casar multi layer

New wire rope designsfor multi layer drums

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New wire rope designs for multi layer drums

by Dipl.- Ing. Roland Verreet

The bending fatigue mechanism

Bending cycles over sheaves

Bending cycles over single layer, grooved drums

Bending cycles over multi layer drums

Bending fatigue damage distribution in reeving systems with a

single layer drum

Bending fatigue damage distribution in reeving systems with a

multi layer drum

Multi layer spooling on helical drums

Multi layer spooling on Lebus drums

The influence of the D/d ratio

The influence of rope pretension

The influence of the rope diameter tolerance

Remedy 1: Shifting the crossover zones

Remedy 2: Spooling aids

Rope solutions

Rope solution 1: Langs lay ropes

Rope solution 2: Ropes with bigger outer wires

Rope solution 3: Ropes with compacted outer strands

Rope solution 4: Hammered ropes

Fill factors, spinning factors, weight factors, discard numbers

Rope data Casar Starfit

Rope data Casar Ultrafit

Rope data Casar Parafit

Additional Casar Literature

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The author:

Roland Verreet • Wire Rope Technology AachenGrünenthaler Str. 40a • D- 52072 AachenTel. +49 241 173147 • Fax +49 241 12982 • e-mail: [email protected]

© 3/2003. Cartoons by Rolf Bunse, PR GmbH. The author would like to thank Dr. Isabel Ridge,University of Reading, for proofreading the text and making usefull suggestions. Alexander Frings,thanks for the help during the typesetting. Reproduction, in whole or in part, only with the writtenpermission of the author.

New wire rope designs for multi layer drums

by Dipl.- Ing. Roland Verreet

The steel wire rope of a properly designed and maintained crane should have areasonably long service life and one day be discarded because of fatigue, the wirerope equivalent of old age.

But often wire ropes don´t get very old: they might die prematurely because of exces-sive abrasion or corrosion (the wire rope equivalents of skin cancer). Here, properwire rope relubrication might be the answer.

Wire ropes might also die prematurely because of mechanical or structural damages(the wire rope equivalents of being run over by a bus). Improved crane design andproper wire rope and crane usage will help to avoid these problems.

But what about drum crushing? If a wire rope dies because of damages receivedwhen spooling on and off a drum, is that part of normal rope life? Many crane designersand users think so.

But they are wrong: When drum crushing occurs, the wire rope damages itself. Drumcrushing is the wire rope equivalent of suicide. This paper explains the mechanismsand shows how drum crushing can be avoided.

The bending fatigue mechanism

If a wire rope is subjected to repetitive bending, small cracks will form in the surfaceof individual rope wires, especially at the points of contact with other wires or withthe groove of a sheave or drum. With increasing number of bending cycles, the crackwill grow, reducing the load brearing wire cross section. Once the remaining wirecross section is no longer able to carry its share of the load, the wire will fail.

A typical fatigue break is characterized by a break section perpendicular to the wireaxis. Figure 1 shows a rope with fatigue breaks. Figure 2 shows the cross section of arope wire broken due to fatigue.

Fig. 1: Steel wire ropes with fatigue breaks

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Bending cycles over sheaves

One bending cycle for a given rope section is defined as a change from a straight to abent and back to a straight condition (Fig. 3a) or from a bent to a straight and back toa bent condition (Fig. 3b). Every time the rope section travels over a sheave, it issubjected to one bending cycle. Of course, during a typical lift, not every rope sectionwill travel over the same number of sheaves and onto the drum. Therefore, along therope length, the wire rope will fatigue the most in those sections which travel overthe greatest number of sheaves, i.e. where it is subjected to the greatest number ofbending cycles.

Fig. 2: Break section of a rope wire broken due to bending fatigue

Bending cycles over single layer, grooved drums

If a rope section travels on and off a grooved single layer drum, it will also undergoa change from a straight to a bent and back to a straight condition, i.e. according tothe definition, it will also undergo one bending cycle.

But is a bending cycle on a drum comparable to a bending cycle on a sheave? For agrooved single layer drum, the answer is Yes. Tests and practical experience haveshown that a bending cycle on a grooved single layer drum will cause the same amount

a b

Fig. 3: Definition of one bending cycle

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of rope fatigue as a bending cycle on asheave, provided the line pulls and diametersare the same. In both cases, the rope will bebent around smooth, curved surfaces of thesame geometry. We could say that the rope„does not know“ if it is bent around a sheaveor a drum.

