Professional Documents
Culture Documents
Imperial Edition
Bridon - the worlds leading specialist
in the manufacture of wire and rope
solutions for the most demanding
applications, delivering reassurance
through unrivalled experience.
02 BRIDON Mining
Contents
Introduction ...................................... 2-3
Product Selection..............................4-7 Bridons products are manufactured
under controls that conform to quality
Products ..........................................8-23 management system ISO 9001:2000.
Services & Training ............................24
Technical Information....................25-62
Contacts ............................................63
ISO 14001
All statements, technical information and recommendations
contained herein are believed to be reliable, but no guarantee is Bridon operates environmental
given as to their accuracy and/or completeness. The user must
determine the suitability of the product for his own particular management systems which, where
purpose, either alone or in combination with other products and required by legislation or risk, comply with
shall assume all risk and liability in connection therewith.
the requirements of EN ISO 14001:2004
Whilst every attempt has been made to ensure accuracy in the
and are assessed and registered by
content of the tables, the information contained in this catalogue
does not form part of any contract. accredited certification bodies.
BRIDON Mining 03
Product Selection
Tiger 6T Compound
Hoist Rope 6x22(9/12/Brangle), 6x23(10/12/Brangle)
Blair Hoist 6x25(12/12/Brangle), 6x26(13/12/Brangle)
6x27(14/12/Brangle), 6x28(15/12/Brangle)
Improved resistance to wear
Reduced sheave and liner wear
High strength
Effective diameter control
See pages 12-13
Tiger DYFORM 6R
6x19(S), 6x36(WS)
Hoist Rope
Balanced Rope
High quality
Tower Mounted Friction Hoist with Deflectors Readily available
Consistent performance
Good resistance to wear
Improved resistance to fatigue.
Reduced interference in multi-layer coiling applications
See pages 9 & 11
04 BRIDON Mining
Product Selection
Hoist Rope
Parallel Drum Hoist
Hoist Rope
Blair Hoist
Tiger Superflex 17x6, 20x6
Maximum Flexibility
Maximum Resistance to wear
See page 17
Hoist Rope
Balanced Rope Flat ropes 8x4x7, 6x4x12, 8x4x12, 8x4x14, 8x4x19
Tower Mounted Friction Hoist with Deflectors
Maximum flexibility
Good rotational characteristics
See page 18
Hoist Rope
Balanced Rope
Ground Mounted Friction Hoist
BRIDON Mining 05
Product Selection
Haulage Ropes
Tiger 6T Compound
6x22(9/12/Brangle), 6x23(10/12/Brangle)
6x25(12/12/Brangle), 6x26(13/12/Brangle)
6x27(14/12/Brangle), 6x28(15/12/Brangle)
Good resistance to wear
Reduced sheave and liner wear
High strength
Effective diameter control
Good fatigue resistance
See pages 12-13
Haulage Ropes
High quality
Readily available
Consistent performance
Good resistance to wear
See pages 8 & 10
06 BRIDON Mining
Product Selection
Tiger 6CDR
6x19(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 lubrication
See page 20
BRIDON Mining 07
Products
The Powercheck symbol means that BRIDON has carried out a destruction test on a sample of
rope from each production length.
BRIDON has an active program to determine the rotational properties of its range of Rotation
Resistant and low Rotation ropes. BRIDON has developed its own torque turn testing machine and
has adopted a "Twistcheck" testing program for each product and is able to provide actual properties
for any rope.
BRIDON has an active program to determine fatigue properties and specifies material of specific
dimensions and properties, which will enhance fatigue performance. BRIDON design and
manufactures its ropes with fatigue in mind and has machines for fatigue testing mining ropes.
Available as standard. IWRC values available on request
3/4 0.94 21.3 24.0 25.3 26.6 190 214 225 237
7/8 1.27 29.0 32.7 34.4 36.2 258 291 306 322
1 1.67 37.9 42.7 44.9 47.3 337 380 400 421
1.1/8 2.19 48.0 54.0 56.9 59.9 427 481 506 533
1.1/4 2.61 59.2 66.7 70.1 73.9 527 594 624 658
1.3/8 3.15 71.7 80.8 84.8 89.4 638 719 755 796
1.1/2 3.74 85.3 96.2 101.0 106.4 759 856 899 947
1.5/8 4.40 100.0 112.8 118.5 125.0 890 1004 1055 1112
1.3/4 5.11 116.1 130.9 137.5 145.0 1033 1165 1224 1290
The 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 or using this product.
08 BRIDON Mining
Products
Available as standard. IWRC values available on request
The 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 or using this product.
BRIDON Mining 09
Products
Available as standard. IWRC values available on request
3/4 0.90 22.4 24.0 25.3 26.6 199 214 225 237
7/8 1.22 29.0 32.7 34.4 36.2 258 291 306 322
1 1.60 37.9 42.7 44.9 47.3 337 380 400 421
1.1/8 2.02 48.0 54.0 56.9 59.9 427 481 506 533
1.1/4 2.50 59.2 66.7 70.1 73.9 527 594 624 658
1.3/8 3.02 71.7 80.8 84.8 89.4 638 719 755 796
1.1/2 3.60 85.3 96.2 101.0 106.4 759 856 899 947
1.5/8 4.22 100.0 112.8 118.5 125.0 890 1004 1055 1112
1.3/4 4.89 116.1 130.9 137.5 145.0 1033 1165 1224 1290
1.7/8 5.62 133.3 150.2 157.9 166.3 1186 1337 1405 1480
2 6.39 151.6 170.9 179.6 189.2 1349 1521 1598 1684
2.1/8 7.22 171.1 192.9 202.7 213.6 1523 1717 1804 1901
2.1/4 8.09 191.8 216.3 227.3 239.6 1707 1925 2023 2132
The 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 or using this product.
10 BRIDON Mining
Products
Available as standard. IWRC values available on request
The 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 or using this product.
BRIDON Mining 11
Products
3/4 1.01 25.7 29.0 29.6 30.1 229 258 263 268
7/8 1.39 32.4 36.5 40.1 43.6 288 325 357 388
1 1.77 43.0 48.5 51.1 53.6 383 432 455 477
1.1/8 2.26 54.4 61.4 66.4 71.6 484 546 591 637
1.1/4 2.79 71.8 80.0 83.5 87.4 639 712 743 778
1.3/8 3.35 86.3 94.8 99.7 104.9 768 844 887 934
1.1/2 4.00 100.3 113.2 119.0 123.8 893 1007 1059 1102
1.5/8 4.70 118.5 131.1 137.8 144.4 1055 1167 1226 1285
1.3/4 5.99 135.9 153.2 161.0 169.7 1209 1363 1433 1510
1.7/8 6.24 155.4 175.3 184.2 194.3 1383 1560 1639 1729
2 7.12 181.8 204.5 213.3 223.5 1618 1820 1898 1989
2.1/8 8.04 205.0 228.1 238.0 250.1 1824 2030 2118 2226
2.1/4 9.02 225.9 256.2 270.5 277.0 2010 2280 2407 2465
The 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 selecting
or using this product.
12 BRIDON Mining
Products
1.1/8 2.22 56.9 64.0 66.7 69.8 506 570 594 621
1.1/4 2.86 72.0 81.1 84.7 88.7 641 722 754 789
1.3/8 3.48 87.4 98.5 102.9 107.8 778 877 916 959
1.1/2 4.05 102.4 115.4 120.6 127.6 911 1027 1073 1136
1.5/8 4.68 118.0 132.3 137.8 146.6 1050 1177 1226 1305
1.3/4 5.65 142.5 160.7 167.8 175.7 1268 1430 1493 1564
1.7/8 6.12 153.6 173.3 180.9 189.4 1367 1542 1610 1686
2 7.23 182.8 206.1 215.2 225.3 1627 1834 1915 2005
2.1/8 8.18 206.5 232.9 243.3 254.2 1838 2073 2165 2262
2.1/4 8.81 221.4 249.6 260.6 272.8 1970 2221 2319 2428
The 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 selecting
or using this product.
BRIDON Mining 13
Products
18x7
3/4 1.22 27.5 31.0 32.6 34.3 245 276 290 305
7/8 1.64 37.1 41.9 43.9 46.3 330 373 391 412
1 2.15 48.7 54.7 57.5 60.7 433 487 512 540
1.1/8 2.73 61.6 69.4 72.9 76.9 548 618 649 684
1.1/4 3.37 76.2 85.8 90.2 95.1 678 764 803 846
1.3/8 4.06 91.8 103.4 108.7 114.5 817 920 967 1019
1.1/2 4.84 109.2 123.3 129.4 136.4 972 1097 1152 1214
18x19
1.1/4 3.38 74.4 83.8 88.1 92.9 662 746 784 827
1.3/8 4.07 89.7 101.0 106.2 111.9 798 899 945 996
1.1/2 4.85 106.7 120.5 126.5 133.3 950 1072 1126 1186
1.5/8 5.69 125.5 141.5 148.7 156.6 1117 1259 1323 1394
1.3/4 7.26 145.6 164.3 172.6 181.8 1296 1462 1536 1618
1.7/8 7.57 166.6 188.0 197.4 208.0 1483 1673 1757 1851
2 8.62 189.9 214.1 225.0 237.0 1690 1905 2002 2109
2.1/8 9.74 214.5 241.8 254.2 267.8 1909 2152 2262 2383
The 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 selecting or using this product.
Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.
