Download the full Mining Brochure (Imperial) - Bridon

Mining Rope CatalogueImperial Edition

Bridon - the world’s leading specialistin the manufacture of wire and ropesolutions for the most demandingapplications, delivering reassurancethrough unrivalled experience.High quality steel wire ropesfor mining applicationsDrawing from a background of long standing experienceand technology, Bridon is an acknowledged world leaderin the design, manufacture, development and supply ofrope to meet the needs of the mining industry.High performance ropes forHoist, Balance, Guide, Haulage,Rope Driven Conveyor and GeneralEngineering Applications.02 BRIDON Mining

Product SelectionHoist and Balance RopesTiger 6R 6x19(S), 6x36(WS)• High quality• Readily available• Consistent performanceSee pages 8 & 10Parallel Drum HoistHoist Rope•Tiger 34M Class• Good resistance to rotation• Reduced internal torsional stress• Improved flexibilitySee pages 15Blair HoistHoist Rope•Tiger Superflex 17x6, 20x6• Maximum Flexibility• Maximum Resistance to wearSee page 17Hoist Rope•Tower Mounted Friction Hoist with DeflectorsBalanced RopeFlat ropes 8x4x7, 6x4x12, 8x4x12, 8x4x14, 8x4x19• Maximum flexibility• Good rotational characteristicsSee page 18Ground Mounted Friction HoistHoist Rope•Balanced RopeBRIDON Mining05

Product SelectionGuide and Rubbing RopesTiger Half Lock Guide Rope• High strength• Good resistance to wear and corrosion• Reduced stretch• Can be prestretched• Reduced internal cross-cuttingSee page 23Guide and Rubbing Rope•Haulage RopesTiger 6T Compound6x22(9/12/Brangle), 6x23(10/12/Brangle)6x25(12/12/Brangle), 6x26(13/12/Brangle)6x27(14/12/Brangle), 6x28(15/12/Brangle)Haulage Ropes•• Good resistance to wear• Reduced sheave and liner wear• High strength• Effective diameter control• Good fatigue resistanceSee pages 12-13Tiger DYFORM ® 6R6x19(S), 6x36(WS)• High quality• Excellent fatigue resistance• Readily available• Consistent performance• Excellent resistance to wearSee pages 9 & 11Haulage Ropes•Tiger 6R 6x19(S), 6x36(WS)• High quality• Readily available• Consistent performance• Good resistance to wearSee pages 8 & 1006 BRIDON Mining

Product SelectionRope Driven Conveyor RopesRope Driven Conveyor Rope•6x19(S), 6x26(WS), 6x31(WS)• Increased fatigue life• High strength• Reduced stretch• Effective diameter control• Reduced tread pressures• Good resistance to wear and corrosion• Reduced vibration and noise• Extended rope life• Extended splice life• Minimal line stand and terminal pulley maintenanceSee page 19Tiger DYFORM ® 6CDR6x19(S), 6x31(WS)• Superior quality drive rope• Special preformation for long splicing• Special tensile grades• High density and high tolerance cores• Bespoke lubrication• Superior breaking load• Excellent fatigue life• Reduced line stand pulley maintenanceSee page 21Tiger 6CDR6x19(S)(9/9/1), 6x25(F)(12/6+6F/1)• High performance conventional rope• Special preformation for long splicing• Special tensile grades• High density and high tolerance cores• Bespoke lubricationSee page 20BRIDON Mining07

ProductsThe “Powercheck” symbol means that BRIDON has carried out a destruction test on a sample ofrope from each production length.BRIDON has an active program to determine the rotational properties of its range of RotationResistant and low Rotation ropes. BRIDON has developed its own torque turn testing machine andhas adopted a "Twistcheck" testing program for each product and is able to provide actual propertiesfor any rope.BRIDON has an active program to determine fatigue properties and specifies material of specificdimensions and properties, which will enhance fatigue performance. BRIDON design andmanufactures its ropes with fatigue in mind and has machines for fatigue testing mining ropes.Tiger 6R 6x19(S) ClassLay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC IWRC• • • • • • • • •Available as standard. IWRC values available on requestDiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN3/47/811.1/81.1/41.3/81.1/21.5/81.3/40.941.271.672.192.613.153.744.405.1121.329.037.948.059.271.785.3100.0116.124.032.742.754.066.780.896.2112.8130.925.334.444.956.970.184.8101.0118.5137.526.636.247.359.973.989.4106.4125.0145.01902583374275276387598901033214291380481594719856100411652253064005066247558991055122423732242153365879694711121290The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire ropebefore selecting or using this product.08 BRIDON Mining

ProductsTiger DYFORM ® 6R 6x19(S) ClassLay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC IWRC• • • • • • • • •Available as standard. IWRC values available on requestDiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN11.1/81.1/41.3/81.1/21.5/81.3/41.722.192.703.253.884.565.2941.852.965.478.893.8110.2130.947.059.673.788.8105.7124.3147.549.462.677.493.3111.1130.7155.152.066.081.698.3117.1137.6163.537247158270183598111654185306567909411106131344055768983098911631380463587726875104212251455The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire ropebefore selecting or using this product.BRIDON Mining09

ProductsTiger 6R 6x36(WS) ClassLay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC IWRC• • • • • • • • •Available as standard. IWRC values available on requestDiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN3/47/811.1/81.1/41.3/81.1/21.5/81.3/41.7/822.1/82.1/40.901.221.602.022.503.023.604.224.895.626.397.228.0922.429.037.948.059.271.785.3100.0116.1133.3151.6171.1191.824.032.742.754.066.780.896.2112.8130.9150.2170.9192.9216.325.334.444.956.970.184.8101.0118.5137.5157.9179.6202.7227.326.636.247.359.973.989.4106.4125.0145.0166.3189.2213.6239.619925833742752763875989010331186134915231707214291380481594719856100411651337152117171925225306400506624755899105512241405159818042023237322421533658796947111212901480168419012132The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire ropebefore selecting or using this product.10 BRIDON Mining

ProductsTiger DYFORM ® 6R 6x36(WS) ClassLay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC IWRC• • • • • • • • •Available as standard. IWRC values available on requestDiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN11.1/81.1/41.3/81.1/21.5/81.3/41.7/822.1/82.1/42.3/82.1/21.772.262.793.354.004.705.996.247.128.049.0210.0311.1242.153.566.179.694.7111.4129.3148.0168.5190.5213.6237.4263.447.560.274.589.7106.9125.5145.9166.8190.0214.7240.9267.8296.949.963.478.394.3112.3131.9153.2175.3199.7225.6253.2281.4312.052.666.782.499.3118.4139.1161.5184.7210.5237.8266.8296.4328.837547658870884399111511317150016951901211323444235366637989511117129814841691191121442383264244456469783999911741363156017772008225325042777468594733884105412381437164418732116237426382926The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire ropebefore selecting or using this product.BRIDON Mining11

ProductsTiger 6T Compound Layer 6x22(9/12/Brangle),6x23(10/12/Brangle), 6x25(12/12/Brangle)Lay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC IWRC• • • • • • •DiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN3/47/811.1/81.1/41.3/81.1/21.5/81.3/41.7/822.1/82.1/41.011.391.772.262.793.354.004.705.996.247.128.049.0225.732.443.054.471.886.3100.3118.5135.9155.4181.8205.0225.929.036.548.561.480.094.8113.2131.1153.2175.3204.5228.1256.229.640.151.166.483.599.7119.0137.8161.0184.2213.3238.0270.530.143.653.671.687.4104.9123.8144.4169.7194.3223.5250.1277.0229288383484639768893105512091383161818242010258325432546712844100711671363156018202030228026335745559174388710591226143316391898211824072683884776377789341102128515101729198922262465The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.Ropes for friction winding application will weigh approximately 2% less than the above quoted weights.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.12 BRIDON Mining

ProductsTiger 6T Compound Layer 6x26(13/12/Brangle)6x27(14/12/Brangle), 6x28(15/12/Brangle)Lay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC IWRC• • • • • • •DiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN1.1/81.1/41.3/81.1/21.5/81.3/41.7/822.1/82.1/42.222.863.484.054.685.656.127.238.188.8156.972.087.4102.4118.0142.5153.6182.8206.5221.464.081.198.5115.4132.3160.7173.3206.1232.9249.666.784.7102.9120.6137.8167.8180.9215.2243.3260.669.888.7107.8127.6146.6175.7189.4225.3254.2272.8506641778911105012681367162718381970570722877102711771430154218342073222159475491610731226149316101915216523196217899591136130515641686200522622428The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.Ropes for friction winding application will weigh approximately 2% less than the above quoted weights.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.BRIDON Mining13

ProductsTiger DYFORM ® 18M/PI ClassLay Type Lay Direction Finish CoreOrd Langs RightHandLeftHandBright Galv FC FFC WSC• • • • • • •DiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN18x73/47/811.1/81.1/41.3/81.1/218x191.1/41.3/81.1/21.5/81.3/41.7/822.1/81.221.642.152.733.374.064.843.384.074.855.697.267.578.629.7427.537.148.761.676.291.8109.274.489.7106.7125.5145.6166.6189.9214.531.041.954.769.485.8103.4123.383.8101.0120.5141.5164.3188.0214.1241.832.643.957.572.990.2108.7129.488.1106.2126.5148.7172.6197.4225.0254.234.346.360.776.995.1114.5136.492.9111.9133.3156.6181.8208.0237.0267.8245330433548678817972662798950111712961483169019092763734876187649201097746899107212591462167319052152290391512649803967115278494511261323153617572002226230541254068484610191214827996118613941618185121092383The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.Nominal Length Mass is subject to a tolerance of minus 2% to plus 5%.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire ropebefore selecting or using this product.Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.14 BRIDON Mining

ProductsTiger 34M ClassLay Type Lay Direction Finish CoreOrd Langs Right Hand Left Hand Bright Galv FC FFC WSC• • • • • • • • •Available as standard. WSC values available on requestDiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1570 N/mm 2 1770 N/mm 2 1860 N/mm 2 1960 N/mm 2 1570 N/mm 2 1770 N/mm 2 1860 N/mm 21960 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN34x73/47/811.1/81.1/41.3/834x191.3/81.1/21.5/81.3/41.7/822.1/82.1/42.3/82.1/20.951.291.692.142.563.193.704.244.995.796.637.558.5211.3210.6311.7920.327.435.845.556.367.674.688.9104.4121.2138.8158.0178.5200.3222.7246.922.931.040.351.263.576.384.0100.2117.8136.6156.4178.2201.2225.9251.0278.224.032.542.553.966.680.288.3105.3123.7143.6164.4187.2211.6237.3263.7292.525.334.344.756.770.284.693.0110.9130.5151.4173.3197.3222.9250.1278.0308.21812443194055016026647919291079123514061589178319822197204276359456565679748892104812161392158617912010223424762142893784805937147869371101127814631666188321122347260322530539850562575382898711611347154217561984222624742743The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.Nominal Length Mass is subject to a tolerance of minus 2% to plus 5%.This table is for guidance purposes only. Balance ropes are normally designed to achieve a desired weight.Ropes with the required weight and strength will be designed to meet particular shaft requirements.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire ropebefore selecting or using this product.Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.BRIDON Mining15

ProductsTiger DYFORM ® 34LR/PI ClassLay Type Lay Direction Finish CoreBright Galv FC FFC WSCOrd Langs RightHandLeftHand• • • • • • •DiameterinNominalLengthMasslbs/ftNominal Breaking Load1570 1770 1860 1960 2160 1570 1770N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2 N/mm 2Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNNominal Breaking ForcekN1860N/mm 2kN1960N/mm 2kN2160N/mm 2kN34x73/47/811.1/81.1/41.3/834x191.3/81.1/21.5/81.3/41.7/822.1/82.1/42.3/82.1/21.281.742.282.883.564.294.215.035.917.527.848.9410.0911.3212.5913.9629.039.051.164.880.196.592.8110.6130.0150.9172.6196.8222.3249.3277.1307.332.644.057.673.090.3108.8104.6124.7146.5170.1194.6221.8250.6281.0312.5346.434.346.260.676.794.9114.4110.0131.0154.1178.9204.6233.0263.3295.4328.3364.136.148.863.880.9100.0120.6116.0138.1162.3188.3215.5245.5277.4300.0346.0383.739.753.770.289.1110.1132.8127.8152.1178.8207.5237.4270.5305.6330.6381.3422.82583474555777138598269841157134315361751197822192466273529039251365080496893111101304151417321974223025012781308330541153968384510189791166137115921821207423432629292232403214345687208901073103212291444167619182185246926703079341535347862579398011821137135415911847211324072720294233933763The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.Nominal Length Mass is subject to a tolerance of minus 2% to plus 5%.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.16 BRIDON Mining

ProductsTiger Superflex 17x6, 20x6Lay Type Lay Direction Finish CoreBright Galv FC FFC WSCOrd Langs RightHandAvailable as standard.LeftHand• • • • • • •DiameterNominalLengthMassNominal Breaking LoadNominal Breaking Force1080 N/mm 2 1270 N/mm 2 1370 N/mm 2 1570 N/mm 2 1080 N/mm 2 1270 N/mm 2 1370 N/mm 21570 N/mm 2inlbs/ftTons(2000lbs)Tons(2000lbs)Tons(2000lbs)Tons(2000lbs)kNkNkNkN17x61 5/81 3/41 7/822 1/82 1/42 3/820x61 7/822 1/82 1/42 3/82 1/22 5/82 3/42 7/84.325.015.496.227.278.078.935.676.507.478.148.869.9911.1811.6013.1869.7881.0288.4499.67114.73126.42140.9189.45105.85121.14131.25142.82161.25180.24187.32208.5682.0395.18104.06117.20134.96148.67165.64105.18124.40142.49154.29167.88189.68211.93220.36245.1988.55102.71112.26126.42145.52160.24178.67113.49134.28153.61166.53181.25204.63228.68237.67264.52101.47117.65128.67144.96166.76183.84204.85130.01153.84176.09190.81207.55234.52262.05272.39303.0762172178788710211125125479694210781168127114351604166718567308479261043120113231474936110712681373149416881886196121827889149991125129514261590101011951367148216131821203521152354903104711451290148416361823115713691567169818472087233224242697The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.Nominal Length Mass is subject to a tolerance of minus 2% to plus 5%.This table is for guidance purposes only. Balance ropes are normally designed to achieve a desired weight.Ropes with the required weight and strength will be designed to meet particular shaft requirements.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.BRIDON Mining17

ProductsFlat Balance Rope 8x4x7, 6x4x12, 8x4x12, 8x4x14, 8x4x19SingleStitchedConstructionDoubleStitchedFinishClamped Bright Galv• • • • •Available as standard.Nominal DimensionsWidth x b x Thickness sTwiceStitched (d)SingleStitched (e)orClamped (k)NominalDiameter ofthe LoadCarryingWiresSum of theNominalCross-SectionalAreas of theLoadCarryingWiresCalculated Mass Per Unit Lengthof the Lubricated RopeTwiceStitched (d)SingleStitched (e)Clamped(k)Nominal AggregateBreaking Load at a TensileGrade of the Wires of1370N/mm 2 1570N/mm 2mmmmmm mm 2kg/m kg/m kg/m kN kNRope Construction 8 x 4 x 7 = 8 Legs with 4 Strands each having 1+6 Wires = 224 wires110 x 20113 x 20116 x 21119 x 21122 x 22125 x 22128 x 23110 x 18113 x 18116 x 19119 x 19122 x 20125 x 20128 x 211.91.952.02.052.12.152.26356697047397768138516.426.767.117.477.848.228.606.166.496.837.177.537.898.266.046.366.697.027.387.738.098709179641010106011101170Rope Construction 6 x 4 x 12 = 6 Legs with 4 Strands each having 3+9 Wires = 288 wires112 x 26115 x 25118 x 27121 x 27124 x 28127 x 28130 x 29112 x 23115 x 23118 x 24121 x 24124 x 25127 x 25130 x 261.91.952.02.052.12.152.2817860905951998104610958.268.699.149.6110.1010.6011.107.938.358.789.239.6810.2010.707.688.098.518.949.399.8410.301120118012401300137014301500Rope Construction 8 x 4 x 12 K= 8 Legs with 4 Strands each having 3+9 Wires = 384 wires146 x 25149 x 26154 x 27157 x 27160 x 28165 x 28168 x 29146 x 23149 x 23154 x 24157 x 24160 x 25165 x 25168 x 261.91.952.02.052.12.152.2108911471206126713301394146011.0011.6012.2012.8013.5014.1014.8010.6011.2011.7012.3012.9013.6014.2010.3010.8011.4011.9012.5013.1013.801490157016501740182019102000Rope Construction 8 x 4 x 14 K= 8 Legs with 4 Strands each having 4+10 Wires = 448 wires168 x 28172 x 29176 x 29180 x 30184 x 30168 x 25172 x 26176 x 26180 x 27184 x 272.02.052.12.152.21407147915521626170314.3015.0015.7016.5017.2013.7014.4015.1015.8016.6013.3013.9014.6015.3016.0019302030213022302330Rope Construction 8 x 4 x 19 K= 8 Legs with 4 Strands each having 1+6+12 Wires = 608 wires186 x 31190 x 32194 x 33200 x 34204 x 34210 x 36216 x 37186 x 28190 x 29194 x 30200 x 31204 x 31210 x 32216 x 331.91.952.02.052.12.152.2172418161910200721062207231117.5018.4019.3020.3021.3022.3023.3016.8017.8018.6019.5020.4021.4022.4016.2017.0018.0018.9019.8020.8021.80236024902620275028903020317099710501105116012201280134012801350142014901570164017201710180018901990209021902290221023202440255026702710285030003150331034603630The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selecting or using this product.18 BRIDON Mining

