HIGH PERFORMANCE ROPES MANUAL

UHMWPE ROPES

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The SIRIUS rope series are Ultra High Molecular Weight PolyEthylene Ropes (UHMWPE) ropes*
with the application of special coatings & procedures.

When compared to conventional fiber ropes and wire ropes, Sirius ropes have extra high strength,
low weight, superior fatigue, abrasion and UV resistance, flexibility, easy one-man handling and
wire-like elongation characteristics. They are the perfect replacement for wire ropes and are in
service since more than 20 years

The application of coatings & heat setting procedures gives an enhanced structural stability and an
improved coefficient of friction, necessary for the optimum mooring & anchoring operations.
Considerable annual savings for the shipowner / operator derive from the much faster mooring
procedure with the use of the lightweight yet steel-like strong HMPE SIRIUS ropes, with reduced
maintenance costs, easy storage, zero human injuries, clean deck (free from grease) and high
performance.
HMPE fibers are known to have very low coefficient of friction and are very slippery. The
application of specially designed coatings is a standard procedure for this highly advanced fiber
which increases the coefficient of friction (in the cases of un-jacketed ropes) and improves
dramatically the behavior when used in capstans, winches etc. without affecting their
performance. Special coating is also applied during the splicing procedure as an additional anti-slip
factor in the case of un-jacketed ropes.

All SIRIUS ropes are supplied with an extra 3 meter tubular abrasion resistant sleeve at each end,
passing through the body of the rope, movable, to be placed in rough places for protecting the
passage of the rope from such spots.

Finally, SIRIUS ropes have the lowest snap back reaction under load, which is an advantage in favor
of the safety on board for the personnel working near the ropes.

* Also known as: High Modulus PolyEthylene (HMPE) or High Performance PolyEthylene
(HPPE) ropes

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 MANUFACTURING AND TESTING PLAN FOR SIRIUS HMPE ROPES

1. Brief description of manufacturing process

The manufacturing process follows ISO 9001:2008 quality system and includes the following basic
production steps:
• The twisting level where the UHMWPE yarns are twisted in ring twisting machines
• The stranding level includes the construction of the strands in special one-for-one
stranding machines.
• The braiding of the rope is completed in the braiding level in Herzog’s braiding
machines
• The rope undergoes a special coating / heat-setting process.
• After weighing of the final product and cutting of specimens for breaking load testing,
the eye splices are made in one or both ends
• Then follows the marking and packaging to give a complete final product which is taken
away for storage and/or transport.
The Sirius ropes are produced and tested according to ISO 10325 (as well as all the updated
relevant general standards like ISO 9554, ISO 2307 etc)

2. Description of quality control arrangement

The product quality control involves the following quality control steps/procedures:
• Tenacity testing of the UHMWPE yarns.
• Yarn-To-Yarn abrasion test of the UHMWPE yarns
• UV resistance tests of the UHMWPE yarns
• Breaking strength testing of the rope yarns (twisted UHMWPE yarns)
• Breaking testing of rope specimens per batch order.

3. Information regarding packaging and traceability

The ropes are packaged in Polyethylene heat shrinking film. On this, there are two (2) glossy labels
(A4 size) where it is marked /stated:
a) Product name / type b) Weight of the coil c) Length of the coil d) Construction of the rope (e.g.
12Strands) e) production code number and f) Date of Production
The marking on the product, also involves metal labels (2 metal labels per coil) where the unique
code number of the rope coil is marked permanently for traceability purposes. This marking is
being carried out in a way that it is visible, legible and indelible. This unique product code number
is the reference to the manufacturer's certificate.

4. UHMWPE yans technical information

Density 0,97 kg/dm3

Tenacity > 34 gr/den
Elongation (at break) 3,50%
Melting point 145 oC
UV resistance Excellent

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 INSTRUCTIONS & GENERAL GUIDELINES ON SAFE USE FOR SIRIUS HMPE ROPES

A. HARDWARE / DECK PREPARATION (When changing from steel wire to HMPE rope)
1) Smooth / regrind all surfaces on deck and on equipment that were in contact with steel wire
rope to at least 300 microinch finish.