14 BRIDON Mining
Products
Available as standard. WSC values available on request
34x7
3/4 0.95 20.3 22.9 24.0 25.3 181 204 214 225
7/8 1.29 27.4 31.0 32.5 34.3 244 276 289 305
1 1.69 35.8 40.3 42.5 44.7 319 359 378 398
1.1/8 2.14 45.5 51.2 53.9 56.7 405 456 480 505
1.1/4 2.56 56.3 63.5 66.6 70.2 501 565 593 625
1.3/8 3.19 67.6 76.3 80.2 84.6 602 679 714 753
34x19
1.3/8 3.70 74.6 84.0 88.3 93.0 664 748 786 828
1.1/2 4.24 88.9 100.2 105.3 110.9 791 892 937 987
1.5/8 4.99 104.4 117.8 123.7 130.5 929 1048 1101 1161
1.3/4 5.79 121.2 136.6 143.6 151.4 1079 1216 1278 1347
1.7/8 6.63 138.8 156.4 164.4 173.3 1235 1392 1463 1542
2 7.55 158.0 178.2 187.2 197.3 1406 1586 1666 1756
2.1/8 8.52 178.5 201.2 211.6 222.9 1589 1791 1883 1984
2.1/4 11.32 200.3 225.9 237.3 250.1 1783 2010 2112 2226
2.3/8 10.63 222.7 251.0 263.7 278.0 1982 2234 2347 2474
2.1/2 11.79 246.9 278.2 292.5 308.2 2197 2476 2603 2743
The 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 selecting or using this product.
Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.
BRIDON Mining 15
Products
34x7
3/4 1.28 29.0 32.6 34.3 36.1 39.7 258 290 305 321 353
7/8 1.74 39.0 44.0 46.2 48.8 53.7 347 392 411 434 478
1 2.28 51.1 57.6 60.6 63.8 70.2 455 513 539 568 625
1.1/8 2.88 64.8 73.0 76.7 80.9 89.1 577 650 683 720 793
1.1/4 3.56 80.1 90.3 94.9 100.0 110.1 713 804 845 890 980
1.3/8 4.29 96.5 108.8 114.4 120.6 132.8 859 968 1018 1073 1182
34x19
1.3/8 4.21 92.8 104.6 110.0 116.0 127.8 826 931 979 1032 1137
1.1/2 5.03 110.6 124.7 131.0 138.1 152.1 984 1110 1166 1229 1354
1.5/8 5.91 130.0 146.5 154.1 162.3 178.8 1157 1304 1371 1444 1591
1.3/4 7.52 150.9 170.1 178.9 188.3 207.5 1343 1514 1592 1676 1847
1.7/8 7.84 172.6 194.6 204.6 215.5 237.4 1536 1732 1821 1918 2113
2 8.94 196.8 221.8 233.0 245.5 270.5 1751 1974 2074 2185 2407
2.1/8 10.09 222.3 250.6 263.3 277.4 305.6 1978 2230 2343 2469 2720
2.1/4 11.32 249.3 281.0 295.4 300.0 330.6 2219 2501 2629 2670 2942
2.3/8 12.59 277.1 312.5 328.3 346.0 381.3 2466 2781 2922 3079 3393
2.1/2 13.96 307.3 346.4 364.1 383.7 422.8 2735 3083 3240 3415 3763
The 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 selecting
or using this product.
Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.
16 BRIDON Mining
Products
Available as standard.
17x6
1 5/8 4.32 69.78 82.03 88.55 101.47 621 730 788 903
1 3/4 5.01 81.02 95.18 102.71 117.65 721 847 914 1047
1 7/8 5.49 88.44 104.06 112.26 128.67 787 926 999 1145
2 6.22 99.67 117.20 126.42 144.96 887 1043 1125 1290
2 1/8 7.27 114.73 134.96 145.52 166.76 1021 1201 1295 1484
2 1/4 8.07 126.42 148.67 160.24 183.84 1125 1323 1426 1636
2 3/8 8.93 140.91 165.64 178.67 204.85 1254 1474 1590 1823
20x6
1 7/8 5.67 89.45 105.18 113.49 130.01 796 936 1010 1157
2 6.50 105.85 124.40 134.28 153.84 942 1107 1195 1369
2 1/8 7.47 121.14 142.49 153.61 176.09 1078 1268 1367 1567
2 1/4 8.14 131.25 154.29 166.53 190.81 1168 1373 1482 1698
2 3/8 8.86 142.82 167.88 181.25 207.55 1271 1494 1613 1847
2 1/2 9.99 161.25 189.68 204.63 234.52 1435 1688 1821 2087
2 5/8 11.18 180.24 211.93 228.68 262.05 1604 1886 2035 2332
2 3/4 11.60 187.32 220.36 237.67 272.39 1667 1961 2115 2424
2 7/8 13.18 208.56 245.19 264.52 303.07 1856 2182 2354 2697
The 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 selecting
or using this product.
Read page 54 cautionary notice - Restrictions on the use of large diameter multistrand ropes.
BRIDON Mining 17
Products
Available as standard.
Rope Construction 8 x 4 x 7 = 8 Legs with 4 Strands each having 1+6 Wires = 224 wires
110 x 20 110 x 18 1.9 635 6.42 6.16 6.04 870 997
113 x 20 113 x 18 1.95 669 6.76 6.49 6.36 917 1050
116 x 21 116 x 19 2.0 704 7.11 6.83 6.69 964 1105
119 x 21 119 x 19 2.05 739 7.47 7.17 7.02 1010 1160
122 x 22 122 x 20 2.1 776 7.84 7.53 7.38 1060 1220
125 x 22 125 x 20 2.15 813 8.22 7.89 7.73 1110 1280
128 x 23 128 x 21 2.2 851 8.60 8.26 8.09 1170 1340
Rope Construction 6 x 4 x 12 = 6 Legs with 4 Strands each having 3+9 Wires = 288 wires
112 x 26 112 x 23 1.9 817 8.26 7.93 7.68 1120 1280
115 x 25 115 x 23 1.95 860 8.69 8.35 8.09 1180 1350
118 x 27 118 x 24 2.0 905 9.14 8.78 8.51 1240 1420
121 x 27 121 x 24 2.05 951 9.61 9.23 8.94 1300 1490
124 x 28 124 x 25 2.1 998 10.10 9.68 9.39 1370 1570
127 x 28 127 x 25 2.15 1046 10.60 10.20 9.84 1430 1640
130 x 29 130 x 26 2.2 1095 11.10 10.70 10.30 1500 1720
Rope Construction 8 x 4 x 12 K= 8 Legs with 4 Strands each having 3+9 Wires = 384 wires
146 x 25 146 x 23 1.9 1089 11.00 10.60 10.30 1490 1710
149 x 26 149 x 23 1.95 1147 11.60 11.20 10.80 1570 1800
154 x 27 154 x 24 2.0 1206 12.20 11.70 11.40 1650 1890
157 x 27 157 x 24 2.05 1267 12.80 12.30 11.90 1740 1990
160 x 28 160 x 25 2.1 1330 13.50 12.90 12.50 1820 2090
165 x 28 165 x 25 2.15 1394 14.10 13.60 13.10 1910 2190
168 x 29 168 x 26 2.2 1460 14.80 14.20 13.80 2000 2290
Rope Construction 8 x 4 x 14 K= 8 Legs with 4 Strands each having 4+10 Wires = 448 wires
168 x 28 168 x 25 2.0 1407 14.30 13.70 13.30 1930 2210
172 x 29 172 x 26 2.05 1479 15.00 14.40 13.90 2030 2320
176 x 29 176 x 26 2.1 1552 15.70 15.10 14.60 2130 2440
180 x 30 180 x 27 2.15 1626 16.50 15.80 15.30 2230 2550
184 x 30 184 x 27 2.2 1703 17.20 16.60 16.00 2330 2670
Rope Construction 8 x 4 x 19 K= 8 Legs with 4 Strands each having 1+6+12 Wires = 608 wires
186 x 31 186 x 28 1.9 1724 17.50 16.80 16.20 2360 2710
190 x 32 190 x 29 1.95 1816 18.40 17.80 17.00 2490 2850
194 x 33 194 x 30 2.0 1910 19.30 18.60 18.00 2620 3000
200 x 34 200 x 31 2.05 2007 20.30 19.50 18.90 2750 3150
204 x 34 204 x 31 2.1 2106 21.30 20.40 19.80 2890 3310
210 x 36 210 x 32 2.15 2207 22.30 21.40 20.80 3020 3460
216 x 37 216 x 33 2.2 2311 23.30 22.40 21.80 3170 3630
The 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
Products
6x19S
32 3.94 59.51 584 64.40 632
33 4.19 63.28 621 68.48 672
34 4.45 67.18 659 72.70 713
35 4.71 71.19 698 77.04 756
36 4.99 75.31 739 81.50 800
37 5.27 79.56 780 86.09 845
38 5.56 83.91 823 90.81 891
39 5.85 88.39 867 95.65 938
40 6.16 92.98 912 100.62 987
41 6.47 97.69 958 105.71 1037
6x26WS
41 6.51 98.25 964 106.33 1043
42 6.83 103.10 1011 111.58 1095
43 7.16 108.07 1060 116.95 1147
44 7.49 113.16 1110 122.46 1201
45 7.84 118.36 1161 128.09 1257
46 8.53 127.20 1248 137.65 1350
47 8.91 132.79 1303 143.70 1410
48 9.29 138.50 1359 149.88 1470
49 9.68 144.33 1416 156.19 1532
50 10.08 150.28 1474 162.63 1595
51 10.49 156.35 1534 169.20 1660
52 10.90 162.54 1595 175.90 1726
6x31WS
41 6.69 100.97 991 109.28 1072
42 7.02 105.95 1039 114.68 1125
43 7.36 111.06 1089 120.21 1179
44 7.70 116.28 1141 125.86 1235
45 8.06 121.63 1193 131.65 1291
46 8.77 130.71 1282 141.48 1388
47 9.15 136.45 1339 147.70 1449
48 9.55 142.32 1396 154.05 1511
49 9.95 148.32 1455 160.54 1575
50 10.36 154.43 1515 167.15 1640
51 10.78 160.67 1576 173.91 1706
52 11.21 167.03 1639 180.79 1774
53 11.64 173.52 1702 187.82 1843
54 12.08 180.13 1767 194.97 1913
55 12.54 186.86 1833 202.26 1984
56 13.00 193.72 1900 209.68 2057
57 13.46 200.80 1969 217.23 2131
58 13.94 207.80 2039 224.92 2206
59 14.43 215.03 2109 232.75 2283
60 13.88 222.38 2182 240.70 2361
The 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 selecting
or using this product.
