Product Safety - Bridon

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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 Bridon or your rope supplier.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.BRIDON Crane61
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 performanceof the rope (e.g. damage to the drum grooving,such that coiling is erratic and/or the rope is‘pulled down’ into underlying layers, whichmight cause a dangerous condition or,alternatively, cause localised rope damage at‘cross-over’ positions, which might thenradically affect performance; loss/removal ofwear plates protecting the structure leading tomajor structural damage by cutting and/or failureof the wire rope due to mechanical 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 4 metres for ropes up to andincluding 76mm diameter and 8 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).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.Note: The authorised competent person should also be familiar withthe latest versions of International Standard ISO 4309 ‘Cranes- wire ropes - Code of practice for examination and discard’and B.S. 6570 ‘ The selection, care and maintenance of steelwire ropes’ which provide greater detail than that given in therelevant Regulations. Other standards and instructionscovering rope discard may also be applicable. In the case ofsynthetic sheaves (or synthetic linings) refer to the OEM’sinstruction manual or contact the sheave (or lining)manufacturer for specific discard criteria.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.62BRIDON Crane
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Product Safety - Bridon

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