ProductsLay Type Lay Direction Finish CoreOrd Langs RightHandLeftHandBright Galv FC FFC ModifiedCore• • • • •NominalDiameterNominal LengthMassCalculated Minimum Breaking LoadGrade 1670 N/mm 2 Grade 1670 N/mm 2 Grade 1820 N/mm 2 Grade 1820 N/mm 2mm kg/m tonneskN tonnes kN6x19S32 3.94 59.51 584 64.40 63233 4.19 63.28 621 68.48 67234 4.45 67.18 659 72.70 71335 4.71 71.19 698 77.04 75636 4.99 75.31 739 81.50 80037 5.27 79.56 780 86.09 84538 5.56 83.91 823 90.81 89139 5.85 88.39 867 95.65 93840 6.16 92.98 912 100.62 98741 6.47 97.69 958 105.71 10376x26WS41 6.51 98.25 964 106.33 104342 6.83 103.10 1011 111.58 109543 7.16 108.07 1060 116.95 114744 7.49 113.16 1110 122.46 120145 7.84 118.36 1161 128.09 125746 8.53 127.20 1248 137.65 135047 8.91 132.79 1303 143.70 141048 9.29 138.50 1359 149.88 147049 9.68 144.33 1416 156.19 153250 10.08 150.28 1474 162.63 159551 10.49 156.35 1534 169.20 166052 10.90 162.54 1595 175.90 17266x31WS41 6.69 100.97 991 109.28 107242 7.02 105.95 1039 114.68 112543 7.36 111.06 1089 120.21 117944 7.70 116.28 1141 125.86 123545 8.06 121.63 1193 131.65 129146 8.77 130.71 1282 141.48 138847 9.15 136.45 1339 147.70 144948 9.55 142.32 1396 154.05 151149 9.95 148.32 1455 160.54 157550 10.36 154.43 1515 167.15 164051 10.78 160.67 1576 173.91 170652 11.21 167.03 1639 180.79 177453 11.64 173.52 1702 187.82 184354 12.08 180.13 1767 194.97 191355 12.54 186.86 1833 202.26 198456 13.00 193.72 1900 209.68 205757 13.46 200.80 1969 217.23 213158 13.94 207.80 2039 224.92 220659 14.43 215.03 2109 232.75 228360 13.88 222.38 2182 240.70 2361The nominal length mass values are for fully lubricated ropes.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.BRIDON Mining19

ProductsTiger 6CDRLay Type Lay Direction Finish CoreOrd Langs RightHandLeftHandBright Galv FC FFC Bristar• • • • • • •Available as standard. Bristar values available on requestNominalDiameterNominal Length MassCalculated Minimum Breaking ForceGrade 1670 N/mm 2Grade 1820 N/mm 2mmkg/mkNkN6x19S6x25F32 3.79 550 60033 3.95 560 61035 4.61 666 72637 5.11 740 80638 5.42 788 85841 5.66 894 97443 6.51 965 105241 6.21 898 97845 7.43 1069 116548 8.78 1265 137951 9.94 1432 156154 10.93 1589 173257 12.91 1771 193060 13.61 1972 2149The nominal length mass values are for fully lubricated ropes.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.20 BRIDON Mining

ProductsTiger DYFORM ® 6CDRLay Type Lay Direction Finish CoreOrd Langs RightHandLeftHandBright Galv FC FFC Bristar• • • • • • •Available as standard. Bristar values available on requestNominalDiameterNominal Length MassCalculated Minimum Breaking ForceGrade 1670 N/mm 2Grade 1820 N/mm 2mmkg/mkNkN6x19S6x31WS32 4.02 592 64533 4.19 602 65635 4.89 716 78037 5.42 796 86738 5.75 847 92341 6.69 960 104743 6.90 1040 113341 6.58 965 105145 7.88 1148 125148 9.31 1364 148651 10.54 1540 167954 11.59 1708 186257 13.68 1904 207560 14.43 2119 2309The nominal length mass values are for fully lubricated ropes.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selectingor using this product.BRIDON Mining21

ProductsTiger Full Lock Winding RopeLay Type Lay Direction Finish CoreOrd Langs Right Hand LeftHandBright Galv FC FFC WSC• • • •Available as standard. Variable Torque and Turn characteristics available by designNominalDiameterNominal LengthMassNominal Breaking LoadNominal Breaking ForceStandard Tensile High Tensile Standard Tensile High Tensileinlbs/ftShort Tons(2000lbs)Short Tons(2000lbs)kNkN11 1/161 1/81 3/161 1/41 5/161 3/81 7/161 1/21.5151 9/161 5/81 11/161 3/41 13/161 7/81 15/1622 1/162 1/82.432.673.023.463.724.104.584.885.285.525.766.286.817.388.008.599.019.4610.2111.2764.169.478.788.296.3109.9119.1129.5138.9141.2151.1162.9176.5191.1205.5223.7232.7246.7262.5293.768.974.684.694.9103.6118.2128.1139.2149.4151.8162.4175.1189.8205.5220.9240.5250.2265.3282.2315.857061770078585797810601152123612561344144915701700182819902070219523352613613663753844922105211401239132913511445155816881828196621402226236025112810The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.For partially lubricated ropes for Friction Winders reduce mass values by 2%.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selecting orusing this product.22 BRIDON Mining

ProductsTiger Half Lock Guide RopeLay Type Lay Direction Finish CoreOrd Langs Right Hand LeftHandBright Galv FC FFC WSC• • • •NominalDiameterNominal LengthMassNominal Breaking LoadNominal Breaking ForceStandard Tensile High Tensile Standard Tensile High Tensileinlbs/ftTons(2000lbs)Tons(2000lbs)kNkN1 1/81 1/41 3/81 1/21 5/81 3/41 7/822.993.924.565.476.547.438.469.8349.264.575.290.3108.1123.7150.8163.260.479.292.3110.8132.6151.8185.1200.24385746698039611101134214525377048219861180135116471781The nominal length mass values are for fully lubricated ropes.The Nominal breaking Load and Forces quoted are subject to a minus 2.5% tolerance.This table is for guidance purposes only.Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selecting orusing this product.BRIDON Mining23

Services & TrainingBridon International Services employ some of the mosthighly trained professionals in the industry. Ourunderstanding of, and expertise in dealing with, all mannerof issues related to wire and fibre ropes has enabled us todevelop a wide portfolio of cost effective services which areenjoyed by Bridon customers world-wide.24 hours a day, 365 days a year, our engineers andtechnicians are dispatched across the globe to provideexpert assistance and solutions, no matter what theproblem, or wherever the location. With resources andsupport services based at key hubs on every continent,BRIDON really does provide a truly International specialistafter sales service in wire and fibre rope.Repair and MaintenanceRepair and maintenance can be carried out in many forms.All types of ropes including haulage, multi-strand rope,Locked Coil and Spiral Strand are catered for, from abroken wire to a total re-splice.Installation & Replacement ServicesThe service life and safety of a wire rope can depend as muchupon the quality of the installation as upon the quality of theproduct itself. To protect your investment, take advantage ofour installation and replacement service - expert internationalsupport covering virtually all types of equipment which uses orincorporates wire rope. Typical installations include: miningapplications, elevators, excavators, cranes and aerialropeways. Bridon Services has a range of specialisedinstallation equipment, such as back tension winches,spoolers and hydraulic tensioners, that can be employed inconjunction with our skilled engineers to ensure installationsof wire rope are carried out correctly, professionally, andabove all, safely.Inspection & Statutory Examination ServicesWe are also able to provide customers with statutoryexamination services, as required under law, whichsubjects wire rope and lifting equipment (“below the hook”)to stringent testing and examination procedures.Non destructive examination (NDE)The primary cause of wire rope failure is internal degradationthrough corrosion and fatigue. We provide acomprehensives non-destructive examination service,operating to the most meticulous standards. This detects thepresence of defects such as broken wires, both on thesurface and within the rope, loss of metallic cross-sectionalarea and distortions. Results from this examination arerecorded progressively, in digital format, from the surveyhead of the specialist equipment to a notebook or laptop, asthe wire rope passes through the head. The resulting trace isthen analysed and a comprehensive report produced.SplicingIn addition to any basic splicing requirements, BRIDON areable to offer a variety of specialist splicing abilities, such aslong splicing, to meet our client’s needs.Such requirements, which are carried out in-situ, mayentail; rope driven conveyors, aerial haulages, funiculars,tile conveyors etc. and may be long splices or eye splices,including multi-strand and bordeaux connection. All splices,including passenger carrying ropes, are carried out tointernationally recognised standards. Where required allsplicing materials, including liquid rubber for injection to thesplice area, can be provided.TrainingBridon has established a deserved reputation for runninghigh quality training courses, which is no less than would beexpected from a world leader in the design, manufacture andsubsequent use of wire and fibre ropes. Our courses neverstand still and are directly relevant to current legislation,improved technology, and the competitive trading conditionsof today’s markets. In an increasingly competitive world,costs must be continually reduced without compromisingsafety. There is no better way to prepare for this challengethan through a Bridon training course.For further information on training courses, includingpractical workshop based wire rope splicing and socketingcourses, any of which can be fine tuned to suit yourindividual needs, please contact BRIDON.24 BRIDON Mining

Technical Information1. Hoist RopesVarious constructions of ropes may be used forhoisting, the final choice usually being decided uponeconomic grounds. What may be a satisfactory lifeon a shallow high frequency hoist, may be completelyuneconomic on a deep low frequency installation,and therefore the rope designs as well as their sizesmust be considered.1.1 Drum Hoists6 Stranded Ropes – both round and triangularstrand – are satisfactory for all depths of shafts,although perhaps best suited for those up to 1000min depth with fixed guides. They are not suitable forshafts deeper than 600m with rope guides, as theirnatural tendency to twist causes the conveyanceto turn.As a rough guide to the construction of the rope, theratio of drum or sheave diameter to outer wirediameter should be between 1000 and 1500:1,although if abrasion is severe this can be reducedslightly at the expense of a lower fatigue life.For maximum resistance to wear and crossoverdamage the use of Lang’s lay is recommended.Multi-Strand Rotation Resistant Ropes –are now used on permanent drum hoist installations,except where multi layer coiling is employed,due to their relatively low resistance to compressiveforces. Certain constructions are suitable forsinking purposes.Multi-strand ropes with Dyformed (compacted)strands have increased resistance to crushing overropes with conventional strands.Locked Coil Ropes – have gained in popularity andare extensively used throughout the UK. They can beused to advantage on any depth of shaft with eitherfixed or rope guides. As they are virtually non-rotatingunder normal loading conditions they are consideredto be the best rope to operate in shafts deeper than700 metres equipped with rope guides.The cross section is extremely compact and as aresult such ropes can withstand very high radial andcompressive forces This property coupled with theirsmooth outer surface enables them to be used toadvantage on multi layer coiling installations.that the drum or sheave diameter to rope diameter ratioshould be in the region of 100 to 120:1 for satisfactoryservice life on main shaft winders. Ratios as low as50:1 can be tolerated on small ropes in shallow shafts,staple shafts and sinking stage winders.1.2 Friction or Koepe Hoists6 Stranded Ropes – are suitable to depths of 1000metres. Beyond that the torque in these ropes canresult in premature torsional fatigue of the wires.Triangular strands are more usual due to the lowercontact pressures on the friction linings althoughLang’s lay equal laid round strand ropes are quitesuitable for shallow shafts. Round strand ropes withDyformed (compacted) strands are becoming morepopular as they offer higher breaking loads,increased fatigue life and reduced contact pressuresover ropes with conventional strands.With rope guided shafts, alternate left and right handlay ropes are employed to prevent conveyance twist.Tread pressures with stranded ropes are limited to17.5 kgf/cm2 (1.72Mpa) to avoid excessive wear ofthe friction linings.Multi-Strand Rotation Resistant Ropes – can beusefully employed at all depths of shaft and generallysatisfactory lives are obtained. Earlier designs of theropes were subject to severe internal cross-cutting,although modern designs incorporating Dyformed(compacted) strands and plastic enhancement coupledwith modern design and manufacturing techniquesmost of these problems have been eliminated.Tread pressure limits are similar to those of 6stranded ropes.Locked Coil Ropes – are widely used on this type ofhoist particularly in the UK. The advantages offeredby ropes of this construction make them particularlysuited for this type of hoist especially if rope guidesare employed.Due to the large smooth surface area of locked coilropes, tread pressures of up to 28.0 kgf/cm2(2.75Mpa) can be tolerated. The limit is used tominimise friction liner wear, the rope being able towithstand much higher pressures.Because of their compact cross section, it is desirableBRIDON Mining25

Technical Information1.3 Recommended Rope Construction for variouswinder applicationsType of winder applicationSmall drum hoist operation atless than 2.5m/s in a verticalshaft with fixed guidesSmall Drum hoist operating ina vertical shaft with ropeguidesLarge drum hoist operating ina vertical shaft with fixedguidesLarge drum hoist operating ina vertical shaft with ropeguidesBlair multi-rope hoistFriction hoist operating to adepth of 500mRope Construction6x19(9/9/) FC Langs LayFull Locked CoilMulti-strand Rotation ResistantFull Locked CoilCompound Triangular StrandLangs LayFull Locked CoilDyform 6R Ordinary/Langs LayMulti-strand Rotation ResistantFull Locked CoilCompound Triangular StrandLangs LayFull Locked Coil6 strand Ordinary/Langs LayCompound Triangular StrandLangs LayMulti-strand Rotation ResistantFull Locked CoilDyform 6R Ordinary/Langs Lay2. Sinking RopesKibble Ropes – Ropes used for these duties must berotation resistant, to prevent excessive spin of thekibble or bucket in the shaft.Providing the hoist equipment is suitable, flexible fulllocked coil ropes meet these requirements admirably,and have been used successfully for many years.Where very small diameter sinking drums andsheaves are employed, or where a sheave is fittedabove the kibble to enable two parts of rope tosupport the load, multi-strand rotation resistant ropesare suitable.Bridon’s dedicated Mining Department will bepleased to discuss and recommend the best ropesconstruction for optimum performance on your kibblewinder.Stage Ropes – There are several methods ofsuspending the sinking stage or platform and this cangovern the choice of rope construction.Stage ropes are normally required to act has guideropes for the kibble so resistance to wear is anecessary characteristic. In addition a goodresistance to crushing on the multi-layer drum coilingis required.Full locked coil ropes offer excellent performance onthe correct design of equipment.Friction hoist operating to adepth between 500m and1000mFriction Hoists above 1000mSinking stage winderKibble winderTail/Balance rope6 Strand Ordinary/Langs LayCompound Triangular StrandLangs LayMulti-strand Rotation ResistantFull Locked CoilDyform 6R Ordinary/Langs LayLocked Coil Winding RopesMulti Strand RotationResistantDyform 6R Ordinary/Langs LayCompound Triangular StrandLangs LayMulti-strand Rotation ResistantFull Locked CoilAlternate Lay TriangularStrand Langs LayMulti-strand Rotation ResistantFull Locked CoilMulti-strand Rotation ResistantSuperflexFlat ropeWhere smaller drums and sheaves are employedmulti-strand rotation resistant ropes with relativelylarge outer wires or triangular strands with equalnumbers of left and right hand lay can be used. Withtriangular strand ropes however, problems can beexperienced with controlling the turn if slack ropeconditions occur.Bridon’s dedicated Mining Department will bepleased to discuss and recommend the best ropesconstruction for optimum performance on your stagewinder.Under normal circumstances it is recommended thatropes for both applications, but in particular stageropes, should be manufactured from galvanisedmaterial. However, where higher tensile grades ofwire are required galvanised material is not alwaysavailable. In these cases it is strongly recommendedthat the ropes are regularly cleaned andre-lubricated with emphasis on the evaluation ofcorrosion during examination.26 BRIDON Mining