BRIDON Mining 19
Products
Tiger 6CDR
Lay Type Lay Direction Finish Core
Ord Langs Right Left Bright Galv FC FFC Bristar
Hand Hand
Available as standard. Bristar values available on request
mm kg/m kN kN
6x19S
32 3.79 550 600
33 3.95 560 610
35 4.61 666 726
37 5.11 740 806
38 5.42 788 858
41 5.66 894 974
43 6.51 965 1052
6x25F
41 6.21 898 978
45 7.43 1069 1165
48 8.78 1265 1379
51 9.94 1432 1561
54 10.93 1589 1732
57 12.91 1771 1930
60 13.61 1972 2149
The 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 selecting
or using this product.
20 BRIDON Mining
Products
Available as standard. Bristar values available on request
mm kg/m kN kN
6x19S
32 4.02 592 645
33 4.19 602 656
35 4.89 716 780
37 5.42 796 867
38 5.75 847 923
41 6.69 960 1047
43 6.90 1040 1133
6x31WS
41 6.58 965 1051
45 7.88 1148 1251
48 9.31 1364 1486
51 10.54 1540 1679
54 11.59 1708 1862
57 13.68 1904 2075
60 14.43 2119 2309
The 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 selecting
or using this product.
BRIDON Mining 21
Products
Available as standard. Variable Torque and Turn characteristics available by design
Read pages 42-54 Product Safety Instructions and Warnings on the use of steel wire rope before selecting or
using this product.
22 BRIDON Mining
Products
Tons Tons
in lbs/ft kN kN
(2000lbs) (2000lbs)
The 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.
BRIDON Mining 23
Services & Training
Bridon International Services employ some of the most Non destructive examination (NDE)
highly trained professionals in the industry. Our The primary cause of wire rope failure is internal degradation
understanding of, and expertise in dealing with, all manner through corrosion and fatigue. We provide a
of issues related to wire and fibre ropes has enabled us to comprehensives non-destructive examination service,
develop a wide portfolio of cost effective services which are operating to the most meticulous standards. This detects the
enjoyed by Bridon customers world-wide. presence of defects such as broken wires, both on the
24 hours a day, 365 days a year, our engineers and surface and within the rope, loss of metallic cross-sectional
technicians are dispatched across the globe to provide area and distortions. Results from this examination are
expert assistance and solutions, no matter what the recorded progressively, in digital format, from the survey
problem, or wherever the location. With resources and head of the specialist equipment to a notebook or laptop, as
support services based at key hubs on every continent, the wire rope passes through the head. The resulting trace is
BRIDON really does provide a truly International specialist then analysed and a comprehensive report produced.
after sales service in wire and fibre rope.
Splicing
Repair and Maintenance In addition to any basic splicing requirements, BRIDON are
Repair and maintenance can be carried out in many forms. able to offer a variety of specialist splicing abilities, such as
All types of ropes including haulage, multi-strand rope, long splicing, to meet our clients needs.
Locked Coil and Spiral Strand are catered for, from a Such requirements, which are carried out in-situ, may
broken wire to a total re-splice. entail; rope driven conveyors, aerial haulages, funiculars,
tile conveyors etc. and may be long splices or eye splices,
Installation & Replacement Services including multi-strand and bordeaux connection. All splices,
The service life and safety of a wire rope can depend as much including passenger carrying ropes, are carried out to
upon the quality of the installation as upon the quality of the internationally recognised standards. Where required all
product itself. To protect your investment, take advantage of splicing materials, including liquid rubber for injection to the
our installation and replacement service - expert international splice area, can be provided.
support covering virtually all types of equipment which uses or
incorporates wire rope. Typical installations include: mining
applications, elevators, excavators, cranes and aerial
Training
ropeways. Bridon Services has a range of specialised Bridon has established a deserved reputation for running
installation equipment, such as back tension winches, high quality training courses, which is no less than would be
spoolers and hydraulic tensioners, that can be employed in expected from a world leader in the design, manufacture and
conjunction with our skilled engineers to ensure installations subsequent use of wire and fibre ropes. Our courses never
of wire rope are carried out correctly, professionally, and stand still and are directly relevant to current legislation,
above all, safely. improved technology, and the competitive trading conditions
of todays markets. In an increasingly competitive world,
Inspection & Statutory Examination Services costs must be continually reduced without compromising
We are also able to provide customers with statutory safety. There is no better way to prepare for this challenge
examination services, as required under law, which than through a Bridon training course.
subjects wire rope and lifting equipment (below the hook) For further information on training courses, including
to stringent testing and examination procedures. practical workshop based wire rope splicing and socketing
courses, any of which can be fine tuned to suit your
individual needs, please contact BRIDON.
24 BRIDON Mining
Technical Information
1. Hoist Ropes
Various constructions of ropes may be used for that the drum or sheave diameter to rope diameter ratio
hoisting, the final choice usually being decided upon should be in the region of 100 to 120:1 for satisfactory
economic grounds. What may be a satisfactory life service life on main shaft winders. Ratios as low as
on a shallow high frequency hoist, may be completely 50:1 can be tolerated on small ropes in shallow shafts,
uneconomic on a deep low frequency installation, staple shafts and sinking stage winders.
and therefore the rope designs as well as their sizes
1.2 Friction or Koepe Hoists
must be considered.
6 Stranded Ropes are suitable to depths of 1000
1.1 Drum Hoists
metres. Beyond that the torque in these ropes can
6 Stranded Ropes both round and triangular result in premature torsional fatigue of the wires.
strand are satisfactory for all depths of shafts, Triangular strands are more usual due to the lower
although perhaps best suited for those up to 1000m contact pressures on the friction linings although
in depth with fixed guides. They are not suitable for Langs lay equal laid round strand ropes are quite
shafts deeper than 600m with rope guides, as their suitable for shallow shafts. Round strand ropes with
natural tendency to twist causes the conveyance Dyformed (compacted) strands are becoming more
to turn. popular as they offer higher breaking loads,
increased fatigue life and reduced contact pressures
As a rough guide to the construction of the rope, the
over ropes with conventional strands.
ratio of drum or sheave diameter to outer wire
diameter should be between 1000 and 1500:1, With rope guided shafts, alternate left and right hand
although if abrasion is severe this can be reduced lay ropes are employed to prevent conveyance twist.
slightly at the expense of a lower fatigue life.
Tread pressures with stranded ropes are limited to
For maximum resistance to wear and crossover 17.5 kgf/cm2 (1.72Mpa) to avoid excessive wear of
damage the use of Langs lay is recommended. the friction linings.
BRIDON Mining 25
Technical Information
26 BRIDON Mining
Technical Information
3. Balance Ropes
Generally balance ropes are required to have the guides tensioned on the basis of 3000kg plus 500kg
flexibility to suit the particular cage centres, adequate for each 100m of shaft depth. The tensions are
rotation resistant properties combined with good normally varied in the range plus or minus 10% to limit
resistance to wear and corrosion. Bridon's range of harmonic vibration.
multi-strand rotation resistant and Flat Balance ropes
In wet and corrosive shafts the use of galvanised
has the capability to meet the needs for all balance
material is recommended.
rope applications.
Types of tensioning arrangement, terminations and
Bridons Superflex balance ropes were developed for
methods of installation are many and varied and
installations where maximum flexibility is required
Bridons dedicated Mining Department will be please
combined with optimum resistance to wear and
to give advise on these aspects along with types of
corrosion. The range of ropes is almost completely
layouts, methods of lubrication, inspection
non-rotating. As a result there is no torsional effect
procedures and maintenance.
either at the terminal ends or at the loop and therefore
the onset of fatigue at these points is almost entirely
eliminated. 5. Haulage Ropes
Where maximum flexibility is not required alternative
The modern rope haulage system is an integral part
constructions are available to best suit the specific
of the system for both the transportation of men and
winding conditions and give optimum economic
the supply of materials to the mine face.
service life.
Haulage systems fall into 3 main categories
The graph below gives the minimum recommended
Endless
loop diameter to rope diameter ratio for various
Direct
constructions.
Main and Tail
Minimum Loop D:d Ratios Bridons Tiger Brand range has the rope to suit
your system.
60
In general, haulage ropes are required to have
excellent resistance to wear and in some instances
45 corrosion. To achieve this they tend to be of the more
simple construction with fewer larger outer wires.
35
These can be single layer round strand construction
30 30 30
25
or triangular strand construction. On the majority of
systems where the length of travel is high and the
15
frequency of cycle is small, fatigue is generally not a
Flat 20x6SF 17x6SF 14x6SF 34x19NF 18x19 34x7 18x7
Rope
Construction
critical deteriorating factor.
BRIDON Mining 27
Technical Information
On certain installations where resistance to crushing In both conventional and Dyform drive ropes
is required then the use of ropes with steel IWRC alternative cores and manufacturing lubrication are
cores should be considered. available to best suit your conveyor conditions to
ensure maximum economic operating performance.
On endless systems ropes with special preforming
These include the following:-
are supplied to facilitate long splicing.
Man made fibre cores for use in wet conditions
The performance of round strand ropes can be
enhanced by the use of Dyformed strands. Dyform Bristar cores offering lower stretch, increased
ropes offer the following improvements:- fatigue life and improve diameter retention
28 BRIDON Mining
Technical Information
The above figures are for guidance purposes. More precise Extension due to Rotation
figures are available upon request. The elongation caused by a free rope end being allowed
Locked Coil Hoist Ropes to rotate.
