ropes with coated core The core of the rope consists of
natural (NFC) or synthetic fibre
Wire rope consists of three basic (SFC). Fibre cores store lubricants,
components support the strands and dimish
vibrations.
The core
Wires that form a strand Steel core (WC) (fig. 3)
Strands laid helically around There are two typical types of
the core steel core
1. Wire strand core (WSC) (fig. 4)
Rope cores (C) 2 4
The core of a round strand rope
consists of a strand.
The inner part of a single layer rope
surrounded by the outer strands is 2. Independent wire rope core
normally filled by a rope core. Rope (IWRC) (fig. 5)
cores are separated according to the The core of the round strand
material and design. Its main function rope consists of a stranded
is to support the outer strands and, rope.
by using a steel core, also to increase
Independent wire rope core,
the load bearing metallic cross
plastic coated
section.
(fig. 6, 17)
The core consists of a plastic
coated steel core.
5 6

5
Wire Ropes Technical Information 08/2013
 Strand 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
common strand formations, e. g.
Warrington-Seale and Warrington 8 7
Compound are merely combinations
of these basic constructions. The strand mines later use of the rope. There are
basically two different types of lay.
Wire and strand diameter of our wire direction of lay
ropes have been optimized constantly The direction of lay of the strand is
Regular or Cross lay (fig. 10)
by using computer technology. Thus the direction of the helix of the outer
bending properties and service life of wires. There are two types, the right The direction of lay of the wires in the
the running ropes could be improved hand lay (abbreviated to z, fig. 8 a) outer strands will be in opposite
considerably. By an absolutely equal and the left hand lay (abbreviated to direction to the direction of lay of the
load distribution to all wires an early s, fig. 8 b). outer strands in the rope itself.
failure of any individual wire due to
Regular laid ropes are more pressure
overloading will be eliminated.
and deformation resistant.
Standard stranding (fig. 7 a) methods
The stranded rope
cause wire crossings between the direction and type of lay Two types of lay direction are possi-
ble. The lay direction is determined
wire layers within the strand resulting The direction of lay of the rope is the by the outer strands:
in high stress concentrations, where direction of the helix of the outer
crossings occur. Premature damage strands. There are two types, the sZ: right hand regular lay (fig. 10 a)
may be the consequence. In a parallel right hand lay (abbreviated to Z, zS: left hand regular lay (fig. 10 b)
stranded strand (fig. 7 b) all wires are fig. 9 a) and the left hand lay
arranged parallel in the strand struc- (abbreviated to S, fig. 9 b). Lang lay (fig. 11)
ture thus a continous linear contact is
provided. The result is a reduction of When spinning stranded ropes, differ- The direction of lay to the wires in the
compressive stress of the wires. ent methods to combine the strands outer strands equals the direction of
Therefore many of our special ropes are possible. The spinning process lay of the outer strands in the rope.
for running service are made of 9 affects rope properties and deter- Lang lay ropes provide improved
parallel stranded strands. Thus an abrasion resistant properties when
optimum in rope work and a b a b used on multiple rope reeving.
considerably improved service life Two types of lay direction are possi-
will be achieved. ble. The lay direction is determined
by the outer strands:
zZ: right hand lang lay (fig. 11 a)
sS: left hand lang lay (fig. 11 b)

Rope types
In the following parts the most
common rope types will be explained.
Please also read Wire rope selec-
tion to get additional information.

6 10 11
Wire Ropes Technical Information 08/2013
12 13 14 15
Single layer stranded ropes (fig. 12)
Single layer round strand ropes consists of several strands laid in one layer
around a fibre or steel core. They are used e.g. for cranes, excavators,
winches, construction machinery, elevators and as sling rope.

Rotation resistant ropes

Rotation resistant ropes designed to generate reduced levels of torque and
rotation when loaded (fig. 13). 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
16 layer. To achieve an additional reduction of torque and rotation when loaded
special rotation resistant ropes were designed and manufactured. Typical
application for these special ropes are hoisting ropes for cranes working with
only one fall and / or high lifting heights (fig. 14). Further information in
Wire rope selection.

