Technical

TECHNICAL
DOCUMENTATION
INTRODUCTION AND TABLE OF CONTENTS

This manual about the technical properties of Casar Special Wire Ropes is intended
q to help the user of the ropes to find the best rope for his specific application,
q to help the designer to find the data he needs to build a safe, economic and
good machine, and
q to help the distributor of the ropes to give his customers even better assistance.
If you have a question which is not answered by this brochure, please do not hesitate
to contact us. We will do our best to help you.
Introduction and table of contents ....................................................................... 2
Computer aided rope design .............................................................................. 3
What is...? .......................................................................................................... 4
What is a compacted strand? ............................................................................. 5
What is parallel lay rope? ................................................................................... 6
What is a rotation-resistant rope? ....................................................................... 7
What is the effect of the plastic layer? ................................................................ 8
From wire to wire rope ........................................................................................ 9
Breaking load ................................................................................................... 10
Diagrams: Breaking load .................................................................................. 11
Fill factors, weight factors, spin factors ............................................................. 12
Bending fatigue................................................................................................. 13
Diagrams: Bending fatigue ............................................................................... 14
Which rope for which application? .................................................................... 16
Rotation ............................................................................................................ 18
Diagrams: Rotation ........................................................................................... 19
Efficiency .......................................................................................................... 20
Diagrams: Efficiency ......................................................................................... 21
Left hand or right hand lay rope? ...................................................................... 22
Elasticity and elongation ................................................................................... 23
Diagrams: Elasticity and elongation .................................................................. 24
Elongation curves ............................................................................................. 26
Diagrams: General ........................................................................................... 28
The drum .......................................................................................................... 30
Conversion factors............................................................................................ 31
2
R. Verreet, Technical Documentation, 8/1997
COMPUTER AIDED ROPE DESIGN
A steel wire rope is a complex machine part and consists of

a great number of wires and strands of different dimensions.
It is subjected to a wide spectrum of mechanical stresses.
Based on a wide range of empirical data and test results,

Casar Special Wire Ropes are adapted to the technical
requirements and optimized with the help of a computer.
WHAT IS ?
WIRE
STRAND
ROPE
LEFT HAND LAY
RIGHT HAND LAY
ORDINARY LAY
LANGS LAY
CONVENTIONAL STRANDS
COMPACTED STRANDS
4
WHAT IS A COMPACTED STRAND?

Some of the Casar Special Wire Ropes
are made out of conventional strands,
some are made out of compacted strands.
conventional strand
compacted strand
In order to produce a compacted strand, a conventional strand made out of round

wires is drawn through a compacting tool. During this procedure, the wires are
plastically deformed, the strand diameter is reduced and the surface is made
smooth. The contact conditions between the individual wires and the strand-tostrand contacts improve.
Ropes made out of compacted strands have a higher breaking load, a greater
flexibility and better rope- to- sheave contact conditions than comparable ropes
made out of conventional strands. Because of the larger outer wires and the
smaller exposed area they are more resistant to abrasion and corrosion.
WHAT IS A PARALLEL LAY ROPE?

In a cross (non-parallel) lay strand all wires have different
lay lengths, and in a cross (non-parallel) lay rope all
strands have different lay lengths. The high stress concentration at the crossover points leads to an early
internal failure.
cross (non-parallel) lay

stress concentration
parallel lay
stress distribution
In a parallel lay strand all wires have the same lay length,
and in a parallel lay rope all strands have the same lay
length. The linear contact leads to an optimal stress
distribution.
6
WHAT IS A ROTATION-RESISTANT ROPE?

In a conventional rope,
an external load creates
a moment which tries
to untwist the rope and
to rotate the load.
A rotation- resistant
Casar Special Wire Rope
has a steel core which is
an independent rope,
closed in the opposite direction to the outer
strands. Under load, the
core tries to twist the rope
in the one direction, the
outer strands try to twist it
in the opposite direction.
The geometrical design
of a rotation-resistant
Casar Special Wire Rope
is such that the moments
in the core and the outer
strands compensate each
other over a wide loadspectrum, so that even
with great lifting heights
no rope twist occurs.
WHAT IS THE EFFECT OF THE PLASTIC LAYER?

The plastic layer ...
greatly lowers,
or even removes,
the incidence of birdcaging
keeps out water
and abrasive elements
acts as a cushion
between the layers
stabilizes the rope

during the installation
seals in lubricant
prevents interstrand nicking
lowers the noise level

whilst the rope working
prevents internal
wire breaks
prevents
metal-to-metal contact
absorbs dynamic energy
stabilizes the rope structure
... solves rope problems !

8
FROM WIRE TO WIRE ROPE

using Casar Powerplast as an example
entrance control
wire stock
Length
in m
for 1000 m
of wire rope
spooling
spooling
spooling
spooling
spooling
408 000
stranding
stranding
stranding
stranding
stranding
37 800
quality
control
quality
control
quality
control
quality
control
quality
control
compacting
compacting
compacting
compacting
compacting
quality
control
quality
control
quality
control
quality
control
quality
control
spooling
spooling
spooling
spooling
spooling
closing
of rope core
37 800
37 800
1 050
quality
control
plastic extrusion
1 050
closing
of rope
1 050
final
quality control
spooling
1 050
finishing
BREAKING LOAD
How do Casar Special Wire Ropes
achieve their high breaking loads?
Conventional steel wire rope constructions can meet a requirement
for higher breaking loads only by increasing the tensile strength of
the individual wires.
Casar Special Wire Ropes are already designed for the highest
breaking loads by a combination of various technologies:
q
A large number of strands increases the metallic area of the rope.
Parallel lay leads to a more compact rope construction.
A plastic layer reduces internal stresses.
Compacting of the strands increases the fill factor