BRIDON Mining 29
Technical Information
30 BRIDON Mining
Technical Information
9. Bend Fatigue
Bend fatigue testing of ropes usually consists of cycling a However, the benefit of such testing can be particularly
length of rope over a sheave while the rope is under a helpful to the rope manufacturer when developing new or
constant tension and as part of its ongoing development improving existing products.
programme Bridon has tested literally thousands of ropes
If designers or operators of equipment are seeking optimum
in this manner over the years on its in-house own design
rope performance or regard bending fatigue life as a key
bend testing equipment.
factor in the operation of equipment, such information can
Through this work, Bridon has been able to compare the be provided by Bridon for guidance purposes.
effects of rope construction, tensile strength, lay direction,
Service life curve for various D:d ratios
sheave size, groove profile and tensile loading on bend
fatigue performance under ideal operating conditions. At
100
the same time it has been possible to compare rope life to
discard criteria (e.g. as laid down in ISO 4309) with that to
Relative Rope Service Life
80
complete failure of the rope, i.e. to the point where the rope
has been unable to sustain the load any longer. As part of
the exercise, it has also been possible to establish the 60
residual breaking strength of the rope at discard level of
deterioration. 40
0
Number of bends to rope failure
0 5 10 15 20 25 30 35 40 45 50 55 60 65
D:d ratio
0.200 0.5
0.300 EB = 1 -
What needs to be recognised, however, is that very few
0.400 D/d
ropes operate under these controlled operating conditions,
0.500
making it very difficult to use this base information when 0.600
attempting to predict rope life under other conditions. Other 0.700
influencing factors, such as dynamic loading, differential 0.800
0.900
loads in the cycle, fleet angle, reeving arrangement, type of
1.000
coiling on the drum, change in rope direction, sheave 0 10 20 30 40
alignment, sheave size and groove profile, can have an D:d ratio
equally dramatic effect on rope performance.
BRIDON Mining 31
Technical Information
32 BRIDON Mining
Technical Information
Rope Torque
To calculate the torque generated in a particular rope when Imperial
subjected to a tensile load, multiply the load by the torque
Rope length (ft) = (A + B) x A x C x
value and combine the units.
12d2
Example: for 20mm dia. Tiger 34LR 34x7 Class at 6000 kg f load
where A, B, C and d are quoted in inches.
Torque generated = torque value x load
Metric
= 0.16 . 6000
= 960 kgf.mm Rope length (m) = (A + B) x A x C x x 106
d2
Bending Loads
where A, B and C are quoted in metres and d quoted in mm.
As the rope is bent over the headsheave or drum, an
NOTE: Ropes are normally manufactured to a maximum oversize
additional force is induced into the steel which must be
tolerance of 4%. Therefore the actual diameter d could be nominal
added to the static and dynamic tensions to obtain the total
diameter + 4%.
force imposed. There are many methods of calculation for
this bending force, although the one most commonly used is:
WARNING
Bending force = EdA
D Wire rope will fail if worn-out, shock loaded, overloaded,
misused, damaged, improperly maintained or abused.
where E = Elastic Modulas as given under
Elongation of Wire Rope kgf/mm2 Always inspect wire rope for wear, damage or
d = diameter of outer wire in rope mm abuse before use
A = Area in rope mm2
Never use wire rope which is worn-out, damaged
D = Diameter of sheave or drum mm
or abused
Size of Outer Wires in Rope
Never overload or shock load a wire rope
It is sometimes useful to know the size of the outer wires in
Inform yourself: Read and understand the guidance on
ropes i.e. when estimating the amount of external wear or
product safety given in this catalogue; also read and
calculating bending stress. These can be calculated with
understand the machinery manufacturers handbook
reasonable accuracy for all constructions of 6 strand ropes
using the following formula. Refer to applicable directives, regulations,
standards and codes concerning inspection,
6 strand round strand
examination and rope removal criteria
Diameter of outer wires = Nominal diameter or rope
No. of outer wires per Protect yourself and others - failure of wire rope
strand + 3 may cause serious injury or death!
Example:
26mm diameter 6 x 36 (14/7 and 7/7/1)
round strand Right
No. of outer wires per strand = 14 hand
Left hand Fleet Angle:
Fleet
Diameter of = 26 = 1.5mm Left angle Right hand Fleet Angle:
outer wire 14+3 hand
Fleet
Calculations of Drum Capacity Groove Pitch: mm
angle
Rope Oscillation
BRIDON Mining 33
Technical Information
34 BRIDON Mining
Technical Information
Ordinary Langs
BRIDON Mining 35
Technical Information
Guide to Examination
The continued safe operation of lifting equipment, lifting Some of the More Common Types of Wire
accessories (e.g. slings) and other systems employing wire Fractures Can Include:
rope depends to a large extent on the operation of well
programmed periodic rope examinations and the A Severed B Tension C Fatigue D Corrosion
by wear fatigue
assessment by the competent person of the fitness of the
rope for further service.
36 BRIDON Mining
Technical Information
Troubleshooting Guide
Typical examples of Wire Rope deterioration
BRIDON Mining 37
Technical Information
Troubleshooting Guide
The following is a simplified guide to common wire rope problems. More detailed advice can be obtained from any Bridon
distributor. In the event of no other standard being applicable, Bridon recommends that ropes are inspected/examined in
accordance with ISO 4309.
Problem Cause/Action
Mechanical damage caused by the rope contacting the Generally results from operational conditions.
structure of the installation on which it is operating or an
Check sheave guards and support/guide sheaves to
external structure - usually of a localised nature.
ensure that the rope has not jumped out of the
intended reeving system.
Broken wires or crushed or flattened rope on lower layers Check tension on underlying layers. Bridon
at crossover points in multi - layer coiling situations. recommends an installation tension of between 2% and
10% of the minimum breaking force of the wire rope.
Wire breaks usually resulting from crushing or abrasion.
Care should be taken to ensure that tension is retained
in service. Insufficient tension will result in these lower
layers being more prone to crushing damage.
38 BRIDON Mining
Technical Information
Troubleshooting Guide
Problem Cause/Action
Pigtail or severe spiralling in rope. Check that the sheave and drum diameter is large
enough - Bridon recommends a minimum ratio of the
drum/sheave to nominal rope diameter of 18:1.
Two single axial lines of broken wires running along the Check sheave and drum groove radii using sheave
length of the rope approximately 120 degrees apart gauge to ensure that they are no smaller than nominal
indicating that the rope is being nipped in a tight rope radius + 5% - Bridon would recommend that the
sheave. sheave/drum groove radii are checked prior to any
rope installation.
One line of broken wires running along the length of the Check to see if the groove diameter is no greater than
rope indicating insufficient support for the rope, generally 15% greater than the nominal rope diameter.
caused by oversize sheave or drum grooving.
Repair or replace drum/sheaves if necessary.
Short rope life resulting from evenly/randomly distributed Bending fatigue is accelerated as the load increases
bend fatigue wire breaks caused by bending through the and as the bending radius decreases (see page 31).
reeving system. Consider whether either factor can be improved.
Fatique induced wire breaks are characterised by flat Check wire rope construction - Dyform ropes are
ends on the broken wires. capable of doubling the bending fatigue life of a
conventional steel wire rope.
BRIDON Mining 39
Technical Information
Troubleshooting Guide
Problem Cause/Action
Short rope life resulting from localised bend fatigue wire Bending fatigue is accelerated as the load increases
breaks. and as the bending radius decreases (see page 30).
Consider whether either factor can be improved.
Fatique induced wire breaks are characterised by flat
ends on the broken wires. Check wire rope construction - Dyform ropes are
capable of doubling the bending fatigue life of a
conventional steel wire rope.
Broken rope - ropes are likely to break when subjected to Review operating conditions.
substantial overload or misuse particularly when a rope
has already been subjected to mechanical damage.
Wave or corkscrew deformations normally associated Check sheave and drum groove radii using sheave
with multistrand ropes. gauge to ensure that they are no smaller than nominal
rope radius +5% - Bridon recommends that the
sheave/drum groove radii are checked prior to any
rope installation.
Rotation of the load in a multi - fall system resulting in Review rope selection.
cabling of the rope falls.
Consider use of rotation resistant or low rotation rope.
Possibly due to induced turn during installation or
Review installation procedure (See pages 42 - 54)
operation.
or operating procedures.
Core protrusion or broken core in single layer six or eight Caused by repetitive shock loading - review
strand rope. operating conditions.
40 BRIDON Mining
Technical Information
Troubleshooting Guide
Problem Cause/Action
Rope accumulating or stacking at drum flange - due to Review drum design with original equipment
insufficient fleet angle. manufacturer - consider adding rope kicker, fleeting
sheave etc.
Sunken wraps of rope on the drum normally associated Check correct rope diameter.
with insufficient support from lower layers of rope or
If grooved drum check groove pitch.
grooving.
Check tension on underlying layers - Bridon recommend
an installation tension of between 2% and 10% of the
minimum breaking force of the wire rope - Care should
be taken to ensure that tension is retained in service.
Insufficient tension will result in these lower layers being
more prone to crushing damage.
Short rope life induced by excessive wear and abrasion. Check fleet angle to drum.
BRIDON Mining 41
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
The following Instructions and Warnings combine to Ensure that the rope does not make any direct
provide guidance on Product Safety and are intended for contact with the floor and that there is a flow of air
use by those already having a working knowledge of wire under the reel.
ropes, as well as the new user. They should be read,
followed and passed on to others.
WARNING
Failure to read, understand and follow these instructions
Failure to do so may result in the rope becoming
could result in harmful and damaging consequences.
contaminated with foreign matter and start the onset
A Warning statement indicates a potential hazardous of corrosion before the rope is even put to work.
situation which could result in a significant reduction in rope
performance and/or put at risk, either directly or indirectly,
Support the reel on a simple A-frame or cradle,
the safety or health of those persons within the danger
located on ground which is capable of supporting the
zone of the rope and its associated equipment.
total mass of rope and reel. (See Fig. 2) Ensure that
Note: As a result of the creation of the single European market and the rope is stored where it is not likely to be affected
the New Approach Directives which set out essential requirements by chemical fumes, steam or other corrosive agents.
(e.g. for safety) designers, manufacturers, suppliers, specifiers and
users need to keep themselves abreast of any changes to the
appropriate Regulations and national standards.
1. Storage
Never store wire rope in areas subject to elevated Ensure that the rope is stored and protected in such a
temperatures as this may seriously affect its future manner that it will not be exposed to any accidental
performance. In extreme cases its original as- damage either during the storage period or when
manufactured strength may be severely reduced placing the rope in, or taking it out of storage.
rendering it unfit for safe use.