Technical Information3. Balance RopesGenerally balance ropes are required to have theflexibility to suit the particular cage centres, adequaterotation resistant properties combined with goodresistance to wear and corrosion. Bridon's range ofmulti-strand rotation resistant and Flat Balance ropeshas the capability to meet the needs for all balancerope applications.Bridon’s Superflex balance ropes were developed forinstallations where maximum flexibility is requiredcombined with optimum resistance to wear andcorrosion. The range of ropes is almost completelynon-rotating. As a result there is no torsional effecteither at the terminal ends or at the loop and thereforethe onset of fatigue at these points is almost entirelyeliminated.Where maximum flexibility is not required alternativeconstructions are available to best suit the specificwinding conditions and give optimum economicservice life.The graph below gives the minimum recommendedloop diameter to rope diameter ratio for variousconstructions.15FlatRope25Minimum Loop D:d Ratios30 30 3020x6SF 17x6SF 14x6SF 34x19NF 18x19 34x7 18x7ConstructionFor advice on the best rope for your installationscontact Bridon’s dedicated Mining Department.4. Guide andRubbing RopesBridon’s Tiger Brand range of guide and rubbingropes are normally constructed of central king wire,covered by one or two layers of round wires which areclosed in a final layer of half lock and round wires.The precise construction depending upon thediameter and the tensile grade of wires used to meetthe breaking force requirement. Bridon’s CAD ropedesign system ensures that the largest possible outerhalf lock and round wires are used to give maximumresistance to wear and corrosion.The choice of size and breaking load depends uponthe local regulations for factor of safety and thetensioning required. A typical arrangement is a factorof safety of 5:1 at the point of suspension with the354560guides tensioned on the basis of 3000kg plus 500kgfor each 100m of shaft depth. The tensions arenormally varied in the range plus or minus 10% to limitharmonic vibration.In wet and corrosive shafts the use of galvanisedmaterial is recommended.Types of tensioning arrangement, terminations andmethods of installation are many and varied andBridon’s dedicated Mining Department will be pleaseto give advise on these aspects along with types oflayouts, methods of lubrication, inspectionprocedures and maintenance.5. Haulage RopesThe modern rope haulage system is an integral partof the system for both the transportation of men andthe supply of materials to the mine face.Haulage systems fall into 3 main categoriesEndlessDirectMain and TailBridon’s Tiger Brand range has the rope to suityour system.In general, haulage ropes are required to haveexcellent resistance to wear and in some instancescorrosion. To achieve this they tend to be of the moresimple construction with fewer larger outer wires.These can be single layer round strand constructionor triangular strand construction. On the majority ofsystems where the length of travel is high and thefrequency of cycle is small, fatigue is generally not acritical deteriorating factor.5.1 Single ConstructionRound Strand6x7(6/1) Fibre Core Langs lay is recommended tomaximise the resistance to wear.Triangular Strand6x8TS, 6x9TS, 6x10TS.However, when travel distances become shorter andthe cycle frequency is higher then fatigue canbecome a factor dictating rope removal, particularlywhen drive wheels, drums and sheaves are smaller.To combat this more complex (compoundconstructions) with smaller outer wires can be used.5.2 Compound ConstructionRound Strand6x19S, 6x26WS, 6x25F, 6x36WS.Triangular Strand6x22TS, 6x23TS, 6x25TS, 6x28TS.Where wet and corrosive conditions exist the use ofgalvanised ropes, man made fibre cores or acombination of both is recommended.BRIDON Mining27

Technical InformationOn certain installations where resistance to crushingis required then the use of ropes with steel IWRCcores should be considered.On endless systems ropes with special preformingare supplied to facilitate long splicing.The performance of round strand ropes can beenhanced by the use of Dyformed strands. Dyformropes offer the following improvements:-• Higher breaking loads• Improved fatigue life• Increased resistance to crushing• Reduced interference on drums and Clifton(surge) wheelsBristar Cores offer the following improvements:-• Reduced stretch• Increased fatigue life• Increased dimension stability (diameter retention)Contact our dedicated Mining Department for adviseon the best construction for your haulage application.6. Conveyor Drive RopesBridon has had a close working relationship with theO.E.M. of cable driven conveyors for many years. Thishas resulted in Bridon being the major supplier of cablebelt driving ropes world wide. Extensive research anddevelopment has resulted in Bridons Tiger Brand rangeof driving ropes such that Bridon can offer rope solutionsto give optimum lowest cost conveying of material.The Tiger Brand range offers the followingrope options:-Conventional Driving Ropes6x19S, 6x26WS, 6x25F, 6x31WS, 6x36WS.The type of construction used depends upon thediameter, stress levels, the type of conveyor andit’s layout.Dyform Driving Ropes6x19S Dyform, 6x26WS Dyform,6x31WS Dyform, 6x36WS Dyform.Dyform Driving Ropes offer the following advantages:-• Higher breaking forces• Increased fatigue life• Increased resistance to wear• Reduced line stand pulley wear during the earlypart of service lifeDriving ropes are generally supplied in galvanisedmaterial although ropes manufactured from brightwire are available. They are produced under thehighest quality system from high specification wireand cores specially designed and manufactured foruse on rope driven conveyors. All ropes have specificstrand preformation to facilitate long splicing andmaximisation of splice life.In both conventional and Dyform drive ropesalternative cores and manufacturing lubrication areavailable to best suit your conveyor conditions toensure maximum economic operating performance.These include the following:-• Man made fibre cores for use in wet conditions• Bristar cores offering lower stretch, increasedfatigue life and improve diameter retention• Special lubrication, both manufacturing andservice, to ensure maximum life in severecorrosive conditionsZebra Drive RopesJoint development with rope driven conveyormanufacturers and operators has resulted in Bridon’sZebra range of conveyor drive ropes.Extensive laboratory and on site testing has shownthe following advantages of Zebra over conventionaland Dyform drive ropes:• Increased fatigue life. In excess of 10 timesconventional cables in laboratory tests• Equivalent or increased breaking loads• Reduced stretch both constructional and elastic• Superior diameter retention• Smooth outer surface• Reduced tread pressures• Superior resistance to internal corrosionThese improvements in physical properties haverealised the following proven cost saving advantages:• Zebra can be retro fitted to existingconveyors at minimal cost• Reduced line pulley wear• Reduced steel terminal pulley and surge/Koepelining maintenance• Reduced vibration and noise• Extended rope life• Extended splice lifeFor an assessment of potential cost saving on yourconveyor contact Bridon’s directly.Bridon’s commitment to lowest cost conveying doesn’tstop there. On long conveyors splicing and splicemaintenance can be both inconvenient and costly.Bridon’s unique Service Department can provide expertengineers to install, splice, inspect and maintain yourdrive cables. Driving ropes are a major costcomponent part of the conveyor. LOOK AFTER THEM !In addition Bridon recognised the implications indown time and cost for splicing on long conveyorswith numerous splices. To minimise splicing andsplice repairs Bridon increased their productioncapacity from piece weights of 60 tons to pieceweights of approximately 135 tons. If you think longerropes can assist in reducing operating costs pleasecontact our Mining Department who will be pleased todiscuss the possibilities.28 BRIDON Mining

Technical Information7. Properties of Extension of Steel Wire RopesAny assembly of steel wires spun into a helical formation,either as a strand or wire rope, when subjected to a tensileload, can extend in three separate phases, depending onthe magnitude of the applied load.There are also other factors which produce rope extensionwhich are very small and can normally be ignored.Phase 1 - Initial or PermanentConstructional ExtensionAt the commencement of loading a new rope, extension iscreated by the bedding down of the assembled wires with acorresponding reduction in overall diameter. This reductionin diameter creates an excess length of wire which isaccommodated by a lengthening of the helical lay. Whensufficiently large bearing areas have been generated onadjacent wires to withstand the circumferential compressiveloads, this mechanically created extension ceases and theextension in Phase 2 commences. The Initial Extension ofany rope cannot be accurately determined by calculationand has no elastic properties.The practical value of this characteristic depends uponmany factors, the most important being the type andconstruction of rope, the range of loads and the numberand frequency of the cycles of operation. It is not possibleto quote exact values for the various constructions of ropein use, but the following approximate values may beemployed to give reasonably accurate results.The above figures are for guidance purposes. More precisefigures are available upon request.Locked Coil Hoist RopesImmediate permanent extension 0.08Additional initial extension 0.08Gradual permanent extension 0.08Total extension approx. 0.25Phase 2 - Elastic Extension% of rope lengthFibre Core Steel CoreLightly loaded 0.25 0.125Factor of safety about 8:1Normally loaded 0.50 0.25Factor of safety about 5:1Heavily loaded 0.75 0.50Factor of safety about 3:1Heavily loaded Up to 2.00 Up to 1.00with many bendsand/or deflectionsFollowing Phase 1, the rope extends in a manner whichcomplies approximately with Hookes Law (stress isproportional to strain) until the Limit of Proportionality orElastic Limit is reached.It is important to note that wire ropes do not possess aYoung’s Modulus of Elasticity, but an ‘apparent’ Modulus ofElasticity can be determined between two fixed loads.The Modulus of Elasticity also varies with different ropeconstructions, but generally increases as the crosssectionalarea of steel increases. By using the valuesgiven, it is possible to make a reasonable estimate ofelastic extension, but if greater accuracy is required it isadvisable to carry out a modulus test on an actual sampleof the rope. As rope users will find it difficult to calculatethe actual metallic steel area , the values normally quotedare based on the circumscribed rope area (area of a circle,related to the nominal diameter of the rope).Elastic Extension =W = load applied (kg)L = rope length (mm)E = elastic modulus (kg/mm 2 )A = circumscribed rope area (mm 2 )Phase 3 - Permanent ExtensionThe permanent, non-elastic extension of the steel causedby tensile loads exceeding the yield point of the material.If the load exceeds the Limit of Proportionality, the rate ofextension will accelerate as the load is increased, until aloading is reached at which continuous extension willcommence, causing the wire rope to fracture without anyfurther increase of load.Thermal Expansion and ContractionThe coefficient of linear expansion (∝) of steel wire rope is0.0000125 = (12.5 x10 -6 ) per o C and therefore the changein length of 1 metre of rope produced by a temperaturechange of t o C would be;Change in length ∆| = ∝|o t where∝WL(mm)EA= coefficient of linear expansion|o = original length of rope (m)t = temperature change ( o C)The change will be an increase in length if the temperaturerises and a decrease in length if the temperature falls.Extension due to RotationThe elongation caused by a free rope end being allowedto rotate.Extension due to WearThe elongation due to inter-wire wear which reduces thecross-sectional area of steel and produces extraconstructional extension.Example: What will be the total elongation of a 200 metrelength of 28mm diameter Tiger 6R wire rope at a tension of10 tonnesf (tf) and with an increase in temperature of 20 o C.Permanent Constructional Extension = 0.25% ofrope length = 500mmWL 10000 x 200 000Elastic Extension = = = 540mmEA 6000 x 615.8Thermal Expansion = ∆1 = ∝|o t = 0.0000125 x 200,000 x 20 = 50mmTherefore total extension = 500 + 540 + 50 = 1090mmBRIDON Mining29

Technical Information8. Pressures between Ropes and Sheaves or DrumsIn addition to bending stresses experienced by wire ropesoperating over sheaves or pulleys, ropes are also subjectedto radial pressure as they make contact with the sheave.This pressure sets up shearing stresses in the wires,distorts the rope’s structure and affects the rate of wear ofthe sheave grooves. When a rope passes over a sheave,the load on the sheave results from the tension in the ropeand the angle of rope contact. It is independent of thediameter of the sheave.Load on bearing =Assuming that the rope is supported in a well fitting groove,then the pressure between the rope and the groove isdependent upon the rope tension and diameter but isindependent of the arc of contact.Pressure, P =2TDdP = pressure (kg/cm 2 )T = rope tension (kg)D = diameter of sheave or drum (cm)d = diameter of rope (cm)Maximum Permissible PressuresNumber ofouter wiresin strands2T sin θ25 - 8 Ordinary lay5 - 8 Lang’s lay9 - 13 Ordinary lay9 - 13 Lang’s lay14 - 18 Ordinary lay14 - 18 Lang’s layTriangular strandCastironkgf/cm 220253540424755Groove materialLow 11 to 13%carbon Mn steelcast steel orequivalentalloysteelskgf/cm 2 kgf/cm 2404560707585100105120175200210240280It should be emphasised that this method of estimation ofpressure assumes that the area of contact of the rope inthe groove is on the full rope diameter, whereas in fact onlythe crowns of the outer wires are actually in contact with thegroove. The local pressures at these contact points may beas high as 5 times those calculated and therefore thevalues given above cannot be related to the compressivestrength of the groove material.If the pressure is high, the compressive strength of thematerial in the groove may be insufficient to preventexcessive wear and indentation and this in turn will damagethe outer wires of the rope and effect its working life. Aswith bending stresses, stresses due to radial pressureincrease as the diameter of the sheave decreases.Although high bending stresses generally call for the use offlexible rope constructions having relatively small diameterouter wires, these have less ability to withstand heavypressures than do the larger wires in the less flexibleconstructions. If the calculated pressures are too high forthe particular material chosen for the sheaves or drums orindentations are being experienced, consideration shouldbe given to an increase in sheave or drum diameter. Sucha modification would not only reduce the groove pressure,but would also improve the fatigue life of the rope.The pressure of the rope against the sheave also causedistortion and flattening of the rope structure. This can becontrolled by using sheaves with the correct groove profilewhich, for general purposes, suggests an optimum grooveradius of nominal rope radius +10%. The profile at thebottom of the groove should be circular over an angle ofapproximately 120 o , and the angle of flare between thesides of the sheave should be approximately 52 o .Hardness of Rope WireRopegradeMin. TensileStrength2160N / mm 21960N / mm 21770N / mm 21570N / mm 2ApproximateEquivalentAPI 9AGradeEEIPSEIPSIPSPSApproximateHardnessBrinel480 / 500470 / 480445 / 470405 / 425Rockwell‘C’Suggested pulley hardness: 250-300 Brinell for Mn steel orequivalent alloy steel.If the calculated pressure is too high for the particularmaterial chosen for the pulley or drum, considerationshould be given to increase in pulley or drum diameter.Such a modification would not only reduce the groovepressure, but would also improve the fatigue life of the ropeby reducing the bending stresses imposed.5251494530 BRIDON Mining

Technical Information9. Bend FatigueBend fatigue testing of ropes usually consists of cycling alength of rope over a sheave while the rope is under aconstant tension and as part of its ongoing developmentprogramme Bridon has tested literally thousands of ropesin this manner over the years on its in-house own designbend testing equipment.Through this work, Bridon has been able to compare theeffects of rope construction, tensile strength, lay direction,sheave size, groove profile and tensile loading on bendfatigue performance under ideal operating conditions. Atthe same time it has been possible to compare rope life todiscard criteria (e.g. as laid down in ISO 4309) with that tocomplete failure of the rope, i.e. to the point where the ropehas been unable to sustain the load any longer. As part ofthe exercise, it has also been possible to establish theresidual breaking strength of the rope at discard level ofdeterioration.Effects of D:d Ratio and loading on fatigue life -Typical example Dyform 6However, the benefit of such testing can be particularlyhelpful to the rope manufacturer when developing new orimproving existing products.If designers or operators of equipment are seeking optimumrope performance or regard bending fatigue life as a keyfactor in the operation of equipment, such information canbe provided by Bridon for guidance purposes.Service life curve for various D:d ratiosRelative Rope Service Life10080604020Number of bends to rope failure10% MBL20% MBL5% MBL005 10 15 20 25 30 35 40 45 50 55 60 65D:d ratioWhen considering the use of a steel wire rope around aminimum D:d ratio, it is generally accepted that at below4:1 the effect on the strength of the rope needs to beconsidered. Permanent distortions within the rope will occurwhen using ratios of 10:1 and less and that a minimum ratioof 16:1 be used for a rope operatingaround sheaves.Approximate loss in breaking strength due to bending30 29 28 27 2625 24 23 22 21 20 19 18 17 16Sheave D:d ratioWhat needs to be recognised, however, is that very fewropes operate under these controlled operating conditions,making it very difficult to use this base information whenattempting to predict rope life under other conditions. Otherinfluencing factors, such as dynamic loading, differentialloads in the cycle, fleet angle, reeving arrangement, type ofcoiling on the drum, change in rope direction, sheavealignment, sheave size and groove profile, can have anequally dramatic effect on rope performance.Efficiency % MBF0.0000.1000.2000.300EB = 1 -0.50.400D/d0.5000.6000.7000.8000.9001.0000 10 20 30 40D:d ratioBRIDON Mining31

