LIVE POLL

What is needed to achieve a perfect spooled multi-layer drum without major

rope issues?

LIVE POLL

Which of the following factors DOES NOT

influence the stability of hook blocks?

LIVE POLL

Which of the following reeving configurations is the least stable against

block rotation?

LIVE POLL

What is the most important consideration relating to the safe operation of the

boom hoist rope?

Wire Rope Challenges for Crawler Cranes

Tony Fastuca

Panelists

Mario Hartl Justin BrownDave Sleightholm

Wire Rope Challenges for Crawler Cranes

Hartl MarioHead of Field Engineering, Teufelberger Wire Rope September, 2017

Multi-layer spooling

“What is needed to achieve a perfect spooled rope on a multi-layer drum without major issues” …for “high-lift jobs” on crawler-cranes

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Multi-layer spooling “What is needed to achieve a perfect spooled rope on a multi-layer drum without major issues” …for high-lift jobs on crawler-cranes

Proper Correlation Multi-layer Drum & Wire Rope

High Performance Rotation Resistant Steel Wire Rope

Proper Rope Installation

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Correlation Multi-layer Drum & Wire Rope

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Correlation Multi-layer Drum & Wire Rope

Play = Pitch– act. Rope-Ø

Pitch Multi-layer drum: 105% nom.Rope-Ø

act. Rope-Ø ~ 103.5 – 104.5% nom.Rope-Ø

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Correlation Multi-layer Drum & Wire Rope Play 0

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Correlation Multi-layer Drum & Wire Rope

Excessive play (Gap)

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Correlation Multi-layer Drum & Wire Rope

Influence of the fleet angle on the spooling behavior

Min-Max – fleet angle acc.to. ISO 16625:

Rotation Resistant Ropes 0,5° to 1,5°- max. 2,0°Non-Rotation Resistant Ropes 0,5° to 3,5°- max. 4,0°

Fleet angle ≤0,5°

Rope climbs up the flange

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

High Performance Rotation Resistant Steel Wire Rope…for high-lift jobs on crawler-cranes

15-18 Outer Strands (high rotation resistance)

Compacted Outer Strands (high wear resistance)

High Resistance Against Radial Deformation

Dimensional Stability (Rope-Ø) Under Lateral Pressure

High Flexibility and Efficiency

Use lang’s lay to minimize the wear (multi-layer application)

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

High Performance Rotation Resistant Steel Wire Rope…for high-lift jobs on crawler-cranes

35x7- WSC - RHRL

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

High Performance Rotation Resistant Steel Wire Rope…for high-lift jobs on crawler-cranes

35x7- WSC - RHRL

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Rope Installation

„Wire ropes may only be installed by technical experts or trained persons under competent supervision“

…….Incorrect wire rope installation may be hazardous to those involved with installation and subsequent operation. Further incorrect handling can have unchangeable negative consequences to the rope and its lifetime.

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Rope Installation

Back-Tension During Installation

apply a minimum of 2½ - 5% of the MBL with

- a traction winch

- a break disc on a spooling device or reel

- or at least use a auxiliary break (wood) or tighten the first layer by hammering

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Rope Installation

Back-Tension During Installation

apply a minimum of 2½ - 5% of the MBL with

- a traction winch

- a break disc on a spooling device or reel

- or at least use a auxiliary break (wood) or tighten the first layer by hammering

No Counterbends

try to stick to the bending direction of the reel

Fleet- angles

Minimize fleet angle and stick to the regulations acc. ISO 16625

Train the rope before max. SWL

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Rope Installation

Loose spooling of safety wraps

High loading of the second layer

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Proper Rope Installation

High loading of the 2nd and 3rd layer

Loose spooling of safety wraps

Wire Rope Challenges for Crawler Cranes – Multi-layer spooling

Multi-layer spooling

Multi-layer spooling

“What is needed to achieve a perfect spooled rope on a multi-layer drum without major issues” …for “high-lift jobs” on crawler-cranes

a) a regular lay rotation resistant rope

b) an uncompact rotation resistant rope

c) actual rope-Ø should be 1% smaller than the drum pitch

d) fleet angles ≥2° for rotation resistant ropes