Bending cycles over multi layer drums

If a rope section travels on and off a groovedmulti layer drum, it will also undergo achange from a straight to a bent and back toa straight condition, i.e. according to thedefinition, it will also undergo a bendingcycle. But here, the conditions are different(Fig. 4):

Rope sections spooling in the first layer willalso be bent around a smooth drum surface,but when the second layer comes in they willbe spooled over, compressed and damagedon the upper side by the second rope layer.

Rope sections spooling in the second andhigher layers will be damaged on all sides:first they will be damaged in Zone A duringthe contact with the neighbouring wrap whenentering the drum (Fig. 5).

Then they will be bent around a very roughsurface created by the previous rope layer,leading to wire damage in Zones B1 and B2(Fig. 6).

Then the next wrap will come in, damagingthe rope section in Zone C, and displacingthe rope section, leading to additional da-mage in Zones B1 and B2 (Fig. 7).

Finally the next layer will damage the ropesection in Zones D1 and D2 at the side, or, ifwe are looking at a crossover zone, on thetop (Fig. 8).

It is obvious that by these mechanisms therope section will be damaged far more thanby one bend on a single layer drum (Fig. 9).But by how much more?

A

B1

C

D1 D2

B2

Fig. 5: First damage

Fig. 6: Second damage

Fig. 7: Third damage

Fig. 8: Fourth damage

Fig. 9: Final situation

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In Germany, two multi-layer test stands (one at University of Stuttgart and the otherat Casar Drahtseilwerk Saar GmbH) have been built to find out. Fig. 10 shows theCasar test stand.

Let us introduce a multi layer damage factor, defined as the number of bending cyclesuntil discard on a single layer drum or on a sheave versus the number of bendingcycles until discard on a multi layer drum. First tests performed at the two locationsseem to indicate that (surprisingly?) this multi layer damage factor increases withincreasing design factor, i. e. with decreasing wire rope line pull.

Fig. 4: Problems during multi layer spooling

Fig. 10: Multi layer test strand at Casar. Two multi layer drums can be seen in thebackground. The rope spools from one drum to the other via the sheaves in the 45ttensioning unit in the foreground. This unit can slide, pivot and vary the fleet anglesbetween the rope and the drums.

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Figure 11 shows the multi layer damage factor as a function of the rope design factor.Based on the first results, for a D/d ratio of about 25 the multi layer damage factor (orsuicide factor) can be approximated by

Multi layer damage factor = 2.85 + 0.65 • Rope design factor

Bending fatigue damage distribution in reeving systems with a single layer drum

It is not possible to predict the bending fatigue damage distribution along the hoistrope even for simple crane with a four part reeving system and a drum without knowingits operating conditions.

Let us suppose the crane picks up a load in the lowest hook position (Fig. 12a), liftsit to the highest hook position (Fig. 12b) and then lowers it back to the starting position(reverse bends in Fig. 12 for illustration only). This action will create a bendingfatigue distribution as in Figure 13.

Rope design factor [ - ]

3 4 5 6 7 8 9 10 11 12 13

4

6

8

10

12

14

16

18

Mul

ti la

yer

dam

age

fact

or [

- ]

14 15 16 17 18 19 20

Fig. 11: Multi layer damage factor as a function of the rope design factor

Fig. 12: Crane configuration, lowest (a) and highest (b) hook position

a b

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The highest fatigue damage does not occur on the fastest moving part of the rope, thefall going to the drum, but at the opposite end: It accumulates on the slower fallswhich stay in the reeving system and never get to the drum.

If the same crane randomly lifts loads to varying heights, the bending fatigue damagedistribution might look completely different. The damage maximum will be difficultto locate, but it will normally not be in a rope section which will spool onto the drum.

Bending fatigue damage distribution in reeving systems with a multi layer drum

If the above crane has a multi layered drum, every bend on the drum will be as muchas 4 to 40 times as detrimental to rope life as on a single layer drum or on a sheave.When adding up the damages caused by the bending cycles, every bend on the drum

Rope length from fixed point [ % ]

0 10 20 30 40 50 60 70 80 90 100

0

2

4

6

8

10

12

14

16

Num

ber

of c

ycle

s [

- ]

Rope length from fixed point [ % ]

0 10 20 30 40 50 60 70 80 90 100

0

2

4

6

8

10

12

14

16

Num

ber

of c

ycle

s [

- ]

Rope length spooling on drum

Fig. 13: Damage distribution along the rope length (single layer drum)

Fig. 14: Damage distribution along the rope length (multi layer drum)

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will have to be multiplied by the multi layer damage factor, and that will change thedamage distribution completely.