of the rope elements.
The tensile strength of the wires is chosen according

to the requirements.
The high breaking loads of Casar Special Wire

Ropes offer the user the following advantages:
q
Design advantages by reducing the sheave and drum diameters

and the size of motor and gearbox.
Longer service life due to lower specific stress on the rope.
Increased safety.
10
DIAGRAMS: BREAKING LOAD
0.70
0.65
0.65
CASAR Powerplast
CASAR Quadrolift
CASAR Starlift
CASAR Eurolift
BREAKING LOAD 2: Comparison of the fill factors of rotationresistant ropes. The fill factors of Casar Special Wire Ropes are
in general considerably higher than the fill factors of conventional
ropes.
10
CASAR Quadrolift
CASAR Powerplast
CASAR Rammbolift
CASAR Eurolift
CASAR Powerlift
CASAR Starlift
18 x 7
40%
40%
8-strand rope to 60%
60%
to 80%
80
2P
reduction of breaking load [ % ]
90%
to 110%
90%
to 110%
90%
to 110%
90%
to 110%
90%
to 110%
90%
to 110%
100
6-strand rope to 60%
breaking load on swivel [% of minimum breaking load]
18 x 7
0.40
120
20
36 x 7
0.45
BREAKING LOAD 1: Comparison of the fill factors of non

rotation-resistant ropes. The fill factors of Casar Special Wire
Ropes are considerably higher than the fill factors of conventional
ropes.
40
0.55
0.50
0.40
60
0.60
CASAR Powerlift
CASAR Multilift F
CASAR Multilift
CASAR Superlift
CASAR Turbolift
CASAR Stratolift
CASAR Superplast
CASAR Turboplast
0.45
6 x 36 IWRC
0.50
8 x 19 FC
0.55
CASAR Stratoplast
0.60
CASAR
Rammbolift
fill factor [ ]
0.75
0.70
fill factor [ ]
0.75
18 x 7
6-strand rope
8-strand rope
4
2P
2
1
10
20
30
40
D/d [ ]
BREAKING LOAD 3: Breaking loads of steel wire ropes tested

with a swivel. The breaking loads of 6-strand and 8-strand ropes
decrease considerably, whereas the rotation-resistant Casar
Special Wire Ropes achieve values in the range of their minimum
breaking loads.
BREAKING LOAD 4: Breaking loads of steel wire ropes when

tested on sheaves, depending on the ratio sheave diameter/rope
diameter. The factors of safety cover the reduction of the breaking
loads.
220
tensile strength [ kp/mm2 ]
200
Pdyn = k P
180
k = 1 + 1 + (2 H M E )
PL
L
160
140
120
L
100
80
P
[F] 200
400
600
800
1000
Pdyn
P
L
H
M
E
=
=
=
=
=
=
dynamic load
static load
rope length
height; slack
metallic area rope
modulus of elasticity rope
1200
60
0 [C]
100
200
300
400
500
600
700
temperature [ C ]
BREAKING LOAD 5: Tensile strength of steel wires as a function

of temperature (exposure time 10 min., cooled in air). Temperatures up to 300C (~600F) reduce residual stresses, higher
temperatures reduce the tensile strength drastically.
BREAKING LOAD 6: Formula to determine the dynamic load

caused by a falling weight. Dynamic loads are not covered by the
safety factor and should be avoided at all costs.
11
ds
tra
pla
nd
sti
s
cl
ay
er
av
era
ge
fill
fac
av
tor
era
ge
we
igh
av
t fa
era
cto
ge
r
sp
in
fa c
tor
*
cte
mp
a
co
ro
tat
ion
re s
is t
an
FILL, WEIGHT AND SPIN FACTORS
0,653
0,90
0,77
0,748
0,86
0,79
0,710
0,91
0,84
0,608
0,92
0,87
0,661
0,87
0,86
0,688
0,86
0,84
0,660
0,89
0,86
0,730
0,85
0,84
0,755
0,85
0,84
0,650
0,89
0,86
0,755
0,85
0,84
0,660
0,90
0,88
0,655
0,90
0,90
0,627
0,90
0,82
0,663
0,85
0,83
0,566
0,90
0,86
0,477
0,94
0,85
0,684
0,86
0,84
* rope diameters up to 40 mm, 1770 N/mm2
12
BENDING FATIGUE
Why do Casar Special Wire Ropes
attain the longest service lives?
Conventional rope designs often do not meet the requirements of
modern reeving systems. Shorter service lives result. Casar Special
Wire Ropes offer various design advantages which lead to longer
service lives.
q
A larger number of strands increases the number of contact areas

within the rope and on sheaves and drums.
Parallel lay prevents the crossover of strands and improves

the contact conditions within the rope.
A plastic layer reduces the danger of structural damage

and internal wire breaks.
Compaction of the strands improves the contact conditions

within the rope and on sheaves and drums.
A large number of strands with smooth surfaces increases

the flexibility of the rope.
The long service lives of Casar Special Wire Ropes

offer the user the following practical advantages:
q
Reduced downtime due to fewer rope changes.
Reduced costs for rope changes.
Minimised rope costs.
Optimum price/performance ratio.
13
180
190
200
210
220
tensile strength [ kp/mm2 ]
230
240
BENDING FATIGUE 5: Comparison of numbers of cycles until

discard and break for ropes of different tensile strength under
constant load.
14
max.
groove diameter =
nominal rope diameter + 6%
number of cycles
CASAR Stratolift
on plastic sheave

