Wire rope installation guide

TABLE OF CONTENTS

Important safety information 2

New wire ropes and existing sheaves 3
Ordering hoist rope 4
Ordering governor and/or compensation rope 7
Other factors to consider 8
Handling wire rope 10
Installing new hoist rope 12
Attaching wedge sockets 15
Tensioning hoist rope 19
Surface line 19
Preventing hoist rope rotation 20
Installing new governor rope 21
Other hoist rope configurations 22
Field lubrication 24
Rope replacement criteria* 25

Some information for this manual was taken with permission from the “Installation Manual -
Basic Field Practices for Installation of Elevators and Escalators” by Kermit Kraus and published
by Elevator World.
*Excerpts from ASME A17.1b-2009/CSA B44b-09, Part 8 and ASME A17.6-2010, Section 1.10 are
used by kind permission of the American Society of Mechanical Engineers. All rights reserved.

1
Important safety information
READ THIS BEFORE INSTALLATION

The practices outlined in this instal- Working in the hoistway and han-
lation guide are general procedures dling wire rope can be dangerous.
for wire rope installation. Techniques, Therefore:
codes and materials are constantly ALWAYS FOLLOW SAFE WORKING
being updated. The installer is PRACTICES. Make sure landing doors
responsible for knowing and fol- are locked or barricaded. Use lock-out
lowing any and all applicable codes. tags to prevent accidental switching
Also see The Elevator Industry Field on of power.
Employees’ Safety Handbook, edited
ALWAYS WEAR PROTECTIVE
by the NEII Safety Committee and
CLOTHING. Use helmets, goggles and
published by Elevator World.
gloves - wire rope ends are sharp and
can ‘fishhook’ into exposed skin. Use
anti-fall harnesses as required.

2
New wire ropes and existing sheaves
READ THIS BEFORE INSTALLATION

IT IS STRONGLY RECOMMENDED PREVENT UNTWISTING. Regardless

that the sheaves of existing elevators of the manufacturer, all wire ropes
be carefully checked and re-grooved have the propensity to untwist lead-
or replaced as necessary prior to rope ing to weakening of the rope struc-
replacement. The diameter of the ture and reduced rope service life.
new ropes is greater than that of Care must always be taken during
the old ropes and failure to bring the handling, installation and tensioning
sheave grooves into the machine to prevent untwisting of the ropes.
manufacturer’s specified tolerances
can lead to vibration, metal shavings
and other problems.

3
Ordering hoist rope
QUANTITY, DIMENSIONS AND STRANDING

While the information on the next 4 Determine the stranding and

three pages may be provided on the construction of the rope.
existing wire rope tag, it should be Stranding is the number of strands
noted that the tag information may per rope and the number of wires
not always be accurate. per strand (an 8-strand rope with 19
1 Count the number of ropes. wires per strand has 8 x 19 strand-
ing). Determine whether the rope
2 Determine the length of
has 6, 8 or 9 strands by looking at
each rope.
the shackles where the stranding is
This can often be found on the instal-
easier to see. The rope construction
lation layout.
(Seale, Warrington, Filler Wire, etc.)
3 Determine the diameter of can be found by matching up the
the ropes. rope cross-section with the cross-
The crosshead data plate on top of sections shown on the next page.
the car should show the diameter or
A 6-strand hoist rope is usually 6 x
the diameter may be stamped on the
25 Filler Wire construction with Right
existing shackles. If not, use a caliper,
Regular lay. If there is not a cross-
micrometer or Go/No Go gauge and
head data plate and the building is
measure from crown to crown.
over 50 years old, the ropes used are
usually 6 x 25 Filler Wire with Right
Regular lay.
YES NO An 8-strand hoist rope is usually 8 x
19 Seale.

4
Ordering hoist rope
TYPICAL CONSTRUCTIONS

In North America, some typical rope

constructions for re-roping are:

8 x 19 Seale
with natural fiber core
(hoist/compensation/governor)

8 x 19 Warrington
with natural fiber core
(governor)

8 x 25 Filler Wire
with natural fiber core
(compensation/governor)

6 x 25 Filler Wire
with natural fiber core
(hoist/compensation/governor)

9 x 21 Filler Wire
with IWRC (full steel core)
(hoist)

5
Ordering hoist rope
LAY, GRADE AND BREAKING LOAD

5 Determine the lay of the rope. Extra High Strength Traction rope is
Compare a Right Regular lay to a frequently specified for high-rise/
Right Lang lay rope: high-speed hoisting conditions. Grade
Right Regular is sometimes expressed as tensile
strength in Newtons/square millime-
ter (N/mm2) or pounds/square inch
(psi).
Right Lang Minimum wire tensile strengths
Rope Grade Outer Wire Tensile Strength
N/mm2 • psi
Iron 680 • 100,000
Traction 1180 •170,000
Note that the orientation of the indi- EHS Traction 1670 •245,000
vidual wires is parallel to the center-
7 Determine the breaking load.
line in a Right Regular lay rope.
This is found on the crosshead data
Right Regular lay is assumed if the plate. For example, if a breaking load
lay is not indicated on your order. of 14,500 lbs • 6450 kg is indicated
6 Determine the grade or tensile for 1/2 in • 12.7 mm diameter 8 x 19
strength of the rope. ropes, refer to the information in your
Hoist ropes are Traction or Extra Draka catalog or call your Draka repre-
High Strength Traction (traction rope sentative for the correct grade (in this
can also be used for hoist, governor case, traction grade).
and compensation applications).