As an example, Fig. 14 shows the damage distribution for the above crane for a multilayer damage factor of 10. As we can see, now the zone with the greatest amount ofdamage is part of the rope length which will spool onto the drum.

Multi layer spooling on helical drums

On helical drums, wire ropes are expected to spool from one flange to the other in aperfect helix, climb into the second layer and spool back again in a perfect helix (Fig.15).

The wire rope, however, will behave completely differently (Fig. 16): After havingspooled from one flange to the other, the rope will climb into the second layer andthen spool away from the flange only for a short distance. It will cross over one wrapof the first layer, then fall into the gap between two adjacent wraps and follow thebed formed by those two wraps of the first layer (going the wrong direction). It willthen violently hit the wrap climbing up into the second layer and be kicked to theside. After crossing over another wrap it will again fall into a gap between two wrapsof the first layer, and the process will start again. This way, the rope will zig-zagaround the drum barrel: During every revolution of the drum the rope will

• be kicked to the side by 1 rope diameter (= -1 d),• spool in the wrong direction for half a rope diameter (= +1/2 d),• be kicked to the side by 1 rope diameter (= -1 d), and• spool in the wrong direction for half a rope diameter (= +1/2 d).

Now, add this up: - 1 d + 1/2 d - 1 d + 1/2 d = - 1d !!!

This means that in the second layer, during every revolution of the drum, the ropereally spools back by one rope diameter! But couldn´t that be done better?

First layer Second layerFirst layer Second layer

Fig. 15: Helical drum, theoreticalspooling behaviour

Fig. 16: Helical drum, real spoolingbehaviour

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Multi layer spooling on Lebus drums

Lebus improved the spooling tremendously by eliminating the helix in the first layer.On Lebus drums the rope first spools parallel to the flange, then is guided to the sideby half a rope diameter (Fig. 17). It then spools parallel to the flange again, until it isguided to the side by half a rope diameter (exactly on the opposite side of the firstevent).

First layer Second layer

Fig. 17: Lebus drum

Therefore, in the first layer during every revolution of the drum the rope will

• spool parallel to the flange (= ±0 d),• be guided to the side by 1/2 rope diameter (= +1/2 d),• spool parallel to the flange (= ±0 d) and• be guided to the side by 1/2 rope diameter (= +1/2 d).

Now, add this up: ± 0 d + 1/2 d ± 0 d + 1/2 d = + 1 d !!!

So during every revolution the rope really spools forward by one rope diameter! Thereal advantage, however, only shows in the second and consecutive layers.

After climbing into the second layer, the rope will spool parallel to the flange until itcrosses over the last wrap of the first layer exactly at the point where this one ismoving half a rope diameter against the flange. After crossing this wrap, the ropewill fall over on the other side (displacing by another half a rope diameter. The storywill repeat itself after every half a turn of the drum.

Therefore, in the second layer during every revolution of the drum the rope will

• spool parallel to the flange (= ±0 d),• be kicked to the side by 1/2 rope diameter (= -1/2 d),• spool parallel to the flange (= ±0 d) and• be kicked to the side by 1/2 rope diameter (= -1/2 d).

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Now, add this up: ± 0 d - 1/2 d ± 0 d - 1/2 d = - 1 d !!!

So during every revolution of the drum the rope really spools backward by one ropediameter. But what is the difference to the helical drum? There, in the second layerthe rope was also kicked to the side repeatedly!

Look at the figures: On the helical drum, every time the rope is kicked to the side it isby one full rope diameter. On the Lebus drum the displacement is only half a ropediameter, the layer underneath does the second half.

The zones where the rope is kicked to the side are called crossover zones, becausehere the rope crosses over a wrap of the previous layer. Figure 18 shows a ropespooling in the parallel zone of a Lebus type drum. Figure 19 shows the rope enteringthe crossover zone.