Technical Information10. Fleet AngleOf all the factors which have some influence on the windingof a rope on a smooth drum, the fleet angle, arguably, hasthe greatest effect.Fleet angle is usually defined as the included anglebetween two lines, one which extends from a fixed sheaveto the flange of a drum and the other which extends fromthe same fixed sheave to the drum in a line perpendicularto the axis of the drum. (See illustration).Illustration of Fleet AngleAt the sheaveWhere a fleet angle exists as the rope enters a sheave, itinitially makes contact with the sheave flange. As the ropecontinues to pass through the sheave it moves down theflange until it sits in the bottom of the groove. In doing so,even when under tension, the rope will actually roll as wellas slide. As a result of the rolling action the rope is twisted,i.e. turn is induced into or out of the rope, either shorteningor lengthening the lay length of the outer layer of strands.As the fleet angle increases so does the amount of twist.Fleet angleSheaveTo reduce the amount of twist to an acceptable level thefleet angle should be limited to 2.5 O for grooved drums and1.5 O for plain drums and when using rotation-resistant lowrotation and parallel-closed ropes the fleet angle should belimited to 1.5 O .DrumIf the drum incorporates helical grooving, the helix angle ofthe groove needs to be added or subtracted from the fleetangle as described above to determine the actual fleetangle experienced by the rope.At the drumWhen spooling rope onto a drum it is generallyrecommended that the fleet angle is limited to between 0.5 Oand 2.5 O . If the fleet angle is too small, i.e. less than 0.5 O ,the rope will tend to pile up at the drum flange and fail toreturn across the drum. In this situation, the problem maybe alleviated by introducing a ‘kicker’ device or byincreasing the fleet angle through the introduction of asheave or spooling mechanism.If the rope is allowed to pile up it will eventually roll awayfrom the flange creating a shock load in both the rope andthe structure of the mechanism, an undesirable and unsafeoperating condition.Excessively high fleet angles will return the rope across thedrum prematurely, creating gaps between wraps of ropeclose to the flanges as well as increasing the pressure onthe rope at the cross-over positions.Even where helical grooving is provided, large fleet angleswill inevitably result in localised areas of mechanicaldamage as the wires ‘pluck’ against each other. This isoften referred to as ‘interference’ but the amount can bereduced by selecting a Langs lay rope if the reeving allows.The “interference” effect can also be reduced by employinga Dyform rope which offers a much smoother exteriorsurface than conventional rope constructions.However, for some applications it is recognised that forpractical reasons it is not always possible to comply withthese general recommendations, in which case the rope lifecould be affected.11. Rope TorqueThe problem of torsional instability in hoist ropes would notexist if the ropes could be perfectly torque balanced underload. The torque generated in a wire rope under load isusually directly related to the applied load by a constant‘torque factor’. For a given rope construction the torquefactor can be expressed as a proportion of the ropediameter and this has been done below..Variation with rope construction is relatively small andhence the scope for dramatically changing the stability of ahoisting system is limited. Nevertheless the choice of thecorrect rope can have a deciding influence, especially insystems which are operating close to the critical limit. Itshould be noted that the rope torque referred to here ispurely that due to tensile loading. No account is taken ofthe possible residual torque due, for example, to ropemanufacture or installation procedures.Torsional StabilityThe torque factors quoted on page 33 are approximatemaximum values for the particular constructions. Tocalculate the torque value for a particular rope size multiplyby the nominal rope diameter. Example: for 20mm dia.Tiger 34LR 34x7 Class at 20% of minimum breaking force:-Torque value= torque factor x rope dia.= 0.8% x 20mm= 0.16mmFloating sheaves or specially designed fleet anglecompensating devices may also be employed to reducethe fleet angle effect.32 BRIDON Mining

Technical InformationRope TorqueTo calculate the torque generated in a particular rope whensubjected to a tensile load, multiply the load by the torquevalue and combine the units.Example: for 20mm dia. Tiger 34LR 34x7 Class at 6000 kg f loadTorque generatedBending Loads= torque value x load= 0.16 . 6000= 960 kgf.mmAs the rope is bent over the headsheave or drum, anadditional force is induced into the steel which must beadded to the static and dynamic tensions to obtain the totalforce imposed. There are many methods of calculation forthis bending force, although the one most commonly used is:Bending force = EdADwhere E = Elastic Modulas as given under‘Elongation of Wire Rope’ – kgf/mm 2d = diameter of outer wire in rope – mmA = Area in rope – mm 2D= Diameter of sheave or drum – mmSize of Outer Wires in RopeIt is sometimes useful to know the size of the outer wires inropes i.e. when estimating the amount of external wear orcalculating bending stress. These can be calculated withreasonable accuracy for all constructions of 6 strand ropesusing the following formula.6 strand round strandDiameter of outer wires = Nominal diameter or ropeNo. of outer wires perstrand + 3Example:26mm diameter 6 x 36 (14/7 and 7/7/1)round strandNo. of outer wires per strand = 14Diameter of = 26 = 1.5mmouter wire 14+3Calculations of Drum CapacityThe following formula gives an approximate indicationregarding length of rope of a given diameter (d) which canbe installed onto a winch/drum.ImperialRope length (ft) = (A + B) x A x C x π12d 2where A, B, C and d are quoted in inches.MetricRope length (m) = (A + B) x A x C x π x 10 6d 2where A, B and C are quoted in metres and d quoted in mm.NOTE: Ropes are normally manufactured to a maximum oversizetolerance of 4%. Therefore the actual diameter ‘d’ could be nominaldiameter + 4%.LefthandFleetangleWARNINGWire rope will fail if worn-out, shock loaded, overloaded,misused, damaged, improperly maintained or abused.• Always inspect wire rope for wear, damage orabuse before use• Never use wire rope which is worn-out, damagedor abused• Never overload or shock load a wire rope• Inform yourself: Read and understand the guidance onproduct safety given in this catalogue; also read andunderstand the machinery manufacturer’s handbook• Refer to applicable directives, regulations,standards and codes concerning inspection,examination and rope removal criteriaProtect yourself and others - failure of wire ropemay cause serious injury or death!Rope OscillationRighthandFleetangleLeft hand Fleet Angle: °Right hand Fleet Angle: °Groove Pitch:Groove Radius:No. of Crossovers:Length of Crossovers:Drum hoists operating with multiple layers of rope oftenexperience severe oscillation of the rope between theheadgear sheave and the hoist drum during some part ofthe hoisting cycle. Advice should be sought fromBRIDON’S Mining Division.mmmmmmBRIDON Mining33

Technical InformationHow to order hoist ropesCustomer informationI. Particulars of shaft:1. Suspended Hoist Rope (From Lowest level to Headgear pulley)2. Type of ventilation (upcast/downcast)3. Shaft water inflow4. PH value5. Availability of chloride content6. Range of temperature variation7. Other conditions affecting the ropeII. Particulars of hoisting:1. Type of hoisting One Rope MultiropeCage Skip Kibble Counterweight2. Application MineralMineral & Manriding3. Speed of lifting, m/sec4. Acceleration of lifting, m/sec 25. Preventative deceleration, m/sec 26. Guides If AvailableRopeRigid: Wood Steel Rollers ShoeIII. Particulars of the winder:1. Type Drum Winder Friction Winder-tower or Ground Mounted Drum2. Drum diameter3. Drum width4. Diameter of Headgear pulley, (mm)5. Width of Headgear Pulley6. Diameter tolerance taking into account the bottom of the pulley7. Type of lining8. Diameter of deflector sheave (Tower mounted Friction winding only)9. Number of hoist ropes10. Number of balance ropes11. Type of balance ropes12. Weight of 1 m of balance ropes13. Loop radius of balance ropesIV. Particulars of the hoist conveyance:1. Mass of empty conveyance with suspension gear of hoistand balance ropes2. Mass of conveyance (2) or counterweight with suspension gear3 Mass of payload, t4 Number of cycles per day/monthV. Particulars of the rope:1. Rope Specification2. Nominal diameter, mm3. Construction4. Lay Direction5. Type of core6. Weight of 1 m7. Length of the rope, m8. Number of individual lengths9. Preferred Lubrication10. Galvanised/Ungalvanised11. Rope Tensile12. Minimum Breaking Load, kgf13. Nominal Breaking Load, kgf14. Aggr. Breaking Load of all wires15. Lubrication Core: Strands Rope:16. Safety factor: ratio of ABL of all wires to the end load Without Mass of Ropes, min.With Mass of Ropes, min.18. Causes of rope failure during operation19. Notes:34 BRIDON Mining

Technical InformationSummary Technical Information (For guidance purposes only)Bridon supply a range of ‘Tiger’ High Performance steel wire ropes specifically designed and manufactured to meet theneeds of today’s mine winder specifications and the demanding applications to which they are exposed. High performanceropes are normally selected by customers when they require the specific characteristics of improved performance, highstrength, low extension or low rotation.Rope ConstructionTorque Factor at 20% of MBFRope Modules at20% of MBF kN/mm 2 %OrdinaryLangsTIGER 6R F 6 x 7 Class 61.80 8.1 12.0TIGER 6R F 6 x 19 Class 54.00 8.1 12.0TIGER 6R F 6 x 36 Class 50.80 8.1 12.0TIGER Dyform 6R F 6 x 7 Class 66.90 8.1 12.0TIGER Dyform 6R F 6 x 19 Class 54.20 8.1 12.0TIGER Dyform 6R F 6 x 36 Class 50.30 8.1 12.0TIGER 6T F 6 x 8 Class Single layer 68.70 n/a 13.4TIGER 6T F 6 x 25 Class Compound layer 61.80 n/a 13.4TIGER 18M F 18 x 7 Class 42.30 n/a 6.6TIGER 18M F 18 x 19 Class 41.80 n/a 5.6TIGER Dyform 18 18 x 7 Class 65.70 n/a 4.5TIGER Dyform 18 18 x 19 Class 65.70 n/a 3.8TIGER 34M F 34 x 7 Class 41.20 n/a 4.1TIGER 34M F 34 x 19 Class 40.70 n/a 5.1TIGER 34LR 34 x 7 Class 72.60 n/a 0.8TIGER 34LR 34 x 19 Class 72.60 n/a 1.8TIGER Superflex 14 x 6 40.20 n/a 3.9TIGER Superflex 17 x 6 38.30 n/a 2.6TIGER Superflex 20 x 6 36.30 n/a 1.3TIGER 6R CDR 6 x 19 Class 50.00 n/a 12.0TIGER 6R CDR 6 x 25 Class 46.40 n/a 12.0TIGER 6R CDR 6 x 31 Class 46.40 n/a 12.0TIGER Dyform 6R CDR 6 x 19 Class 54.20 n/a 12.0TIGER Dyform 6R CDR 6 x 26 Class 50.30 n/a 12.0TIGER Dyform 6R CDR 6 x 31 Class 50.30 n/a 12.0TIGER Zebra CDR 6 x 19 63.90 n/a 9.6TIGER Zebra CDR 6 x 26 59.30 n/a 9.6TIGER Zebra CDR 6 x 31 59.30 n/a 9.6TIGER FL Hoist Class 98.10 VariableTIGER FL Aerial Track Class 110.00 VariableTIGER HL Guide Class 117.00 VariableBRIDON Mining35

Technical InformationGuide to ExaminationThe continued safe operation of lifting equipment, liftingaccessories (e.g. slings) and other systems employing wirerope depends to a large extent on the operation of wellprogrammed periodic rope examinations and theassessment by the competent person of the fitness of therope for further service.Some of the More Common Types of WireFractures Can Include:A Severedby wearB Tension C Fatigue D CorrosionfatigueExamination and discard of ropes by the competent personshould be in accordance with the instructions given in theoriginal equipment manufacturer’s handbook. In addition,account should be taken of any local or application specificRegulations.The competent person should also be familiar, asappropriate, with the latest versions of related International,European or National standards such as ISO 4309 “Cranes- Wire ropes - code of practice for examination.Particular attention must be paid to those sections ofrope which experience has shown to be liable todeterioration. Excessive wear, broken wires,distortions and corrosion are the more commonvisible signs of deterioration.Note: This publication has been prepared as an aid for ropeexamination and should not be regarded as a substitute for thecompetent person.E PlasticwearF Martensite G ShearedendWear is a normal feature of rope service and the use of thecorrect rope construction ensures that it remains asecondary aspect of deterioration. Lubrication may help toreduce wear.Broken wires are a normal feature of rope service towardsthe end of the rope’s life, resulting from bending fatigueand wear. The local break up of wires may indicate somemechanical fault in the equipment. Correct lubrication inservice will increase fatigue performance.Distortions are usually as a result of mechanical damage,and if severe, can considerably affect rope strength.Visible rusting indicates a lack of suitable lubrication,resulting in corrosion. Pitting of external wire surfacesbecomes evident in some circumstances. Broken wiresultimately result.Internal corrosion occurs in some environments whenlubrication is inadequate or of an unsuitable type.Reduction in rope diameter will frequently guide theobserver to this condition. Confirmation can only be madeby opening the rope with clamps or the correct use of spikeand needle to facilitate internal inspection.Note: Non-destructive testing (NDT) using electromagnetic meansmay also be used to detect broken wires and/or loss in metallic area.This method complements the visual examination but does notreplace it.Pictures courtesy of S.M.R.E. Crown Copyright 1966Factors Affecting RopePerformanceMulti-coiling of the rope on the drum can result in severedistortion in the underlying layers.Bad coiling (due to excessive fleet angles or slackwinding) can result in mechanical damage, shownas severe crushing, and may cause shock loadingduring operation.Small diameter sheaves can result in permanent set ofthe rope, and will certainly lead to early wire breaks dueto fatigue.Oversize grooves offer insufficient support to the ropeleading to increased localised pressure, flattening of therope and premature wire fractures. Grooves are deemed tobe oversize when the groove diameter exceeds thenominal rope diameter by more than 15% steel, 20%polyurethane liners.Undersize grooves in sheaves will crush and deform therope, often leading to two clear patterns of wear andassociated wire breaks.Excessive angle of fleet can result in severe wear of therope due to scrubbing against adjacent laps on the drum.Rope deterioration at the Termination may be exhibited inthe form of broken wires. An excessive angle of fleet canalso induce rotation causing torsional imbalance.36 BRIDON Mining

Technical InformationTroubleshooting GuideTypical examples of Wire Rope deterioration1 Mechanical damage9 Typical wire fracturesdue to rope movementas a result of bendover sharp edgefatigue.projection whilst underload.2 Localised wear due to10 Wire fractures at theabrasion on supportingstrand, or corestructure.interface, as distinctfrom ‘crown’ fractures.3 Narrow path of wear11 Break up of IWRCresulting in fatigueresulting from highfractures, caused bystress application.working in a grosslyoversize groove, orover small supportrollers.4 Two parallel paths of12 Looped wires as abroken wires indicativeresult of torsionalof bending through animbalance and/or shockundersize groove in theloading.sheave.5 Severe wear,13 Typical example ofassociated with highlocalised wear andtread pressure.deformation.6 Severe wear in Langs14 Multi strand rope ‘birdLay, caused bycaged’ due to torsionalabrasion.imbalance.7 Severe corrosion.15 Protrusion of ropecentre resulting frombuild up of turn.8 Internal corrosion16 Substantial wear andwhilst external surfacesevere internalshows little evidence ofcorrosion.deterioration.BRIDON Mining37

Technical InformationTroubleshooting GuideThe following is a simplified guide to common wire rope problems. More detailed advice can be obtained from any Bridondistributor. In the event of no other standard being applicable, Bridon recommends that ropes are inspected/examined inaccordance with ISO 4309.ProblemMechanical damage caused by the rope contacting thestructure of the installation on which it is operating or anexternal structure - usually of a localised nature.Cause/Action•Generally results from operational conditions.•Check sheave guards and support/guide sheaves toensure that the rope has not “jumped out” of theintended reeving system.•Review operating conditions.Opening of strands in rotation resistant, low rotation andparallel closed ropes - in extreme circumstances the ropemay develop a “birdcage distortion” or protrusion of innerstrands.Note - rotation resistant and low rotation ropes are designedwith a specific strand gap which may be apparent ondelivery in an off tension condition. These gaps will closeunder load and will have no effect on the operationalperformance of the rope.•Check sheave and drum groove radii using sheavegauge to ensure that they are no smaller than nominalrope radius +5% - Bridon recommends that the sheaveand drum groove radii are checked prior to any ropeinstallation.•Repair or replace drum/sheaves if necessary.•Check fleet angles in the reeving system - a fleet anglein excess of 1.5 degrees may cause distortion(see page 32).•Check installation method - turn induced duringinstallation can cause excessive rope rotation resultingin distortion (See pages 42 - 54).•Check if the rope has been cut “on site “ prior toinstallation or cut to remove a damaged portion fromthe end of the rope. If so, was the correct cuttingprocedure used? Incorrect cutting of rotation resistant,low rotation and parallel closed ropes can causedistortion in operation (See page 47).•Rope may have experienced a shock load.Broken wires or crushed or flattened rope on lower layersat crossover points in multi - layer coiling situations.Wire breaks usually resulting from crushing or abrasion.•Check tension on underlying layers. Bridonrecommends an installation tension of between 2% and10% of the minimum breaking force of the wire rope.Care should be taken to ensure that tension is retainedin service. Insufficient tension will result in these lowerlayers being more prone to crushing damage.•Review wire rope construction. Dyform wire ropes aremore resistant to crushing on underlying layers thanconventional rope constructions.•Do not use more rope than necessary.•Check drum diameter. Insufficient bending ratioincreases tread pressure.38 BRIDON Mining