2) Repaint all surfaces on deck and on equipment that were in contact with steel wire rope.

3) Additional care: Cover the metal surfaces (of the chocks especially) with PES (or even better
with UHMWPE material) chafe clothing for better protection against abrasion.

Β. INSTALLATION ON A WINCH
1a) Uncoiling from a coil: always start from the inside and from the bottom: The first turn uncoil in
a counter-clockwise direction

1b) Uncoiling from a reel: the reel must be free to rotate and remove the rope from the top of the
reel.

2a) Wind carefully the rope on the storage drum using an appropriate device. Apply a small
reference tension but mind the tension as well as the speed level to avoid the generation of
excessive heat due to friction/abrasion. The first wraps must be as tight and firm as possible to
avoid the slipping down of the wraps.

2b) The first layer must be wound on as close as possible. The next layers should be stacked on the
valleys of the previous layer (as shown in the picture) or in a crossed over manner. NEVER stack a
layer exactly above the previous one.

3) Be careful of the twist that may be introduced to the rope while winding it on the winch. Studies
have proved that loss of strength amounts to 7% per turn per meter.

4) Drum Capacity estimation (source: OCIMF MEG3)

Β
Α L=((A∗B∗(B+ C ))÷d 2 )∗π∗0,9
Α, Β, C and D: reel sizes in cm
D = rope diameter in mm
C L = rope length in m

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5) On the tension drum, the rope must have at least 8 to 10 wraps to avoid slippage due to low
coefficient of friction of the Sirius ropes (Applied coatings improve this characteristic of HMPE
ropes and give them better grip over capstans, drums etc).

C. USING OF MOORING TAILS

1) When Sirius ropes are used in a mooring line, this line must always include a mooring tail. The
tails must have good elongation properties in order to avoid shock loads. A shock load may
damage the rope and lead to instant failure (even if the rope looked and/or was in good condition)
Proposed materials are Nylon, Mixed PES / Polyolefin and PES.

2) The Minimum Breaking Load (MBL) of the Polyester or Mixed mooring tails must be at least 25%
greater than the one of the Sirius rope. For Nylon mooring tails please calculate +37%.

3) The connection of a Sirius rope with the mooring tail can be done with the use of a shackle
(roller or bolt type). The Safe Working Load of the shackle must be equal or greater than the SWL
of the tail. For longer service time & safety reasons, Sirius rope must be connected to the bolt /
roller of the shackle.
A cow hitch can also be used for direct connection but keep in mind that it may reduce the
strength of the arrangement by 10%. Knots are forbidden as they may reduce the line's strength by
up to 50%.

D. POINTS THAT NEED ATTENTION

1) The maximum Safe Working Load of a Sirius rope must be 20% of its Minimum Breaking Load.
This safety factor of 5:1 is our recommendation for increased safety and longer service life.

2) The Safe Working Load of the bitts and other deck hardware should be equal or greater than the
Minimum Breaking Load of a Winch Line passing through them.

3) The winch brake should be adjusted to release at 60% of the MBL of the line.

4) The winch drum diameter should be at least 16 times larger than the rope diameter. The
diameter (D in the drawing) of the surface of bitts, fairleads and chocks, where the Sirius rope
makes contact and bends around with an angle greater than 15 degrees, must be at least 4 to 5
times larger than the rope diameter.

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6) The length (L in the drawing) of the eye splice must be at least 4 times the diameter of the
bollard, for example, that is to be placed. This way, we will calculate the eye splice length more
accurately as per your requirements.

7) Check for sharp edges on flanges, winch drums and general in every hardware equipment on
deck that the rope makes contact with.

8) Working in high ambient temperatures (above 45 degrees Celsius, up to 70) can reduce the
service life of the Sirius line. On the other hand, below zero temperatures impose no danger for
the rope (working limit is minus 50 degrees Celsius)

E. SAFETY ISSUES
1) STAY AWAY from the snap back area, as seen in the drawing below, when the line is under
tension. HMPE ropes have a very reduced snap back reaction, limited and almost negligible,
however, it is good for the personnel to get acquainted with the behavior of the synthetic ropes,
especially after having worked many years with wire ropes (that also have no snapback reaction).