Fig. 18: Lebus drum, rope spooling inparallel zone

Fig. 19: Lebus drum, rope spooling incrossover zone

The influence of the D/d ratio

The influence of the D/d ratio (ratio drum diameter versus nominal rope diameter) onthe rope damage has not yet been tested in the laboratory. Practical experience,however, suggests that the rope damage increases considerably with decreasing D/dratio. Because of the bending stiffness of the wire ropes D/d- ratios below 20 shouldby any means be avoided, especially if the rope might spool with low tension in thelower layers.

Fig. 20 shows a two layer drum with a small D/d ratio. The width of the drum causessevere fleet angles, resulting in bad spooling. Fig. 21 shows a modern crane withmulti layer drums. The D/d ratio in the first layer is about 20.

Fig. 22 shows the author in front of a double drum winder installation in South Africa.The D/d ratios greater than 100 considerably reduce the damage caused by the multilayer spooling. They also allow for very high rope speeds.

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Fig. 20: The worst solution: Small diameter, great width

Fig. 21: Modern cranes operate with D/d ratios between 20 and 30.

Fig. 22: Mine hoist drum winders have D/d ratios greater than 100.

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The influence of rope pretension

If the lower layers have not been spooled onto the drum under high tension, the lowerwraps will be displaced by the incoming rope section, allowing it to slide down betweenthem, leading to severe rope damage.

This effect is especially pronounced on ungrooved multi layer drums. Fig. 23 showsthe force pyramid of an ungrooved drum. If the lower layers are not sufficientlytensioned, the incoming rope section will slide along the drum circumference (in anattempt to tension the neighbouring wraps) and at the same time cut into the lowerlayers (Fig. 24).

Fig. 23: Force pyramid on un-grooved drum

Fig. 24: The pyramid collapsesand the incoming rope cuts in.

Figs. 25 and 26 show rope damage created by spooling the wire rope onto the secondlayer of an ungrooved drum only once!

The crane operator might not always be aware of the fact that the rope has cut intodeeper layers on the drum. He might just cover the problem by two additional ropelayers, slew the crane and start lowering the load. The cut-in rope section might actlike a new fixed point: it might not come off the drum. As the drum continues to turn,the downward motion of the load will be reversed abruptly to an upward motion,leading to a high shock load which will severely damage and might even break therope. Fig. 27 shows a cut-in rope.

The proper force pyramid is shown in Fig. 28: The drum is grooved to stabilize thelowest layer, the voids at the flanges are filled with a riser helping the rope climbfrom the first to the second layer and the lower layers are pretensioned.

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Fig. 25: Severe relative motion hasdestroyed the rope during the first lift

Fig. 26: Consequences of a rope“cutting in”

Fig. 27: Cut- in wire rope Fig. 28: Correct drum layout

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The influence of the rope diameter tolerance

In the first layer and in the “parallel sections” of the consecutive layers the rope willbe guided by the drum grooves or the parallel rope sections below it, regardless of itsdiameter tolerance. In the crossover zones, however, it will be guided by theneighbouring wrap only. If the rope diameter matches the drum pitch, the crossoveron the drum surface will take place in a band parallel to the drum axis (Fig. 29).

If, however, the rope diameter is too small, the second wrap will spool at bit furtherthan intended before being kicked to the side by the first wrap. The third wrap willagain spool a bit further before being kicked by the second etc, resulting in an inclinedcrossover zone (Fig. 30 and 31). The next layer will not accept the crossover pointsdefined by the previous one, resulting in rope displacements and severe rope damagein this area.

Fig. 29: Rope diameter correct: The crossover zone is parallel to the drum axis.

Fig. 30: Rope diameter too small: The crossover zone is inclined towards the drum axis(causing severe rope damage)

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If on the other hand the rope diameter is too big, the second wrap will be kicked to theside by the first wrap at bit earlier than intended. The third wrap will again be kickedtoo early by the second etc, resulting in a crossover zone inclined in the oppositesense.

The normal range of the wire rope diameter tolerances is 5%. ISO, e.g. allows wirerope diameters from nominal dia. -1% to nominal dia. +4%. For proper spooling, thisrange must be reduced to about 2%.

Lebus usually uses drums with a pitch of

drum pitch = 1.04 ÷ 1,05 • nominal rope diameter.

The wire rope diameter range of tolerance is limited to 2% (nominal dia. +2% tonominal dia. +4%).