6
Ordering governor and/or compensation rope

The ordering procedure for compen- 3 Determine the grade or tensile

sation and governor ropes is similar strength of the ropes.
to hoist ropes EXCEPT you may have Look at the rope tag to determine
to rely on the rope tag to a greater breaking load, then use the Draka
degree because there is no crosshead catalog or call your Draka represen-
data plate for compensation or gover- tative for the correct rope grade.
nor ropes. Governor and compensation ropes
1 Measure the diameter of are either Iron or Traction grade and
the ropes. NEVER Extra High Strength Traction.
Use a caliper, micrometer or Go/No 4 Confirm the rope lay.
Go gauge and measure from crown to The lay of governor and compensa-
crown. tion ropes is always Right Regular
2 Confirm the stranding of and NEVER Right Lang.
the ropes. 5 Preformed ropes
The shackles are the best place Always replace governor and com-
to look. Almost all compensation pensation ropes with preformed
and governor ropes have 8 strands, ropes.
though they can be Seale, Warrington
or Filler Wire construction.

7
Other factors
INFORMATION WORTH NOTING

Rope tags Preforming

All new rope comes with a metal tag Preformed rope is the industry stan-
listing such information as diameter, dard and provides longer rope service
breaking load, grade, construction life while being easier to handle. All
classification, manufacturer and Gustav Wolf ropes sold by Draka
lubrication procedures. Note that the Elevator in North America are pre-
installer is responsible for filling in formed.
information such as the month/year Coating
of installation, month/year of first Bright (uncoated) is the industry
shortening and name of organization standard and comes without any
who installed the ropes. coating on the rope other than lubri-
Wire rope cores cation. For protection from weather
Natural fiber is the most common and corrosion (e.g. outdoor and mine
core used in elevator ropes in North elevators), the use of a galvanized
America. However, in some high-rise/ coating is often recommended.
high-speed, most MRL and certain Compacted strands
hydraulic applications, the use of For applications with reverse bends
steel-reinforced natural fiber or full (such as basement machines), the
steel core (IWRC) ropes is becoming use of compacted strand wire rope
more common. has been shown to increase rope
service life. Draka Elevator offers
CompactTrac™ compacted strand
wire rope made by Gustav Wolf.

8
Other factors
INFORMATION WORTH NOTING

Stretch Prestretching
Elevator wire rope stretch results Some wire rope manufacturers
from two main factors; promote pre-stretched rope at a pre-
Elastic stretch is an increase in rope mium price. Laboratory testing has
length due to increase in load (as load shown that standard Gustav Wolf
increases, the rope becomes longer natural fiber core rope sold by Draka
and narrower and vice versa); Elevator exhibits comparable elonga-
tion to commonly used brands of
Constructional stretch is an increase
pre-stretched natural fiber core rope
in rope length due to the settling/
without the associated increase in
compression of the core and strands
price.
when a load is applied (most occurs
shortly after the rope is put into ser- Contact your Draka Elevator repre-
vice). sentative for more information on
Gustav Wolf low-stretch natural fiber
Ropes made by different manu-
core rope.
facturers and ropes of different
strandings, constructions, grades,
etc. exhibit different stretch charac-
teristics.
For more information on wire rope
stretch, contact Draka Elevator.

9
 Handling wire rope
MOVING, STORING, UNREELING AND PREVENTING ROTATION

Moving the reels YES

Reels are best transported on the
job site by rolling on a clean flat
surface or by lifting from a pipe in the
reel center hole.
Storage
Wire rope should be stored indoors, YES
off the ground and covered to protect
it from moisture, dirt, dust, sunlight,
etc.
Unreeling
Care must be taken to unroll and not
laterally pull wire rope when paying it
off the reel (see the examples to the NO
right).
Kinking and dragging ropes over
sharp edges must be avoided.
Preventing rotation
Ropes must be prevented from
rotating during installation since NO
free-hanging ropes will untwist under
their own weight. The use of reeving
splices is recommended.

Art courtesy Gustav Wolf Steel Wire and Steel

Wire Ropes.

10
Handling wire rope
INSPECTION AND SEIZING

Constantly inspect the rope Seizing rope ends

The installer should continually Rope ends should always be seized
inspect wire rope during installation with cable bands to prevent untwist-
to identify any areas which may have ing of the strands. Untwisted rope
been damaged in shipment or while ends will weaken the rope and can
in storage on the job site. cause premature rope failure.
Per ASME A17.1b-2009/CSA B44b-09 Prior to cutting the rope, the ends
[Link] and ASME A17.6-2010 1.10.5, must be seized in three places with
where one suspension rope has been cable bands. See the diagram and
damaged during installation or accep- table below for spacing.
tance testing prior to being subjected
to elevator service, it shall be permis-
sible to replace a single damaged
rope with a new rope, provided that
the requirements of [Link].1 through
[Link].6 and [Link] and [Link]
through [Link] respectively are met.