discard and break on steel sheaves and on plastic sheaves. On
plastic sheaves, the fatigue life is higher, but the residual life (%)
between discard and break is lower.
[ ] until discard
[]
number of cycles
discard
CASAR
Powerplast
break
CASAR Starlift
100 000
CASAR Powerplast
200 000
on steel sheave

discard and break for ungalvanized and galvanized ropes, in
both cases lubricated. Under the same test conditions, the
galvanized rope achieves higher numbers of cycles.
CASAR
Powerlift
CASAR
Eurolift
CASAR
Starlift
D/d = 20
load proportional to
minimum breaking load
18 x 7
number of cycles
100 000
CASAR Stratolift (galvanized)
200 000
300 000
CASAR Powerplast
300 000
BENDING FATIGUE 2: Comparison of numbers of cycles for

rotation-resistant ropes. Under the same test conditions, Casar
Special Wire Ropes achieve much higher numbers of cycles than
conventional ropes.
[ ] until discard and break
400 000
CASAR Stratolift (ungalvanized)
number of cycles

discard and break for non rotation-resistant ropes. Under the
same test conditions, Casar Special Wire Ropes achieve much
higher numbers of cycles than conventional ropes.
50 000
CASAR
Starlift
100 000
CASAR
Quadrolift
number of cycles
CASAR Turbolift
CASAR Stratolift
6 x 36 IWRC
100 000
CASAR Turboplast
CASAR Stratoplast
200 000
D/d = 20
load proportional
to minimum
breaking load
18 x 7
D/d = 20
150 000
18 x 7
300 000
6 x 36 FC
number of cycles
DIAGRAMS: BENDING FATIGUE
optimum
groove diameter
BENDING FATIGUE 6: Rope life as a function of the groove

diameter of the sheaves. The optimal groove diameter is nominal
rope diameter plus 6% (B). For larger groove diameters, the
service life decreases steadily (C), for smaller groove diameters
it decreases rapidly (A).
DIAGRAMS: BENDING FATIGUE

100
D/d = 20
25
50
log. number of broken wires [ ]
numbers of broken wires 30 x d [ ]
30
20
tensile strength 200 kp/mm2
load 111 %
15
tensile strength 180 kp/mm2
load 100 %
10
20
10
5
0
0
30.000
60.000
number of cycles
90.000
[]
120.000
5.000
10.000
20.000
50.000
log. number of cycles
BENDING FATIGUE 7: Number of visible broken wires depending on the number of cycles in a bending fatigue test. The number
of wire ropes breaks increases steadily according to a powerfunction.
100.000
200.000
500.000
[]
BENDING FATIGUE 8: Number of broken wires depending on

the number of cycles. Rope A: Casar Stratolift. Rope C: (competition) fatigues too early. Rope B: (test rope) is dangerous,
because the discard criterion is reached shortly after the first wire
is broken.
200
[%]
100
number of cycles
actual breaking load
[%]
lubricated + relubricated
150
lubricated
100
50
unlubricated
~ 100%
0
0
discard
number of cycles
0
100
break
BENDING FATIGUE 9: Breaking load of running steel wire ropes

depending on the number of cycles. Normally, the actual breaking load increases during the first half of the service life. When the
discard criterion is reached, the rope can still achieve its minimum breaking load.
500
400
1 800 000
800 000
1 600 000
[]
2 000 000
900 000
[]
300
tension [ N / mm2 ]
BENDING FATIGUE 10: Number of cycles until discard for

unlubricated, lubricated (= 100%) and relubricated steel wire
ropes. Relubrication during service life considerably, increases,
lack of lubrication reduces the service life drastically.
1 000 000
700 000
600 000
1 400 000
1 200 000
number of cycles
number of cycles
200
[%]
500 000
400 000
300 000
1 000 000
800 000
600 000
200 000
400 000
100 000
200 000
10
12
14
16
18
20
22
24
rope diameter [ mm ]
26
28
30
BENDING FATIGUE 11: Number of cycles until discard (lower

curve) and break (upper curve) depending on the nominal rope
diameter. For every combination of sheave diameter and line pull
there is an optimum rope diameter.
200
240
280
320 360 400 440 480

sheave diameter [ mm ]
520
560
600
BENDING FATIGUE 12: Number of cycles until discard (lower

curve) and break (upper curve) depending on the sheave diameter. The service life of a wire rope increases with increasing
sheave diameter.
15
WHICH ROPE FOR WHICH APPLICATION?
Tower crane
Hoist rope
Tower crane
Boom hoist rope
Tower crane
Trolley rope
Tower crane
Installation rope
Tower crane
Pendant rope
Mobile crane
Hoist rope
Mobile crane
Boom hoist rope
Mobile crane
Pendant rope
Deck crane
Hoist rope
Deck crane
Boom hoist rope
Offshore crane
Hoist rope
Offshore crane
Boom hoist rope
Grabbing crane
Holding- and closing rope
Grabbing crane
Pendant crane
Grabbing crane
Boom hoist rope
Bulk handling rope
Hoist-, closing-, grab rope
Bulk handling rope
Trolley- and compensation rope
Elevator
Hoist rope
Container crane
Hoist rope
Container crane
Boom hoist rope
Floating crane
Hoist rope
Floating crane
Boom hoist rope
Electrical hoist
Hoist rope
Ladle crane
Hoist rope
Floating grab
Holding- and closing rope
Floating grab
Pendant rope
Shovel
Hoist rope
Shovel
Crowd line
Shovel
Boom line
Dragline
Hoist rope
Dragline
Drag rope
Dragline
Boom hoist rope
Cable crane
Hoist rope
Cable crane
Trolley rope
Scraper
Traction and haulback rope
Scraper
Boom hoist rope
CASAR DRAHTSEILWERK SAAR GMBH