Remedy 1: Shifting the crossover zones

As discussed above, even with correct rope diameters and even when usingsophisticated drum designs, the wire rope will have to be kicked to the side by theneighbouring wrap twice with every revolution of the drum. This will inevitablylead to wire rope damage.

The bad news is, this damage is very much concentrated on the crossover zones. Fig.32 shows a typical rope section from a crossover zone (Zone A of Fig. 5) of a ropetested on the Casar test stand.

The good news, however, is that the damage is periodical: we will always have ashort damaged zone followed by a long undamaged zone followed by a short damaged

Fig. 31: Rope damage caused by instable support (the crossover zones are no longerparallel to the drum axis)

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zone etc.... And that gives us the opportunity to spread the damage by cutting off arope section a bit longer than the length of the damaged zone at the drum end of therope well before the discard state of the rope is reached (Fig. 33).

This action will move all the damaged rope sections out of the damaging crossoverzones on the drum into comfortable positions in the parallel zones. Relativelyundamaged rope sections will move into the crossover zones instead. This action caneasily double or even triple the life of the wire rope.

Fig. 32: Typical rope damage in the crossover zone

Fig. 33: Shifting of the damaged rope zones on the drum

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Remedy 2: Spooling aids

As explained above, the rope is destroyed on multi layer drums by spooling againstadjacent rope wraps. A spooling aid can help guide the rope during spooling and canprevent it from constantly hitting its neighbouring wrap.

It must be guaranteed, however, that the spooling aid is calibrated to the effectiverope diameter. An incorrectly calibrated spooling aid might just do the opposite ofwhat it is supposed to do: it might constantly guide the incoming rope against itsneighbouring wrap and destroy the rope in very short time.

And don´t forget: the wire rope diameter will reduce over time!

Rope solutions

We have seen that during drum crushing, the wire rope is not damaged by otherobjects. No, the rope is destroyed by constantly hitting itself! Spooling on a multilayer drum is a constant hammering of one rough rope surface against another roughsurface of the same rope! Drum crushing really is the wire rope equivalent of suicide!

How can we prevent this self- destruction?

Rope solution 1: Langs lay ropes

Practical experience has shown in the past that during multi layer spooling Langs layropes (Fig. 34) perform much better than regular lay ropes (Fig. 35). This is becausethe outer wires of neighbouring wraps cannot form indentations which wouldinevitably lead to mutual destruction.

Rope solution 2: Ropes with bigger outer wires

It is also a known fact that ropes with bigger, more robust outer wires perform betterin multi layer spooling. The diameter of the outer wires of a Seale 19 strand (Fig. 36)is 42 % bigger than those of a Warrington- Seale 36 strand (Fig. 37). Their metalliccross- section is 100 % bigger and therefore much more robust and abrasion resistant.Of course, the fatigue performance of a Seale 19 strand is worse than that of a WS 36strand, but who cares if not fatigue but drum crushing is the problem?

Rope solution 3: Ropes with compacted outer strands

A great deal of the damage caused during multi- layer spooling is caused by individualouter wires forming indentations with the outer wires of the neighbouring wrap (Fig.38). If, however, the rope has compacted outer strands (Fig. 39), indentations cannotoccur so readily and the damage is greatly reduced.

Rope solution 4: Hammered ropes

As we have seen above, most of the damage a wire rope will be subjected to duringmulti layer spooling is caused by the rough outer surface of the rope itself. So itwould only seem logical to smoothen the rope surface in order to reduce the damage.

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Fig. 36: Seale 19 strand, a very robuststrand design

Fig. 37: Warrington- Seale 36 strand, avery fatigue resistant strand design

No indentations

Fig. 34: Langs lay ropes: No indentations of outer wires

Fig. 35: Regular lay ropes: Indentations of outer wires

Indentations

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Steel wire ropes cross sections are often referred to as being “round”. But they arenot round at all! Depending on the number of outer strands of the rope, the crosssections resemble a hexagon or an octogon much more than a circle! The sequence ofcrowns and valleys along the circumference is the main cause for all the problems wehave discussed above! So, in order to avoid the problems, we must really make therope cross section round!