Parallel-closed stranded ropes (fig. 15)

Parallel-closed stranded ropes 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, excavators,
16c 16d construction 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.
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

Generally the compacted ropes may be divided into:
Compacted strand stranded rope (fig. 16 e)
16e 16f
Rope in which the strands, prior to closing of the rope, are subject to a
compacting process such as drawing, rollingor swaging. Fig. 16 a, c shows
the standard, fig. 16 b, d the compacted strand.
Compacted (swaged) stranded rope (fig. 16 f)
Rope which is subjected to a compacting (usually swaging) process after
closing the rope, thus reducing its diameter.
The advantages of compacted ropes are: higher breaking load, better
flexibility, smooth surface and a higher resistance to abrasion.

7
Wire Ropes Technical Information 08/2013
 Ropes with plastic coated steel core (cushioned core rope) (fig. 17)
The interior structure of some of our special ropes is plastic coated.
This structure is characterised by a number of improvements
reduced friction between rope core and outer strands
high bending cycle strength
high structural strength
excellent vibration-resistant properties
improved corrosion protection of the wire core

17
Surface treatment of wires / rope lubrication
The most common surface treatment for the wires of a rope are, either
ungalvanized or bright (U), galvanized (B) and heavy galvanized (A).
Ropes are lubricated during manufacturing process. The lubricant has two
important functions. It reduces friction between the wires in the strand and
the strands within the rope and thus supports the movements of the rope
during running over sheaves or spooling on drums. In addition it protects
from corrosion.
To maintain the positive characteristics of the base lubrication ropes have to
be relubricated regularly.

Explanation of important terms

Nominal rope diameter
The nominal rope diameter is a size which defines a rope in combination

with other characteristics. Together with the tolerances the manufacturer or

an existing standard provides, the range for the actual rope diameter can
be determined.
Actual diameter (fig. 18)
To measure the actual diameter it is important to do it the correct way.
Only the measurement according fig. 18 b will lead to the required result.
The measurement according to fig. 18 a is wrong.
Fill factor
18
The fill factor is the relation of the metallic cross section of the rope to the
area of its circumscribed circle.
Wire tensile strength grade (R)
A level of requirement of tensile strength of a wire and its corresponding
range. It is designated by the value according to the lower limit of tensile
strength and is used when specifying wire and when determining the cal-
culated minimum aggregate breaking force a rope, expressed in N/mm.
Common tensile strength grades are 1770 N/mm2, 1960 N/mm2 and
2160 N/mm2.
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.

8
Wire Ropes Technical Information 08/2013
Rope selection
Wire ropes are divided into four main groups:

Slings Track rope Structural cables Running ropes

are load handling ropes. are used in cable ways. are ropes being anchored at two are ropes running above sheaves,
fixed points and do not run over drums or traction sheaves,
sheaves or spool on a winch, [Link] ropes, luffing ropes,
e. g. guy and pendant ropes, elevator ropes, haulage ropes etc.
suspension ropes.

The most suitable rope for a given application is the one best able to with-
stand 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 pre-
mature 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.
At the beginning of the wire rope selection the most important decision is:
Do I need a rotation resistant or a non-rotation resistant rope?

What is the difference between both rope types?

