Ropeway Ropes
Technical
Information
Technical Information
Our commitment
ArcelorMittal Bourg-en-Bresse controls all the essential International specifications *
parameters for the correct production of special high
performance ropes used in the aerial transport of EUROPE UE 2016-424
EN 12385-8
people and materials: suitable specific equipment, an EN 12385-9
approved production process, a systematic check on EN 12927
raw material, an inspection system and traceability SWITZERLAND Ordonnances Fédérales
at each stage of production, trained and experienced
ITALY DM 1175 - DD 144
specialists. EN 12385-8
EN 12385-9
ArcelorMittal Bourg-en-Bresse runs an internal DNV- SPAIN B.O.E 293
Certified Quality Assurance System complying with the EN 12385-8
requirements of ISO 9001. EN 12385-9
AUSTRIA DSB 80 – Örnorm 9500
As a result of its continuous improvement process, GERMANY BO-Seil und BO-Schlepp
the plant is also certified OHSAS 18001 for safety USA ANSI B77 1
management.
CANADA CAN/CSA Z98-01
Furthermore, all of our products are CE marked. CHINA GB 12352-2018
GB 8918-2018
SOUTH KOREA D 101 75 678
(*) Our products are manufactured to European
standard by default. We can adapt our products
to any worldwide specifications. Please contact
us for further details.
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Technical Information
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Technical Information
Recommandations
Storage and maintenance
The rope must be adequately maintained and regularly lubricated, as often as it is necessary, but at least when the rope works
in extreme conditions and before/after prolonged inactivity. The lubricant must be compatible with the original grease. Before
re-lubrication, the wire rope must be dry and cleaned by scraping or using a cryogenic spray. Cleaning by cloth, high pressure
cleaner or solvents is forbidden.
When stored, the rope should be kept in a dry and ventilated environment with no direct contact with the floor and an air flow
under the reel. Visual inspection is necessary before the use of a stored wire rope. In case of doubt of the quality of the wire
rope, we can help you to find and make additional inspection analysis.
EWRIS handling recommendations
At all times, contact of the rope with
any metallic pieces should be avoided
to prevent early damage. © EWRIS 2010
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Technical Information
Dimensional control
Diameter (NF EN 12385-1)
The diameter must be measured
with an appropriate measuring
instrument covering at least 2 strands.
Measurements must be made at
two positions spaced at least one
metre apart and for each position,
2 measurements must be taken at
right angles.
3 7
Lay Length
On ropes dedicated to people transportation, lay length is a very important parameter.
Lay length is the distance measured parallel to the centre line of a wire rope in which a strand makes one complete spiral or
turn around the rope. If the lay length is not well defined or modified during the installation phase or during utilisation, the rope
can generate some vibrations on the pillar or others elements of the structure.
Lay length
Stra
nd
1
Stra Stra Stra Stra Stra Stra
nd nd nd nd nd nd
1 2 3 4 5 6
Checking the lay length is a quite complicated operation. We recommend the following process :
1. Stick a paper strip on the rope. The paper strip should be pulled tight.
2. Draw a thin straight line on it using a corner piece. This line will represent the rope axis.
3. Using a chalk stick, identify the track of the rope.
4. Remove the paper strip from the rope.
5. Make the measurement directly on the paper strip.
Remark: the paper strip can be stored for further investigations.
The lay length should ideally be measured on 5 lay lengths minimum.
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Technical Information
Lubrication for hauling ropes
Type of %
Lubrication Method mass Note Illustration
Lubrication
Closing
For stainless wire ropes and
No grease specific demands
Dry 0.0
slight oil only (oil is applied to avoid trouble
Stranding in the die during assembly)
No grease,
Closing
oil only
For ropeway ropes, mining ropes
A-1 0.5 on Koepe sheave and plastified
wire ropes
Lubrication +
Stranding
tight wipe
Closing Lubrication +
wipe 1.5
A-3 - Hoisting applications
Lubrication + 1.75
Stranding
wipe
Lubrication +
Closing
wipe 2.0 Not available direct from the mill.
A-4 - (Can be performed by our distributors
on specific demand)
Lubrication + 2.5
Stranding
wipe
Please note that the lubricant must be compatible with the rubber used on the pulleys
Compaction
Thanks to the rope compaction, the metallic section
is increased, which leads to a higher breaking
load than a non compacted wire rope of the same
diameter. The outside strand area is also increased
and smoother, which decreases the contact
pressure between the rope and the drum/sheaves,
Round Wire Rope Compacted Rope
and thus increases the fatigue properties.
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Technical Information
Lubrication for Full Locked Coil ropes
Type of %
Lubrication Method mass Note Illustration
Lubrication
Core
No grease Stainless wire ropes
Dry Z Layer 0%
Slight oil and specific demends
Outer Shape
Core +
Specific demands for
A-1 Z Layer - 0.30%
indoor applications
Outer Shape -
Core +
A-2 Z Layer + 1% Ropeway ropes
Outer Shape -
Core +
Ropeway ropes in
A-3 Z Layer + 1.15% aggressive environments
Outer Shape +
Crush resistance
Crushing is the effect of external pressure on a
rope which damages the rope by distorting the
cross-sectional shape of the rope, its strands,
core or all three. Crush resistant ropes withstand
or resist external forces.