A C
B

Spacing of seizings (in • mm)

Rope diameter A B C
3/8 1
/4 • 6.4 4 • 102 2 • 51
1/2 1
/4 • 6.4 4 • 102 2 • 51
5/8 1
/4 • 6.4 5 • 127 2 1/2 • 64
3/4 1
/4 • 6.4 6 • 152 3 • 76
7/8 1
/4 • 6.4 6 1/2 • 165 3 1/4 • 83
1 1
/4 • 6.4 7 • 178 3 1/2 • 89

11
 Installing new hoist rope
OVERHEAD 1:1 ROPING

Overhead 1:1 roping, with its simple path from

cab to counterweight, is the most common
elevator hoist rope configuration.
Position the car
On a new installation, if the car was not erected
at the top landing, raise it there with a hoist.
Lock it into position by setting the safety.
Position the counterweight
Place the counterweight in the pit and use
proper support to hold it above the floor by this
formula:
Rope stretch* + runby + buffer height
Runby is the space between the bottom of the
counterweight and the top of the buffer and it
can vary due to the specifics of the installation
and/or local code (which always takes prece-
dence). In this example a runby of 6 in • 152
mm is assumed.
For example, if your rope under load has a
stretch of 7 in • 178 mm per 100 ft • 30 m of
rope and the rope length is 200 ft • 60 m, it will
supported
stretch 14 in • 356 mm. After adding in runby (6 counterweight
frame
in • 152 mm) and buffer height (e.g. 18 in • 457
rope stretch
mm), the counterweight should be braced with + runby
+ buffer height
steel supports 14 + 6 + 18 in • 965 mm above
the pit floor.
*Contact Draka Elevator for the amount of anticipated
stretch per 100 feet of your particular hoist rope.

12
Installing new hoist rope
PULL THE NEW ROPE INTO POSITION

Pull the new rope into position

Rope, either from a reel or a coil, is fed from
the top landing to the top of the car. Unreel it
as shown on page 10. Do not allow the rope to
kink or reverse bend.
The rope is then fed into the machine room and
through the first sheave groove.
The rope is then run down to a helper at the
counterweight. It’s sometimes helpful to attach
a weight to the rope end using a temporary loop
secured with a rope clip.
Use a board as a brake on the reel (like in the
YES diagram on page 10) to keep the reel from
overspinning.

supported
counterweight
frame

13
 Installing new hoist rope
USE OF REEVING SPLICES IN REPLACING ROPE

In re-roping operations, an old rope can

be used to pull a new rope into posi-
tion. Reeving splices temporarily marry
old and new rope ends together. When
the old rope is pulled, it guides the new
rope over or under the sheaves and to
the attachment point at either the car
or counterweight.
Reeving splices are designed for spe-
cific rope lays and diameters, so make
sure to select the proper splice size.
They carry a limited working load:
Reeving Splice Working Loads
Part Rope Size Working load
Number in • mm lbs • kg
RS-2103 3/8 • 9.5 300 • 136
RS-2105 1/2 • 12.7 2000 • 907
RS-2107 5/8 • 15.9 2000 • 907

The weight of the rope load can be cal-

culated from the Net Weight column
shown in the Draka Elevator catalog.
Reeving splices are to be used ONCE
and then discarded.

14
 cotter pin
ready for
tightening/
insertion

Attaching the wedge sockets

OVERHEAD 1:1 ROPING

Wedge sockets (for hoist and com-

pensating ropes) should be attached
as shown to both the car and counter-
weight frames. The threaded rod must
be placed with enough exposed thread
to permit installation of the washer,
nuts and cotter pin. Nuts and cotter
pin ready for
tightening/
Prior to cutting the rope, make sure insertion
the rope is secure and will not fall (Optional isolation
down the hoistway. If the rope is set bushing spring
assembly shown)
in the sheave groove, that should give
enough grip to hold the rope, but you
will also need to use a rope clamp
attached to the rail to hold the rope.
Mark the cut point of the rope, making
sure to leave enough slack for instal-
lation (2 to 3 ft • 610 to 915 mm), then
seize and cut the rope.
The socket bodies and wedges are
color coded and/or marked with their
associated rope diameter.
It is common on passenger eleva-
tors to install isolation bushing spring
assemblies on both the car and coun-
terweight wedge sockets to isolate
the car from vibration, provide a more
comfortable ride and possibly aid in
equalizing the load on the ropes.

15
 Attaching the wedge sockets
ATTACH THE ROPE AT THE CAR

1 Run the rope down though the

wedge socket body.

DRAKA
DRAKA
2 Thread the rope dead end
back up through the top of the
wedge socket body. Leave a
loop of rope just large enough to
DRAKA
DRAKA

DRAKA

DRAKA
insert the wedge.