19
Rotation resistant ropes
Due to that, under load the core tries to twist the rope in the one direction
As explained in the part Rope types rotation resistant ropes designed to (fig. 19 a), the outer strands try at the same time to twist the rope in the
generate reduced levels of torque and rotation when loaded. opposite direction (fig. 19 b). The result is, that high performance rotation
Please note! Ropes called rotation resistant ropes may have different levels resistant ropes almost compensate the torque over a particular load spectrum.
of rotation resistance e.g. torque and rotation when loaded. To give you Because of these excellent rope properties the high performance rotation
advise to the different rope properties we have separated the rotation restistant ropes are used with lifting heights and lifting unguided loads on a
resistant ropes into two classes: single fall. Up to now these ropes were also called non-rotation ropes.
1. Rotation resistant ropes The high performance rotation ropes can be used with or without a swivel;
These are rope constructions, e. g. 18 x 7, 17 x 7 (fig. 13), with two layers if possible, the use of a swivel is preferred.
of strands laid helically around a core, the direction of lay of the outer
strands being opposite to that of the underlying layer.
WARNING! Dont 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!
2. High performance rotation resistant ropes (fig. 14)
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. 19).
9
Wire Ropes Technical Information 08/2013
 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.
20
WARNING! Dont use these ropes attached to a swivel or have How to determine the correct rope lay direction?
one or both ends rotate freely under load! If this is not observed
serious injury, considerable damage or death will occur! First step: Check how the rope runs from the drum into the reeving.
There are two possibilities:

Right-hand or left-hand lay rope? overwound drum (fig. 20 right)

underwound drum (fig. 20 left)
For the installation of ropes on winches there is the basic rule:
Second step: Put your hand on the rope on the drum
Right-hand lay rope for a left drum
Left-hand lay rope for a right drum Index finger shows in the direction of the rope running into the reeving
Thumb shows to the rope fix point on the 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 Third step: Decision
or from a left drum into a right reeving only a test can prove whether a left- If you need your left hand to fulfill the requirements of the second step,
hand or a right-hand lay rope must be installed. then you need a left-hand rope (fig. 20 top figures).
By using multiple layer spooling systems we recommend to follow the above If you need your right hand to fulfill the requirements of the second step,
mentioned basic rule. then you need a right-hand rope (fig. 20 lower figures).

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

10
Wire Ropes Technical Information 08/2013
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

11
Wire Ropes Technical Information 08/2013
 Steel wire rope end finishing
In most cases a steel wire rope manufactured on a master reel is not ready
to be put to work. A rope must be cut to size and the rope ends finished to
enable the rope to fulfill its task.
Not only the correct rope selection, but also a properly fitted rope end
terminations is necessary to achieve safe and satisfactory service life.
PFEIFER has a very skilled work force and our employees are educated and
trained in the specialised field of rope end finishing.

Commonly there are three ways of rope end finishing

Cutting to size and seizing or fusing of rope ends 21
Forming a loop in the rope
Attaching a fitting to the rope

PFEIFERs facilities are fitted with precision working equipment to ensure high
quality ready for use ropes.
Coiling and cutting to size: a stock arrangement for effective rope finishing
ensures short processing time (fig. 21).
Rope end seizing: seizing of rope ends avoids loosening of the rope struc-
ture. Firm seizing is absolutely necessary for rotation resistant ropes as they
are not preformed (fig. 22).
Cutting of ropes (fig. 23)
22 23
Fusing: we can taper and fuse rope ends up to a rope diameter of 34 mm.
Larger diameters, the rope ends will be welded. Such end treatment simplifies
the mounting of ropes on winches or in open wedge sockets. (fig. 24)
Swaging: aluminium ferrules or steel fittings are cold bonded to the wire rope
under extremely high pressure. Two presses, with a pressing force of 3000 t
each, enable us to swage steel wire ropes up to 80mm diameter. Swaging
reduces the minimum breaking load of ropes.
Casting: is the end finishing of a rope where there is no reduction of the
minimum breaking load. For casting the most common used materials are
zinc or resin. Two socketing towers with 5 socketing boxes each, allow
short processing time with a large number of ropes. In our plant ropes up
to 120mm diameter have already been tilted with sockets. PFEIFER is very
24 25
experienced in casting rope fittings either in our facilities or on site (fig. 26).
Pre-stressing: to achieve exact rope lengths under specified working condi-
tions, it is necessary to pre-stress ropes with a deteremined load. A pre-
stressing machine with a capacity rating of 6000 kN (in high precision class
1) and a pre-stressing tunnel with a length of 240 meters, enable us to do
various elongation-, tensile and breaking tests (fig. 27).
Testing: only a test of the rope fitted with the required end terminations will
qualify the produced quality. Regular testing is necessary to guarantee a
continuos high quality (fig. 28).