Technical InformationTroubleshooting GuideProblemWires looping from strands.Cause/Action•Insufficient service dressing.•Consider alternative rope construction.•If wires are looping out of the rope underneath acrossover point, there may be insufficient tension on thelower wraps on the drum.•Check for areas of rope crushing or distortion.“Pigtail” or severe spiralling in rope.•Check that the sheave and drum diameter is largeenough - Bridon recommends a minimum ratio of thedrum/sheave to nominal rope diameter of 18:1.•Indicates that the rope has run over a small radius orsharp edge.•Check to see if the rope has “jumped off” a sheave andhas run over a shaft.Two single axial lines of broken wires running along thelength of the rope approximately 120 degrees apartindicating that the rope is being “nipped” in a tightsheave.•Check sheave and drum groove radii using sheavegauge to ensure that they are no smaller than nominalrope radius + 5% - Bridon would recommend that thesheave/drum groove radii are checked prior to anyrope installation.•Repair or replace drum/sheaves if necessary.One line of broken wires running along the length of therope indicating insufficient support for the rope, generallycaused by oversize sheave or drum grooving.•Check to see if the groove diameter is no greater than15% greater than the nominal rope diameter.•Repair or replace drum/sheaves if necessary.•Check for contact damage.Short rope life resulting from evenly/randomly distributedbend fatigue wire breaks caused by bending through thereeving system.Fatique induced wire breaks are characterised by flatends on the broken wires.•Bending fatigue is accelerated as the load increasesand as the bending radius decreases (see page 31).Consider whether either factor can be improved.•Check wire rope construction - Dyform ropes arecapable of doubling the bending fatigue life of aconventional steel wire rope.Continued on next pageBRIDON Mining39

Technical InformationTroubleshooting GuideProblemShort rope life resulting from localised bend fatigue wirebreaks.Fatique induced wire breaks are characterised by flatends on the broken wires.Cause/Action•Bending fatigue is accelerated as the load increasesand as the bending radius decreases (see page 30).Consider whether either factor can be improved.•Check wire rope construction - Dyform ropes arecapable of doubling the bending fatigue life of aconventional steel wire rope.•Localised fatigue breaks indicate continuous repetitivebends over a short length. Consider whether it iseconomic to periodically shorten the rope in order tomove the rope through the system and progressivelyexpose fresh rope to the severe bending zone. In orderto facilitate this procedure it may be necessary to beginoperating with a slightly longer length of rope.Broken rope - ropes are likely to break when subjected tosubstantial overload or misuse particularly when a ropehas already been subjected to mechanical damage.•Review operating conditions.Corrosion of the rope both internally and/or externally canalso result in a significant loss in metallic area. The ropestrength is reduced to a level where it is unable to sustainthe normal working load.Wave or corkscrew deformations normally associatedwith multistrand ropes.•Check sheave and drum groove radii using sheavegauge to ensure that they are no smaller than nominalrope radius +5% - Bridon recommends that thesheave/drum groove radii are checked prior to anyrope installation.•Repair or replace drum/sheaves if necessary.•Check fleet angles in the reeving system - a fleet anglein excess of 1.5 degrees may cause distortion(see page 32).•Check that rope end has been secured in accordancewith manufacturers instructions (see page 46).•Check operating conditions for induced turn.Rotation of the load in a single fall system.•Review rope selection.•Consider use of rotation resistant or low rotation rope.Rotation of the load in a multi - fall system resulting in“cabling” of the rope falls.Possibly due to induced turn during installation oroperation.•Review rope selection.•Consider use of rotation resistant or low rotation rope.•Review installation procedure (See pages 42 - 54)or operating procedures.Core protrusion or broken core in single layer six or eightstrand rope.•Caused by repetitive shock loading - reviewoperating conditions.40 BRIDON Mining

Technical InformationTroubleshooting GuideProblemRope accumulating or “stacking” at drum flange - due toinsufficient fleet angle.Sunken wraps of rope on the drum normally associatedwith insufficient support from lower layers of rope orgrooving.Cause/Action•Review drum design with original equipmentmanufacturer - consider adding rope kicker, fleetingsheave etc.•Check correct rope diameter.•If grooved drum check groove pitch.•Check tension on underlying layers - Bridon recommendan installation tension of between 2% and 10% of theminimum breaking force of the wire rope - Care shouldbe taken to ensure that tension is retained in service.Insufficient tension will result in these lower layers beingmore prone to crushing damage.•Make sure that the correct rope length is being used.Too much rope (which may not be necessary) mayaggravate the problem.Short rope life induced by excessive wear and abrasion.•Check fleet angle to drum.•Check general alignment of sheaves in the reevingsystem.•Check that all sheaves are free to rotate.•Review rope selection. The smooth surface of Dyformwire ropes gives better contact with drum and sheavesand offers improved resistance to “interference”between adjacent laps of rope.External corrosion.•Consider selection of galvanised rope.•Review level and type of service dressing.Internal corrosion.•Consider selection of galvanised rope.•Review frequency amount and type of service dressing.•Consider selection of plastic impregnated (PI) wire rope.BRIDON Mining41

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeThe following Instructions and Warnings combine toprovide guidance on Product Safety and are intended foruse by those already having a working knowledge of wireropes, as well as the new user. They should be read,followed and passed on to others.Failure to read, understand and follow these instructionscould result in harmful and damaging consequences.A ‘Warning’ statement indicates a potential hazardoussituation which could result in a significant reduction in ropeperformance and/or put at risk, either directly or indirectly,the safety or health of those persons within the dangerzone of the rope and its associated equipment.Note: As a result of the creation of the single European market andthe ‘New Approach’ Directives which set out ‘essential requirements’(e.g. for safety) designers, manufacturers, suppliers, specifiers andusers need to keep themselves abreast of any changes to theappropriate Regulations and national standards.Ensure that the rope does not make any directcontact with the floor and that there is a flow of airunder the reel.WARNINGFailure to do so may result in the rope becomingcontaminated with foreign matter and start the onsetof corrosion before the rope is even put to work.Support the reel on a simple A-frame or cradle,located on ground which is capable of supporting thetotal mass of rope and reel. (See Fig. 2) Ensure thatthe rope is stored where it is not likely to be affectedby chemical fumes, steam or other corrosive agents.1. Storage1.1 Unwrap the rope and examine the rope immediatelyafter delivery to check its identification and conditionand verify that it is in accordance with the details onthe Certificates and/or other relevant documents.Note: The rope should not be used for lifting purposes without theuser having a valid Certificate in his possession.Check the rope diameter and examine any ropeterminations to ensure that they are compatible withthe equipment or machinery to which they are to befitted. (See Fig. 1)1.2 Select a clean, well ventilated, dry, undercoverlocation. Cover with waterproof material if the deliverysite conditions preclude inside storage.Rotate the reel periodically during long periods ofstorage, particularly in warm environments, to preventmigration of the lubricant from the rope.WARNINGFig 1Never store wire rope in areas subject to elevatedtemperatures as this may seriously affect its futureperformance. In extreme cases its original asmanufacturedstrength may be severely reducedrendering it unfit for safe use.WARNINGFailure to do so may seriously affect its conditionrendering it unfit for safe use.1.3 Examine ropes in storage periodically and, whennecessary, apply a suitable dressing which iscompatible with the manufacturing lubricant. Contactthe rope supplier, Bridon or original equipmentmanufacturer’s (OEM) manual for guidance on typesof dressings available, methods of application andequipment for the various types of ropesand applications.Re-wrap the rope unless it is obvious that this will bedetrimental to rope preservation. (Refer to the relevantProduct Data sheets on rope dressings for moredetailed information.)WARNINGFig 2Failure to apply the correct dressing may renderthe original manufacturing lubricant ineffective andrope performance may be significantly affected.Ensure that the rope is stored and protected in such amanner that it will not be exposed to any accidentaldamage either during the storage period or whenplacing the rope in, or taking it out of storage.42 BRIDON Mining

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeWARNINGFailure to carry out or pay attention to any of theabove could result in a loss of strength and/or areduction in performance. In extreme cases therope may be unfit for safe use.2. Certification and MarkingMake sure that the relevant Certificate has beenobtained before taking the rope into use for a liftingoperation. (Refer to statutory requirements)Check to verify that the marking on the rope or itspackage matches the relevant Certificate.Note: The rating of a component part of a machine or liftingaccessory is the responsibility of the designer of the machine oraccessory. Any re-rating of a lifting accessory must be approved by acompetent person.Retain the Certificate in a safe place for identificationof the rope when carrying out subsequent periodicstatutory examinations in service. (Refer to statutoryrequirements)3. Handling and Installation3.1 Handling and installation of the rope should becarried out in accordance with a detailed plan andshould be supervised by a competent person.WARNINGIncorrectly supervised handling and installationprocedures may result in serious injury topersons in the vicinity of the operation as well asthose persons directly involved in the handling andinstallation.3.2 Wear suitable protective clothing such as overalls,industrial gloves, helmet, eye protectors and safetyfootwear (and respirator, particularly where theemission of fumes due to heat is likely).WARNINGFailure to wear suitable protective clothing andequipment may result in skin problems from overexposure to certain types of rope lubricants anddressings; burns from sparks, rope ends, moltenlubricants and metals when cutting ropes orpreparing sockets for re-use; respiratory or otherinternal problems from the inhalation of fumeswhen cutting ropes or preparing sockets for reuse;eye injuries from sparks when cutting ropes;lacerations to the body from wire and rope ends;bruising of the body and damage to limbs due torope recoil, backlash and any sudden deviationfrom the line of path of rope.3.3 Ensure that the correct rope has been supplied bychecking to see that the description on the Certificateis in accordance with that specified in the purchaser’sorder.3.4 Check by measurement that the nominal diameter ofthe new rope conforms to the nominal size stated onthe Certificate.For verification purposes, measure the diameter byusing a suitable rope vernier fitted with jaws broadenough to cover not less than two adjacent strands.Take two sets of measurements spaced at least 1metre apart, ensuring that they are taken at thelargest cross-sectional dimension of the rope. Ateach point take measurements at right angles toeach other.The average of these four measurements should bewithin the tolerances specified in the appropriateStandard or Specification.For a more general assessment of rope diameter usea rope calliper. (See Fig 1)3.5 Examine the rope visually to ensure that no damageor obvious signs of deterioration have taken placeduring storage or transportation to theinstallation site.3.6 Check the working area around the equipment for anypotential hazards which may affect the safeinstallation of the rope.3.7 Check the condition of the rope-related equipment inaccordance with the OEM’s instructions.Include the following -Sheave and Drum SizesRegulations throughout the world quote variousminimum D:d ratios for differing rope constructionsand these must be considered when selecting asuitable hoist rope. However as guidance thefollowing D:d ratios are recommended.6 Stranded ropes 80:1Multi Stranded ropes 80:1Locked coil ropes 100-120:1 depending uponrope diameter.(In addition the drum to outer wire ratio should bebetween 1000 and 1500:1)Factors such as speed can necessitate an increasein the D:d ratio and in certain circumstances a D:dratio below the recommended value can be toleratedbut some reduction in rope life should be expected.BRIDON’s Mining Division will be pleased to adviseon this subject.Sheave GroovesGroove diameters should be such that they canaccommodate a new rope taking into account therelevant oversize tolerance and the fleet anglesinvolved to provide adequate circumferential support.BRIDON Mining43

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeA groove diameter of 7.5% greater than the nominalrope diameter is normally acceptable. However incertain cases experience has shown that clearancesbetween 10 and 12.5% are required to obtainoptimum performance.Before installing a new rope all sheave groovesshould be checked to ensure they provide therecommended clearance.Drum GroovesOn single layer drum hoists spiral grooving isrecommended. Where multilayer coiling is necessarythen parallel grooves or one of the patterned coilingsystems should be used. In all cases correct pitch,clearance and groove depth are essential to obtaingood rope performance.When a new rope is fitted a variation in sizecompared with the old worn rope will be apparent.The new rope may not fit correctly into the previouslyworn groove profile and unnecessary wear and ropedistortion is likely to occur. This may be remedied bymachining out the grooves before the new rope isinstalled. Before carrying out such action the sheavesor drum should be examined to ensure that there willbe sufficient strength remaining in the underlyingmaterial to safely support the rope.The competent person should be familiar with therequirements of the appropriateapplication/machinery standard.Note: General guidance to users is given in ISO 4309 Code ofpractice for the selection, care and maintenance of steel wire rope.Transfer the wire rope carefully from the storage areato the installation site.CoilsPlace the coil on the ground and roll it out straightensuring that it does not become contaminated withdust/grit, moisture or any other harmful material.(See Fig. 5)Dimensions for grooving of drumsGeneral recommendations for stranded ropesP = nominal diameter + 5%R = nominal radius + 7.5%A gap between the last turn on the bottom layer ofrope on the drum and the flange can be corrected byfitting a packing (or false cheek) of suitable thicknesson the inside of the flange.WARNINGFailure to carry out any of the above could result inunsatisfactory and unsafe rope performance.Note: Grooves must have clearance for the rope and provideadequate circumferential support to allow for free movement of thestrands and facilitate bending. When grooves become worn and therope is pinched at the sides, strand and wire movement is restrictedand the ability of the rope to bend is reduced. (See Fig. 4)Fig 5If the coil is too large to physically handle it may beplaced on a ‘swift’ turntable and the outside end ofthe rope pulled out allowing the coil to rotate.(See Fig. 5)WARNINGNever pull a rope away from a stationary coil asthis will induce turn into the rope and kinks willform. These will adversely affect ropeperformance. (See Fig. 6)Fig 4WrongWrongFig 6WrongNote the kinksformingSheave groovetoo narrowSheave groovetoo widerIgHTSheave groove correctlysupporting the rope for33% of its circumference44 BRIDON Mining

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeReelsPass a shaft through the reel and place the reel in asuitable stand which allows it to rotate and be brakedto avoid overrun during installation. Where multi-layercoiling is involved it may be necessary for the reel tobe placed in equipment which has the capability ofproviding a back tension in the rope as it is beingtransferred from reel to drum. This is to ensure thatthe underlying (and subsequent) laps are woundtightly on the drum. (See Fig. 7)Ensure that the reel stand is mounted so as not tocreate a reverse bend during reeving (i.e. for a winchdrum with an overlap rope, take the rope off the top ofthe reel). (See Fig. 7)3.9 Ensure that any equipment or machinery to be ropedis correctly and safely positioned and isolated fromnormal usage before installation commences. Referto the OEM’s instruction manual and the relevant‘Code of Practice’.3.10 When releasing the outboard end of the rope from areel or coil, ensure that this is done in a controlledmanner. On release of the bindings and servingsused for packaging, the rope will want to straightenitself from its previously bent position. Unlesscontrolled, this could be a violent action. Stand clear.Fig 7Position the reel and stand such that the fleet angleduring installation is limited to 1.5 degrees.(See Fig. 8)WARNINGFailure to control could result in injury.Ensure that the as-manufacturedcondition of the rope is maintainedduring installation.If a loop forms in the rope ensure that it does nottighten to form a kink.WARNINGANGLE OFFLEETCENTRE LINEOF REELCENTRE LINEOF SHEAVEFig 8A kink can severely affect the strength of a sixstrand rope and can result in distortion of arotation- resistant or low rotation rope leading toits immediate discard.Fig 9If installing the new rope with the aidof an old one, one method is to fit awire rope sock (or stocking) to eachof the rope ends. Always ensure thatthe open end of the sock (orstocking) is securely attached to therope by a serving or alternatively by aclip(See Fig. 9). Connect the two endsvia a length of fibre rope of adequatestrength in order to avoid turn beingtransmitted from the old rope into thenew rope. Alternatively a length offibre or steel rope of adequatestrength may be reeved into thesystem for use as a pilot/messengerline. Do not use a swivel during theinstallation of the rope.BRIDON Mining45