3 Insert the wedge into the loop.

DRAKA
DRAKA

DRAKA
DRAKA

DRAKA

16
 DRAKA
Attaching the wedge sockets
ATTACH THE ROPE AT THE CAR

4 Pull down on the rope with one

hand to keep it taut. Use a quick
pull on the dead end to seat the
wedge.

DRAKA
5 The washer and nuts can now be
tightened. Use the lower nut to
lock the upper nut and washer
against the crosshead or the
counterweight frame. Insert and
bend the cotter pin. (Optional
isolation bushing spring assembly
shown.)

6 Install two wire rope retaining clips

to hold the dead end in place. For
clip locations, see diagram 6 at 8x rope dia.
(max)
right. Apply no more than
4x rope dia.
8 ft/lbs • 11 N/m of torque on the (max)
bolt and nut.

17
 DRAKA
DRAKA

DRAKA
Attaching the wedge sockets
ATTACH THE ROPE AT THE COUNTERWEIGHT

The counterweight wedge sockets

should be attached to the counter-
weight frame like the wedge sockets
at the car frame.
Run the rope down through the DRAKA

DRAKA
counterweight wedge socket body.
Repeat the technique shown in steps
1 through 5 on pages 16 - 17.
The rope should be as taut as you can
get it using only manual effort.
If the rope is still slack, the rope may
need to be re-seated in the wedge
socket. Use a hammer and a drift pin
to tap the wedge down until the rope
loosens. Repeat steps 2 through 4 on
pages 16 - 17 to tighten the rope.

18
Tensioning hoist rope

Final ‘set’ under load counted. If the quantity of rotations

After all ropes are installed (and the is greater than one per 100 ft • 30 m
counterweight loaded on new instal- then the ropes should be adjusted by
lations), release the car and let the carefully rotating the wedge sockets
weight of the car and counterweight prior to tensioning, installing the
rest on the ropes. The rope and retaining clips or tying off the hoist
wedge will rise about 1 in • 2.5 cm to ropes.
the final ‘set’ under load. Tension the hoist ropes
All wedges must be visible within Use a rope tension measuring device*
the socket bodies after the ropes are to determine which ropes are carry-
loaded. ing the most load. Any ropes tighter
Surface line than the rest can be slackened and
Some hoist ropes come with a paint- equalized using the hammer/drift pin
ed surface line which can serve as an method shown above.
aid to the installers in determining Equalize final rope tension by adjust-
if the ropes have untwisted (which ing the wedge socket rod nuts until
weakens the rope structure and all ropes carry tension within a 10%
reduces the rope service life). range of each other. DO NOT let the
Proper use of the surface line requires wedge socket rotate during the ten-
that after rope installation the eleva- sioning process. Rotating the socket
tor should be run from the lowest body will let the rope untwist and
to the top landing and the number weaken the rope. Hold the wedge
of rotations of the surface line be socket body to prevent rotation.

*Draka offers several rope tension measuring devices including the

Micelect RTS which measures tension of multiple ropes simultaneously.
Refer to Draka Tech Tip #10 for details on the benefits of maintaining
proper rope tension.

19
 Preventing hoist rope rotation
TIE OFF THE HOIST ROPES

Install the retaining clips

Retaining clips bear no load - they are
used only to keep the wedge in place
should there be a momentary loss of
load on the rope. Cut any surplus rope
off the rope dead end to leave a tail
of about 6 in • 152 mm.
Install two wire rope retaining clips to
hold the dead end in place like step 6
above. Retaining clips are required at
the car and counterweight.
Tie off the hoist ropes
Once equal tension is established,
the ropes need to be tied off or
secured so that the wedge sockets
do not rotate while the elevator is in
operation.
Take a length of wire rope (1/2 in •
12.7 mm dia. is customary, but see
local codes for approved diameter)
and thread it through the wedge
socket bodies.
Use wire rope clips to tie together the
ends of the binding rope.

20
Installing new governor rope
USE OF GOVERNOR ROPE WEDGE SOCKETS

Governor rope does not require the pre-

cise tensioning needed by hoist ropes.
The governor rope reel is placed on top
of the car and run over the governor
sheave in the machine room.
The rope is attached to
the crosshead with a gov-
dotted line is
ernor rope wedge socket the installed
governor rope
(basically a rodless hoist
rope wedge socket) in
the method described on
pages 16 - 17.
The elevator is slowly lowered and the
rope paid out. At the bottom of the
hoistway, enough slack is paid out to
pass around the tail end sheave and
reach the bottom of the car. The tail
end sheave should be propped up as
high as it can go.
The rope is seized and attached under-
neath the car frame with another gov-
ernor wedge socket.

tail end sheave

propped up

21
 Other hoist rope configurations
OVERHEAD 2:1 ROPING

Other roping configurations include the

overhead 2:1, which is popular because
it permits the use of smaller traction
motors.
The same basic principles of hoist rope
installation apply. There are several
methods of installation, including
using a pull rope to raise the hoist rope
end to the attachment point at the top
of the hoistway.