Casarstrae 1 66459 Kirkel
Postfach 187 66454 Kirkel
Telefon: (0 68 41) 80 91 - 0
Teletex: 68 41 972 Casar
Telefax: (0 68 41) 86 94
16
17
ROTATION
Why are Casar Special Wire Ropes
so rotation-resistant?
Conventional wire ropes try to untwist under load. Stability can often
only be achieved by overloading the core of the ropes.
Rotation-resistant Casar Special Wire Ropes are stabilized against
rotation by various technologies.
q
A wire rope core, closed in the opposite direction of the outer

strands, creates a stabilizing moment.
A compacted core increases the rotational stability.
A favourable ratio of the metallic areas leads to stability without

overloading the core.
The high rotational stability of Casar Special Wire

Ropes offers the user the following advantages:
q
No block rotation even with great lifting heights.
Long service life because of an untwisted rope structure.
Great safety in crane operations.
18
DIAGRAMS: ROTATION
0.12
0.12
CASAR Stratoplast
0.10
opening moment
torque factor [ ]
CASAR Multilift F
CASAR Multilift
CASAR Starlift
CASAR Quadrolift
CASAR Superplast
CASAR Turboplast
CASAR Stratoplast
CASAR Superlift r
0.02
CASAR Turbolift r
0.04
CASAR Stratolift r
0.06
untwisted
CASAR Powerlift
-0.04
-0.08
0
500
500
spec. rope twist [ deg mm/m ]
1000
ROTATION 1: Torque factors for different Casar Special Wire

Ropes. The torque factor is defined as the moment of the rope
under a given load, divided by the load and the rope diameter.
0.10
40/m
0.14
0.08
20/m
40/m
0.06
twisted
0.04
0.12
torque factor [ ]
torque factor [ ]
1000
ROTATION 2: Torque factors of Casar Stratoplast and Casar

Powerlift against the rope twist (forcible twist). The high torque of
Casar Powerlift under forcible twist guarantees a high resistance
against rotation of the load.
0.16
10/m
0/m
0.10
0.08
-10/m
-20/m
0.06
untwisted
CASAR Stratoplast
19/180
20/m
0.02
10/m
twisted
0
untwisted
0.02
-10/m
-20/m
0.04
0.06
-40/m
-40/m
CASAR Starlift
19/180
0.08
0.04
0.10
0
20
40
60
80
load [ kn ]
100
120
140
ROTATION 3: Torque factor of Casar Stratoplast depending on

the load for different levels of rotation. For higher loads, the
forcible twist does not influence the torque factor very much.
40 000
20
40
60
80
load [ kn ]
100
120
140
ROTATION 4: Torque factor of Casar Starlift as a function of the

load for different levels of rotation. The forcible twist influences the
torque factor of the rope considerably. Any rotation of the load
creates a high moment in the opposite direction, stabilizing the
system.
8 x 36 IWRC
Stratoplast
spec. rope twist [ deg mm / m ]
closed
0.04
0
closing moment
0.08
CASAR Alphalift r
torque factor [ ]
0.08
30 000
k<
d
De
4,8 h d
D
h
h >> D
20 000
Superplast
10 000
Quadrolift
k
D
e
d
h
=
=
=
=
=
torque factor
rope spacing at block
rope spacing at top
nominal rope diameter
length of fall
Powerplast
Starlift
Eurolift
Powerlift
10
20
30
40
50
60
load [ % of minimum breaking load ]
70
ROTATION 5: Specific rope twist as a function of the load. When

tested on a swivel, 6-strand and 8-strand ropes untwisted under
very low loads. Casar Powerlift, Casar Starlift and Casar Powerplast only started untwisting at high loads.
ROTATION 6: Formula to determine the stability of a block. If the

conditions of the formula are met, the block will be stable (static
situation). The formula can also be used to determine the minimum rope spacing or the greatest stable length of fall.
19
EFFICIENCY
Why are Casar Special Wire Ropes
so flexible?
Modern machines demand flexible wire ropes.
Casar Special Wire Ropes are designed to provide maximum flexibility. The high flexibility is achieved by a combination of different
technologies.
q
A larger number of wires and strands allows easier bending.
Intensive lubrication in all stages of production reduces

the internal friction.
The smooth surfaces of the compacted strands prevent

indentations and allow easier relative motion of the elements.
Cold-resistant lubricants and cold-elastic plastics guarantee

good flexibility at low temperatures.
The high flexibility of Casar Special Wire Ropes

offers the user the following advantages:
q
Improved running properties due to lower friction losses.
Reduction of motor capacity.
Easy handling during installation.
Excellent spooling on the drum.
20
DIAGRAMS: EFFICIENCY
100
100
CASAR Stratolift r
98
CASAR Quadrolift
98
CASAR Powerlift
CASAR Turbolift r
6 x 37 + Fe
efficiency [ % ]
efficiency [ % ]
CASAR Stratoplast r
CASAR Eurolift
CASAR Starlift
96
94
CASAR Powerplast
96
94
92
92
90
90
0.5
1.0
1.5
2.0
EFFICIENCY 1: Efficiencies of rotation-resistant steel wire ropes

on sheaves with roller bearings for low loads. Casar Special Wire
Ropes show higher efficiencies than conventional steel wire
ropes. D/d = 20
0.5
1.0
1.5
2.0

on sheaves with roller bearings for low loads. Most rotationresistant wire ropes show lower efficiencies than non rotationresistant wire ropes.
100.0
100
30 x d
20 x d
10 x d
efficiency [ % ]
efficiency [ % ]
CASAR Powerlift
99.5
18 x 7
99.0
90
80
CASAR Starlift
CASAR Starlift ungalvanized
98.5
70
10
20
30

on sheaves with roller bearings for high loads. Casar Special Wire
Ropes show higher efficiencies than conventional steel wire
ropes. D/d = 20
100
CASAR Powerlift -40C (-40F)
40
0.5
1.0
1.5
2.0
EFFICIENCY 4: Efficiency of a steel wire rope on sheaves with

roller bearings against load for different sheave diameters. The
efficiency decreases considerably with decreasing sheave diameter.
100
CASAR Starlift 20C (70F)
CASAR Starlift galvanized