42 BRIDON Mining
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
3.3 Ensure that the correct rope has been supplied by
WARNING
checking to see that the description on the Certificate
Failure to carry out or pay attention to any of the is in accordance with that specified in the purchasers
above could result in a loss of strength and/or a order.
reduction in performance. In extreme cases the
3.4 Check by measurement that the nominal diameter of
rope may be unfit for safe use.
the new rope conforms to the nominal size stated on
the Certificate.
2. Certification and Marking
For verification purposes, measure the diameter by
Make sure that the relevant Certificate has been using a suitable rope vernier fitted with jaws broad
obtained before taking the rope into use for a lifting enough to cover not less than two adjacent strands.
operation. (Refer to statutory requirements) Take two sets of measurements spaced at least 1
metre apart, ensuring that they are taken at the
Check to verify that the marking on the rope or its
largest cross-sectional dimension of the rope. At
package matches the relevant Certificate.
each point take measurements at right angles to
Note: The rating of a component part of a machine or lifting each other.
accessory is the responsibility of the designer of the machine or
The average of these four measurements should be
accessory. Any re-rating of a lifting accessory must be approved by a
within the tolerances specified in the appropriate
competent person.
Standard or Specification.
Retain the Certificate in a safe place for identification
For a more general assessment of rope diameter use
of the rope when carrying out subsequent periodic
a rope calliper. (See Fig 1)
statutory examinations in service. (Refer to statutory
requirements) 3.5 Examine the rope visually to ensure that no damage
or obvious signs of deterioration have taken place
3. Handling and Installation
during storage or transportation to the
3.1 Handling and installation of the rope should be installation site.
carried out in accordance with a detailed plan and
3.6 Check the working area around the equipment for any
should be supervised by a competent person.
potential hazards which may affect the safe
installation of the rope.
WARNING
3.7 Check the condition of the rope-related equipment in
Incorrectly supervised handling and installation accordance with the OEMs instructions.
procedures may result in serious injury to Include the following -
persons in the vicinity of the operation as well as
Sheave and Drum Sizes
those persons directly involved in the handling and
installation. Regulations throughout the world quote various
minimum D:d ratios for differing rope constructions
and these must be considered when selecting a
3.2 Wear suitable protective clothing such as overalls, suitable hoist rope. However as guidance the
industrial gloves, helmet, eye protectors and safety following D:d ratios are recommended.
footwear (and respirator, particularly where the
emission of fumes due to heat is likely). 6 Stranded ropes 80:1
Multi Stranded ropes 80:1
Locked coil ropes 100-120:1 depending upon
WARNING rope diameter.
(In addition the drum to outer wire ratio should be
Failure to wear suitable protective clothing and
between 1000 and 1500:1)
equipment may result in skin problems from over
exposure to certain types of rope lubricants and Factors such as speed can necessitate an increase
dressings; burns from sparks, rope ends, molten in the D:d ratio and in certain circumstances a D:d
lubricants and metals when cutting ropes or ratio below the recommended value can be tolerated
preparing sockets for re-use; respiratory or other but some reduction in rope life should be expected.
internal problems from the inhalation of fumes
BRIDONs Mining Division will be pleased to advise
when cutting ropes or preparing sockets for re-
on this subject.
use; eye injuries from sparks when cutting ropes;
lacerations to the body from wire and rope ends; Sheave Grooves
bruising of the body and damage to limbs due to Groove diameters should be such that they can
rope recoil, backlash and any sudden deviation accommodate a new rope taking into account the
from the line of path of rope. relevant oversize tolerance and the fleet angles
involved to provide adequate circumferential support.
BRIDON Mining 43
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
A groove diameter of 7.5% greater than the nominal When a new rope is fitted a variation in size
rope diameter is normally acceptable. However in compared with the old worn rope will be apparent.
certain cases experience has shown that clearances The new rope may not fit correctly into the previously
between 10 and 12.5% are required to obtain worn groove profile and unnecessary wear and rope
optimum performance. distortion is likely to occur. This may be remedied by
machining out the grooves before the new rope is
Before installing a new rope all sheave grooves
installed. Before carrying out such action the sheaves
should be checked to ensure they provide the
or drum should be examined to ensure that there will
recommended clearance.
be sufficient strength remaining in the underlying
Drum Grooves material to safely support the rope.
On single layer drum hoists spiral grooving is The competent person should be familiar with the
recommended. Where multilayer coiling is necessary requirements of the appropriate
then parallel grooves or one of the patterned coiling application/machinery standard.
systems should be used. In all cases correct pitch,
clearance and groove depth are essential to obtain Note: General guidance to users is given in ISO 4309 Code of
good rope performance. practice for the selection, care and maintenance of steel wire rope.
Coils
Fig 4 Fig 6
Wrong
Wrong Wrong
Note the kinks
forming
rIgHT
44 BRIDON Mining
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
Reels Ensure that the reel stand is mounted so as not to
create a reverse bend during reeving (i.e. for a winch
Pass a shaft through the reel and place the reel in a
drum with an overlap rope, take the rope off the top of
suitable stand which allows it to rotate and be braked
the reel). (See Fig. 7)
to avoid overrun during installation. Where multi-layer
coiling is involved it may be necessary for the reel to 3.9 Ensure that any equipment or machinery to be roped
be placed in equipment which has the capability of is correctly and safely positioned and isolated from
providing a back tension in the rope as it is being normal usage before installation commences. Refer
transferred from reel to drum. This is to ensure that to the OEMs instruction manual and the relevant
the underlying (and subsequent) laps are wound Code of Practice.
tightly on the drum. (See Fig. 7)
3.10 When releasing the outboard end of the rope from a
reel or coil, ensure that this is done in a controlled
manner. On release of the bindings and servings
used for packaging, the rope will want to straighten
itself from its previously bent position. Unless
controlled, this could be a violent action. Stand clear.
WARNING
Fig 7
Failure to control could result in injury.
Position the reel and stand such that the fleet angle
during installation is limited to 1.5 degrees.
Ensure that the as-manufactured
(See Fig. 8)
condition of the rope is maintained
during installation.
BRIDON Mining 45
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
3.11 Monitor the rope carefully as it is being pulled into the Length of serving for locked coil winding ropes and
system and make sure that it is not obstructed by any half locked coil guide ropes
part of the structure or mechanism which may cause
The length of rope to be served depends on the
the rope to come free.
object of the serving and on the size and type of the
rope. If the serving is to restrain the cut end of a rope
it must be longer than one intended to restrain the
end of a short sample to be cut from a rope. a rope
of the stranded type exerts only a moderate bursting
force on a serving but a large locked coil rope exerts
a considerable bursting force and, should the serving
burst, the rope will unlay itself violently over a long
length. Thus, for the cut end of a stranded rope, two
servings each of a length at least six times the rope
diameter should be used and kept in place until the
rope end is otherwise secured. For the cut end of a
large locked coil rope a serving or servings each a
length of twenty times the rope diameter is advisable,
and such servings should be backed up by a
minimum of six two-bolt clamps set clear of the
served length until the rope end is otherwise
secured. Servings should be left permanently on
locked coil winding ropes so that there is one about
0.6m (2ft) clear of the capel to allow proper
examination of the rope at this point and another
Fig 10 between the capel and the nearest pulley or driving
sheave in the head frame. This is to localise any
WARNING unlaying of the rope end, or of broken wires, in the
event of some incident.
Failure to monitor during this operation could
One serving either side of the cut is normally
result in injury.
sufficient for preformed ropes. For non-preformed
ropes, multi-layer (i.e. rotation-resistant and low
This entire operation should be carried out carefully and rotation ropes) and parallel closed ropes (i.e. DSC
slowly under the supervision of a competent person. ropes) a minimum of two servings each side of the
cut will be necessary (See Fig. 10).
3.12 Take particular care and note the manufacturers
instructions when the rope is required to be cut. Arrange and position the rope in such a manner that
Apply secure servings on both sides of the cut mark. at the completion of the cutting operation the rope
(See Fig. 10 for typical method of applying a serving ends will remain in position, thus avoiding any
to a multi-layer rope.) backlash or any other undesirable movement.
Ensure that the length of serving is at least equal to two Cut the rope with a high speed abrasive disc cutter.
rope diameters. (Note: Special servings are required for Other suitable mechanical or hydraulic shearing
spiral ropes, i.e. spiral strand and locked coil.) equipment may be used although not recommended
when a rope end is required to be welded or brazed.
For serving instructions for FL and HL ropes refer to
Bridon.
46 BRIDON Mining
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
When terminating a rope end with a wedge socket,
WARNING
ensure that the rope tail cannot withdraw through the
When using a disc cutter be aware of the danger socket by securing a clamp to the tail or by following
from sparks, disc fragmentation and fumes. the manufacturers instructions.
(Refer 3.2.)
(See Fig. 11 for two recommended methods of
securing the rope tail of a wedge socket termination).
Ensure adequate ventilation to avoid any build-up of
fumes from the rope and its constituent parts
including any fibre core (natural or synthetic) any rope
lubricant(s) and any synthetic filling and/or covering
material.
WARNING
WARNING
After cutting, the rope cross-sections of non- The loop back method uses a rope grip and the loop
preformed ropes, multi-layer ropes and parallel should be lashed to the live part of rope by a soft wire
closed ropes must be welded, brazed or fused and serving or tape to prevent flexing of the rope
tapered such that all wires and strands in the rope are in service.
completely secured.
The method of looping back should not be used if
there is a possibility of interference of the loop with
WARNING the mechanism or structure.
Failure to correctly secure the rope end is likely to
lead to slackness, distortions, premature removal WARNING
from service and a reduction in the breaking force
of the rope. Failure to secure in accordance with instructions
could lead to loss of the rope and/or injury.
BRIDON Mining 47
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
the termination is fitted in accordance with the OEMs
WARNING
instruction manual or manufacturers instructions.
Any looseness or uneven winding will result in
When re-using a socket and depending on its type
excessive wear, crushing and distortion of the rope.
and dimensions, the existing cone should be pressed
out. Otherwise, heat may be necessary.
With plain barrel drums it is difficult to achieve
satisfactory multi-layer coiling beyond three layers.