22
Other hoist rope configurations
BASEMENT 1:1 ROPING

Another roping configuration is the

basement type 1:1 that features a
machine at or below ground level that
uses deflecting sheaves to guide the
rope into the hoistway.
The same basic principles of hoist rope
installation apply. There are several
methods of installation, including
using a pull rope attached to the hoist
rope end to raise the hoist rope from
the pit.

23
 Field lubrication

Wire rope comes factory-lubricated. show a visible and slippery film of oil,
However, with usage, time and expo- then the ropes need to be lubricated.
sure to the environment, it is neces- Type of lubricant
sary that the ropes be re-lubricated In North America, Draka recommends
in the field. Failure to re-lubricate can the use of DrakaLube™ which reduces
result in accelerated sheave groove wear, protects against corrosion and
wear, internal notching, crown wear, displaces moisture in the rope core.
core degradation and even rouging.
Application methods
Draka strongly recommends an annu- Automatic lubricators are the most
al lubrication application every spring. time-efficient way to lubricate ropes.
Ropes should be field lubricated Make sure to manually lubricate the
prior to summer and the increased ropes that are over the sheave when
temperature and humidity it brings. the car is at its lowest landing, as
Summertime is when the air condi- the oiler does not touch that sec-
tioners in the machine rooms and tion of the ropes. Manual methods,
offices are operating. Condensation such as paintbrushes or rollers, are
caused by the combination of an air also acceptable. Whichever method
conditioned machine room and a you choose, take care to avoid over-
humid hoistway must be kept from lubrication.
entering the rope core.
Prior to lubricating, clean all lubrica-
NOTE: Governor ropes should tion build-up and dirt from the ropes
NEVER be re-lubricated. using an automatic metal-brush
Signs of a rope needing lubrication cleaner or wire brush. DO NOT use
If there is no established lubrication solvents to clean ropes; solvents will
policy, the easiest way to check the break down the rope lubricant and
ropes is to stop and safely secure the rope will deteriorate.
the car and lightly wipe a finger on See Draka Tech Tip #6 for detailed
the ropes. If the finger test does not instructions on lubrication.

24
Replacement Criteria

NOTES ON THIS SECTION: diameter of the rope. For example, the rope
For more details, see ASME code/standard lay for 3/8 in • 9.5 mm ropes is 2.44 in • 62
excerpts below (the applicable code/standard mm, for 1/2 in • 12.7 mm ropes is 3.25 in • 83
differs by jurisdiction and therefore we have mm and for 5/8 in • 15.9 mm ropes is 4.06 in
listed both ASME A17.1b-2009/B44b-09 and • 103 mm.
ASME A17.6-2010 information in this guide - 2) Valley breaks: The valley wires are located
local code always takes precedence). in the valleys of two adjacent strands. They
Replacement criteria for steel wire ropes fall do not make contact with the sheave and
into four categories: therefore should not experience abrasion.
Valley breaks are attributed to rope fatigue
1) Crown breaks: The crown wires are those
due to bending.
that make contact with the sheave and they
will show signs of abrasion. If enough abra- 3) Diameter reduction: If the ropes reach a
sion and/or rope fatigue due to bending takes specified diameter reduction, they should be
place, the crown wires will break. When using replaced even if no crown or valley breaks are
this criterion, an inspector is looking for the present.
number of total crown wire breaks within a 4) Red dust or rouge: The existence of red
rope lay. dust, or rouge, is also a factor in determining
A rope lay is approximately 6.5 times the rope replacement.

FROM ASME A17.1b-2009/CSA B44b-09, PART 8

[Link].3(cc) Wire suspension and compen- the rope exceeds the values shown in column
sating ropes A of Table [Link].3(cc)(1); or
[Link].3(cc)(1) Wire suspension and compen- (b) if the distribution of the broken wires is
sating ropes shall be replaced: unequal, and broken wires predominate in
one or two strands, when the number of bro-
(a) if the broken wires are equally distributed
ken wires per rope lay in the worst section of
among the strands, when the number of bro-
the rope exceeds the values shown in column
ken wires per rope lay in the worst section of
B of Table [Link].3(cc)(1); or
Table [Link].3(cc)(1) Wire Suspension and Compensation Ropes
Types of Wire Ropes A B C
6x19 class 24-30* 8-12* 12-20*
8x19 class 32-40* 10-16* 16-24*
*The upper limits may be used when inspections are made monthly by a competent person.