CASAR Starlift ungalvanized
CASAR Powerplast 20C (70F)
efficiency [ % ]
efficiency [ % ]
98
96
CASAR Powerplast -40C (-40F)
94
90
80
92
70
90
0
0.5
1.0
1.5
2.0
EFFICIENCY 5: Efficiencies of steel wire ropes on sheaves with

roller bearings against load for different temperatures. The influence of low temperatures is minimized by the use of special
lubricants and plastics. D/d = 20
0.5
1.0
1.5
2.0
EFFICIENCY 6: Efficiencies of galvanized and ungalvanized

steel wire ropes on sheaves with roller bearings for low loads.
Galvanized ropes show lower efficiencies. D/d = 20
21
LEFT HAND OR RIGHT HAND LAY ROPE?

The choice of the correct direction of lay is essential for the proper functioning of a reeving
system. A wrong direction of lay leads to torque build-up, to spooling problems and to structural
damage to the rope.
One layer spooling

For drums with one layer, the direction of lay has to be chosen according to the following
rule:
right hand drum - left hand lay rope
left hand drum - right hand lay rope
Multiple layer spooling

With multiple layer spooling, the direction of the spooling changes from layer to layer. So the
direction of lay of the rope would also have to be changed from layer to layer. Here the direction
of lay should be chosen for the layer which is working the most.
right hand layer - left hand lay rope
left hand layer - right hand lay rope
Multiple-part reeving
In a multiple part reeving system very often the influence of the fleet angles between the sheaves
is greater than the influence of the drum. In this case, the direction of lay of the rope should be
chosen depending on the direction of the reeving.
right hand reeving - left hand lay rope
left hand reeving - right hand lay rope
And here is how you determine the direction of the winding of the drum or reeving system:
Place yourself at the fix point ( ) of the rope on the drum (at the reeving system) and follow the
turns of the rope with your finger.
right hand drum - left hand lay rope
left hand drum - right hand lay rope
If you move your finger clockwise, the drum

(reeving system) is right hand, and needs a
left hand lay rope.
If you move your finger counterclockwise, the

drum (reeving system) is left hand, and needs
a right hand lay rope.
22
ELASTICITY AND ELONGATION

What gives Casar Special Wire Ropes
the best stress-strain behaviour?
Conventional steel wire ropes often have insufficient modulus of
elasticity and too high permanent elongations.
Casar Special Wire Ropes are optimized with regard to their stressstrain properties by various features:
q
The full steel construction provides a high modulus of elasticity.
The compact rope structure guarantees minimal permanent

elongations in the working range.
The homogeneous load distribution on all rope elements creates

high elongations at break.
The plastic layer absorbs dynamic energy.
The balanced stress-strain properties

of Casar Special Wire Ropes
offer the user the following advantages:
q
High rigidity of suspended structures.
Less retentioning for suspended structures and positioning

machines.
High safety against dynamic failure.
23
DIAGRAMS: ELASTICITY AND ELONGATION

1.3
0.8
0.8
ELASTICITY 1: Moduli of elasticity for non rotation-resistant

Casar Special Wire Ropes. The modulus of elasticity of a steel
wire rope is about half the modulus of plain steel. (Average values
from a great number of tests)
ELASTICITY 2: Moduli of elasticity for rotation-resistant Casar

Special Wire Ropes. The modulus of elasticity of a steel wire rope
is about half the modulus of plain steel. (Average values from a
great number of tests)
4.5
4.72
CASAR Rammbolift
CASAR
Quadrolift
CASAR Powerplast
CASAR
Starlift
CASAR Eurolift
3.5
CASAR
Powerlift
elongation at break [ % ]
4.0
CASAR
Technolift
CASAR Alphalift
CASAR
Stratoplast
CASAR Turboplast
CASAR
Superplast
CASAR
Superlift
3.5
CASAR Turbolift
4.0
CASAR Stratolift
elongation at break [ % ]
4.65
4.5
3.0
3.0
ELASTICITY 3: Elongation at break for non rotation-resistant

Casar Special Wire Ropes. The elongations at break range from
3.2 to 4.7 percent. (Average values from a great number of tests)
ELASTICITY 4: Elongation at break for rotation-resistant Casar