Any work that must be performed near to a line under tension, must be done very quickly and
with extreme caution.

2) Conduct regular inspections on the rope and the hardware (see more on the inspection
practices).

3) Keep the ropes clean: wash them with tap water on a regular basis (the time frame is to be
decided upon operators' experience) to remove any dirt or sea salt (that will act as “razors” and

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damage the fibers).

4) Unnecessary stay of the rope under constant load and high temperature can reduce its service
life.

5) Never let two ropes rub one another when they are under tension. There can be excessive heat
build-up that will damage the fibers locally and impose a weak point in the line.

6) Avoid as much as possible the introduction of twist in your mooring line. Twist can reduce
significantly the strength efficiency of an HMPE rope.

7) Every six (or 9 months maybe) reverse your mooring line (bring the rear part of the rope in front
and vice versa) so that the wear is distributed and get a longer service life.

8) Avoid making knots at all costs. They can reduce the line's strength by up to 50%. Make eye
splices instead.

9) Avoid shock loads (always use a mooring tail)

10) Use chafe gear (Pes webbings, Pes clothing) for the contact of the rope with metal surfaces
(bitts, bollards, chocks etc) no matter in how good condition these hardware are. Sirius ropes
always have PES tubular webbings in the eye splices and 3m of the same PES tubular webbing that
covers the body of the rope. Upon request, Katradis Marine Ropes SA may also provide these
webbings with Velcro tape for easier and better application on the rope.

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F. STORAGE CONDITIONS
1) Store the ropes in a clean environment, under mild environmental conditions (avoid storage in
high temperatures) and away from direct sunlight.

2) Store the ropes away from heat generating sources and acid (especially sulfuric acid) and
alkaline environment. Good ventilation of the storage place is also preferable.

G) INSPECTION PRACTICES AND RETIREMENT CRITERIA

1) The rope should be inspected in all of the length used after each usage. An experienced person
from the crew, assigned by master or by the company, must be charged with the visual inspections.
A diary log must be kept where as much information as possible must be recorded (rope life
history/mooring line history). Also keep in mind that in order to have an indication of the
remaining/current breaking strength of a line, the originally received coil, should have an extra
length of about 10 to 12 meters. This way, a breaking test in a specimen could be performed
without limiting/affecting the line's length. For this extra length, the purchaser should make this
notification during the order placement.
The visual inspection must check the following (Check also Annex A):

FOR 12STRANDS ROPES:

a. One strand of the rope is pulled out. If it is possible, try and work it back to the rope, if it is in
good condition (no significant wear), and look out for the cause (possibly some snagging on deck
equipment). RETIRE THE ROPE? NO

b. The rope has suffered extreme compression but there are no fused/melted fibers. Try to flex the
rope to remove compression. RETIRE THE ROPE? NO

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c. The rope's diameter is inconsistent. Possibly due to shock loading there are broken internal
strands/rope yarns. REPAIR THE ROPE (CUT AND RESPLICE, IF ALLOWED and if remaining length is
sufficient for mooring operations) OR RETIRE

d. The rope has extensive wear and/or reduced volume. The percent of the volume decreased
means greater decrease in line's strength. REPAIR THE ROPE (CUT AND RESPLICE IF ALLOWED and if
remaining length is sufficient for mooring operations) OR RETIRE

e. The rope's surface is discolored. Most probable cause is chemical contamination. There may also
be some fiber fusion or some fibers may be brittle. REPAIR THE ROPE (CUT AND RESPLICE IF
ALLOWED and if remaining length is sufficient for mooring operations) OR RETIRE

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FOR ROPES WITH BRAIDED NON LOAD BEARING COVER:
For covered ropes (in case of a worn jacket or a pulled strand for example) there could be a local
repair in the jacket (as long as it is verified that the load bearing core is in good condition and
hasn't suffered any damage)
When the cover is damaged we recommend inspection of the inner strength member. If the inner strength member is
damaged then it may be necessary to downgrade the rope. The cause of the damage should be determined and if possible
removed.