Fig. 38: Conventional outer strands allow for indentations between outer wires

Fig. 39: Compacted outer strands prevent indentations between outer wires

Casar Drahtseilwerk Saar has achieved tremenduously round cross sections andextremely smooth wire rope surfaces by hammering different types of steel wireropes using a rotary swager. Great care has been taken to avoid internal wire ropedamage caused by the swaging process itself. Figure 40 shows a conventional steelwire rope in unswaged condition (top) and with two different degrees of diameterreduction.

The hammered ropes have been tested on normal bending fatigue machines and onthe Casar multi-layer test stand shown in Figure 10. The results have been veryencouraging: On the multi-layer test stand, on average the swaged ropes achievedabout 3 times the life of the comparable unswaged designs.

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Fig. 40: The same rope before swaging (top), after swaging (normal reduction, middle)and after swaging (severe reduction, bottom).

Hammered ropes have much greater contact areas with the grooves of sheaves anddrums than conventional steel wire ropes with a “rough” surface. This leads to muchlower bearing pressures and as a consequence to much lower sheave, drum and ropewear.

Casar offers a variety of hammered steel wire ropes. They can be identified in theCasar rope catalogues by the name ending “fit”. The following pages show a 14strand rotation resistant rope (Casar Starfit) and two non rotation resistant ropes (CasarUltrafit and Casar Parafit). Compared with conventional steel wire ropes, these ropedesigns offer an increased breaking strength and excellent rope life on multi layerdrums.

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April 27, 2000. Joe Bloggs (left) invents the swaged rope.

Average fill factor��Spinning factor 1960 N/mm��Spinning factor 2160 N/mm��Average weight factor��Total number of wires��Number of wires in outer strands��Discard number on 6 x d��Discard number on 30 x d

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DIN 15020, Group of mechanisms 2m - 5m, Regular lay

*

*

*

22

121314

151617

181920

212223

242526

272829

303234

363840

424446

4850

81,1794,89110,23

125,72145,90163,28

183,93203,94226,56

247,40271,50303,59

324,61354,15379,31

413,81448,16475,58

505,02583,07659,96

736,77813,79909,05

996,511101,831192,12

1312,751414,86

70,682,695,9

109,4126,9142,1

160,0177,4197,1

215,2236,2264,1

282,4308,1330,0

360,0389,9413,8

439,4507,3574,2

641,0708,0790,9

867,0958,6

1037,1

1142,11230,9

159,1186,0216,1

246,4286,0320,0

360,5399,7444,1

484,9532,1595,0

636,2694,1743,4

811,1878,4932,1

989,81142,81293,5

1444,11595,01781,7

1953,22159,62336,6

2573,02773,1

16,2218,9722,03

25,1329,1632,63

36,7640,7645,28

49,4554,2660,68

64,8870,7875,81

82,7189,5795,05

100,94116,53131,90

147,25162,65181,69

199,17220,22238,26

262,37282,78

175,3205,0238,1

271,5315,2352,7

397,3440,5489,4

534,4586,4655,8

701,2765,0819,3

893,8968,0

1027,3

1090,81259,41425,5

1591,41757,81963,6

2152,52380,02575,0

2835,53056,1

17,8820,9024,28

27,6932,1435,96

40,5144,9249,90

54,4959,8066,87

71,5078,0083,55

91,1498,71

104,75

111,24128,43145,36

162,28179,24200,23

219,49242,69262,57

289,15311,64

135,22158,09183,65

209,44243,08272,03

306,43339,76377,45

412,17452,31505,78

540,80590,02631,92

689,40746,64792,32

841,36971,39

1099,49

1227,461355,771514,48

1660,181835,661986,07

2187,052357,16

13,7916,1218,73

21,3624,7927,74

31,2534,6538,49

42,0346,1251,58

55,1560,1664,44

70,3076,1480,79

85,8099,05112,12

125,17138,25154,43

169,29187,18202,52

223,02240,36

147,27172,18200,01

228,10264,73296,26

333,72370,03411,07

448,88492,60550,83

588,98642,57688,21

750,81813,14862,89

916,311057,921197,42

1336,801476,531649,39

1808,061999,172162,98

2381,862567,12

15,0217,5620,40

23,2626,9930,21

34,0337,7341,92

457750,2356,17

60,0665,5270,18

76,5682,9287,99

93,44107,88122,10

136,32150,56168,19

184,37203,86220,56

242,88261,77

mm kg/%mmm2 kN t kN t kN t kN t

1960 N/mm2

(200kp/mm2)2160 N/mm2

(220kp/mm2)1960 N/mm2

(200kp/mm2)2160 N/mm2

(220kp/mm2)

®

Further diameters upon request !