25
 Replacement Criteria
FROM ASME A17.1b-2009/CSA B44b-09, PART 8

(c) if four or five wires, side by side, are broken (b) if wire breaks predominate in one or two
across the crown of any strand, when the strands, when the number of broken wires per
number of broken wires per rope lay in the rope lay in the worst section of rope exceeds
worst section of rope exceeds values shown in 6 to 12; or
column C of Table [Link].3(cc)(1); or (c) if there is more than one valley break per
Table [Link].3(cc)(3)
rope lay.
Nom. Size Max. Reduced Diameter
in. in. • decimal in. [Link].3(cc)(3) On any type of elevator, the
3/8 11/32 • 0.344 suspension, compensation and governor
7/16 13/32 • 0.406 ropes shall be replaced when their actual
1/2 15/32 • 0.469 diameter is reduced below the value shown in
9/16 17/32 • 0.531 Table [Link].3(cc)(3):
5/8 37/64 • 0.578
11/16 41/64 • 0.641 [Link] Replacement of a Single Suspension
3/4 45/64 • 0.703 Rope
1 15/16 • 0.938
If one rope of a set is worn or damaged and
(d) if in the judgment of the inspector, any requires replacement, the entire set of ropes
unfavorable condition, such as fretting cor- shall be replaced, except, where one rope
rosion (red dust or rouge), excessive wear of has been damaged during installation or
individual wires in the strands, unequal ten- acceptance testing prior to being subjected
sion, poor sheave grooves, etc., exists, the cri- to elevator service, it shall be permissible to
teria for broken wires will be reduced by 50% replace a single damaged rope with a new
of the values indicated in Table [Link].3(cc) rope, provided that the requirements of
(1) for any of the three conditions described [Link].1 through [Link].6 are met.
above; or
[Link].1 The wire rope data for the replace-
(e) if there is more than one valley break per ment rope must correspond to the wire rope
rope lay. data specified in [Link](a), (b), (c), (f), and (g)
[Link].3(cc)(2) On winding drum machines, for the other ropes.
the ropes shall be replaced: [Link].2 The replacement rope shall be pro-
(a) if the broken wires are equally distributed vided with a wire rope data tag conforming to
among the strands, when the number of bro- [Link].
ken wires per rope lay in the worst section of
rope exceeds 12 to 18; or

26
Replacement Criteria
FROM ASME A17.1b-2009/CSA B44b-09, PART 8

[Link].3 The suspension ropes, including the (c) When replacing suspension, compensat-
damaged rope, shall not have been shortened ing, and car or drum counterweight ropes, all
since their original installation. ropes in a set shall be replaced, except as
permitted by [Link].
[Link].4 The diameter of any of the remain-
ing ropes shall not be less than the nominal (d) The ropes in the set shall be new, all from
diameter minus 0.4 mm (0.015 in.). the same manufacturer, and of the same
material, grade, construction, and diameter.
[Link].5 The tension of the new replacement
rope shall be checked and adjusted as neces- (e) Data tags conforming to [Link] shall be
sary at semi-monthly intervals over a period applied.
of not less than two months after installation. (f) Suspension, car, and drum counterweight
If proper equalization of rope tension cannot rope fastenings shall conform to 2.20.9.
be maintained after six months, the entire set
of hoist ropes shall be replaced. [Link] Replacement of Governor or Safety
Rope
[Link].6 The replacement rope shall be pro-
vided with the same type of suspension-rope [Link].1 Governor ropes shall be of the same
fastening used with the other ropes. size, material, and construction as the rope
specified by the governor manufacturer,
[Link] Replacement of Ropes Other than except that a rope of the same size but of
Governor Ropes different material or construction shall be
[Link].1 Replacement of all ropes, except permitted to be installed in conformance with
governor ropes (see [Link]) shall conform to [Link].
the following: [Link].2 The replaced governor ropes shall
(a) Replacement ropes shall be as specified comply with 2.18.5.
by the original elevator manufacturer or be [Link].3 After a governor rope is replaced, the
at least equivalent in strength, weight, and governor pull-through force shall be checked
design. as specified in [Link].2(b).
(b) Ropes that have been previously used in [Link].4 A test tag indicating the date when
another installation shall not be reused. the pull-through test was performed shall be
attached.

NOTE: Some in the industry believe that all ropes for an installation
must be cut from the same master reel. This is not stated in ASME
A17.1/CSA B44.