Depending on the extent of the damage either a small repair or an extensive

repair is recommended.

Small Repairs
The most durable method to make small repairs on the jacket braid requires the
use of nylon whipping twine and polyurethane glue.

Remove all the damaged yarns and coat the free yarn ends with the glue, in order to
prevent further unraveling of the cover. Start whipping at least three centimeters
away from the damage, as shown in the drawing. Lay a loop of twine across the
rope, leaving a free tail after the damage zone of about ten centimeters. This tail
has to be grasped later, so avoid covering it completely with whipping. With the
working end of the twine, make multiple wraps around the rope from the tail
end toward the apex of the loop, covering the loop until the whipping is at least
three centimeters beyond the damage.

To finish the whipping, insert the working end of the small twine through the loop. Pull on the very end or tail of the small
twine until the loop slides completely out of sight. Clip the ends close to the whipping.
If necessary, a temporary cover repair can be made using high quality adhesive tapes such as vinyl electrical tape, etc. A more
permanent repair, as described above, should replace the tape as soon as possible.

Extensive repairs
For extensive repairs the following tools are needed: replacement cover, some
sewing twine and a large sewing needle. Optionally additional protection can be
obtained by a two-component polyurethane.

Remove all the damaged yarns and inspect the rope. After
inspection coat the free yarn ends with the glue, in order to
prevent further unraveling of the cover. Wrap the damaged
part in the replacement cover.
Please note that the sides should be folded back, see sketch and photo. Stitch
the web together, with a special knot that will prevent the stitching yarn from
loosening when it is torn.
Protect the beginning and the end of the replacement cover with whipping.
Start whipping at least three centimeters away from the edge, as shown in the
drawing. Lay a loop of twine across the rope, leaving a free tail after the damage
zone of about ten centimeters. This tail has to be grasped later, so avoid covering
it completely.
With the working end of the twine, make multiple wraps around the rope
from the tail end toward the apex of the loop, covering the loop until the
whipping is at least
three centimeters beyond the damage.
To finish the whipping, insert the working end of the twine through the loop. Pull
on the very end or tail of the twine until the loop slides completely out of sight.
Clip the ends close to the whipping.
REPLACEMENT
COVER

ROPE

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 ANNEX A

Resplice
ROPE TYPE AND CONDITION Retire
(if localized)
For 12strand ropes

-Bulk of surface yarns or strands reduced by 50% or more for a linear

X X
distance equal to the rope diameter
-Rope suspected of being shock loaded X
-Exposure to excess temperature as specified for type of fibre X
-Burns or melting visible for a length of over four rope diameters X X
-Abrasion on inside radius of eye, with bulk of surface yarns or strands reduced by
50% or more X X

-Rust on nylon (might indicate chemical damage) X X

-Oil and grease Wash in mild detergent
X X
-Heavy surface fuzz-progressive
Remove source of abrasion
-UV degradation, splinters on yarn surface X
For braided cover and core ropes
-More than four consecutive pulled cover stands (which cannot be reincorporated into
cover braid) X X
-More than 3 cut cover strands X X
-Multiple cut yarns of filaments within distance of one pitch length X X
-Core visible through cover, because of cover damage X
-Core damage-pulled, cut, abraded, powdered, or melted strands X
-Herniation-core pokes through cover (sheath) X
-5% of yarns cut or badly abraded in score between strands X X
-Cover yarns cut or abraded more than 50% on one
or more crowns of rope X X

-Strand cut to 5% of diameter within one lay length X X

-Powdering between adjacent strand contact surfaces X X
-Hockle or backturn X X
-10% abrasion of one strand within one lay length X X
Thermal damage
-Hard, melted, flattened areas of the rope which can indicate serious
damage to the rope X X

-Melting or fusing affecting 20% or more of rope yarns

--If within one lay length X
--If over more than one lay length X
Short-term exposure to temperature above 65 ˚C X

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