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Technical Information
Groove characteristics for sheaves,
saddle and grooved drums
Grooves in sheaves and drums should be circular and smooth.
Sheaves
To ensure good support, the rope must contact the During a wire rope’s lifetime, the rope diameter will
groove for approx 130-140° of arc, which leads to the decrease. This is due first to the elongation of the rope, and
following recommendation for the groove diameter: then the wear on the rope wires. This diameter variation
begins quickly but then slows down. The wire rope will
create a new groove in the sheave which corresponds to
1.05d < dg < 1.1d the reduced diameter. If a new wire rope is installed in a
worn sheave, without resurfacing, the new rope will wear
Optimal value = 1.075 more quickly. The lifetime can be divided by 10.
Groove
Diameter
With:
• d = nominal rope diameter with 0/+4% tolerances;
New wire Rope with min.
• dg = groove diameter. rope diameter
New wire rope on Wire rope after reduction
correct groove diameter on correct groove
dg
Worn groove New wire
diameter rope
Groove worn by the rope Worn groove too small
with its reduced diameter for a new wire rope
Grooved drums
The groove diameter dg and the pitch diameter p must With:
comply with the following criteria: • d = rope diameter under tension of 5%MBL
• dg = groove diameter
• p = pitch between 2 grooves
dg = 1.0173d
p
1.035dg < p < 1.09dg
Optimal value = 1.06
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Technical Information
Test resources
Wire
Prior to the manufacture of our ropes, a sample
is taken from each wire spool and tested according
to the international standards:
• Tensile test
• Torsion test
• Bending test
Wire rope
For each manufactured wire rope, the breaking load is 1800
checked with a test. During this test, the stress/strain curve is
1600
recorded and a modulus measurement can be made
1400
on request.
1200
Load (kN)
1000
800
600
400
200
0
0 50 100 150 200
Elongation (mm)
900
800
700
600
Load (kN)
500
400
The Bourg-en-Bresse site has 3 test benches:
300
200 tons, 350 tons and 1500 tons.
200
100
0
0 10 20 30 40 50
Elongation (mm)
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Technical Information
Banc de test: Lutèce
In association with our partners, Mécamont and TEC Câbles, we
have developed and invested in a 120m test bench, capable of
simulating speeds of up to 20 metres per second on cables from
30-60mm in diameter. This test simulates a cable lifespan of 25
years in just 2 months.
Our whole production process is part of a continuous control system
which includes breaking strength testing, radial deformation and
diameter reduction measuring.
It is out of these rigorous monitoring processes that the “Lutèce
Project” was born to fulfil the need to create products at the forefront
of technology, able to respond to important changing market
requirements.
Together, we are setting the performance benchmarks for the future.
Operational since the beginning of 2019, our latest product
innovations have been tested on the Lutèce bench to ensure we
are providing our customers with reliable solutions.
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Technical Information
Installation and maintenance
Choosing the right rope b) Installing the rope
The characteristics listed in the tables featured in this These operations must be carried out by experienced,
catalogue correspond to usual levels of performances. competent persons who have received professional
They are given for information purposes only and have training in rope work. Safety and risk prevention will be
no contractual value. We recommend you contact our carefully studied and integrated into the written procedure
team and check that the rope characteristics comply with for rope installation.
regulatory and technical requirements, as these may vary Procedure must take into account the characteristics and
according to national codes or the particular specifications design requirements of the lift.
of constructors. It must also be approved by the manufacturer of the lift or
We pay careful attention to what our clients have to say the client who will specify the initial setting conditions in
and are, as far as possible, ready to adapt our product writing (e.g. rope sag).
design to fit your exact project requirements or to upgrade Elementary caution should be exercised in unwinding the
rope performances compared to existing products. rope, i.e. contacts and stress liable to cause irreversible
Parameters such as breaking strength, length of lay, rope damage. The following type of means should be used:
diameters adequately adjusted to attachment geometries support placed on the ground, deviation sheaves
and choice have to be assessed during a contract review (diameter must be above 25 times the dia. of the rope),
and be part of written agreements related to this contract. devices presenting the rope extremities from rotating and
untwisting during the rope installation.
Rope assembly and maintenance
c) Tensioning and positioning the rope
a) Packing and storing
Particular attention should be paid to respect rope tension
The ropes are wound in the factory on metal or wooden
settings and to the position of the tension appliances which
reels designed for handling in the horizontal axis position
must allow them to operate according to the constructor’s
with appropriate means.
specifications.