WARNING
The direction of coiling of the rope on the drum is
When melting out sockets which have previously
important, particularly when using plain barrel drums,
been filled with hot metal, the emission of toxic
and should be related to the direction of lay of the
fumes is likely. Note that white metal contains a
rope in order to induce close coiling.
high proportion of lead.
(See Fig. 12 for proper method of locating rope
anchorage point on a plain drum.)
Correctly locate and secure any connection pins and
fittings when assembling end terminations to fixtures.
Proper method of locating rope anchorage point Refer to manufacturers instructions.
on a plain drum
WARNING
RIGHT HAND
LAY ROPE-
Failure to pay attention to any of the above could
UNDERWIND
result in unsafe operation and
START ROPE potential injury.
AT LEFT
RIGHT HAND
FLANGE
LAY ROPE-
RIGHT
HAND
OVERWIND 3.16 Limit switches, if fitted, must be checked and
re-adjusted, if necessary, after the rope has
LEFT
been installed.
HAND LEFT HAND
LAY ROPE- 3.17 Record the following details on the Certificate after
UNDERWIND
installation has been completed: type of equipment,
location, plant reference number, duty and date of
LEFT installation and any re-rating information/signature of
HAND LEFT HAND
LAY ROPE-
competent person. Then safely file the Certificate.
OVERWIND
3.18 Run in the new rope by operating the equipment
slowly, preferably with a low load, for several cycles.
note: Thumb indicates side of rope anchorage
This permits the new rope to adjust itself gradually to
working conditions.
Fig 12
Note: Unless otherwise required by a certifying authority, the rope
When multi layer coiling has to be used it should be should be in this condition before any proof test of the equipment or
realised that after the first layer is wound on a drum, machinery is carried out.
the rope has to cross the underlying rope in order to
Check that the new rope is spooling correctly on the
advance across the drum in the second layer. The
drum and that no slack or cross laps develop.
points at which the turns in the upper layer cross
those of the lower layer are known as the cross-over If necessary, apply as much tension as possible
points and the rope in these areas is susceptible to to ensure tight and even coiling, especially on the
increased abrasion and crushing. Care should be first layer.
taken when installing a rope on a drum and when
Where multi-layer coiling is unavoidable,
operating a machine to ensure that the rope is coiled
succeeding layers should coil evenly on the
and layered correctly.
preceding layers of rope.
3.15 Check the state of re-usable rope end terminations
for size, strength, defects and cleanliness before use.
Non-destructive testing may be required depending
on the material and circumstances of use. Ensure that
48 BRIDON Mining
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
Note: Shortening the rope re-positions the areas of maximum
WARNING
deterioration in the system. Where conditions permit, begin operating
Irregular coiling usually results in severe surface with a rope which has a slightly longer length than necessary in order
wear and rope malformation, which in turn is likely to allow for periodic shortening.
to cause premature rope failure.
When a non-preformed rope, multi-layer rope or
parallel closed rope is used with a wedge socket and
3.19 Ensure that the as-manufactured condition of the is required to be shortened, it is essential that the end
rope is maintained throughout the whole of the of the rope is secured by welding or brazing before
handling and installation operation. the rope is pulled through the main body of the
socket to its new position. Slacken the wedge in the
3.20 If samples are required to be taken from the rope for
socket. Pass the rope through the socket by an
subsequent testing and/or evaluation, it is essential
amount equivalent to the crop length or sample
that the condition of the rope is not disturbed. Refer
required. Note that the original bent portion of the
to the instructions given in 3.12 and, depending on
rope must not be retained within the wedge socket.
the rope type and construction, any other special
Replace the wedge and pull up the socket. Prepare
manufacturers instructions.
and cut in accordance with section 3.12. Ensure that
4. In Service the rope tail cannot withdraw through the socket, see
section 3.13.
4.1 Inspect the rope and related equipment at the
beginning of every work period and particularly
following any incident which could have damaged the WARNING
rope or installation.
Failure to observe this instruction will result in a
The entire length of rope should be inspected and significant deterioration in the performance of the
particular attention paid to those sections that rope and could render the rope completely unfit for
experience has proven to be the main areas of further service.
deterioration. Excessive wear, broken wires, distortion
and corrosion are the usual signs of deterioration. For
In cases where severe rope wear takes place at one
a more detailed examination special tools are
end of a wire rope, the life of the rope may be
necessary (see Fig. 13) which will also facilitate
extended by changing round the drum end with the
internal inspection (see Fig. 14.)
load end, i.e. turning the rope end for end before
deterioration becomes excessive.
Fig 13
4.2 Remove broken wires as they occur by bending
backwards and forwards using a pair of pliers until
they break deep in the valley between two outer
strands (see Fig. 15). Wear protective clothing such
as overalls, industrial gloves, helmet, eye protectors
and safety footwear during this operation.
Fig 14
BRIDON Mining 49
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
Note: Broken wires are a normal feature of service, more so towards
WARNING
the end of the ropes life, resulting from bending fatigue and wear.
The local break up of wires may indicate some mechanical fault in Failure to take adequate precaution could result in
the equipment. injury or damage to health.
Rope distortion is usually a result of mechanical 4.8 Lubricants selected for in-service dressing must be
damage and can significantly reduce rope strength. compatible with the rope manufacturing lubricant and
should be referenced in the OEMs instruction manual
or other documents approved by the owner of the
4.5 An authorised competent person must examine the
appliance.
rope in accordance with the appropriate Regulations.
If in doubt contact the rope supplier or Bridon.
4.6 Do not carry out any inspection, examination,
dressing/lubrication, adjustment or any other 4.9 Take particular care when applying any in-service
maintenance of the rope whilst it is suspending a lubricant/dressing. Application systems which involve
load, unless otherwise stated in the OEMs instruction pressure should only be operated by trained and
manual or other relevant documents. authorised persons and the operation carried out strictly
in accordance with the manufacturers instructions.
Do not carry out any inspection or maintenance of the
rope if the appliance controls are unattended unless the Most wire ropes should be lubricated as soon as they
surrounding area has been isolated or sufficient warning are put into service and at regular intervals thereafter
signs have been posted within the immediate vicinity. (including cleaning) in order to extend
safe performance.
If the appliance controls are attended, the authorised
person must be able to communicate effectively with
the driver or controller of the appliance during the WARNING
inspection process.
A dry rope unaffected by corrosion but subject to
4.7 Never clean the wire rope without recognising the bend fatigue, is likely to achieve only 30% of that
potential hazards associated with working on a normally attained by a lubricated rope.
moving rope.
50 BRIDON Mining
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
4.10 The authorised person responsible for carrying out Handle the rope in accordance with the instructions
wire rope maintenance must ensure that the ends of given in section 3. Serve the rope, using the buried
the rope are secure. At the drum end this will involve wire technique (see Fig. 10) and apply a rope clamp
checking the integrity of the anchorage and ensuring or grip as close to the cut mark as practically
that there are at least two and a half dead laps tightly possible. Do not use solder to secure the servings.
coiled. At the outboard end the integrity of the
Ensure that the sample is kept straight throughout the
termination must be checked to ensure that it is in
whole procedure and ensure that the minimum
accordance with the OEMs manual or other
sample length is 3 metres for ropes up to and
documents approved by the owner of the appliance.
including 40mm diameter and 12 metres for larger
Adjust the lengths of ropes in multi-rope systems in diameter ropes.
order that equal forces (within approved limits)
The rope should be cut with a high speed abrasive
are evident.
disc cutter or an oxyacetylene torch. Weld the rope
If a wire rope needs cutting refer to 3.12. ends of the sample as described in section 3.12, after
which the clamp or grip can be removed.
When securing rope ends refer to 3.13.
The identification of the rope must be established and
When re-usable end terminations are used refer to 3.15.
the sample suitably marked and packed. It is
When re-connecting any end terminations to fixtures recommended that the 3 metre sample is retained
refer to 3.15. straight and secured to a wood batten for
transportation. For a 12 metre sample, coil to a
4.11
diameter as large as practically possible and never
less than 2 metres.
WARNING
Note: Samples taken for destruction testing are required to be
Damage to, or removal of component parts terminated in accordance with a recognised resin socketing
(mechanical or structural) caused by abnormal standard (e.g. BS EN 13411-4 or ISO 7596).
contact with wire rope can be hazardous to the
safety of the appliance and/or the performance of
WARNING
the rope (e.g. damage to the drum grooving, such
that coiling is erratic and/or the rope is pulled Failure to comply with these procedures will result in
down into underlying layers, which might cause a measured breaking force values which are not truly
dangerous condition or, alternatively, cause representative of the actual strength of the rope.
localised rope damage at cross-over positions,
which might then radically affect performance;
5. Wire Rope Discard
loss/removal of wear plates protecting the
structure leading to major structural damage by 5.1 Discard the wire rope in accordance with current
cutting and/or failure of the wire rope due to Regulations and in accordance with the OEMs
mechanical severance). instruction manual.
Check that the rope end, from which the sample will WARNING
be taken, is secured by welding or brazing. If not,
Take particular care when removing ropes with
select the sample length further away from the rope
mechanical damage as they may fail abruptly
end and prepare new servings (see 3.12).
during the change-out procedure.
BRIDON Mining 51
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
Take the utmost care when removing exhausted/failed
WARNING
ropes from drums and sheaves as they may be grossly
distorted, lively and tightly coiled. Wire rope which bends around sheaves, rollers or
drums will deteriorate through bending fatigue.
Reverse bending and high speed will accelerate
WARNING
the process. Therefore, under such conditions
Failure to take adequate precautions could result select a rope with high bending fatigue resistance.
in injury. Refer to Product Data Information, and if in doubt
ask for advice.
5.5 Record the date and reason for discard on the Abrasion weakens the rope by removing metal
Certificate before filing for future reference. from both the inner and outer wires. Therefore,
a rope with large outer wires should normally
5.6 Pay attention to any Regulations affecting the safe
be selected.
disposal of steel wire rope.