Special Wire Ropes. The elongations at break range from 3.1 to
4.7 percent. (Average values from a great number of tests)
0.75
1.2
CASAR Stratolift
1.0
permanent elongation [ % ]
modulus of elasticity [ x 105 N/mm2 ]
CASAR
Rammbolift
CASAR
Eurolift
Powerplast
0.9
CASAR
1.0
CASAR Quadrolift
1.1
CASAR
Powerlift
CASAR Technolift
CASAR Alphalift
CASAR Stratoplast
CASAR Turboplast
CASAR Superlift
0.9
CASAR Turbolift
1.0
CASAR Superplast
1.1
1.2
CASAR Starlift
1.2
CASAR Stratolift
1.3
8 x 19 FE
0.8
0.6
0.4
0.2
8 x 19 FE
0.25
CASAR Stratolift
0
0
20
40
60
80
previous load [ % of minimum breaking load ]
100
ELASTICITY 5: Modulus of elasticity depending on the previous

load for Casar Stratolift and a conventional rope with fibre core.
The modulus increases with increasing load. Casar Stratolift
shows a much higher modulus.
24
0.50
10
20
30
40
previous load [ % of minimum breaking load ]
50
ELASTICITY 6: Permanent elongation depending on the previous load for Casar Stratolift and a conventional rope fibre core.
The permanent elongation increases with increasing load. Casar
Stratolift shows a much lower elongation.
DIAGRAMS: ELASTICITY AND ELONGATION

1.00
500
elongation after unloading [ % ]
450
400
load [ kN ]
350
300
250
200
150
100
0.75
load 80 % of minimum breaking load
0.50

0.25
50
0
0
0
0.5
1.0
1.5
2.0 2.5 3.0

elongation [ % ]
3.5
4.0
4.5
5.0
1 min
ELASTICITY 7: Load-elongation diagram (Casar Powerplast).

During the test, the computer determines the increase of the
modulus of elasticity, the total and permanent elongation, the
energy absorption, the elongation at break, the diameter change
and other required data.
24 h
12
10
6 WKP
97
0
10
20
30
40
50
CASAR Powerplast
CASAR Rammbolift
CASAR Turboplast L
CASAR Dragplast L
CASAR Turbolift Kr/L
CASAR Stratoplast
CASAR Eurolift
CASAR Turboplast Kr
CASAR Stratolift
CASAR Technolift
Powerlift
Stratoplast r
CASAR Starlift
Starlift
Eurolift
Stratolift
Turboplast r
Stratoplast l
Turbolift r
CASAR Powerlift
99
CASAR Quadrolift
Superlift
98
absorbed specific energy [ Nm/(m mm2) ]

at 80% of minimum breaking load
rope diameter [ % of actual rope diameter ]
30 min 60 min
time after unloading
ELASTICITY 8: Permanent elongation after unloading depending on the time. The effect prestressing disappears to a great
extend with increasing time. Here 6-strand rope as an example.
100
60
ELASTICITY 9: Rope diameter of a new rope depending on the

load in a break test. During service, the rope diameter is of cause
reduced by additional factors, e. g., abrasion.
ELASTICITY 10: Absorbed energy at 80% of the minimum

breaking load for Casar Special Wire Ropes. Langs lay ropes
have a higher energy absorption than regular lay ropes, ropes
with an internal plastic layer have a higher energy absorption than
full steel ropes.
12
200
CASAR Dragplast
10
rope wire
CASAR Stratoplast l
A
A: energy input
B: energy output
strand
wire rope
150
C: energy converted into permanent

deformation and heat
stress [ kp/mm2 ]
specific energy [ Nm /( m mm2 ) ]
5 min
B
4
100
undrawn
steel
50
C
2
0
0
20
40
60
80
ELASTICITY 11: Specific energy of Casar Special Wire Ropes.
elongation [ % ]
ELASTICITY 12: Comparison of the stress-elongation- curves of

steel, rope wire, strand and wire rope.
25
ELONGATION CURVES
2.0
The knowledge of the elongation properties of a

steel wire rope can be of great importance to the
equipment manufacturer or user. Therefore we
present the load-elongation diagrams of the most
important Casar Special Wire Ropes, here.
1.8
1.6
1.4
The diagrams show the average values of a

great number of cyclical loading and unloading
tests performed with ropes of different diameters
and tensile strength. The diagrams are independent of the rope diameter. The influence of
the tensile strength is negligible.
CASAR Powerlift
elongation [ % ]
The upper curves show the total elongations

depending on the load. The lower curves show
the permanent elongations remaining in the rope
after unloading depending on the previous load.
1.2
CASAR Starlift
1.0
0.8
0.6
CASAR Powerlift
0.4
CASAR Starlift
0.2
0
Please note: setting in the end fitting can cause

additional elongation.
R = Regular Lay; L = Langs Lay
20
40
60
80
elongation curves 1
2.0
2.0
1.8
1.8
CASAR Powerplast
CASAR Stratolift R
1.6
1.6
1.4
1.4
CASAR Eurolift
elongation [ % ]
elongation [ % ]
CASAR Turbolift R
1.2
1.0
0.8
1.2
1.0
0.8
CASAR
Stratolift R
0.6
0.6
CASAR
Powerplast
0.4
CASAR
Turbolift R
0.4
CASAR
Eurolift
0.2
0.2
0
26
20
40
60
elongation curves 2
elongation curves 3
20
40
60
80
80
ELONGATION CURVES
2.0
2.0
1.8
1.8
1.6
1.6
CASAR Superplast L
CASAR Superplast R
CASAR Turboplast R/L

