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AS 2759-2004

[Pending Revision]

Steel wire rope — Use, operation and maintenance

Specifies procedures for the selection, storage, handling, maintenance, use, inspection and discard of helically laid steel wire ropes.
Published: 07/09/2004
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Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
1 Scope and general
1.1 Scope
1.2 Application
1.3 Innovations
1.4 Referenced documents
1.5 Definitions
2 Selection
2.1 General
2.2 Physical properties
2.3 Temperature
2.3.1 High temperature effects
2.3.2 Low temperature effects
2.4 Working load limit
2.4.1 General
2.4.2 Design factors
3 Storage and handling
3.1 Storage
3.2 Uncoiling and handling (see Figure 3.2)
4 Cutting and fitting
4.1 Rope end preparation
4.2 Seizing
4.2.1 Purpose
4.2.2 Seizing materials
4.2.3 Length
4.2.4 Cutting
5 Rope fittings and their efficiencies
5.1 Selection of fittings and end attachments
5.2 Types of fittings
5.2.1 General
5.2.2 Hand-spliced eyes
5.2.3 Ferrule-secured rope attachments
5.2.4 Swaged end fittings
5.2.5 Poured sockets
5.2.6 Wedge grip capels
5.2.7 Wedge-type sockets
5.2.8 Wire-rope grips
6 Poured sockets
6.1 General
6.2 Qualifying and quality control
6.2.1 Personnel
6.2.2 Poured socket systems
6.2.3 Type testing
6.2.4 Proof testing
6.3 Specifications for sockets
6.3.1 General purpose sockets
6.3.2 Sockets for strand and higher capacity wire rope
6.3.3 Reuse of sockets
6.3.4 Inspection of sockets prior to socketing
6.4 Socketing material
6.4.1 Resin socketing
6.4.2 Metal socketing
6.4.3 Lift applications
6.5 Preparation of wire rope or strand and socket ready for fitting
6.5.1 Temporary seizing
6.5.2 Permanent seizing
6.5.3 Cutting the wire rope
6.5.4 Forming the brush
6.5.5 Cores
6.5.6 Degreasing
6.5.7 Hooking
6.5.8 Position of wires in socket
6.5.9 Preparation procedures
6.6 Resin socketing
6.6.1 Resin systems
6.6.2 Resin socketing procedure
6.7 Metal socketing
6.7.1 Socketing metals
6.7.2 Containers
6.7.3 Metal socketing procedure
6.8 Inspection
6.9 In-service inspection advice
6.10 Flow chart presentation of socketing procedures for stranded steel wire ropes
7 Splicing
7.1 Splicing tools
7.2 Tucking lengths for eye splices
7.3 Number of tucks for eye splices
7.3.1 Cores of the rope
7.3.2 Le Blanc splices
7.3.3 Ordinary lay—Slings, anchorages and standing rigging
7.3.4 Ordinary lay—Crane ropes
7.3.5 Lang’s lay ropes
7.4 Preparation of rope for splicing an eye
7.5 Tucking method
7.5.1 General
7.5.2 First set of tucks
7.6 Tucking sequence for five-tuck eye splices
7.6.1 Different methods
7.6.2 Method No. 1
7.7 Long splicing
7.7.1 General
7.7.2 Length of splice
7.7.3 Method of splicing
7.7.3.1 Preliminary
7.7.3.2 Marrying
7.7.3.3 Running in
7.7.3.4 Tucking
7.7.4 Long splices in wire rope cored or steel strand cored ropes
7.7.5 Long splices in flattened strand ropes
8 Dimensions of sheaves, drums and anchorages
8.1 Grooves for sheaves and drums
8.1.1 Round grooves
8.1.2 Traction drive V-grooves
8.2 Diameter of sheaves and drums
8.3 Diameter of dead eyes or end anchorages
8.4 Radial bearing pressures
8.4.1 General
8.4.2 In a crane or hoist
8.4.3 Other than in a crane
9 Ropes used on drums
9.1 Arrangement of rope on drums
9.2 Rope anchorages
9.3 Fleet angles
9.4 Drum capacity
10 Rope rotation
10.1 General
10.2 Swivels
10.2.1 Bottom hook application
10.2.2 Dead end application
10.3 Height of lift and multi-part reeving
11 Initial operation
12 Lubrication of wire ropes in service
12.1 General
12.2 Cleaning
12.3 Application of lubricants
12.4 Type of lubricant
12.5 Characteristics of lubricants
13 Rope inspection
13.1 Regular inspection
13.2 Special inspection
13.3 Frequency
13.4 Measuring diameter
13.5 Inspection log
13.6 Positions
13.7 Internal inspections
13.8 Non-destructive testing
14 Rope discard
14.1 General
14.2 Construction
14.3 Fractured strands
14.4 Broken wires
14.4.1 Number of wire breaks
14.4.2 Rate of increase of wire breaks
14.4.3 Wire breaks at terminations
14.4.4 Localized groupings of wire breaks
14.4.5 Tensile breaks
14.4.6 Abrasion breaks
14.4.7 Fatigue breaks
14.4.8 Martensitic failures
14.5 Plastic deformation
14.6 Physical damage
14.7 Heat or electric arcing
14.8 Corrosion
14.9 Wear
14.10 Stretch
14.11 Reduction of rope diameter
14.12 Decreased elasticity
14.13 Deformation
14.13.1 General
14.13.2 Flattened portions (see Figure 14.13.2)
14.13.3 Bends (see Figure 14.13.3)
14.13.4 Kinks (see Figures 14.13.4(a) to 14.13.4(c))
14.13.5 Local diameter decrease (see Figure 14.13.5)
14.13.6 Local diameter increase
14.13.7 Scuffing (see Figures 14.13.7(A), 14.13.7(B) and 14.13.7(C))
14.13.8 Core dislodgement (see Figure 14.13.8)
14.13.9 Birdcaging (see Figures 14.13.9(A) to 14.13.9(E))
14.13.10 Waviness (see Figures 14.13.10(A) and 14.13.10(B))
14.14 Damage while on drums
14.15 Damage caused by sheaves
Appendix A
Appendix B
Appendix C
C1 Scope
C2 Types of ferrules
C3 Designation
C3.1 Flat oval tube and ferrule blanks (Types A and B)
C3.2 Ferrules for the preparation of cylindrical-conical swage joints (Type C)
C4 Dimensions and tolerances
C4.1 Wall thickness
C4.2 Straightness of flat oval tubes
C4.3 Twist of flat oval tubes
C5 Material properties
C5.1 Composition
C5.2 Strength properties
C6 Manufacture
C7 Testing
C7.1 General
C7.2 Batch sampling
C7.3 Additional testing
C8 Marking
C9 Selection of ferrule blanks for a given rope
C9.1 General
C9.2 Fill factor
C10 Standard dimensions for swaged ferrules
C10.1 Selection of ferrule size
C10.2 General
C11 Preparation of the rope for pressing
C12 Pressing of the rope ferrule
C12.1 General
C12.2 Strength properties
C13 Application temperatures
C14 Testing
C15 Inspection
C16 Type testing of terminations
C16.1 General
C16.2 Special wire ropes
C16.3 Proof testing of terminations
Cited references in this standard
DIN 3093-1
Wrought aluminium alloy ferrules, Part 1: Tubing blanks of oval cross section and constant wall thickness
DIN 3093-2
Wrought aluminium alloy ferrules, Part 2: Ferrule secured terminations—Safety requirements
[Current]
Thimbles for wire rope
[Current]
Cranes, hoists and winches, Part 1: General requirements
[Current]
Wire-rope slings, Part 2: Care and use
Content history
[Superseded]
DR 01306