By applying the relevant coefficient of utilisation Rope with a steel core is more resistant to crushing
(safety factor) and, where applicable, the efficiency of and distortion.
the rope termination, the required minimum breaking
6.6 Corrosion
load or force of the rope will be determined, the
values of which are available from the relevant Rope with a large number of small wires is more
National, European or International standards or from susceptible to corrosion than rope with a small
specific Product Data literature. number of large wires. Therefore, if corrosion is
If in doubt ask for advice from Bridon or expected to have a significant effect on rope
Bridons distributor. performance select a galvanised rope with as large
an outer wire size as possible bearing in mind the
6.2 Bending fatigue
other conditions (e.g. bending and abrasion) under
The size and number of sheaves in the system will which the rope will be operating.
influence the performance of the rope.
52 BRIDON Mining
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
6.7 Connecting Ropes
6.10 Operating Temperatures
In the event that it is necessary to connect one rope
Wire rope with a steel core should be selected if there
to another (in series) it is essential that they have the
is any evidence to suggest that a fibre core will not
required strength, are of the same type and both have
provide adequate support to the outer strands and/or
the same lay direction (i.e. connect right lay to right
if the temperature of the working environment may be
lay).
expected to exceed 100C.
BRIDON Mining 53
Technical Information
Product Safety: Instructions & Warnings on the use of steel wire rope
WARNING
CAUTIONARY NOTICE RESTRICTIONS ON THE being in the region of half the breaking strength
USE OF LARGE DIAMETER MULTISTRAND ROPES. of the rope.
All wire ropes are prone to damage if they are not The best way of preventing difficulties of this sort
properly supported when used at high loads. is to avoid conditions that are likely to generate
Larger Multistrand ropes are particularly damagingly high contact stresses. A simple
susceptible to this form of abuse, due to their rigid method of assessing the severity of the contact
construction and the relatively fine wire sizes conditions is to firstly calculate the tread pressure
involved in their manufacture/construction. based on the projected nominal area and then
Instances have been recorded of ropes being apply a factor (of say 10*) to allow for the highly
heavily worked over plain drums and failing localised and intermittent nature of the actual wire
"prematurely", despite the nominal tension being contacts, as indicated below :-
Note: Contact stresses which exceed 10% of the wire UTS should be Worked example:
considered a cause for concern, especially if the rope is operating at
Consider case of a 50mm Multistrand rope (MBL=2100kN)
a low factor of safety.
operating at a 3:1 factor of safety. Then, for the Contact
[* This is because the true contact area is very much less than the stress < 200 Mpa say, the following minimum bending
projected nominal area.] diameters are indicated:
54 BRIDON Mining
Technical Information
BASE METAL
Aluminium 0.3 10 20
Carbon 1.0 None Listed
Chromium 0.4 0.5
Cobalt 0.3 0.1
Copper 0.5 0.2
Iron Balance 5 10
Manganese 1.0 5 5
Molybdenum 0.1 5 10
Nickel 0.5 1
Phosphorus 0.1 0.1 0.3
Silicon 0.5 10
Sulphur 0.5 None Listed
Vanadium 0.25 0.5
Boron 0.1 10 20
Titanium 0.1 10
Nitrogen 0.01 5 9
Lead 0.1 0.15
Arsenic 0.01 0.2
Zirconium 0.05 5 10
COATED
Sodium 0.5 None Listed
Calcium 0.5 2
Boron 1.0 10 20
Phosphorus 1.0 0.1 0.3
Iron 1.0 5 10
Zinc 1.0 5 10
Oil may be applied 5.0 5 10
Physical Data
Specific Gravity: 7.5 - 8.5 Vapour Pressure: N/A
Melting Point: 1350 - 1500 oC Vapour Density: N/A
Appearance & Odour: Solid. Odourless Metal Evaporation: N/A
Solubility in water: Insoluble % Volatiles: N/A
Flash Point: None Boiling Point: > 2800 oC
BRIDON Mining 55
Technical Information
BASE METAL
Aluminium 0.3 10 20
Carbon 1.0 None Listed
Chromium 0.4 0.5
Cobalt 0.3 0.1
Copper 0.5 0.2
Iron Balance 5 10
Manganese 1.0 5 5
Molybdenum 0.1 5 10
Nickel 0.5 1
Phosphorus 0.1 0.1 0.3
Silicon 0.5 10
Sulphur 0.5 None Listed
Vanadium 0.25 0.5
Boron 0.1 10 20
Titanium 0.1 10
Nitrogen 0.01 5 9
Lead 0.1 0.15
Arsenic 0.01 0.2
Zirconium 0.05 5 10
COATED
Zinc 10.0 5 10
Aluminium 1.5 10 20
Iron 5.0 5 10
Sodium 0.5 None Listed
Calcium 0.5 2
Boron 1.0 100 20
Phosphorus 1.0 0.1 0.3
Sulphur 0.5 None Listed
Oil may be applied 5.0 5 10
Wax may be applied 5.0 2 6
Physical Data
Specific Gravity: 7.5 - 8.5 Vapour Pressure: N/A
Melting Point: 1350 - 1500 oC Vapour Density: N/A
Appearance & Odour: Solid. Odourless Metal Evaporation: N/A
Solubility in water: Insoluble % Volatiles: N/A
Flash Point: None Boiling Point: > 2800 oC
56 BRIDON Mining
Technical Information
Oil mist 5 10 If heated rope lubricants contacts skin, severe burns may result.
Paraffin wax fume 2 6 Prolonged or repeated skin contact may cause irritation,
Bitumen 5 10 dermatitis or more serious skin disorders.
Silica, fused
Total inhalable dust 0.3 Fibre Cores
Respirable dust 0.1
Being in the centre of a steel wire rope, the materials
Aluminium flake 10 20
(natural or synthetic) from which fibre cores are produced
Zinc oxide, fume 5 10
do not present a health hazard during normal rope
Butane 1430 1780
handling. Even when the outer core strands are removed
(for example when the rope is required to be socketed) the
There are no other known constituents of any wire rope
core materials present virtually no hazard to the users,
lubricant used that are classified as hazardous in the
except, maybe, in the case of a used rope where, in the
current edition of EH40.
absence of any service dressing or as a result of heavy
General advice on handling ropes with lubricants working causing internal abrasive wear of the core, the core
may have decomposed into a fibre dust which might be
To avoid the possibility of skin disorders, repeated or inhaled, although this is considered extremely unlikely.
prolonged contact with mineral or synthetic hydrocarbons
must be avoided and it is essential that all persons who The principal area of hazard is through the inhalation of
come into contact with such products maintain high fumes generated by heat, for example when the rope is
standards of personal hygiene. being cut by a disc cutter.
BRIDON Mining 57
Technical Information
Under these conditions, fillings and coverings, which are Inner wires: All wires of intermediate layers positioned
generally polypropylene, polyethylene and polyamid (but in between the centre wire and outer layer of wires in a spiral
some cases may be of natural fibre) are likely to produce rope or all other wires except centre, filler, core and outer
toxic fumes. wires of a stranded rope.
General Information Core wires: All wires of the core of a stranded rope.
Occupational protective measures Centre wires: Wires positioned either at the centre of a
1) Respiratory protection - Use general and local spiral rope or at the centres of strands of a stranded rope.
exhaust ventilation to keep airborne dust or fumes Layer of wires: An assembly of wires having one pitch
below established occupational exposure standards circle diameter. The exception is Warrington layer
(OESs). Operators should wear approved dust and comprising alternately laid large and small wires where the
fume respirators if OESs are exceeded. smaller wires are positioned on a larger pitch circle
(The OES for total dust is 10mg/m3 and for respirable diameter than the larger wires. The first layer is that which is
dust is 5mg/m3). laid immediately over the strand centre.
2) Protective equipment - Protective equipment should
be worn during operations creating eye hazards. A Note: Filler wires do not constitute a separate layer.
welding hood should be worn when welding or burning. Tensile strength grade of wires: A level of requirement of
Use gloves and other protective equipment tensile strength of a wire and its corresponding tensile
when required. strength range. It is designated by the value according to
3) Other - Principles of good personal hygiene should the lower limit of tensile strength and is used when
be followed prior to changing into street clothing or specifying wire and when determining the calculated
eating. Food should not be consumed in the minimum breaking force or calculated minimum aggregate
working environment. breaking force of a rope.
Emergency medical procedures Wire finish: The condition of the surface finish of a wire,
1) Inhalation - Remove to fresh air; get medical attention. e.g. bright, zinc coated.
2) Skin - Wash areas well with soap and water.
3) Eyes - Flush well with running water to remove
particulate; get medical attention.
4) Ingestion - In the unlikely event that quantities of rope or
any of its components are ingested, get medical attention.
58 BRIDON Mining
Technical Information
Rope Terminology
Strands Combined parallel lay: Parallel lay strand construction
having three or more layers of wires, e.g. 14-7+7-7-1;
Strand: An element of rope usually consisting of an 16-8+8-8-1; 14-14-7F-7-1; 16-16-8F+8-1.
assembly of wires of appropriate shape and dimensions
laid helically in the same direction in one or more layers Note: The first two examples above are also referred to as
around a centre. Warrington-Seale construction. The latter two examples are also
referred to as Seale-Filler construction.
Note: Strands containing three or four wires in the first layer or certain
shaped (e.g. ribbon) strands may not have a centre. Multiple operation lay strand: Strand construction
containing at least two layers of wires, at least one of which
Round strand: A strand with a cross-section which is is laid in a separate operation. All of the wires are laid in the
approximately the shape of a circle. same direction.
Triangular strand: A strand with a cross-section which is Cross-lay: Multiple operation strand construction in which
approximately the shape of a triangle. the wires of superimposed wire layers cross over one
Note: Triangular strands may have built-up centres (i.e. more than another and make point contact, e.g. 12/6-1.
one wire forming a triangle). Compound lay: Multiple operation strand which contains a
Oval strand: A strand with a cross-section which is minimum of three layers of wires, the outer layer of which is
approximately the shape of an oval laid over a parallel lay centre, e.g. 16/6+6-6-1.