1.4
CASAR Stratoplast R/L
elongation [ % ]
elongation [ % ]
1.4
1.2
1.0
CASAR
Turboplast L
CASAR
Stratoplast R/L
0.8
0.6
1.2
1.0
0.8
CASAR Superplast L
0.6
0.4
CASAR
Superplast R
0.4
0.2
0.2
CASAR Turboplast R
0
0
0
20
40
60
80
20
40
60
80
elongation curves 4
elongation curves 5
2.0
2.0
1.8
1.8
CASAR Technolift
1.6
1.6
1.4
1.4
elongation [ % ]
elongation [ % ]
CASAR Douzeplast
1.2
1.0
0.8
CASAR Douzeplast
0.6
CASAR Superlift R
1.2
1.0
0.8
CASAR
Quadrolift
0.6
CASAR Technolift
0.4
0.4
0.2
0.2
CASAR Superlift R
CASAR Quadrolift
0
20
40
60
80
20
40
60
80
elongation curves 6
elongation curves 7
27
DIAGRAMS: GENERAL
16
15
specific surface [ mm2/ mm mm ]
Brinell hardness HB 30 [ kp/mm2 ]
650
600
550
500
450
5
outer surface
surface of steel bar
400
160
180
200
220
tensile strength [ kp/mm 2 ]
240
260
GENERAL 1: Brinell hardness HB 30 of the wire surface depending on the tensile strength of the wire.
9
12
number of outer wires [ ]
15
18
GENERAL 2: Surface of a seale strand, divided by the strand

diameter and the strand length, depending on the number of
outer wires. The outer (exposed) surface is only slightly larger
than the surface of a steel bar, the total surface is much larger.
1.0
percentage of metallic area [ % ]
100
0.9
fill factor [ ]
total surface of all elements
10
0.8
0.7
0.6
0.5
80
outer layer
60
40
inner wires
20
10
20
number of wires [ ]
30
40
GENERAL 3: Fill factor of a seale strand depending on the total

number of wires. The fill factor increases steadily with the number
of wires.
12
9
number of outer wires [ ]
15
18
GENERAL 4: Percentage of the total metallic area for the outer

and inner wires of a seale strand depending on the number of the
core increases steadily, and the percentage of the outer wires
decreases steadily with increasing number of outer wires.
24
22
1/8/8
1/4/4
1/9/9
1/5/5
1/10/10
1/6/6
1/11/11
20
1/7/7
1/12/12
angle of lay [ deg ]
1/3/3
16
12
10
8
6
18
16
14
12
1/13/13
1/14/14
1/15/15
1/16/16
1/17/17
10
6
GENERAL 5: Seale strand 1+N+N, for N=3 to N=16. With

increasing N, the diameter of the center wire is increasing while
the diameter of the outer wires is decreasing.
28
8
9
10
lay length factor [ ]
11
12
GENERAL 6: Angle of lay depending on the lay length factor for

6-, 10-, 12-, and 16-strand ropes.
DIAGRAMS: GENERAL
90
80
80
remaining metallic area [ % ]
100
90
remaining metallic area [ % ]
100
70
60
50
40
30
d
20
10
70
60
50
40
30
h d
20
10
0
0
0.2
0.4
0.6
0.8
1.0
0.8
ratio s/d [ ]
0.6
0.4
0.2
GENERAL 7: Reduction of the metallic area by abrasion. Remaining metallic area of the outer wire depending on the ratio of
the width of the abrasion ellipse s vs. the wire diameter d.
0.1
0.2
0.3
0.4
0.5
0.6
ratio h/d [ ]
0.7
0.8
0.9
1.0
GENERAL 8: Reduction of the metallic area by abrasion. Remaining metallic area of the outer wire depending on the ratio of
the remaining height of the wire h vs. the wire diameter d.
18
30
number of required torsions [ ]
14
12
10
8
R = 15
R = 10
R = 7.5
R=5
R = 3.75
R = 2.5
R = 1.75
number of required bends [ ]
16
20
10
0
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0.5
1.0
1.5
2.0
0.035
240
220
0.030
200
180
thikness of
zinc coating
[ mm ]
weight of the zinc coating per surface unit [ g/m2 ]
GENERAL 9: Quality control for rope wire according to DIN 2078.

Number of required bends in a bending test depending on the
wire diameter. R = radius of bend. Tensile strength 1770 N/mm2 .
260
2.5
Da
b
Da
Di
d
L
Di
0.020
120
4.5
5.0
=
=
=
=
=
reel wide
flange diameter
barrel diameter
rope diameter
rope length
drawn galvanized
0.015
80
4.0
GENERAL 10: Quality control for rope wire according to DIN

2078. Number of required torsions in a torsion test depending on
the wire diameter. Tensile strength 1770 N/mm2 .
160
100
3.5
heavy galvanized
0.025
140
3.0
wire diameter [ mm ]
wire diameter [ mm ]
0.01
60
40
. ( Da2
0.005
- Di2 ) . b
4 . d2
<L<
. ( Da2
- Di2 ) . b
4 . d2
20
0
0
1.0
2.0
wire diameter[ mm ]
3.0
4.0
GENERAL 11: Quality control for rope wire according to DIN

2078. Required weight of the zinc coating per surface unit and
thickness of the coating for drawn galvanized and heavy galvanized wires depending on the wire diameter.
GENERAL 12: Formula to calculate the rope length on a reel.
29
THE DRUM
The drum is an important element of a hoisting system. We distinguish between
grooved and ungrooved drums, and between single and multiple layer drums. In
order to guarantee good spooling on the drum, the following rules should be
considered:
Single layer drum

q The direction of layer of the rope has to be chosen opposite to the direction
of winding on the drum.
Multiple layer spooling