27
 Replacement Criteria
FROM ASME A17.6-2010, SECTION 1.10

Notes: teria shall be documented in the Maintenance

(1) Replacement criteria for steel wire rope Control Program (see ASME A17.1/CSA B44,
are based on the worst conditions of diameter requirement [Link].1).
and wire breaks. Crown wires are subject to [Link] Criteria for replacement include at
both wear that reduces the diameter of the least one of the following:
rope and the breaks that occur in the wear
area. Breaks that are visible and occur outside (a) if the broken crown wires are equally dis-
of the crown wear area with the crown wire tributed among the strands, when the num-
intact are called valley breaks. ber of broken wires per rope lay in the worst
section of rope exceeds the values shown in
(2) Where ropes are subjected to reverse the “Normal Wear Conditions,” first column
bends or where ropes are installed on non- of Table [Link]-1
metallic sheaves or sheaves with nonmetallic
liners or inserts, extra attention must be given (b) if the distribution of breaks is unequal
to the rope due to possible acceleration of val- and broken crown wires predominate in one
ley breaks. or two strands, when the number of broken
wires per rope lay in the worst section of rope
1.10.1 Traction Drive Machines or the minimum diameter exceeds the values
[Link] Replacement requirements for steel shown in the “Normal Wear Conditions,” first
wire suspension ropes for traction eleva- column of Table [Link]-1
tors shall be as follows (see Nonmandatory
Appendix A): (c) if four wires, side by side, are broken across
the crown of any strand, when the number
(a) The steel wire rope(s) shall be replaced of broken wires per rope lay in the worst sec-
if the rope is permanently kinked, bent, or tion of rope exceeds the values shown in the
deformed in any way (see 1.10.5). “Normal Wear Conditions,” first column of
(b) For rope diameters equal to or greater than Table [Link]-1
8 mm (0.315 in.), the ropes shall be replaced in (d) if an unfavorable condition exists, such
accordance with [Link](a) through [Link](g) as but not limited to corrosion due to exter-
and 1.10.3. nal conditions, excessive wear of individual
(c) For rope diameters less than 8 mm (0.315 wires in the strands, unequal tension, poor
in.), the ropes shall be replaced in accordance sheave grooves; the criteria for broken crown
with [Link](a) through (g), [Link].1 and wires shall be the values indicated in the
[Link].2, and 1.10.3. In addition, other replace- “Unfavorable Wear Conditions,” second
ment criteria based on the application shall be column of Table [Link]-1 for any of the condi-
permitted to be applied. The replacement cri- tions described above

28
Replacement Criteria
FROM ASME A17.6-2010, SECTION 1.10

Table [Link]-1 Wire Breaks: Crown Wire Breaks Per Lay Length
6-Strand Normal Wear Unfavorable Wear Ropes
Rope Applications Conditions Conditions Showing Rouge
Distributed breaks (max.) 24 12 12
Unequal breaks (max.) 8 4 4
4 Side-by-Side breaks 12 6 6
8 and 9-Strand Normal Wear Unfavorable Wear Ropes
Rope Applications Conditions Conditions Showing Rouge
Distributed breaks (max.) 32 16 16
Unequal breaks (max.) 10 5 5
4 Side-by-Side breaks 16 8 8
General notes:
(a) Where ropes are subjected to reverse bends or where ropes are installed on nonmetallic
coated, plastic, fiber-reinforced plastic sheaves or sheaves with nonmetallic liners or inserts,
extra attention must be given to any steel wire rope (6, 8, or 9 strand) due to possible accelera-
tion of valley breaks.
(b) This table does not apply to Winding Drum Machines. See 1.10.2 for replacement criteria.
(c) No more than one valley break per lay length and no valley breaks allowed if visible rouge.
(d) For ropes less than 8 mm, also see [Link].2 for additional replacement requirements.

(e) if red dust or rouge exists, the criteria for of the minimum breaking force at the time of
broken wires shall be the values indicated replacement.
in the “Rope Showing Rouge,” third column [Link].2 Steel wire ropes of less than 8 mm
of Table [Link]-1 for any of the conditions (0.315 in.) in diameter shall be replaced when
described above there is evidence of rouge.
(f) if there is more than one valley break per 1.10.2 Winding Drum Machines
rope lay Suspension ropes shall be replaced on wind-
(g) if there are any valley breaks at any loca- ing drum machines if:
tion where rouge exists (a) the broken crown wires are equally distrib-
[Link].1 The elevator manufacturer using uted among the strands, when the number of
information from the rope manufacturer broken wires per rope lay in the worst section
and considering the application, shall estab- of rope exceeds 12;
lish the design life limit to ensure that the (b) the broken crown wires predominate in
residual strength of wire ropes less than 8 one or two strands, when the number of bro-
mm (0.315 in.) diameter is not less than 60%

29
 Replacement Criteria
FROM ASME A17.6-2010, SECTION 1.10

ken wires per rope lay in the worst section for wire breaks under “Unfavorable Wear
of rope exceeds 6; Conditions” shall apply. See Table [Link]-1.
(c) there is more than one valley break per 1.10.4 Replacement of Ropes
rope lay; or Replacement of all ropes, except governor
ropes (see ASME A17.1/CSA B44, requirement
(d) there are any valley breaks at any location
[Link]), shall conform to the requirements of
where rouge exists.
[Link] through [Link].
1.10.3 All Elevator Types
[Link] Replacement ropes shall be as speci-
The suspension, compensation, and governor
fied by the original elevator manufacturer or
ropes shall be replaced when their actual
be at least equivalent in strength, weight, and
diameter is reduced below the value shown
design.
in Table 1.10.3-1 (see page 32). For nominal
diameters not listed in Table 1.10.3-1, the [Link] Ropes that have previously been
minimum diameter reduction shall be cal- installed and used on another installation
culated using the criteria outlined in General shall not be reused.
Notes (a) and (b) of Table 1.10.3-1. Normal [Link] When replacing suspension, compen-
wear diameters, unfavorable wear, and rouge sating, and car or drum counterweight ropes,
conditions as listed in the table shall apply. all ropes in a set shall be replaced, except as
Compensation and governor ropes shall also permitted by 1.10.5.
conform to [Link](a) and [Link](a) through
[Link](g). [Link] The ropes in the set shall be new, all
from the same manufacturer and of the same
Measurement for diameter shall be taken material, grade, construction, and diameter.
on a straight portion of rope at the worst
location. Two measurements at the same [Link] Data tags conforming to ASME
position at right angles shall be taken. The A17.1/CSA B44, requirement [Link] shall be
ropes shall be replaced if both of these mea- applied.
surements are below the replacement value. [Link] Suspension, car, and drum coun-
However, if only one of the measurements is terweight rope fastenings shall conform to
below the replacement value, then the criteria ASME A17.1/CSA B44, requirement 2.20.9.

