General Information

Hoisting ropes in underground mining operations play a vital role in the production cycle, not only to hoist minerals but also to transport men and materials safely and efficiently. Winding ropes are therefore clearly safety critical throughout their operating life.

Casar specialises in this technology and is a world leader in the manufacture of sophisticated wire rope products for a broad range of lifting applications. In Australia Casar has established a strong position in the mining industry.

Quality and high tech designEvery effort is made to maintain and improve the quality of Casar wire rope products for the mining industry. Careful attention to quality and engineering design details ensures that a Casar rope will routinely outperform conventional six strand and rotation resistant ropes. Special features of Casar mining ropes include galvanising, compacted strands and a plastic layer between steel core and the outer strands. The internal plastic layer stabilises the construction and experience has shown that Casar winding ropes are less prone to torsional distortions like waviness and slack outer strands.

Reliability and value for moneyCasar Special Mining Ropes offer benefits such as increased reliability of the hoisting system and reduced downtime due to less servicing and fewer rope changes. The higher breaking strengths of Casar Special Mining Ropes allow for an increase of payload for the same diameter. The increased capacity of the shaft will lead to increased profitability of the mine.

How to select the most suitable designThis catalogue sets out a range of different mine hoisting applications that Casar ropes can be used for and identifies which rope construction should be used in particular circumstances.

In order to assist you in rope selection, tables that follow give factors that can be used to calculate for example the rope minimum breaking loads (MBL) and masses for a given rope diameter. This allows for automated rope diameter selection given basic winding system parameters. The detailed specifications of various Casar mining ropes are given in 1mm diameter increments, but with rope factors it is also possible to calculate the rope specifications for intermediate diameters, e.g. 42.5mm or 53.5mm, which Casar can manufacture on request.

Tailor made rope constructionWithin a particular rope construction family Casar are able to deliver a wide range of fill factors and strength to mass ratios. An example of this is the comparison between Starplast M (with no compacted strands) and Starplast VM (with fully compacted strands). By varying the degree of strand compaction, Casar can manufacture ropes with every metallic cross sectional area, any breaking strength or any specific weight between the figures of Starplast M and Starplast VM. We are therefore able to adapt the rope specifications to the exact requirements of your shaft. This is the core competence of Casar.

Casar Mining Rope Factors

FillFactor

FF[-]

SpinFactor

SF[-]

WeightFactor

WF[-]

Wir Dia.Factor

DF[-]

CrossSectionFactor

CF[-]

MBLFactor

BLF 1770

[-]

MBLFactor

BLF 1960

[-]

MassFactor

MF[-]

0.6590 0.68459 0.8700 0.0630 0.5176 0.7749 0.8581 0.00450

0.6517 0.8372 0.8700 0.0748 0.5119 0.7585 0.8399 0.00445

0.6571 0.8415 0.8900 0.0546 0.5161 0.7441 0.8239 0.00459

0.6746 0.8200 0.9100 0.0545 0.5298 0.7690 0.8515 0.00482

0.67238 0.7938 0.8800 0.0500 0.5685 0.7987 0.8845 0.00500

Caculating the MBL in kN for a given rope diameter and a given tensile strengthMBL 1770 [kN] = 1.77 • FF • SF • II • (d[mm])2 / 4 or MBL 1770 [kN] = BLF 1770 • (d[mm])2

MBL 1960 [kN] = 1.96 • FF • SF • II • (d[mm])2 / 4 or MBL 1960 [kN] = BLF 1960 • (d[mm])2

Caculating a minimum rope diameter in mm for a given MBL and a given tensile strengthdmin 1770 [mm] = 4 • MBL 1770 [kN] / (FF • SF • II • 1.77) or

dmin 1770 [mm] = MBL 1770 [kN] / BLF 1770

dmin 1960 [mm] = 4 • MBL 1960 [kN] / (FF • SF • II • 1.96) or

dmin 1960 [mm] = MBL 1960 [kN] / BLF 1960

Caculating the outer wire diameter of the rope for a given rope diameter = DF • d

Caculating the rope mass for a given rope diameterRope mass [kg/m] = MF • d2

CASAR SPECIAL MINING ROPES

General Information

Koepe friction winders are either installed in a ground or tower mounted configuration. The number of head and tail rope pairs can vary between 1 and 10 depending on the hoisting duty of the winder. In general the combined unit mass of the head and tail ropes are equal to ensure balanced winding. Single layer rope constructions are widely used for shallower shaft Koepe winders,

but for depths exceeding 900 m it is critical that non-spin or rotation resistance constructions are used. For free looping tail ropes, non-spin ropes with swivels under both conveyances are recommended. For multi-rope winders, rope load balancing and equal driving sheave/drum circumferences are critical to ensure good rope life.

Double drum and BMR winders are almost always ground mounted. For these winders, single layer rope constructions can be used even in very deep shafts in even in excess of 3000 m. However, in such cases the lay length changes from the manufactured state would be significant. Rope load balancing and accurate drum spooling between rope pairs are critical on BMR winders. Ropes which offer high drum crushing resistance are

preferred for these applications as the ropes normally deteriorate first at the _ turn and layer crossovers on parrellel grooved drums. In cases where the ropes are free to rotate during the winding cycle (e.g. kibble winders) or where the shaft uses rope guides, non-spin or rotation resistant constructions are used.

Ground mounted Koepe friction winder single rope

Ground mounted Koepe friction winder multi-rope

Tower mounted Koepe friction winder single-rope no deflection sheave

Tower mounted Koepe friction winder multi-rope no deflection sheaves

Tower mounted Koepe friction winder single-rope with deflection sheave

Tower mounted Koepe friction winder multi-rope with deflection sheaves

Double drum winder

Blair mult-rope (BMR) winder

CASAR SPECIAL MINING ROPES