26

12 27 28
Wire Ropes Technical Information 08/2013
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 %

WARNING:
Make long splices according DIN 3089
section 2.
Spliced eye 80 % 80 % Open wedge socket symmetric
Please note that by splicing wire ropes
with a steel core, the metallic cross
section is to be reduced by the core!

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! 13
Wire Ropes Technical Information 08/2013
 Correct handling of wire ropes

!
Spooling of Correct:
Lay wire rope rings
wire ropes
on clean ground.
Please consider the
preferred bending
direction when re-
winding the rope.

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

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.

14
Wire Ropes Technical Information 08/2013
 !
Storage and Correct:
Store wire ropes dry
transport
and cool.
of wire ropes 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 transpor-
tation of wire
rope reels and
rings will cause
irreparable damage
to wires, strands or
the rope structure.

!
Applying of pretension Correct:
in the multiplayer The reel is braked
mechanical at the
spooling flange of the reel.

Wrong:
The squeezing of
ropes with wooden
beams or similar
items cause
irreparable damage
to the rope structure.

15
Wire Ropes Technical Information 08/2013
 Discard
Warning: Considering security crane ropes should be Looping on a wire rope
taken off operation in time, if one of the following criterias
apply:

Broken strand
Local concentration of wire breaks
Achievement of type and number of wire breaks according to the tablets
At least two wire breaks in strand valley or adjacent strands within one
lay length (approx. 6 d)
Corkscrew deformation of more than 1/10 of the rope diameter
(g / d 0,1); d: nominal rope diameter, g: height of waviness
Corkscrew (fig. 30) 31
Hairpin like escape of wires (fig. 31)
Through corrosion and wear heavy loose strand
Decrease of diameter regarding the nominal rope diameter at uniform
decrease of:
7,5 % at non-rotation resistant ropes with steel core
5,0 % at rotation resistant ropes
Local increase of diameter of more than 5% compared with the diameter
of the rest of the rope
Heavy corrosion: The surface of the wires is strongly affected or rosty
dust comes out of the rope
Loose rope structere (fig. 32)
Constriction (fig. 33)
Kinks or flattened areas(fig. 34 + 36)
32
Bends or other deformations (fig 35)
bluish discoloration, broken or fused wires due to heat effects or Constriction due to a broken rope core
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 4309-2010 maintenance and
care, inspection and storage. Consequently, these criteria do not replace the
instructions andrequirements for inspection and maintenance of wire ropes as
written in the standard.
33
If in doubt on the estimation of the cable damage, the rope must be
discarded or your rope specialist needs to be contacted: Flattened wire rope caused by over-ride
wireropes@[Link] or via phone +49 (0) 83 31-937-267.

34
Corkscrew deformation Basket deformation Bend caused by a pinched Kind caused by mechanical impact
rope sling

16 29 30 35 36
Wire Ropes Technical Information 08/2013
Approved rope quality
Be aware that not only the usual catalog values such as weigh/length and
minimum tensile strength determine the wire rope property PFEIFER is
analyzing all properties of the wire rope with extensive tests.
Equipped with this knowledge we can choose the optimum wire rope for
your application.

Testing machines to determine Testing facility for measuring

the bending strength. the resistance against lateral
pressure.

37 m high test tower to analyze

the suitability in the multilayer
spooling.

Different applications require different qualities of

corrosion protection.
Many available galvanization qualities do not meet
the requirements of individual applications.
We are one of few providers which can test the
galvanizing quality in in-house laboratories and
fulfill exceptional customer needs.

We are authorized to issue

certificates for all kind of ropes.
These certificates document that
regulatory requirements are in
place to the standards.
Tensile test facility with a capacity of Upon request we provide for
up to 6000 kN to determine the cable example test reports, inspection
system breaking forces. Tension certificates, certificates of
fatigue tests are also possible on these Germanischer Lloyd and
systems. manufacturer declarations.