q Wedges should be provided to help the rope to climb into the second
and third layer.
q The first layers must be installed under tension.
q The direction of lay of the rope should be chosen according to the rules
(see page 22).
In the second and higher layers, adjacent wraps are no longer separated by the
walls on the drum, so that the wraps can form indentations. In order to avoid
premature rope destruction, the following rules should be observed in selecting the
correct type of rope:
q In Langs lay rope, indentations between outer wires do not occur. So Langs lay
rope should be preferred to regular lay rope.
q In rope with compacted outer strands, indentations between outer wires do not
occur. So rope with compacted outer strands should be preferred to conventional rope (see page 31).
q Eight strand rope should be preferred to six strand rope (see page 31),
because it has a more closely circular cross- section.
Under the pressure of the overwinding layers, the rope of the lower layers is subject
to high radial forces which might cause structural damage.
q Ropes with an internal plastic layer show excellent results because of their high
structural stability.
30
Conventional outer strands:
Compacted outer strands:
Between conventional outer strands of adjacent rope wraps, there is danger of mutual
indentations of the outer wires. The indentations can lead to severe external damage to
the ropes.
The outer wires of compacted outer strands

cannot form indentations. This is why ropes
with compacted outer strands are so suitable
for multiple layer spooling.
Six strand ropes:
Eight strand and ten strand ropes:
Six strand ropes can form deep indentations,

because they have deep valleys between the
outer strands. The indentations can lead to
severe external damage to the ropes.
Eight strand and ten strand ropes do not form

deep indentations, because their cross- section is very round. This is why eight strand
ropes and ten strand ropes are so suitable for
multiple layer spooling.
CONVERSION FACTORS
Length
1m
= 1000 mm
= 3,28 ft
Force
1 kN
= 101,97 kp
= 0,10197 t metric-f = 224,8 lbs-f
Tensile Strength
1 N/mm2
= 0,10197 kp/mm2 = 145,04 p.s.i.
Cross Section
1 mm2
= 0,00155 sq.inch
Weight
1 metric t = 1000 kg = 1,102 short t = 0,9842 long t= 2204,6 lbs
Weight per Length Unit 1 kg/m
= 39,37 inch
= 10 bar
= 0,672 lbs/ft.
Copyright 1991/1997 CASAR Drahtseilwerk Saar GmbH, content subject to alterations.

Technical author: Roland Verreet, WRTA Wire Rope Technology Aachen.
Realisation, Layout and Typesetting: PR Werbeagentur u. Verlag GmbH, Aachen.
31
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
CASAR DRAHTSEILWERK SAAR GMBH

Casarstrae 1 D-66 459 Kirkel
Postfach 18 7 D-66 454 Kirkel
Phone ++ 49-68 41/ 80 91-0
Fax
++ 49-68 41/ 86 94
Sales Dept.
Phone ++ 49-68 41/ 80 91-39/44
Fax
++ 49-68 41/ 80 91-29
http://www.casar.de

Technical

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Technical

Încărcat de

Drepturi de autor:

Formate disponibile

TECHNICAL

INTRODUCTION AND TABLE OF CONTENTS

R. Verreet, Technical Documentation, 8/1997

COMPUTER AIDED ROPE DESIGN

A steel wire rope is a complex machine part and consists of

Based on a wide range of empirical data and test results,

R. Verreet, Technical Documentation, 8/1997

LEFT HAND LAY

RIGHT HAND LAY

R. Verreet, Technical Documentation, 8/1997

WHAT IS A COMPACTED STRAND?

In order to produce a compacted strand, a conventional strand made out of round

R. Verreet, Technical Documentation, 8/1997

WHAT IS A PARALLEL LAY ROPE?

cross (non-parallel) lay

R. Verreet, Technical Documentation, 8/1997

WHAT IS A ROTATION-RESISTANT ROPE?

WHAT IS THE EFFECT OF THE PLASTIC LAYER?

stabilizes the rope

lowers the noise level

... solves rope problems !

R. Verreet, Technical Documentation, 8/1997

FROM WIRE TO WIRE ROPE

A large number of strands increases the metallic area of the rope.

Parallel lay leads to a more compact rope construction.

A plastic layer reduces internal stresses.

Compacting of the strands increases the fill factor

The tensile strength of the wires is chosen according

The high breaking loads of Casar Special Wire

Design advantages by reducing the sheave and drum diameters

Longer service life due to lower specific stress on the rope.

R. Verreet, Technical Documentation, 8/1997

DIAGRAMS: BREAKING LOAD

8-strand rope to 60%

6-strand rope to 60%

breaking load on swivel [% of minimum breaking load]

BREAKING LOAD 1: Comparison of the fill factors of non

BREAKING LOAD 3: Breaking loads of steel wire ropes tested

BREAKING LOAD 4: Breaking loads of steel wire ropes when

tensile strength [ kp/mm2 ]

BREAKING LOAD 5: Tensile strength of steel wires as a function

R. Verreet, Technical Documentation, 8/1997

BREAKING LOAD 6: Formula to determine the dynamic load

FILL, WEIGHT AND SPIN FACTORS

* rope diameters up to 40 mm, 1770 N/mm2

R. Verreet, Technical Documentation, 8/1997

A larger number of strands increases the number of contact areas

Parallel lay prevents the crossover of strands and improves

A plastic layer reduces the danger of structural damage

Compaction of the strands improves the contact conditions

A large number of strands with smooth surfaces increases

The long service lives of Casar Special Wire Ropes

Reduced downtime due to fewer rope changes.

Reduced costs for rope changes.

Minimised rope costs.

Optimum price/performance ratio.

R. Verreet, Technical Documentation, 8/1997

BENDING FATIGUE 5: Comparison of numbers of cycles until

BENDING FATIGUE 4: Comparison of numbers of cycles until

BENDING FATIGUE 3: Comparison of numbers of cycles until

CASAR Stratolift (galvanized)

BENDING FATIGUE 2: Comparison of numbers of cycles for

[ ] until discard and break

CASAR Stratolift (ungalvanized)