Care should be taken:
• To avoid the inversion of the reel. d) Splices, shortening and fastening of end attachments
• To prevent the rope coming into contact with parts These are the final operations to be performed on the
liable to damage it through shock, friction or chemical ropes once installed, and include; final rope length
pollution corrosion risks. The rope must not come into adjustments, splices, shorter wings, socketing with molten
contact with the ground. metal or resin. These operations must be carried out by
• To prevent any risk of fire exposure (blow torch) or specialists. Depending on national codes currently in
electric contact (no earth clamp on the rope when using force, approval from an official body may be required with
a welding post). regard to the qualifications of these specialists and the
working procedures.
The rope may be stored for a long period provided that
its qualities and protection system are maintained. Requirements concerning the geometry of the splices or
the selection of approved products for socketing may vary
according to the national codes or the technical criteria
drawn up by the manufacturers.
The customer shall take steps to find out what
requirements and obligations are to be respected and
bring them to the attention of the specialist in writing at
the time of ordering rope fixing work.
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Technical Information
At the written request of the customer, ArcelorMittal Surveillance, inspection of ropes
will send a team:
The requirements regarding rope surveillance and discard
• Either responsible for all the assembly work. criteria are detailed in the corresponding national and
• Or only the wire rope work: splice, shortening, international standards and recommendations. However,
socketing. In this case, the company in charge of the we recommend that the frequency of rope inspection
rope installation work must carry out the supervision should constantly be adapted to real life working and
and take full responsibility of the following operations. environment conditions.
Prior to splicing: Cable maintenance
• The adjustment of the appliance tensioning device Lubricants
according to the cableway manufacturer’s or operator’s
The products incorporated in the ropes when
requirements.
manufacturing are selected by the rope maker in
• The tensioning of the rope using the appropriate pulling compliance with operating requirements and the
devices (clamps jaws and winches) in compliance with applicable standards to be specified in the order.
safety and risk prevention procedures.
Not using adequate products could dangerously modify
• The positioning of the two rope ends in the working the friction ratio of the rope on the sheaves or damage
area for splicing in accordance with cableway the liners.
manufacturer’s or operation’s requirements to help the
In any circumstances, the ropeway manufacturer’s
splicing specialist.
recommendations should always be followed when
• The mobilisation of the necessary number of operators applying maintenance and cleaning products. You are
to help the splicing specialist. advised not to use chemical solvents or products liable
to cause corrosion on the cable itself or on the organs
After the splice has been made:
coming into contact with it.
• The traceability form should be drawn up, mentioning We recommend consulting the ropeway manufacturer
the positioning of its tensioning carriage device: a) After before using any rope maintenance lubricants, solvents, or
the splice has been made and before rope operation. any other chemical products. These should not be applied
b) After 100 hours of rope running in. on the rope surface as they will wash the rope internal
• The positioning of the tensioning carriage on the guide lubrication out. This might also, sooner or later, initiate
should be indelibly marked. a) After the splice has been some corrosion process.
made and before rope operation. b) After 100 hours of
rope running in.
The specialist in charge of the wire rope works (splice,
shortening, socketing) will draw up a work report,
mentioning the dimensions measured and compliance
with contractual requirements.
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Technical Information
Means of preventing localised damage Repairing stranded
The cables are submitted to particular stress in such In the case of localised or accidental damage, and
zones as: provided that the prescriptive requirements are respected,
• For carrying-hauling ropes: rope sections previously a rope may be repaired by substituting one or two strands,
positioned inside fix grips (e.g. attachments for adopting the same requirements and process as that used
fixed seats). for making a splice. A standard rope can generally be
repaired, taking into account the requirements stated in
• For track ropes: deviations on pylon shoes and tension
applicable national regulations and applicable standards
devices, sockets.
by locally changing one or two strands, rising a process
By displacing the attachments on the ropes or the ropes on divided from one used for complete splices.
the ropeway, the risk of stress concentration on such areas
can be significantly decreased. It is therefore essential to
follow the manufacturer’s ropeway recommendations and
to respect the instructions given by applicable national
regulations and standards, especially concerning the
amplitude and frequency of such planned displacements.
Rope repairs
When the prescriptive criteria are reached, repair work can
most of the time be carried out in order to be able to safely
continue to operate once the rope is repaired. It is essential
that these operations are carried out by skilled and trained
specialists. Depending on national codes, approval from
an official body may be required with their regard to the
qualification of specialists and working procedures.
Repairing Lock Coil carrying ropes
The possibility of rupture of the external wires on this
kind of rope must be carefully monitored. This should be
accompanied by a more thorough inspection in the case
it occurs on a particular zone such as deviation or an
anchoring.
• 1 wire broken: check that the distance between the two
extremities is not more than 25mm and that the two
wire extremities are not raised out of their place as they
have a tendency to do. Apply a sealing joint in the gap.
• 2 wires broken in the same rope lay length: repair is
necessary. In case of such a repair, it is mandatory
to observe the various corresponding requirements
stated in applicable national regulations and applicable
standards, in order to make sure that the results of the
planned repair will totally comply with them.
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