WeightMetallic

areaNominaldiameter

Calculated aggregate breaking load Minimum breaking load

with tensile strength of wire

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is a 14-strand rotationresistant, hammered rope.

is fully lubricated.

has a plastic layer between thesteel core and the outerstrands.

has a very high breakingstrength

has a very smooth surface andis therefore especially suitedfor multi layer spooling.

®

®

regular lay or

langs lay

24

89

10

111213

141516

171819

202122

232425

262728

293032

343638

404244

464850

34,2245,8256,71

65,3177,7993,47

107,61124,22145,06

160,01179,95197,06

224,27237,91265,14

286,37317,51349,43

369,79395,19425,38

451,24490,53561,22

648,83700,97784,99

870,87951,04

1046,62

1146,741252,191351,47

30,140,349,9

57,568,582,3

94,7109,3127,7

140,8158,4173,4

197,4209,4233,3

252,0279,4307,5

325,4347,8374,3

397,1431,7493,9

571,0616,9690,8

766,4836,9921,0

1009,11101,91189,3

67,189,8111,1

128,0152,5183,2

210,9243,5284,3

313,6352,7386,2

439,6466,3519,7

561,3622,3684,9

724,8774,6833,7

884,4961,41100,0

1271,71373,91538,6

1706,91864,02051,4

2247,62454,32648,9

6,849,1611,33

13,0515,5518,68

21,5124,8328,99

31,9835,9739,38

44,8247,5552,99

57,2463,4669,84

73,9178,9885,02

90,1998,04112,17

129,68140,10156,89

174,06190,08209,18

229,19250,27270,11

73,999,0

122,5

141,1168,0201,9

232,4268,3313,3

345,6388,7425,6

484,4513,9572,7

618,6685,8754,8

798,8853,6918,8

974,71059,51212,2

1401,51514,11695,6

1881,12054,32260,7

2476,92704,72919,2

7,5410,0912,49

14,3917,1320,59

23,7027,3631,95

35,2439,6443,40

49,4052,4058,40

63,0869,9376,96

81,4587,0493,69

99,39108,04123,61

142,91154,40172,90

191,82209,48230,53

252,58275,81297.67

57,076,394,5

108,8129,6155,7

179,3207,0241,7

266,6299,8328,3

373,6396,4441,7

477,1529,0582,1

616,1658,4708,7

751,8817,2935,0

1081,01167,81307,8

1450,91584,41743,7

1910,52086,12251,6

5,817,789,63

11,1013,2215,88

18,2821,1024,64

27,1830,5733,48

38,1040,4245,04

48,6553,9459,36

62,8267,1472,27

76,6683,3395,34

110,23119,08133,36

147,95161,57177,81

194,81212,73229,59

62,183,1

102,9

118,5141,1169,6

195,2225,4263,2

290,3326,5357,5

406,9431,7481,1

519,6576,1634,0

671,0717,0771,8

818,7890,0

1018,3

1177,21271,81424,3

1580,11725,61899,0

2080,62272,02452,1

6,338,48

10,49

12,0814,3917,29

19,9122,9826,84

29,6033,2936,46

41,4944,0249,05

52,9858,7464,65

68,4273,1278,70

83,4990,76

103,84

120,04129,69145,24

161,13175,96193,64

212,17231,68250,05


1960 N/mm2

(200kp/mm2)2160 N/mm2

(220kp/mm2)1960 N/mm2

(200kp/mm2)2160 N/mm2

(220kp/mm2)

®

WeightMetallic

areaNominaldiameter




25

is an 7-strand hammered rope.


has a plastic layer between thesteel core and the outerstrands.

has a very high breakingstrength


may not be used with a swivel.

