AS 2759-2004

1-AS 2759-2004 STEEL WIRE ROPE-USE, OPERATION AND MAINTENANCE
4-PREFACE
5-CONTENTS
8-SECTION 1 SCOPE AND GENERAL
8-1.1 SCOPE
8-1.2 APPLICATION
8-1.3 INNOVATIONS
8-1.4 REFERENCED DOCUMENTS
9-1.5 DEFINITIONS
10-SECTION 2 SELECTION
10-2.1 GENERAL
10-2.2 PHYSICAL PROPERTIES
11-2.3 TEMPERATURE
11-2.3.1 High temperature effects
11-2.3.2 Low temperature effects
11-2.4 WORKING LOAD LIMIT
11-2.4.1 General
12-2.4.2 Design factors
13-SECTION 3 STORAGE AND HANDLING
13-3.1 STORAGE
13-3.2 UNCOILING AND HANDLING (see Figure 3.2)
16-SECTION 4 CUTTING AND FITTING
16-4.1 ROPE END PREPARATION
16-4.2 SEIZING
16-4.2.1 Purpose
16-4.2.2 Seizing materials
17-4.2.3 Length
17-4.2.4 Cutting
20-SECTION 5 ROPE FITTINGS AND THEIR EFFICIENCIES
20-5.1 SELECTION OF FITTINGS AND END ATTACHMENTS
20-5.2 TYPES OF FITTINGS
20-5.2.1 General
20-5.2.2 Hand-spliced eyes
20-5.2.3 Ferrule-secured rope attachments
21-5.2.4 Swaged end fittings
21-5.2.5 Poured sockets
21-5.2.6 Wedge grip capels
21-5.2.7 Wedge-type sockets
21-5.2.8 Wire-rope grips
25-SECTION 6 POURED SOCKETS
25-6.1 GENERAL
25-6.2 QUALIFYING AND QUALITY CONTROL
25-6.2.1 Personnel
25-6.2.2 Poured socket systems
25-6.2.3 Type testing
26-6.2.4 Proof testing
26-6.3 SPECIFICATIONS FOR SOCKETS
26-6.3.1 General purpose sockets
26-6.3.2 Sockets for strand and higher capacity wire rope
26-6.3.3 Reuse of sockets
26-6.3.4 Inspection of sockets prior to socketing
26-6.4 SOCKETING MATERIAL
26-6.4.1 Resin socketing
26-6.4.2 Metal socketing
26-6.4.3 Lift applications
27-6.5 PREPARATION OF WIRE ROPE OR STRAND AND SOCKET READY FOR FITTING
27-6.5.1 Temporary seizing
27-6.5.2 Permanent seizing
27-6.5.3 Cutting the wire rope
28-6.5.4 Forming the brush
28-6.5.5 Cores
28-6.5.6 Degreasing
28-6.5.7 Hooking
29-6.5.8 Position of wires in socket
29-6.5.9 Preparation procedures
30-6.6 RESIN SOCKETING
30-6.6.1 Resin systems
30-6.6.2 Resin socketing procedure
30-6.7 METAL SOCKETING
30-6.7.1 Socketing metals
30-6.7.2 Containers
31-6.7.3 Metal socketing procedure
31-6.8 INSPECTION
32-6.9 IN-SERVICE INSPECTION ADVICE
32-6.10 FLOW CHART PRESENTATION OF SOCKETING PROCEDURES FOR STRANDED STEEL WIRE ROPES
36-SECTION 7 SPLICING
36-7.1 SPLICING TOOLS
37-7.2 TUCKING LENGTHS FOR EYE SPLICES
37-7.3 NUMBER OF TUCKS FOR EYE SPLICES
37-7.3.1 Cores of the rope
37-7.3.2 Le Blanc splices
38-7.3.3 Ordinary lay-Slings, anchorages and standing rigging
38-7.3.4 Ordinary lay-Crane ropes
38-7.3.5 Lang's lay ropes
38-7.4 PREPARATION OF ROPE FOR SPLICING AN EYE
41-7.5 TUCKING METHOD
41-7.5.1 General
42-7.5.2 First set of tucks
42-7.6 TUCKING SEQUENCE FOR FIVE°TUCK EYE SPLICES
42-7.6.1 Different methods
44-7.6.2 Method No. 1
48-7.7 LONG SPLICING
48-7.7.1 General
48-7.7.2 Length of splice
49-7.7.3 Method of splicing
56-7.7.4 Long splices in wire rope cored or steel strand cored ropes
57-7.7.5 Long splices in flattened strand ropes
58-SECTION 8 DIMENSIONS OF SHEAVES, DRUMS AND ANCHORAGES
58-8.1 GROOVES FOR SHEAVES AND DRUMS
58-8.1.1 Round grooves
58-8.1.2 Traction drive V-grooves
58-8.2 DIAMETER OF SHEAVES AND DRUMS
58-8.3 DIAMETER OF DEAD EYES OR END ANCHORAGES
59-8.4 RADIAL BEARING PRESSURES
59-8.4.1 General
59-8.4.2 In a crane or hoist
59-8.4.3 Other than in a crane