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire rope3.11 Monitor the rope carefully as it is being pulled into thesystem and make sure that it is not obstructed by anypart of the structure or mechanism which may causethe rope to come free.Fig 10WARNINGFailure to monitor during this operation couldresult in injury.This entire operation should be carried out carefully andslowly under the supervision of a competent person.3.12 Take particular care and note the manufacturer’sinstructions when the rope is required to be cut.Apply secure servings on both sides of the cut mark.(See Fig. 10 for typical method of applying a servingto a multi-layer rope.)Ensure that the length of serving is at least equal to tworope diameters. (Note: Special servings are required forspiral ropes, i.e. spiral strand and locked coil.)Length of serving for locked coil winding ropes andhalf locked coil guide ropesThe length of rope to be served depends on theobject of the serving and on the size and type of therope. If the serving is to restrain the cut end of a ropeit must be longer than one intended to restrain theend of a short sample to be cut from a rope. a ropeof the stranded type exerts only a moderate burstingforce on a serving but a large locked coil rope exertsa considerable bursting force and, should the servingburst, the rope will unlay itself violently over a longlength. Thus, for the cut end of a stranded rope, twoservings each of a length at least six times the ropediameter should be used and kept in place until therope end is otherwise secured. For the cut end of alarge locked coil rope a serving or servings each alength of twenty times the rope diameter is advisable,and such servings should be backed up by aminimum of six two-bolt clamps set clear of theserved length until the rope end is otherwisesecured. Servings should be left permanently onlocked coil winding ropes so that there is one about0.6m (2ft) clear of the capel to allow properexamination of the rope at this point and anotherbetween the capel and the nearest pulley or drivingsheave in the head frame. This is to localise anyunlaying of the rope end, or of broken wires, in theevent of some incident.One serving either side of the cut is normallysufficient for preformed ropes. For non-preformedropes, multi-layer (i.e. rotation-resistant and lowrotation ropes) and parallel closed ropes (i.e. DSCropes) a minimum of two servings each side of thecut will be necessary (See Fig. 10).Arrange and position the rope in such a manner thatat the completion of the cutting operation the ropeends will remain in position, thus avoiding anybacklash or any other undesirable movement.Cut the rope with a high speed abrasive disc cutter.Other suitable mechanical or hydraulic shearingequipment may be used although not recommendedwhen a rope end is required to be welded or brazed.For serving instructions for FL and HL ropes refer toBridon.46 BRIDON Mining

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeWARNINGWhen using a disc cutter be aware of the dangerfrom sparks, disc fragmentation and fumes.(Refer 3.2.)Ensure adequate ventilation to avoid any build-up offumes from the rope and its constituent partsincluding any fibre core (natural or synthetic) any ropelubricant(s) and any synthetic filling and/or coveringmaterial.When terminating a rope end with a wedge socket,ensure that the rope tail cannot withdraw through thesocket by securing a clamp to the tail or by followingthe manufacturer’s instructions.(See Fig. 11 for two recommended methods ofsecuring the rope tail of a wedge socket termination).WARNINGSome special ropes contain synthetic materialwhich, when heated to a temperature higher thannormal production processing temperatures, willdecompose and may give off toxic fumes.WARNINGRope produced from carbon steel wires in the formshipped is not considered a health hazard. Duringsubsequent processing (e.g. cutting, welding,grinding, cleaning) dust and fumes may beproduced which contain elements which mayaffect exposed workers.The products used in the manufacture of steel wireropes for lubrication and protection present minimalhazard to the user in the form shipped. The user musthowever, take reasonable care to minimise skin andeye contact and also avoid breathing their vapourand mist.After cutting, the rope cross-sections of nonpreformedropes, multi-layer ropes and parallelclosed ropes must be welded, brazed or fused andtapered such that all wires and strands in the rope arecompletely secured.WARNINGFailure to correctly secure the rope end is likely tolead to slackness, distortions, premature removalfrom service and a reduction in the breaking forceof the rope.Fig 11The loop back method uses a rope grip and the loopshould be lashed to the live part of rope by a soft wireserving or tape to prevent flexing of the ropein service.The method of looping back should not be used ifthere is a possibility of interference of the loop withthe mechanism or structure.WARNINGFailure to secure in accordance with instructionscould lead to loss of the rope and/or injury.3.13 Ensure that any fittings such as clamps or fixtures areclean and undamaged before securing rope ends.Make sure that all fittings are secure in accordancewith the OEM’s instruction manual or manufacturer’sinstructions and take particular note of any specificsafety requirements e.g. torque values (andfrequency of any re-application of torque).3.14 When coiling a rope on a plain (or smooth) barreldrum ensure that each lap lies tightly against thepreceding lap. The application of tension in the ropegreatly assists in the coiling of the rope.BRIDON Mining47

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeWARNINGAny looseness or uneven winding will result inexcessive wear, crushing and distortion of the rope.With plain barrel drums it is difficult to achievesatisfactory multi-layer coiling beyond three layers.The direction of coiling of the rope on the drum isimportant, particularly when using plain barrel drums,and should be related to the direction of lay of therope in order to induce close coiling.(See Fig. 12 for proper method of locating ropeanchorage point on a plain drum.)Proper method of locating rope anchorage pointon a plain drumSTART ROPEAT LEFTFLANGERIGHTHANDLEFTHANDLEFTHANDRIGHT HANDLAY ROPE-UNDERWINDRIGHT HANDLAY ROPE-OVERWINDLEFT HANDLAY ROPE-UNDERWINDLEFT HANDLAY ROPE-OVERWINDnote: Thumb indicates side of rope anchorageFig 12When multi layer coiling has to be used it should berealised that after the first layer is wound on a drum,the rope has to cross the underlying rope in order toadvance across the drum in the second layer. Thepoints at which the turns in the upper layer crossthose of the lower layer are known as the cross-overpoints and the rope in these areas is susceptible toincreased abrasion and crushing. Care should betaken when installing a rope on a drum and whenoperating a machine to ensure that the rope is coiledand layered correctly.3.15 Check the state of re-usable rope end terminationsfor size, strength, defects and cleanliness before use.Non-destructive testing may be required dependingon the material and circumstances of use. Ensure thatthe termination is fitted in accordance with the OEM’sinstruction manual or manufacturer’s instructions.When re-using a socket and depending on its typeand dimensions, the existing cone should be pressedout. Otherwise, heat may be necessary.WARNINGWhen melting out sockets which have previouslybeen filled with hot metal, the emission of toxicfumes is likely. Note that white metal contains ahigh proportion of lead.Correctly locate and secure any connection pins andfittings when assembling end terminations to fixtures.Refer to manufacturer’s instructions.WARNINGFailure to pay attention to any of the above couldresult in unsafe operation andpotential injury.3.16 Limit switches, if fitted, must be checked andre-adjusted, if necessary, after the rope hasbeen installed.3.17 Record the following details on the Certificate afterinstallation has been completed: type of equipment,location, plant reference number, duty and date ofinstallation and any re-rating information/signature ofcompetent person. Then safely file the Certificate.3.18 ‘Run in’ the new rope by operating the equipmentslowly, preferably with a low load, for several cycles.This permits the new rope to adjust itself gradually toworking conditions.Note: Unless otherwise required by a certifying authority, the ropeshould be in this condition before any proof test of the equipment ormachinery is carried out.Check that the new rope is spooling correctly on thedrum and that no slack or cross laps develop.If necessary, apply as much tension as possibleto ensure tight and even coiling, especially on thefirst layer.Where multi-layer coiling is unavoidable,succeeding layers should coil evenly on thepreceding layers of rope.48 BRIDON Mining

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeWARNINGIrregular coiling usually results in severe surfacewear and rope malformation, which in turn is likelyto cause premature rope failure.3.19 Ensure that the as-manufactured condition of therope is maintained throughout the whole of thehandling and installation operation.3.20 If samples are required to be taken from the rope forsubsequent testing and/or evaluation, it is essentialthat the condition of the rope is not disturbed. Referto the instructions given in 3.12 and, depending onthe rope type and construction, any other specialmanufacturer’s instructions.4. In Service4.1 Inspect the rope and related equipment at thebeginning of every work period and particularlyfollowing any incident which could have damaged therope or installation.The entire length of rope should be inspected andparticular attention paid to those sections thatexperience has proven to be the main areas ofdeterioration. Excessive wear, broken wires, distortionand corrosion are the usual signs of deterioration. Fora more detailed examination special tools arenecessary (see Fig. 13) which will also facilitateinternal inspection (see Fig. 14.)Fig 13Note: Shortening the rope re-positions the areas of maximumdeterioration in the system. Where conditions permit, begin operatingwith a rope which has a slightly longer length than necessary in orderto allow for periodic shortening.When a non-preformed rope, multi-layer rope orparallel closed rope is used with a wedge socket andis required to be shortened, it is essential that the endof the rope is secured by welding or brazing beforethe rope is pulled through the main body of thesocket to its new position. Slacken the wedge in thesocket. Pass the rope through the socket by anamount equivalent to the crop length or samplerequired. Note that the original bent portion of therope must not be retained within the wedge socket.Replace the wedge and pull up the socket. Prepareand cut in accordance with section 3.12. Ensure thatthe rope tail cannot withdraw through the socket, seesection 3.13.WARNINGFailure to observe this instruction will result in asignificant deterioration in the performance of therope and could render the rope completely unfit forfurther service.In cases where severe rope wear takes place at oneend of a wire rope, the life of the rope may beextended by changing round the drum end with theload end, i.e. turning the rope ‘end for end’ beforedeterioration becomes excessive.4.2 Remove broken wires as they occur by bendingbackwards and forwards using a pair of pliers untilthey break deep in the valley between two outerstrands (see Fig. 15). Wear protective clothing suchas overalls, industrial gloves, helmet, eye protectorsand safety footwear during this operation.Fig 14In the case of ropes working over drums or sheaves itis particularly necessary to examine those areasentering or leaving the grooves when maximum loads(i.e. shock loads) are experienced, or those areaswhich remain for long periods in exposed placessuch as over a head gear pulleys.On some running ropes, but particularly relevant tostanding ropes (e.g. guide ropes) the areas adjacentto terminations should be given special attention(see Fig. 14).Fig 15WARNINGDo not shear off the ends of broken wires withpliers as this will leave an exposed jagged edgewhich is likely to damage other wires in the ropeand lead to premature removal of the rope fromservice. Failure to wear adequate protectiveclothing could result in injury.BRIDON Mining49

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeNote: Broken wires are a normal feature of service, more so towardsthe end of the rope’s life, resulting from bending fatigue and wear.The local break up of wires may indicate some mechanical fault inthe equipment.Record the number and position in the rope of anyremoved broken wires.4.3 Do not operate an appliance if for any reason (e.g.rope diameter, certified breaking force, ropeconstruction, length or strength and type of ropetermination) the wire rope and its termination isconsidered unsuitable for the required duty.4.4 Do not operate an appliance if the wire rope fitted hasbecome distorted, been damaged or has deterioratedto a level such that discard criteria has been reachedor is likely to be reached prior to normal expected lifebased on historical performance data.WARNINGRope distortion is usually a result of mechanicaldamage and can significantly reduce rope stren gth.4.5 An authorised competent person must examine therope in accordance with the appropriate Regulations.4.6 Do not carry out any inspection, examination,dressing/lubrication, adjustment or any othermaintenance of the rope whilst it is suspending aload, unless otherwise stated in the OEM’s instructionmanual or other relevant documents.Do not carry out any inspection or maintenance of therope if the appliance controls are unattended unless thesurrounding area has been isolated or sufficient warningsigns have been posted within the immediate vicinity.If the appliance controls are attended, the authorisedperson must be able to communicate effectively withthe driver or controller of the appliance during theinspection process.4.7 Never clean the wire rope without recognising thepotential hazards associated with working on amoving rope.WARNINGFailure to pay attention or take adequateprecaution could result in injury.If cleaning by cloth/waste, the material can besnagged on damaged surfaces and/or broken wires.If cleaning by brush, eye protectors must be worn. Ifusing fluids it should be recognised that someproducts are highly inflammable. A respirator shouldbe worn if cleaning by a pressurised spray system.WARNINGFailure to take adequate precaution could result ininjury or damage to health.Only use compatible cleaning fluids which will notimpair the original rope lubricant nor affect the ropeassociated equipment.WARNINGThe use of cleaning fluids (particularly solventbased) is likely to ‘cut back’ the existing ropelubricant leading to a greater quantity of lubricantaccumulating on the surface of the rope. This maycreate a hazard in appliances and machinery whichrely on friction between the rope and the drivesheave (e.g. lifts, friction winders and cableways).4.8 Lubricants selected for in-service dressing must becompatible with the rope manufacturing lubricant andshould be referenced in the OEM’s instruction manualor other documents approved by the owner of theappliance.If in doubt contact the rope supplier or Bridon.4.9 Take particular care when applying any in-servicelubricant/dressing. Application systems which involvepressure should only be operated by trained andauthorised persons and the operation carried out strictlyin accordance with the manufacturer’s instructions.Most wire ropes should be lubricated as soon as theyare put into service and at regular intervals thereafter(including cleaning) in order to extendsafe performance.WARNINGA ‘dry’ rope unaffected by corrosion but subject tobend fatigue, is likely to achieve only 30% of thatnormally attained by a ‘lubricated’ rope.Do not dress/lubricate the rope if the applicationrequired it to remain dry. (Refer OEM’sinstruction manual.)Reduce the period between examinations when ropesare not subjected to any in-service dressing andwhen they must remain dry.Note: The authorised person carrying out a rope inspection must becapable of recognising the potential loss of safe performance ofsuch a rope in comparison with lubricated rope.Clean the rope before applying a freshdressing/lubricant if it is heavily loaded with foreignmatter e.g. sand, dust.50 BRIDON Mining

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire rope4.10 The authorised person responsible for carrying outwire rope maintenance must ensure that the ends ofthe rope are secure. At the drum end this will involvechecking the integrity of the anchorage and ensuringthat there are at least two and a half dead laps tightlycoiled. At the outboard end the integrity of thetermination must be checked to ensure that it is inaccordance with the OEM’s manual or otherdocuments approved by the owner of the appliance.4.11Adjust the lengths of ropes in multi-rope systems inorder that equal forces (within approved limits)are evident.If a wire rope needs cutting refer to 3.12.When securing rope ends refer to 3.13.When re-usable end terminations are used refer to 3.15.When re-connecting any end terminations to fixturesrefer to 3.15.WARNINGDamage to, or removal of component parts(mechanical or structural) caused by abnormalcontact with wire rope can be hazardous to thesafety of the appliance and/or the performance ofthe rope (e.g. damage to the drum grooving, suchthat coiling is erratic and/or the rope is ‘pulleddown’ into underlying layers, which might cause adangerous condition or, alternatively, causelocalised rope damage at ‘cross-over’ positions,which might then radically affect performance;loss/removal of wear plates protecting thestructure leading to major structural damage bycutting and/or failure of the wire rope due tomechanical severance).4.12 Following any periodic statutory examination orroutine or special inspection where any correctiveaction is taken the Certificate should be updated anda record made of the defects found, the extent of thechanges and the condition of the rope.4.13 Apply the following procedures for the selection andpreparation of samples, from new and used lengthsof rope, for the purpose of examination and testing todestruction.Check that the rope end, from which the sample willbe taken, is secured by welding or brazing. If not,select the sample length further away from the ropeend and prepare new servings (see 3.12).Handle the rope in accordance with the instructionsgiven in section 3. Serve the rope, using the buriedwire technique (see Fig. 10) and apply a rope clampor grip as close to the cut mark as practicallypossible. Do not use solder to secure the servings.Ensure that the sample is kept straight throughout thewhole procedure and ensure that the minimumsample length is 3 metres for ropes up to andincluding 40mm diameter and 12 metres for largerdiameter ropes.The rope should be cut with a high speed abrasivedisc cutter or an oxyacetylene torch. Weld the ropeends of the sample as described in section 3.12, afterwhich the clamp or grip can be removed.The identification of the rope must be established andthe sample suitably marked and packed. It isrecommended that the 3 metre sample is retainedstraight and secured to a wood batten fortransportation. For a 12 metre sample, coil to adiameter as large as practically possible and neverless than 2 metres.Note: Samples taken for destruction testing are required to beterminated in accordance with a recognised resin socketingstandard (e.g. BS EN 13411-4 or ISO 7596).WARNINGFailure to comply with these procedures will result inmeasured breaking force values which are not trulyrepresentative of the actual strength of the rope.5. Wire Rope Discard5.1 Discard the wire rope in accordance with currentRegulations and in accordance with the OEM’sinstruction manual.5.2 If a wire rope is removed from service at a level ofperformance substantially different to historicallyestablished performance data and without anyobvious reason(s), contact Bridon or Bridon’sdistributor for further guidance.5.3 Only qualified and experienced personnel, taking theappropriate safety precautions and wearing theappropriate protective clothing, should beresponsible for removing the wire rope.WARNINGTake particular care when removing ropes withmechanical damage as they may fail abruptlyduring the change-out procedure.BRIDON Mining51