®

®

®

regular lay

26

89

10

111213

141516

171819

202122

232425

262728

293032

343638

404244

464850

36,9746,5657,09

71,2582,6697,89

114,85130,87149,58

171,09189,23213,70

233,67256,54284.51

309,81337,86366,17

393,92426,46459,06

491,46529,11597,54

678,69757,45848,20

934,701030,491137,59

1240,771351,251454,55

31,439,648,5

60,670,383,2

97,6111,2127,1

145,4160,8181,6

198,6218,1241,8

263,3287,2311,2

334,8362,5390,2

417,7449,7507,9

576,9643,8721,0

794,5875,9967,0

1054,71148,61236,4

72,591,3111,9

139,6162,0191,9

225,1256,5293,2

335,3370,9418,9

458,0502,8557,6

607,2662,2717,7

772,1835,9899,8

963,31037,11171,2

1330,21484,61662,5

1832,02019,82229,7

2431,92648,52850,9

7,399,3111,41

14,2416,5219,56

22,9526,1629,89

34,2037,8242,71

46,7051,2756,86

61,9267,5373,19

78,7385,2491,75

98,23105.75119,43

135,65151,39169,52

186,81205,96227,36

247,99270,07290,71

79,9100,6123,3

153,9178,6211,4

248,1282,7323,1

369,6408,7461,6

504,7554,1614,5

669,2729,8790,9

850,9921,2991,6

1061,61142,91290,7

1466,01636,11832,1

2018,92225,92457,2

2680,12918,73141,8

8,1410,2612,57

15,6918,2121,56

25,3028,8332,95

37,6841,6847,07

51,4756,5062,67

68,2474,4280,65

86,7693,93101,11

108,25116,54131,61

149,49166,84186,82

205,87226,97250,56

273,29297,63320,38

63,0579,4097,34

121,49140,96166,91

195,84223,16255,06

291,75322,68364,41

398,45437,45485,15

528,29576,12624,40

671,71727,21782,78

838,04902,24

1018,93

1157,311291,611446,35

1593,841757,191939,82

2115,762304,162480,29

6,438,109,93

12,3914,3717,02

19,9722,7626,01

29,7532,9037,16

40,6344,6149,47

53,8758,7563,67

68,5074,1579,82

85,4692,00

103,90

118,01131,71147,49

162,53179,18197,81

215,75234,96252,92

68,6886,49

106,04

132,35153,55181,83

213,35243,10277,85

317,82351,51396,97

434,06476,54528,51

575,51627,61680,21

731,74792,20852,74

912,94982,881109,99

1260,741407,041575,62

1736,291914,242113,19

2304,852510,092701,97

7,008,82

10,81

13,5015,6618,54

21,7624,7928,33

32,4135,8440,48

44,2648,5953,89

58,6964,0069,36

74,6280,7886,96

93,09100,23113,19

128,56143,48160,67

177,05195,20215,49

235,03255,96275,52


1960 N/mm2

(200kp/mm2)2160 N/mm2

(220kp/mm2)1960 N/mm2

(200kp/mm2)2160 N/mm2

(220kp/mm2)

®

WeightMetallic

areaNominaldiameter




27

is an 8-strand hammered rope.


has a double parallel lay steelcore, avoiding internal cross-overs.

has a plastic infill.

has an extremely highbreaking strength.


may not be used with a swivel.

®

®

®

regular lay

28

Additional Casar Literature

If you would like to receive additional Casar literature, please copy this form, fill inthe number of copies and your full address and send it to Casar via mail or fax it to

Fax No. ++ 49 6841 8091 359

Please send me free of charge the following brochures:

....... copies of the brochure Casar General Catalogue

....... copies of the brochure Steel wire ropes for cranes: Problems and solutions

....... copies of the brochure New wire rope designs for multi-layer drums

....... copies of the brochure Technical documentation

........copies of the brochure Which rope for my crane?

........copies of the brochure Handling, installation and maintenance

....... copies of the brochure Wire rope end connections

....... copies of the brochure Wire rope inspection

....... copies of the brochure Calculating the service life of running steel wire ropes

....... copies of the brochure A short history of steel wire ropes

....... copies of the brochure The rotation characteristics of steel wire ropes

....... copies of the brochure Analysis of the bending cycle distribution on electric

hoists

....... copies of the CD Casar CD (Macintosh + Windows)

Address:

CASAR DRAHTSEILWERK SAAR GMBHCasarstrasse 1 • D-66459 Kirkel • GermanyP.O. Box 187 • D-66454 Kirkel • GermanyPhone: ++ 49-6841 / 8091-0Phone Sales Dept.: ++ 49-6841 / 8091-350Fax Sales Dept.: ++ 49-6841 / 8091-359E-mail: [email protected]://www.casar.de

casar multi layer

Documents