30
Replacement Criteria
FROM ASME A17.6-2010, SECTION 1.10

1.10.5 Replacement of a Single Suspension [Link] The suspension ropes, including the
Rope damaged rope, shall not have been shortened
If one rope of a set is worn or damaged and since their original installation.
requires replacement, the entire set of ropes [Link] The diameter of any of the remain-
shall be replaced; except, where one rope ing ropes shall not be less than the nominal
has been damaged during installation or diameter minus 0.4 mm (0.015 in.).
acceptance testing prior to being subjected
to elevator service, it shall be permissible [Link] The tension of the new replacement
to replace a single damaged rope with a rope shall be checked and adjusted as neces-
new rope provided that the requirements of sary at semi-monthly intervals over a period
[Link] and [Link] through [Link].6 are met. of not less than 2 months after installation. If
NOTE: Damage includes but is not limited to proper equalization of the rope tension can-
kinked ropes. not be maintained after 6 months, the entire
set of suspension ropes shall be replaced.
[Link] The steel wire rope data for the
replacement rope must correspond to the [Link] The replacement rope shall be pro-
steel wire rope data specified in ASMEA17.1/ vided with the same type of suspension rope
CSA B44, requirement [Link]. fastening used with the other ropes.

[Link] The replacement rope shall be provid-

ed with a data tag conforming to ASME A17.1/
CSA B44, requirement [Link].

NOTE: Some in the industry believe that all ropes for an installation
must be cut from the same master reel. This is not stated in ASME 17.6.

31
 Replacement Criteria
FROM ASME A17.6-2010, SECTION 1.10

Table 1.10.3-1 Imperial Minimum Diameter Table 1.10.3-1 Metric Minimum Diameter
6-, 8-, and 9-Strand Rope Applications 6-, 8-, and 9-Strand Rope Applications
Nominal Normal or Ropes Nominal Normal or Ropes
Rope Unfavorable Showing Rope Unfavorable Showing
Size Wear Conditions Rouge Size Wear Conditions Rouge
1⁄4 in. 0.242 in. Note (1) 4 mm 3.875 mm Note (1)
5⁄16 in. 0.303 in. Note (1) 5 mm 4.844 mm Note (1)
3⁄8 in. 0.352 in. 0.363 in. 6 mm 5.813 mm Note (1)
7⁄16 in. 0.410 in. 0.424 in. 6.5 mm 6.297 mm Note (1)
1⁄2 in. 0.469 in. 0.484 in. 6.7 mm 6.491 mm Note (1)
9⁄16 in. 0.527 in. 0.545 in. 8 mm 7.500 mm 7.750 mm
5⁄8 in. 0.586 in. 0.605 in. 9 mm 8.438 mm 8.719 mm
11⁄16 in. 0.645 in. 0.666 in. 10 mm 9.375 mm 9.688 mm
3⁄4 in. 0.703 in. 0.727 in. 11 mm 10.31 mm 10.66 mm
13⁄16 in. 0.762 in. 0.787 in. 12 mm 11.25 mm 11.63 mm
7⁄8 in. 0.820 in. 0.848 in. 13 mm 12.19 mm 12.59 mm
15⁄16 in. 0.879 in. 0.908 in. 14 mm 13.13 mm 13.56 mm
1 in. 0.938 in. 0.969 in. 15 mm 14.06 mm 14.53 mm
1 1⁄8 in. 1.055 in. 1.090 in. 16 mm 15.00 mm 15.50 mm
1 1⁄4 in. 1.172 in. 1.211 in. 18 mm 16.88 mm 17.44 mm
1 3⁄8 in. 1.289 in. 1.332 in. 19 mm 17.81 mm 18.41 mm
1 1⁄2 in. 1.406 in. 1.453 in. 20 mm 18.75 mm 19.38 mm
22 mm 20.63 mm 21.31 mm

GENERAL NOTES:
(a) Maximum allowable diameter reduction below nominal for rope diameters
less than 8 mm is 3.125%.
(b) Maximum allowable diameter reduction below nominal for rope diameters equal to or greater
than 8 mm are as follows:
(1) Normal wear or unfavorable wear conditions is 6.25%.
(2) Ropes showing rouge is 3.125%.
NOTE: (1) For ropes less than 8 mm, the rope must be replaced if rouge is evident. See [Link].2.

32