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeTake the utmost care when removing ‘exhausted/failed’ropes from drums and sheaves as they may be grosslydistorted, lively and tightly coiled.WARNINGFailure to take adequate precautions could resultin injury.5.4 Store discarded rope in a safe and secure location orcompound and ensure that it is suitably marked toidentify it as rope which has been removed fromservice and not to be used again.WARNINGDiscarded rope can be a danger (e.g. protrudingbroken wires, excessive grease/lubricant and ropemass) to personnel and equipment if not handledcorrectly and safely during disposal.5.5 Record the date and reason for discard on theCertificate before filing for future reference.5.6 Pay attention to any Regulations affecting the safedisposal of steel wire rope.6. Rope Selection CriteriaEnsure that the correct type of wire rope is selectedfor the equipment by referring to the OEM’sinstruction manual or other relevant documents. If indoubt contact Bridon or Bridon’s distributorfor guidance.6.1 Rope StrengthIf necessary, refer to the appropriate Regulationsand/or application standards and calculate themaximum force to which the rope will be subjected.The calculation may take into account the mass to belifted or moved, any shock loading, effects of highspeed, acceleration, any sudden starts or stops,frequency of operation and sheave bearing friction.By applying the relevant coefficient of utilisation(safety factor) and, where applicable, the efficiency ofthe rope termination, the required minimum breakingload or force of the rope will be determined, thevalues of which are available from the relevantNational, European or International standards or fromspecific Product Data literature.If in doubt ask for advice from Bridon orBridon’s distributor.6.2 Bending fatigueThe size and number of sheaves in the system willinfluence the performance of the rope.WARNINGWire rope which bends around sheaves, rollers ordrums will deteriorate through ‘bending fatigue’.Reverse bending and high speed will acceleratethe process. Therefore, under such conditionsselect a rope with high bending fatigue resistance.Refer to Product Data Information, and if in doubtask for advice.6.3 AbrasionWire rope which is subject to abrasion will becomeprogressively weaker as a result of:Externally - dragging it through overburden, sand orother abrasive materials and passing around asheave, roller or drum.Internally - being loaded or bent.WARNINGAbrasion weakens the rope by removing metalfrom both the inner and outer wires. Therefore,a rope with large outer wires should normallybe selected.6.4 VibrationVibration in wire rope will cause deterioration. Thismay become apparent in the form of wire fractureswhere the vibration is absorbed.WARNINGThese fractures may be internal only and will notbe visually identified.6.5 DistortionWire rope can be distorted due to high pressureagainst a sheave, improperly sized grooves or as aresult of multi-layer coiling on a drum.Rope with a steel core is more resistant to crushingand distortion.6.6 CorrosionRope with a large number of small wires is moresusceptible to corrosion than rope with a smallnumber of large wires. Therefore, if corrosion isexpected to have a significant effect on ropeperformance select a galvanised rope with as largean outer wire size as possible bearing in mind theother conditions (e.g. bending and abrasion) underwhich the rope will be operating.52 BRIDON Mining

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire rope6.7 Connecting RopesIn the event that it is necessary to connect one ropeto another (in series) it is essential that they have therequired strength, are of the same type and both havethe same lay direction (i.e. connect ‘right’ lay to ‘right’lay).WARNINGFailure to heed this warning could result incatastrophic failure particularly at a terminationwhich is capable of being pulled apart (i.e. splice)due to unlaying.6.10 Operating TemperaturesWire rope with a steel core should be selected if thereis any evidence to suggest that a fibre core will notprovide adequate support to the outer strands and/orif the temperature of the working environment may beexpected to exceed 100˚C.For operating temperatures above 100˚C de-rating ofthe minimum breaking force of the rope is necessary(e.g. between 100˚C and 200˚C reduce by 10%;between 200˚C and 300˚C reduce by 25%; between300˚C and 400˚C reduce by 35%).Do not use ropes with high carbon wires above 400˚C.6.8 Rope LengthRope length and /or difference in length between twoor more ropes used in a set may be a critical factorand must be considered along with rope selection.WARNINGWire rope will elongate under load. Other factorssuch as temperature, rope rotation and internalwear will also have an effect. These factors shouldalso be considered during rope selection.6.9 Preformed and Non-preformed RopesSingle layer round strand rope is normally suppliedpreformed. However, if a non-preformed rope isselected then personnel responsible for its installationand/or maintenance need to take particular carewhen handling such rope, especially when cutting.For the purposes of this instruction, multi-layer,parallel closed and spiral ropes should be regardedas non-preformed ropes.WARNINGFailure to observe this general guidance couldresult in failure of the ropes to support the load.For temperatures over 400˚C, other materials such asstainless steel or other special alloys should beconsidered.WARNINGRope lubricants and any synthetic filling and/orcovering materials may become ineffective atcertain low or high operating temperature levels.Certain types of rope end terminations also havelimiting operating temperatures and the manufactureror Bridon should be consulted where there is anydoubt. Ropes with aluminium ferrules must not beused at temperatures in excess of 150˚C.BRIDON Mining53

Technical InformationProduct Safety: Instructions & Warnings on the use of steel wire ropeWARNINGCAUTIONARY NOTICE – RESTRICTIONS ON THEUSE OF LARGE DIAMETER MULTISTRAND ROPES.All wire ropes are prone to damage if they are notproperly supported when used at high loads.Larger Multistrand ropes are particularlysusceptible to this form of abuse, due to their rigidconstruction and the relatively fine wire sizesinvolved in their manufacture/construction.Instances have been recorded of ropes beingheavily worked over plain drums and failing"prematurely", despite the nominal tension beingbeing in the region of half the breaking strengthof the rope.The best way of preventing difficulties of this sortis to avoid conditions that are likely to generatedamagingly high contact stresses. A simplemethod of assessing the severity of the contactconditions is to firstly calculate the tread pressurebased on the projected nominal area and thenapply a factor (of say 10*) to allow for the highlylocalised and intermittent nature of the actual wirecontacts, as indicated below :-Type of contact Close-fitting U-groove Oversize U-groove Plain drumLevel of support Good Fair PoorTread path width 100% of rope dia. 50% of rope dia. 20% of rope dia.Tread pressure = 2T/Dd 4T/Dd 10T/DdContact stress = 20T/Dd 40T/Dd 100T/DdNote: Contact stresses which exceed 10% of the wire UTS should beconsidered a cause for concern, especially if the rope is operating ata low factor of safety.[* This is because the true contact area is very much less than theprojected nominal area.]Worked example:Consider case of a 50mm Multistrand rope (MBL=2100kN)operating at a 3:1 factor of safety. Then, for the Contactstress < 200 Mpa say, the following minimum bendingdiameters are indicated:Close-fitting groove – 1400mmOversize U-groove - 2800mmUn-grooved drum - 7000mm54 BRIDON Mining

Technical InformationMaterial Safety DataIntroductionSteel wire rope is a composite material and dependentupon its type may contain a number of discrete materials.The following provides full details of all the individualmaterials which may form part of the finished wire rope.The description and/or designation of the wire rope statedon the delivery note and/or invoice (or certificate, whenapplicable) will enable identification of the component parts.The main component of a steel wire rope is the wire, whichmay be carbon steel, coated (zinc or Zn95/A15) steel orstainless steel.The other three components are (i) the core, which may beof steel of the same type as used in the main strands oralternatively fibre (either natural or synthetic), (ii) the ropelubricant and, where applicable, (iii) any internal filling orexternal covering. No Occupational Exposure Limits(OEL’s) exist for steel wire rope and the values provided inthis publication relate to component elements andcompounds. The actual figures quoted in relation to thecomponent parts are taken from the latest edition of EH40.Rope produced from carbon, coated or stainless steelwires in the as-supplied condition is not considered ahealth hazard. However during any subsequent processingsuch as cutting, welding, grinding and cleaning, dust andfumes may be produced which contain elements that mayaffect exposed workers.The following indicates the order in which specificinformation is provided:-Carbon steel wire, Coated steel wire, Stainless steel wire,Manufacturing rope lubricants, Fibre cores,Filling and covering materials, General informationCarbon Steel Wire - Hazardous IngredientsComponent% Weight (Max)Long term exposure limit(8-hour TWA referenceperiod) mg/m 3Short term exposure limit(10-minute referenceperiod) mg/m 3BASE METALAluminiumCarbonChromiumCobaltCopperIronManganeseMolybdenumNickelPhosphorusSiliconSulphurVanadiumBoronTitaniumNitrogenLeadArsenicZirconiumCOATEDSodiumCalciumBoronPhosphorusIronZincOil may be applied0.31.00.40.30.5Balance1.00.10.50.10.50.50.250.10.10.010.10.010.050.50.51.01.01.01.05.010None Listed0.50.10.255510.110None Listed0.5101050.150.25None Listed2100.155520105100.320910200.3101010Physical DataSpecific Gravity: 7.5 - 8.5Melting Point:1350 - 1500 o CAppearance & Odour: Solid. Odourless MetalSolubility in water:InsolubleFlash Point:NoneVapour Pressure:N/AVapour Density:N/AEvaporation:N/A% Volatiles: N/ABoiling Point:> 2800 o CBRIDON Mining55

Technical InformationMaterial Safety DataCoated (Zinc and ZN95/A 15) Steel Wire - Hazardous IngredientsComponent% Weight (Max)Long term exposure limit(8-hour TWA referenceperiod) mg/m 3Short term exposure limit(10-minute referenceperiod) mg/m 3BASE METALAluminiumCarbonChromiumCobaltCopperIronManganeseMolybdenumNickelPhosphorusSiliconSulphurVanadiumBoronTitaniumNitrogenLeadArsenicZirconiumCOATEDZincAluminiumIronSodiumCalciumBoronPhosphorusSulphurOil may be appliedWax may be applied0.31.00.40.30.5Balance1.00.10.50.10.50.50.250.10.10.010.10.010.0510.01.55.00.50.51.01.00.55.05.010None Listed0.50.10.255510.110None Listed0.5101050.150.255105None Listed21000.1None Listed5220105100.320910102010200.3106Physical DataSpecific Gravity: 7.5 - 8.5Melting Point:1350 - 1500 o CAppearance & Odour: Solid. Odourless MetalSolubility in water:InsolubleFlash Point:NoneVapour Pressure:N/AVapour Density:N/AEvaporation:N/A% Volatiles: N/ABoiling Point:> 2800 o C56 BRIDON Mining

Technical InformationMaterial Safety DataManufacturing Rope LubricantsThe products used in the manufacture of steel wire ropesfor lubrication and protection present minimal hazard to theuser in the as-supplied condition. The user must, however,take reasonable care to minimise skin and eye contact andalso avoid breathing their vapours and mists.A wide range of compounds is used as lubricants in themanufacture of steel wire rope. These products, in themain, consist of mixtures of oils, waxes, bitumens,resins, gelling agents and fillers with minor concentrationsof corrosion inhibitors, oxidation stabilizers andtackiness additives.Most of them are solid at ambient temperatures andprovided skin contact with the fluid types is avoided, nonepresent a hazard in normal rope usage.However, to assist in the assessment of the hazard causedby these products, the following table contains all thecomponents which may be incorporated into a wire ropelubricant and which may be considered hazardous to health.Hazardous Ingredients:ComponentOil mistParaffin wax fumeBitumenSilica, fusedTotal inhalable dustRespirable dustAluminium flakeZinc oxide, fumeButaneLong termexposure limit(8-hour TWAreferenceperiod) mg/m 3There are no other known constituents of any wire ropelubricant used that are classified as hazardous in thecurrent edition of EH40.General advice on handling ropes with lubricantsTo avoid the possibility of skin disorders, repeated orprolonged contact with mineral or synthetic hydrocarbonsmust be avoided and it is essential that all persons whocome into contact with such products maintain highstandards of personal hygiene.5250.30.11051430Short termexposure limit(10-minutereferenceperiod) mg/m 31061020101780The worker should:1) use oil impermeable gloves, or if not available, suitableoil repellent type barrier creams,2) avoid unnecessary contact with oil using protective clothing,3) obtain first aid treatment for any injury, however slight,4) wash hands thoroughly before meals, before using thetoilet and after work,5) use conditioning creams after washing, where provided.The worker should not:1) put oily rags or tools into pockets, especially trousers,2) use dirty or spoiled rags for wiping oil from the skin,3) wear oil soaked clothing,4) use solvents such as paraffin, petrol etc., to remove oilfrom the skin.Concentrations of oil mists, fumes and vapours in the workingatmosphere must be kept as low as is reasonably practicable.Levels quoted in the current edition of HSE Guidance NoteEH40 ‘Occupational Exposure Limits’ must not be exceeded.Health HazardsInhalation of oil mists or fumes from heated rope lubricantsin high concentrations may result in dizziness, headache,respiratory irritation or unconsciousness. Eye contact mayproduce mild transient irritation to some users.Fumes from heated rope lubricants in high concentrationsmay cause eye irritation.If heated rope lubricants contacts skin, severe burns may result.Prolonged or repeated skin contact may cause irritation,dermatitis or more serious skin disorders.Fibre CoresBeing in the centre of a steel wire rope, the materials(natural or synthetic) from which fibre cores are produceddo not present a health hazard during normal ropehandling. Even when the outer core strands are removed(for example when the rope is required to be socketed) thecore materials present virtually no hazard to the users,except, maybe, in the case of a used rope where, in theabsence of any service dressing or as a result of heavyworking causing internal abrasive wear of the core, the coremay have decomposed into a fibre dust which might beinhaled, although this is considered extremely unlikely.The principal area of hazard is through the inhalation offumes generated by heat, for example when the rope isbeing cut by a disc cutter.BRIDON Mining57

Technical InformationMaterial Safety DataUnder these conditions, natural fibres are likely to yieldcarbon dioxide, water and ash, whereas synthetic materialsare likely to yield toxic fumes.The treatment of natural fibres, such as rotproofing, mayalso produce toxic fumes on burning.The concentrations of toxic fumes from the cores, however,will be almost negligible compared with the productsgenerated by heating from the other primary materials, e.g.wire and manufacturing lubricant in the rope.The most common synthetic core material is polypropylene,although other polymers such as polyethylene and nylonmay occasionally be used.Filling and Covering MaterialsFilling and covering materials do not present a health hazardduring handling of the rope in its as-supplied condition.The principal area of hazard is by the inhalation of fumesgenerated by heat, for example when the rope is being cutby a disc cutter.Under these conditions, fillings and coverings, which aregenerally polypropylene, polyethylene and polyamid (but insome cases may be of natural fibre) are likely to producetoxic fumes.General InformationOccupational protective measures1) Respiratory protection - Use general and localexhaust ventilation to keep airborne dust or fumesbelow established occupational exposure standards(OES’s). Operators should wear approved dust andfume respirators if OES’s are exceeded.(The OES for total dust is 10mg/m3 and for respirabledust is 5mg/m 3 ).2) Protective equipment - Protective equipment shouldbe worn during operations creating eye hazards. Awelding hood should be worn when welding or burning.Use gloves and other protective equipmentwhen required.3) Other - Principles of good personal hygiene shouldbe followed prior to changing into street clothing oreating. Food should not be consumed in theworking environment.Emergency medical procedures1) Inhalation - Remove to fresh air; get medical attention.2) Skin - Wash areas well with soap and water.3) Eyes - Flush well with running water to removeparticulate; get medical attention.4) Ingestion - In the unlikely event that quantities of rope orany of its components are ingested, get medical attention.Safety Information1) Fire and explosion - In the solid state, steel componentsof the rope present no fire or explosion hazard. the organicelements present, i.e. lubricants, natural and syntheticfibres and other natural or synthetic filling and coveringmaterials are capable of supporting fire.2) Reactivity - Stable under normal conditions.Spill or leak procedures1) Spill or leak - Not applicable to steel in the solid form.2) Disposal - Dispose of in accordance withlocal Regulations.Rope TerminologyWiresOuter wires: All wires positioned in the outer layer of wiresin a spiral rope or in the outer layer of wires in the outerstrands of a stranded rope.Inner wires: All wires of intermediate layers positionedbetween the centre wire and outer layer of wires in a spiralrope or all other wires except centre, filler, core and outerwires of a stranded rope.Core wires: All wires of the core of a stranded rope.Centre wires: Wires positioned either at the centre of aspiral rope or at the centres of strands of a stranded rope.Layer of wires: An assembly of wires having one pitchcircle diameter. The exception is Warrington layercomprising alternately laid large and small wires where thesmaller wires are positioned on a larger pitch circlediameter than the larger wires. The first layer is that which islaid immediately over the strand centre.Note: Filler wires do not constitute a separate layer.Tensile strength grade of wires: A level of requirement oftensile strength of a wire and its corresponding tensilestrength range. It is designated by the value according tothe lower limit of tensile strength and is used whenspecifying wire and when determining the calculatedminimum breaking force or calculated minimum aggregatebreaking force of a rope.Wire finish: The condition of the surface finish of a wire,e.g. bright, zinc coated.58 BRIDON Mining

