Description of maintenance work on thesuperstructure 8.6 Hoist ropes

The following tables show the number of wire breaks, in a length 6 times and 30 times the rope diameter, at which the rope must be replaced, for the most common rope diameters.

HThe number of visible wire breaks indicated here only applies to the hoist ropes! This information only applies to the initial equipment and original spare parts!

SRemember that other factors may also make it necessary to replace the hoist rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).

DamageDescriptionCauseReplacement

Wire strand fracture (1) Wire breakage clusters (2)

Strand breakage(3)

Individual wires are broken; the broken ends of the wires are protruding from the rope.

General wear caused by aging of the rope or Subsequent damage resulting from damage to the rope.

At the latest, replace hoist rope when the maximum permissible number of wire strand fractures according to the table are visible externally.

Replace hoist rope immediately if wire breakage clusters or strand breakage occur. The frequency of wire breakage increases with rope age. For reasons of safety, it is advisable to replace the hoist rope while the number of broken wires is still low.

Effect of heat Tarnishing colour is visible externally on the rope.

Rope has been subjected to strong heat.

Replace hoist rope immediately.

DamageDescriptionCauseReplacement

Diameter reduction(1)

The diameter of therope has become smaller in large areas.

Structural changes Immediately replace hoist rope if the diameter has decreased by 15% or more with respect to the nominal diameter.

Corrosion or abrasion. Immediately replace hoist rope if the diameter has decreased by 10% or more with respect to the nominal diameter.

Cork-screw deformation of rope(2)

The rope is winds its way along its longitudinal axis in a way which is similar to a corkscrew. The deformation is measured with the attached hook block.

Damage resulting from overloading.

Even a small amount of deformation leads to increased abrasion, wire strand fractures and rough operation of the cable drive.

If deformation ’x’ at a position on the hoist rope is greater than a third of the rope diameter, the hoist rope must be replaced immediately .

Basket-type deformation

(3)

Wires from the outer layer are protruding from the rope. In various areas of the rope, the ply has buckled or is protruding from the rope.

Outer and inner layers have dislocated from one another.

Replace hoist rope immediately.

DamageDescriptionCauseReplacement

Loop formation(1)

Outer layer wires in the form of hair pins are protruding from the rope on the side opposite to the rope pulley.

General wear due to aging of the rope or subsequent damage resulting from damage to the rope.

Immediately replace hoist rope if the rope structure has been substantially altered by the loop formations.

Loosening of wires or strands(2)

Outer wires or strands have become loose. Only the inner strands continue to bear the load.

Corrosion or abrasion. Replace hoist rope immediately

Other causes. The number of broken wires determines when the rope must be replaced.

Formation of nodes(3)

Formation of nodes; repeatedly occurring nodeformed thickening of rope; core often protrudes. The strands bear on each other at narrow locations; increased occurence of wire breakage.

General wear due to aging of the rope or subsequent damage resulting from damage to the rope.

Determine number of broken wires; replace hoist rope immediately if serious node formation occurs.

Constriction (4)

Reduction of rope diameter over short sections.

General wear caused by aging of the rope. Replace hoist rope immediately if serious constriction occurs.