17
Wire Ropes Technical Information 08/2013
 PFEIFER-measurement devices:
by pros for pros!

Measurement devices
Based on our long-term practical experience of rope drive inspection, Rope caliper 40
we created the following measurement devices kit. These measurement
With attached wide jaws
devices are used by our rope experts for each inspection and thereby
approved for general use. Product advantages
Recommended for frequent
measurement of ropes with the
most common diameters up to
40 mm
Enables quick and easy check
wide jaws reduce measuring faults

Measurement Rope caliper 150

equipment case 75 With attached extra wide jaws
Content: and adapter plates for big rope
Rope caliper 75 diameters
made of galvanized steel Product advantages
with attached wide jaws Recommended for frequent meas-
Recommended for the frequent urement of ropes with diameters
measuring of ropes in the most up to 150 mm
common diameters Enables quick and easy check
Rope diameter wide jaws reduce measuring faults
5 28 mm, 12 45 mm,
21 60 mm, 5 60 mm
Further combinations of the 5 differ- Propeller
ent groove gauges kits on request Stainless steel
Product advantages Rope diameter
Stellen Sie sich Ihren Messmittel- 15 mm, 20 mm, 24 mm
koffer nach Ihren Bedrfnissen Further sizes on request
zusammen!
Product advantages
Recommended for the frequent
check of rope drives with a specific
diameter

Measurement Ring
equipment case 150 Stainless steel
Content: Rope diameter
Rope caliper 150 5 20 mm, 20 40 mm,
Groove gauges Bolt with 5 kits 40 60 mm, 60 75 mm
(see picture measurement equip-
ment case 75) Product advantages
Recommended for the frequent
Rope diameter check of rope drives with the most
5 60 mm common rope diameters
Product advantages
The complete measurement
equipment case for the frequent Rope service starter kit
professional groove inspection!
Content:
2x PFEIFER RL-S Wire rope
lubrication Spray can
1x Groove-gauge-Kit Worker
1x Pair gloves
1x Rope caliper 40
1x Yard stick
1x Steel wire brush
Product advantages
18 Allows quick and easy control as well
as professional care of your wire ropes
Wire Ropes Technical Information 08/2013
Wire rope accessories
Fittings Closed swaged Open and closed spelter socket
Fittings are manufactured using fitting Rope ends are cast in open spelter
spezial steel and are swaged directly Open swaged sockets and closed spelter sockets.
onto the rope end. Therefore you get fitting
a thin rope end termination, which is Swaged thread
fitted by means of drilling. Threaded fitting
fittings are to be fixed securely and
non-rotatable.

Thimble Solid and fork thimbles

Thimbles protect the rope eyes and PFEIFER can supply solid thimbles
increase the life-time expectancy of and forked end thimbles which are
the rope considerably. used to join. DIN 3091 solid thimbles
are drilled to a specific diameter.

Lubrication Open wedge socket

Steel wire ropes need to be regularly The wedge socket is a
lubricated to maximize service life. close-end-fitting which is
commonly used on cranes.

Shackle Swivel
Shackles are universal accessories Swivels are to be used with high
and have a wide range of applica- performance rotation resistant ropes
tions. The two types of shackles only. Swivels rotate under load and
which can be supplied are D can compensate torsion in hoisting
shackles and bow shackles fitted ropes. The ends can be supplied with
with screw bolts or bolt, nut and forks and with eyes.
split pin.
Warning: Dont use
non-rotation resistant or
rotation resistant ropes
with a swivel! If this is
Pouch socket system not observed serious
Fast and safe re-reeving injury, considerable
of wire ropes with the damage or death will
PFEFER pouch socket system. occur!

19
Wire Ropes Technical Information 08/2013
 Our locations worldwide PFEIFER
J&P: Your reliable Partner

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