Technical InformationRope TerminologyStrandsStrand: An element of rope usually consisting of anassembly of wires of appropriate shape and dimensionslaid helically in the same direction in one or more layersaround a centre.Note: Strands containing three or four wires in the first layer or certainshaped (e.g. ribbon) strands may not have a centre.Round strand: A strand with a cross-section which isapproximately the shape of a circle.Triangular strand: A strand with a cross-section which isapproximately the shape of a triangle.Note: Triangular strands may have built-up centres (i.e. more thanone wire forming a triangle).Oval strand: A strand with a cross-section which isapproximately the shape of an ovalFlat ribbon strand: A strand without a centre wire with across-section which is approximately the shape of arectangle.Compacted strand: A strand which has been subjected toa compacting process such as drawing, rolling or swagingwhereby the metallic cross-sectional area of the wiresremains unaltered and the shape of the wires and thedimensions of the strand are modified.Note: Bridon’s brands of Dyform rope contain strands which havebeen compacted.Single lay strand: Strand which contains only one layer ofwires, e.g. 6-1.Parallel lay strand: Strand which contains at least twolayers of wires, all of which are laid in one operation (in thesame direction), e.g. 9-9-1; 12-6F-6-1; 14-7+7-7-1. Eachlayer of wires lies in the interstices of the underlying layersuch that they are parallel to one another, resulting inlinear contact.Note: This is also referred to as equal lay. The lay length of all thewire layers are equal.Seale: Parallel lay strand construction with the samenumber of wires in each wire layer, each wire layercontaining wires of the same size, e.g. 7-7-1; 8-8-1; 9-9-1.Warrington: Parallel lay strand construction having anouter layer of wires containing alternately large and smallwires, the number of wires in the outer layer being twicethat in the underlying layer of wires, e.g. 6+6-6-1; 7+7-7-1.Filler: Parallel lay strand construction having an outer layerof wires containing twice the number of wires than in theinner layer with filler wires laid in the intersticeswires of theunderlying layer of wires, e.g. 12-6F-6-1; 14-7F-7-1.Combined parallel lay: Parallel lay strand constructionhaving three or more layers of wires, e.g. 14-7+7-7-1;16-8+8-8-1; 14-14-7F-7-1; 16-16-8F+8-1.Note: The first two examples above are also referred to asWarrington-Seale construction. The latter two examples are alsoreferred to as Seale-Filler construction.Multiple operation lay strand: Strand constructioncontaining at least two layers of wires, at least one of whichis laid in a separate operation. All of the wires are laid in thesame direction.Cross-lay: Multiple operation strand construction in whichthe wires of superimposed wire layers cross over oneanother and make point contact, e.g. 12/6-1.Compound lay: Multiple operation strand which contains aminimum of three layers of wires, the outer layer of which islaid over a parallel lay centre, e.g. 16/6+6-6-1.RopesSpiral Rope: An assembly of two or more layers of shapedand/or round wires laid helically over a centre, usually asingle round wire. There are three categories of spiral rope,viz. spiral strand, half-locked coil and full-locked coil.Spiral Strand: An assembly of two or more layers of roundwires laid helically over a centre, usually a single roundwire.Half-locked Coil Rope: A spiral rope type having anouter layer of wires containing alternate half lock andround wires.Full-locked Coil Rope: A spiral rope type having an outerlayer of full lock wires.Stranded Rope: An assembly of several strands laidhelically in one or more layers around a core or centre.There are three categories of stranded rope, viz. singlelayer, multi-layer and parallel-closed.Single Layer Rope: Stranded rope consisting of one layerof strands laid helically over a core.Note: Stranded ropes consisting of three or four outer strands may,or may not, have a core. Some three and four strand single layerropes are designed to generate torque levels equivalent to thosegenerated by rotation-resistant and low rotation ropes.Rotation-resistant Rope: Stranded rope having no lessthan ten outer strands and comprising an assembly of atleast two layers of strands laid over a centre, the directionof lay of the outer strands being opposite (i.e. contra - lay)to that of the underlying layer of strands.Low Rotation Rope: Rotation resistant rope having atleast fifteen outer strands and comprising an assembly ofat least three layers of strands laid over a centre intwo operations.Note: this category of rotation resistant rope is constructed in such amanner that it displays little or no tendency to rotate, or if guided,generates little or no torque when loaded.BRIDON Mining59

Technical InformationRope TerminologyCompacted Strand Rope: Rope in which the outerstrands, prior to closing of the rope, are subjected to acompacting process such as drawing, rolling or swaging.Note: Bridon’s products containing compacted strands are identifiedby “Dyform”.Compacted Rope: Rope which is subjected to acompacting process after closing, thus reducing its diameter.Solid Polymer Filled Rope: Rope in which the freeinternal spaces are filled with a solid polymer. The polymerextends to, or slightly beyond, the outer circumference ofthe rope.Cushioned Rope: Stranded rope in which the inner layers,inner strands or core strands are covered with solidpolymers or fibres to form a cushion between adjacentstrands or layers of strands.Cushion Core Rope: Stranded rope in which the core iscovered (coated) or filled and covered (coated) with asolid polymer.Solid Polymer Covered Rope: Rope which is covered(coated) with a solid polymer.Solid Polymer Covered and Filled Rope: Rope which iscovered (coated) and filled with a solid polymer.Rope Grade (Rr): A number corresponding to a wiretensile strength grade on which the minimum breakingforce of a rope is calculated.Note: It does not imply that the actual tensile strength grades of thewires in a rope are necessarily the same as the rope grade.Preformed Rope: Stranded rope in which the wires in thestrands and the strands in the rope have their internalstresses reduced resulting in a rope in which, after removalof any serving, the wires and the strands will not spring outof the rope formation.Note: Multi-layer stranded ropes should be regarded as nonpreformedrope even though the strands may have been partially(lightly) preformed during the closing process.Rope Class: A grouping of rope constructions where thenumber of outer strands and the number of wires and howthey are laid up are within defined limits, resulting in ropeswithin the class having similar strength and rotationalproperties.Rope Construction: System which denotes thearrangement of the strands and wires within a rope, e.g.6x36WS, 6x19S.Note: K denotes compacted strands.Cable-laid Rope: An assembly of several (usually six)single layer stranded ropes (referred to as unit ropes) laidhelically over a core (usually a seventh single layerstranded rope).Braided Rope: An assembly of several round strandsbraided in pairs.Electro-mechanical Rope: A stranded or spiral ropecontaining electrical conductors.Strand and Rope LaysLay direction of strand: The direction right (z) or left (s)corresponding to the direction of lay of the outer layer ofwires in relation to the longitudinal axis of the strand.Lay direction of rope: The direction right (Z) or left (S)corresponding to the direction of lay of the outer strands inrelation to the longitudinal axis of a stranded rope or thedirection of lay of the outer wires in relation to thelongitudinal axis of a spiral rope.Ordinary lay: Stranded rope in which the direction of lay ofthe wires in the outer strands is in the opposite direction tothe lay of the outer strands in the rope. Right hand ordinarylay is designated sZ and left hand ordinary lay isdesignated zS.Note: This type of lay is sometimes referred to as ‘regular’ lay.Lang’s lay: Stranded rope in which the direction of lay ofthe wires in the outer strands is the same as that of theouter strands in the rope. Right hand Lang’s lay isdesignated zZ and left hand Lang’s lay is designated sS.Alternate lay: Stranded rope in which the lay of the outerstrands is alternatively Lang’s lay and ordinary lay. Righthand alternate lay is designated AZ and left hand alternatelay is designated AS.Contra-lay: Rope in which at least one inner layer of wiresin a spiral rope or one layer of strands in a stranded rope islaid in the opposite direction to the other layer(s) of wires orstrands respectively.Note: Contra-lay is only possible in spiral ropes having more thanone layer of wires and in multi-layer stranded ropes.Rope lay length (Stranded Rope): That distance parallelto the axis of the rope in which the outer strands make onecomplete turn (or helix) about the axis of the rope.CoresCore: Central element, usually of fibre or steel, of a singlelayer stranded rope, around which are laid helically theouter strands of a stranded rope or the outer unit ropes of acable-laid rope.Fibre core: Core made from natural fibres(e.g. hemp,sisal) and designated by its diameter and runnage.Fibre Film Core: Core made from synthetic fibres (e.g.polypropylene) and designated by its diameter andrunnage.60 BRIDON Mining

Technical InformationSteel core: Core produced either as an independent wirerope (IWRC)(e.g. 7x7) or wire strand (WSC)(e.g. 1x7).Solid polymer core: Core produced as a single elementof solid polymer having a round or grooved shape. It mayalso contain internal elements of wire or fibre.Insert: Element of fibre or solid polymer so positioned asto separate adjacent strands or wires in the same oroverlying layers and fill, or partly fill, some of the intersticesin the rope. (see Zebra)Rope Characteristics and PropertiesCalculated Minimum aggregate Breaking Force: Valueof minimum aggregate breaking force is obtained bycalculation from the sum of the products of the crosssectionalarea (based on nominal wire diameter) and tensilestrength grade of each wire in the rope, as given in themanufacturer’s rope design.Calculated Minimum breaking Force: Value of minimumbreaking force based on the nominal wire sizes, wire tensilestrength grades and spinning loss factor for the rope classor construction as given in the manufacturer’s rope design.Fill factor: The ratio between the sum of the nominalcross-sectional areas of all the load bearing wires in therope and the circumscribed area of the rope based on itsnominal diameter.Spinning loss factor (k): The ratio between the calculatedminimum breaking force of the rope and the calculatedminimum aggregate breaking force of the rope.Breaking force factor (K): An empirical factor used in thedetermination of minimum breaking force of a rope andobtained from the product of fill factor for the rope class orconstruction, spinning loss factor for the rope class orconstruction and the constant π/4.Minimum breaking force (Fmin): Specified value, in kN,below which the measured breaking force is not allowed tofall in a prescribed test and, for ropes having a grade,obtained by calculation from the product of the square ofthe nominal diameter, the rope grade and the breakingforce factor.Minimum aggregate breaking force (Fe,min): Specifiedvalue, in kN, below which the measured aggregatebreaking force is not allowed to fall in a prescribed test and,for ropes having a grade, obtained from the product of thesquare of the nominal rope diameter (d), the metallic crosssectionalarea factor (C) and the rope grade (Rr).Nominal length mass: The nominal mass values are forthe fully lubricated ropes. For friction winder ropes, thevalues should be reduced by 2%. The nominal length massvalues are subject to a tolerance of plus 2% to minus 5%.Rope torque: Value, usually expressed in N.m, resultingfrom either test or calculation, relating to the torquegenerated when both ends of the rope are fixed and therope is subjected to tensile loading.Rope turn: Value, usually expressed in degrees per metre,resulting from either test or calculation, relating to theamount of rotation when one end of the rope is free torotate and the rope is subjected to tensile loading.Initial extension: Amount of extension which is attributedto the initial bedding down of the wires within the strandsand the strands within the rope due to tensile loading.Note: This is sometimes referred to as constructional stretch.Elastic extension: Amount of extension which followsHooke’s Law within certain limits due to application of atensile load.Permanent rope extension: Non-elastic extension.BRIDON Mining61

Technical InformationConversion Factors S.I. Units1 mm 2 = 0.001 55 in 2 1 in 2 = 645.16 mm 2ForceMass1 kN = 0.101 972 Mp 1 UK tonf = 9964.02N 1 kg = 2.204 62 lb 1 lb = 0.453 592 kg1 N = 0.101 972 kgf 1 lbf = 4.448 22N 1 tonne (t) = 0.984 207 UK ton 1 UK ton = 1.01605 tonnes (t)1 kgf = 9.806 65 N 1 lbf = 0.453 592 kgf 1 kg/m = 0.671 970 lb/ft 1 lb/ft = 1.488 kg/m1 kgf = 1 kp 1 UK tonf = 1.01605 tonne 1 kg = 1000 g 1 kip (USA) = 1000 lb1 N = 1.003 61 x 10 -4 UK tonf 1 UK tonf = 9.964 02 kN 1 Mp = 1 x 10 6 gf1 N = 0.2244 809 lbf 1 UK tonf = 2240 lbf1 tonne (t) = 9.80665 kN1 kgf = 2.204 62 lbf 1 short tonf1 t = 0.984 207 UK tonf (USA) = 2000 lbfLength1 kN = 0.100 361 UK tonf 1 kip (USA) = 1000 lbf1 m = 3.280 84 ft 1 ft = 0.304 8 m1 kip = 453.592 37 kgf 1 km = 0.621 371 miles 1 mile = 1.609 344 kmPressure/StressArea1 N/mm 2 = 0.101972 kgf/mm 21 hectobar = 1 x 10 7 N/m 21 kgf/mm 2 = 9.806 65 N/mm 21 m 2 = 10.763 9ft 2 1 ft 2 = 0.092 903 0 m 21 N/mm 2 = 1 MPa1 kgf/mm 2 = 1 422.33 lbf/in 2 1 lbf/in 2 = 7.031 x 10 -4kgf/mm 21 kgf/mm 2 = 0.634 971 tonf/in 2 1 tonf/in 2 = 1.574 88 kgf/mm 2 Volume1 N/m 2 = 1.45038 x 10 -4 lbf/in 2 1 lbf/in 2 = 6894 76 N/m 2 1 cm 3 = 0.061 023 7 in 3 1 in 3 =16.387 1 cm 31 N/m 2 = 1 x 10 -6 N/mm 2 1 tonf/in 2 = 1.544 43 x 10 8 1 litre (1) = 61.0374 in 3 1 in 3 = 1.6387 x 10 4 mldyn/cm 21 m 3 = 6.10237 x 10 4 in 3 1 yd 3 = 0.764 555 m 31 bar = 14.503 8 lbf/in 21 hectobar = 10 N/mm 262

ContactsBRIDONSales OfficesUNITED KINGDOMDoncasterBalby Carr Bank, DoncasterSouth YorkshireDN4 5JQUnited Kingdomsales@bridon.comPhone: +44(0) 1302 565100Fax: +44(0) 1302 565190UNITED STATESBridon AmericanC280 New Commerce Blvd.Wilkes BarrePA 18706USAbridon@bridonamerican.comPhone: +1 800 521 5555Fax: +1 800 233 8362GERMANYBridon International GmbHMagdeburger Straße 14aD-45881GelsenkirchenGermanyinfo@bridon.dePhone: +49(0) 209 8001 0Fax: +49(0) 209 8001 275RUSSIABridon International MoscowIvovaya Street 2/8Building 1, Office 215129329 MoscowRussiainfo@bridon.ruPhone: +7 499 1808001Fax: +7 499 1809231INDONESIAPT BridonGraha Inti Fauzi2nd FloorJl. Buncit Raya No.22Jakarta 12510bridon@cbn.net.idPhone: +62 (021) 791 81919Fax: +62 (021) 799 2640AFRICAAngolaSonils BaseLuandaAngolaangolaops@bridon.comPhone: + 244 923 726890Fax: + 244 923 854180Kwanda BaseSoyoAngolakwandasupv@bridon.comPhone: + 244 935 939761Fax: + 244 937 638565SOUTH AFRICAmining@bridonafrica.comPhone: +27 (0) 11 867 3987Cell: +27 (0) 79 887 2747Fax: +27 (0) 11 867 3987MIDDLE EASTBridon Middle EastPO Box 16931DubaiUnited Arab Emiratesbridonme@emirates.net.aePhone: +971 488 35 129Fax: +971 488 35 689BRAZILmining@bridonbrazil.comPhone: +55 15 3232 8012Fax: +55 15 3232 8012SINGAPOREBridon Singapore (Pte) Ltd.Loyang Offshore Supply Base(SOPS Way)Box No: 5064Loyang CrescentSingapore 508988bluestrand@bridon.com.sgPhone: +65 654 64 611Fax: +65 654 64 622CHINABridon Hong Kong Ltd.Unit B G/F Roxy Industrial Centre58-66 Tai Lin Pai RoadKwai ChungNorthern TerritoryHong Kongsales@bridon.com.hkPhone: +852 240 11 166Fax: +852 240 11 232Bridon Hangzhou57 Yonghua StreetXiacheng DistrictHangzhou CityZhejiang Province310022.P.R.Chinasales@bridonhangzhou.comPhone: +86 571 8581 8780Fax: +86 571 8813 3310AUSTRALIAmining@bridonaustralia.comPhone: +61 429 999 756NEW ZEALAND6-10 Greenmount DriveEast TamakiPO Box 14 422PanmureAUCKLANDsalesadmin@cookes.co.nzPhone: +64 9 2744299Fax: +64 9 274798263

Ground Floor, Icon Building,First Point, Balby Carr Bank,Doncaster, South YorkshireDN4 5JQ United KingdomMagdeburger Straße14a D-45881,Gelsenkirchen,GermanyC280 New Commerce Blvd.Wilkes Barre,PA 18706,USAPhone: +44(0) 1302 565100Fax: +44(0) 1302 565190Email: mining@bridon.comwww.bridon.comPhone: +49(0) 209 8001 0Fax: +49(0) 209 8001 275info@bridon.dePhone: +1 800 521 5555Fax: +1 800 233 8362bridon@bridonamerican.com08/2011 Edition IMP1