Note: This is also referred to as equal lay. The lay length of all the Single Layer Rope: Stranded rope consisting of one layer
wire layers are equal. of strands laid helically over a core.
Seale: Parallel lay strand construction with the same Note: Stranded ropes consisting of three or four outer strands may,
number of wires in each wire layer, each wire layer or may not, have a core. Some three and four strand single layer
containing wires of the same size, e.g. 7-7-1; 8-8-1; 9-9-1. ropes are designed to generate torque levels equivalent to those
generated by rotation-resistant and low rotation ropes.
Warrington: Parallel lay strand construction having an
outer layer of wires containing alternately large and small Rotation-resistant Rope: Stranded rope having no less
wires, the number of wires in the outer layer being twice than ten outer strands and comprising an assembly of at
that in the underlying layer of wires, e.g. 6+6-6-1; 7+7-7-1. least two layers of strands laid over a centre, the direction
of lay of the outer strands being opposite (i.e. contra - lay)
Filler: Parallel lay strand construction having an outer layer to that of the underlying layer of strands.
of wires containing twice the number of wires than in the
inner layer with filler wires laid in the intersticeswires of the Low Rotation Rope: Rotation resistant rope having at
underlying layer of wires, e.g. 12-6F-6-1; 14-7F-7-1. least fifteen outer strands and comprising an assembly of
at least three layers of strands laid over a centre in
two operations.
BRIDON Mining 59
Technical Information
Rope Terminology
Compacted Strand Rope: Rope in which the outer Braided Rope: An assembly of several round strands
strands, prior to closing of the rope, are subjected to a braided in pairs.
compacting process such as drawing, rolling or swaging.
Electro-mechanical Rope: A stranded or spiral rope
Note: Bridons products containing compacted strands are identified containing electrical conductors.
by Dyform.
Preformed Rope: Stranded rope in which the wires in the Contra-lay: Rope in which at least one inner layer of wires
strands and the strands in the rope have their internal in a spiral rope or one layer of strands in a stranded rope is
stresses reduced resulting in a rope in which, after removal laid in the opposite direction to the other layer(s) of wires or
of any serving, the wires and the strands will not spring out strands respectively.
of the rope formation.
Note: Contra-lay is only possible in spiral ropes having more than
Note: Multi-layer stranded ropes should be regarded as non- one layer of wires and in multi-layer stranded ropes.
preformed rope even though the strands may have been partially
Rope lay length (Stranded Rope): That distance parallel
(lightly) preformed during the closing process.
to the axis of the rope in which the outer strands make one
Rope Class: A grouping of rope constructions where the complete turn (or helix) about the axis of the rope.
number of outer strands and the number of wires and how
they are laid up are within defined limits, resulting in ropes Cores
within the class having similar strength and rotational
Core: Central element, usually of fibre or steel, of a single
properties.
layer stranded rope, around which are laid helically the
Rope Construction: System which denotes the outer strands of a stranded rope or the outer unit ropes of a
arrangement of the strands and wires within a rope, e.g. cable-laid rope.
6x36WS, 6x19S.
Fibre core: Core made from natural fibres(e.g. hemp,
Note: K denotes compacted strands. sisal) and designated by its diameter and runnage.
Cable-laid Rope: An assembly of several (usually six) Fibre Film Core: Core made from synthetic fibres (e.g.
single layer stranded ropes (referred to as unit ropes) laid polypropylene) and designated by its diameter and
helically over a core (usually a seventh single layer runnage.
stranded rope).
60 BRIDON Mining
Technical Information
Steel core: Core produced either as an independent wire Minimum breaking force (Fmin): Specified value, in kN,
rope (IWRC)(e.g. 7x7) or wire strand (WSC)(e.g. 1x7). below which the measured breaking force is not allowed to
fall in a prescribed test and, for ropes having a grade,
Solid polymer core: Core produced as a single element
obtained by calculation from the product of the square of
of solid polymer having a round or grooved shape. It may
the nominal diameter, the rope grade and the breaking
also contain internal elements of wire or fibre.
force factor.
Insert: Element of fibre or solid polymer so positioned as
Minimum aggregate breaking force (Fe,min): Specified
to separate adjacent strands or wires in the same or
value, in kN, below which the measured aggregate
overlying layers and fill, or partly fill, some of the interstices
breaking force is not allowed to fall in a prescribed test and,
in the rope. (see Zebra)
for ropes having a grade, obtained from the product of the
square of the nominal rope diameter (d), the metallic cross-
Rope Characteristics and Properties sectional area factor (C) and the rope grade (Rr).
Calculated Minimum aggregate Breaking Force: Value
Nominal length mass: The nominal mass values are for
of minimum aggregate breaking force is obtained by
the fully lubricated ropes. For friction winder ropes, the
calculation from the sum of the products of the cross-
values should be reduced by 2%. The nominal length mass
sectional area (based on nominal wire diameter) and tensile
values are subject to a tolerance of plus 2% to minus 5%.
strength grade of each wire in the rope, as given in the
manufacturers rope design. Rope torque: Value, usually expressed in N.m, resulting
from either test or calculation, relating to the torque
Calculated Minimum breaking Force: Value of minimum
generated when both ends of the rope are fixed and the
breaking force based on the nominal wire sizes, wire tensile
rope is subjected to tensile loading.
strength grades and spinning loss factor for the rope class
or construction as given in the manufacturers rope design. Rope turn: Value, usually expressed in degrees per metre,
resulting from either test or calculation, relating to the
Fill factor: The ratio between the sum of the nominal
amount of rotation when one end of the rope is free to
cross-sectional areas of all the load bearing wires in the
rotate and the rope is subjected to tensile loading.
rope and the circumscribed area of the rope based on its
nominal diameter. Initial extension: Amount of extension which is attributed
to the initial bedding down of the wires within the strands
Spinning loss factor (k): The ratio between the calculated
and the strands within the rope due to tensile loading.
minimum breaking force of the rope and the calculated
minimum aggregate breaking force of the rope. Note: This is sometimes referred to as constructional stretch.
Breaking force factor (K): An empirical factor used in the Elastic extension: Amount of extension which follows
determination of minimum breaking force of a rope and Hookes Law within certain limits due to application of a
obtained from the product of fill factor for the rope class or tensile load.
construction, spinning loss factor for the rope class or
Permanent rope extension: Non-elastic extension.
construction and the constant /4.
BRIDON Mining 61
Technical Information
1 hectobar = 10 N/mm2
1 hectobar = 1 x 107 N/m2
62
Contacts
BRIDON
Sales Offices
UNITED KINGDOM INDONESIA SINGAPORE
Doncaster PT Bridon Bridon Singapore (Pte) Ltd.
Balby Carr Bank, Doncaster Graha Inti Fauzi Loyang Offshore Supply Base
South Yorkshire 2nd Floor (SOPS Way)
DN4 5JQ Jl. Buncit Raya No.22 Box No: 5064
United Kingdom Jakarta 12510 Loyang Crescent
sales@bridon.com bridon@cbn.net.id Singapore 508988
Phone: +44(0) 1302 565100 Phone: +62 (021) 791 81919 bluestrand@bridon.com.sg
Fax: +44(0) 1302 565190 Fax: +62 (021) 799 2640 Phone: +65 654 64 611
Fax: +65 654 64 622
UNITED STATES AFRICA
Bridon American Angola
CHINA
C280 New Commerce Blvd. Sonils Base Bridon Hong Kong Ltd.
Wilkes Barre Luanda Unit B G/F Roxy Industrial Centre
PA 18706 Angola 58-66 Tai Lin Pai Road
USA angolaops@bridon.com Kwai Chung
bridon@bridonamerican.com Phone: + 244 923 726890 Northern Territory
Phone: +1 800 521 5555 Fax: + 244 923 854180 Hong Kong
Fax: +1 800 233 8362 Kwanda Base sales@bridon.com.hk
Soyo Phone: +852 240 11 166
GERMANY Angola Fax: +852 240 11 232
kwandasupv@bridon.com Bridon Hangzhou
Bridon International GmbH
Phone: + 244 935 939761
Magdeburger Strae 14a Fax: + 244 937 638565 57 Yonghua Street
D-45881 Xiacheng District
Gelsenkirchen Hangzhou City
Germany
SOUTH AFRICA Zhejiang Province
info@bridon.de mining@bridonafrica.com 310022.P.R.China
Phone: +49(0) 209 8001 0 Phone: +27 (0) 11 867 3987 sales@bridonhangzhou.com
Fax: +49(0) 209 8001 275 Cell: +27 (0) 79 887 2747 Phone: +86 571 8581 8780
Fax: +27 (0) 11 867 3987 Fax: +86 571 8813 3310
RUSSIA
MIDDLE EAST AUSTRALIA
Bridon International Moscow
Bridon Middle East mining@bridonaustralia.com
Ivovaya Street 2/8
Phone: +61 429 999 756
Building 1, Office 215 PO Box 16931
129329 Moscow Dubai
Russia United Arab Emirates NEW ZEALAND
info@bridon.ru bridonme@emirates.net.ae 6-10 Greenmount Drive
Phone: +7 499 1808001 Phone: +971 488 35 129 East Tamaki
Fax: +7 499 1809231 Fax: +971 488 35 689 PO Box 14 422
Panmure
BRAZIL AUCKLAND
salesadmin@cookes.co.nz
mining@bridonbrazil.com
Phone: +64 9 2744299
Phone: +55 15 3232 8012
Fax: +64 9 2747982
Fax: +55 15 3232 8012
63
Ground Floor, Icon Building, Magdeburger Strae C280 New Commerce Blvd.
First Point, Balby Carr Bank, 14a D-45881, Wilkes Barre,
Doncaster, South Yorkshire Gelsenkirchen, PA 18706,
DN4 5JQ United Kingdom Germany USA
Phone: +44(0) 1302 565100 Phone: +49(0) 209 8001 0 Phone: +1 800 521 5555
08/2011 Edition IMP1
Fax: +44(0) 1302 565190 Fax: +49(0) 209 8001 275 Fax: +1 800 233 8362
Email: mining@bridon.com info@bridon.de bridon@bridonamerican.com
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