61-SECTION 9 ROPES USED ON DRUMS
61-9.1 ARRANGEMENT OF ROPE ON DRUMS
62-9.2 ROPE ANCHORAGES
64-9.3 FLEET ANGLES
64-9.4 DRUM CAPACITY
68-SECTION 10 ROPE ROTATION
68-10.1 GENERAL
68-10.2 SWIVELS
68-10.2.1 Bottom hook application
68-10.2.2 Dead end application
68-10.3 HEIGHT OF LIFT AND MULTI-PART REEVING
69-SECTION 11 INITIAL OPERATION
70-SECTION 12 LUBRICATION OF WIRE ROPES IN SERVICE
70-12.1 GENERAL
70-12.2 CLEANING
70-12.3 APPLICATION OF LUBRICANTS
71-12.4 TYPE OF LUBRICANT
72-12.5 CHARACTERISTICS OF LUBRICANTS
73-SECTION 13 ROPE INSPECTION
73-13.1 REGULAR INSPECTION
73-13.2 SPECIAL INSPECTION
74-13.3 FREQUENCY
74-13.4 MEASURING DIAMETER
75-13.5 INSPECTION LOG
75-13.6 POSITIONS
75-13.7 INTERNAL INSPECTIONS
76-13.8 NON-DESTRUCTIVE TESTING
80-SECTION 14 ROPE DISCARD
80-14.1 GENERAL
81-14.2 CONSTRUCTION
82-14.3 FRACTURED STRANDS
82-14.4 BROKEN WIRES
82-14.4.1 Number of wire breaks
88-14.4.2 Rate of increase of wire breaks
88-14.4.3 Wire breaks at terminations
88-14.4.4 Localized groupings of wire breaks
88-14.4.5 Tensile breaks
88-14.4.6 Abrasion breaks
89-14.4.7 Fatigue breaks
89-14.4.8 Martensitic failures
89-14.5 PLASTIC DEFORMATION
90-14.6 PHYSICAL DAMAGE
91-14.7 HEAT OR ELECTRIC ARCING
91-14.8 CORROSION
95-14.9 WEAR
97-14.10 STRETCH
98-14.11 REDUCTION OF ROPE DIAMETER
98-14.12 DECREASED ELASTICITY
99-14.13 DEFORMATION
99-14.13.1 General
99-14.13.2 Flattened portions (see Figure 14.13.2)
99-14.13.3 Bends (see Figure 14.13.3)
99-14.13.4 Kinks (see Figures 14.13.4(a) to 14.13.4(c))
102-14.13.5 Local diameter decrease (see Figure 14.13.5)
102-14.13.6 Local diameter increase
102-14.13.7 Scuffing (see Figures 14.13.7(A), 14.13.7(B) and 14.13.7(C))
102-14.13.8 Core dislodgement (see Figure 14.13.8)
102-14.13.9 Birdcaging (see Figures 14.13.9(A) to 14.13.9(E))
103-14.13.10 Waviness (see Figures 14.13.10(A) and 14.13.10(B))
108-14.14 DAMAGE WHILE ON DRUMS
109-14.15 DAMAGE CAUSED BY SHEAVES
110-APPENDIX A - GLOSSARY OF TERMS RELATING TO STEEL WIRE ROPES AND THEIR APPLICATION
118-APPENDIX B - STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS
119-APPENDIX C - WROUGHT ALUMINIUM ALLOY FERRULES (BASED ON DIN 3093.1 AND DIN 3093.2)
119-C1 SCOPE
119-C2 TYPES OF FERRULES
120-C3 DESIGNATION
120-C3.1 Flat oval tube and ferrule blanks (Types A and B)
121-C3.2 Ferrules for the preparation of cylindrical-conical swage joints (Type C)
121-C4 DIMENSIONS AND TOLERANCES
122-C4.1 Wall thickness
123-C4.2 Straightness of flat oval tubes
123-C4.3 Twist of flat oval tubes
124-C5 MATERIAL PROPERTIES
124-C5.1 Composition
124-C5.2 Strength properties
124-C6 MANUFACTURE
124-C7 TESTING
124-C7.1 General
124-C7.2 Batch sampling
125-C7.3 Additional testing
125-C8 MARKING
125-C9 SELECTION OF FERRULE BLANKS FOR A GIVEN ROPE
125-C9.1 General
125-C9.2 Fill factor
125-C10 STANDARD DIMENSIONS FOR SWAGED FERRULES
125-C10.1 Selection of ferrule size
127-C10.2 General
128-C11 PREPARATION OF THE ROPE FOR PRESSING
130-C12 PRESSING OF THE ROPE FERRULE
130-C12.1 General
130-C12.2 Strength properties
131-C13 APPLICATION TEMPERATURES
131-C14 TESTING
131-C15 INSPECTION
131-C16 TYPE TESTING OF TERMINATIONS
131-C16.1 General
131-C16.2 Special wire ropes
131-C16.3 Proof testing of terminations