Technical-Documentation (Casar)

®
TECHNICAL
DOCUMENTATION
INTRODUCTION AND TABLE OF CONTENTS
This manual about the technical properties of Casar Special Wire Ropes is intended
● to help the user of the ropes to find the best rope for his specific application,
● to help the designer to find the data he needs to build a safe, economic and
good machine, and
● to help the distributor of the ropes to give his customers even better assistance.
If you have a question which is not answered by this brochure, please do not hesitate
to contact us. We will do our best to help you.
Introduction and table of contents ....................................................................... 2

Computer aided rope design .............................................................................. 3
What is...? .......................................................................................................... 4
What is a compacted strand? ............................................................................. 5
What is parallel lay rope? ................................................................................... 6
What is a rotation-resistant rope? ....................................................................... 7
What is the effect of the plastic layer? ................................................................ 8
From wire to wire rope ........................................................................................ 9
Breaking load ................................................................................................... 10
Diagrams: Breaking load .................................................................................. 11
Fill factors, weight factors, spin factors ............................................................. 12
Bending fatigue................................................................................................. 13
Diagrams: Bending fatigue ............................................................................... 14
Which rope for which application? .................................................................... 16
Rotation ............................................................................................................ 18
Diagrams: Rotation ........................................................................................... 19
Efficiency .......................................................................................................... 20
Diagrams: Efficiency ......................................................................................... 21
Left hand or right hand lay rope? ...................................................................... 22
Elasticity and elongation ................................................................................... 23
Diagrams: Elasticity and elongation .................................................................. 24
Elongation curves ............................................................................................. 26
Diagrams: General ........................................................................................... 28
The drum .......................................................................................................... 30
Conversion factors............................................................................................ 31
2
R. Verreet, Technical Documentation, 8/1997
COMPUTER AIDED ROPE DESIGN
A steel wire rope is a complex machine part and consists of

a great number of wires and strands of different dimensions.
It is subjected to a wide spectrum of mechanical stresses.
Based on a wide range of empirical data and test results,

Casar Special Wire Ropes are adapted to the technical
requirements and optimized with the help of a computer.
3
WHAT IS …?
WIRE
STRAND
ROPE
LEFT HAND LAY
RIGHT HAND LAY
ORDINARY LAY
LANGS LAY
CONVENTIONAL STRANDS
COMPACTED STRANDS
4
WHAT IS A COMPACTED STRAND?
Some of the Casar Special Wire Ropes

are made out of conventional strands,
some are made out of compacted strands.
conventional strand compacted strand
In order to produce a compacted strand, a conventional strand made out of round

wires is drawn through a compacting tool. During this procedure, the wires are
plastically deformed, the strand diameter is reduced and the surface is made
smooth. The contact conditions between the individual wires and the strand-to-
strand contacts improve.
Ropes made out of compacted strands have a higher breaking load, a greater
flexibility and better rope- to- sheave contact conditions than comparable ropes
made out of conventional strands. Because of the larger outer wires and the
smaller exposed area they are more resistant to abrasion and corrosion.
5
WHAT IS A PARALLEL LAY ROPE?
In a cross (non-parallel) lay strand all wires have different

lay lengths, and in a cross (non-parallel) lay rope all
strands have different lay lengths. The high stress con-
centration at the crossover points leads to an early
internal failure.
cross (non-parallel) lay parallel lay

stress concentration stress distribution
In a parallel lay strand all wires have the same lay length,
and in a parallel lay rope all strands have the same lay
length. The linear contact leads to an optimal stress
distribution.
6
WHAT IS A ROTATION-RESISTANT ROPE?
In a conventional rope,
an external load creates
a moment which tries
to untwist the rope and
to rotate the load.
A rotation- resistant
Casar Special Wire Rope
has a steel core which is
an independent rope,
closed in the opposite di-
rection to the outer
strands. Under load, the
core tries to twist the rope
in the one direction, the
outer strands try to twist it
in the opposite direction.
The geometrical design

of a rotation-resistant
Casar Special Wire Rope
is such that the moments
in the core and the outer
strands compensate each
other over a wide load-
spectrum, so that even
with great lifting heights
no rope twist occurs.
7
WHAT IS THE EFFECT OF THE PLASTIC LAYER?
The plastic layer ...
greatly lowers,
or even removes,
the incidence of birdcaging
keeps out water lowers the noise level
and abrasive elements whilst the rope working
acts as a cushion prevents internal

between the layers wire breaks
stabilizes the rope prevents

during the installation metal-to-metal contact
seals in lubricant absorbs dynamic energy
prevents interstrand nicking stabilizes the rope structure
... solves rope problems !

8
FROM WIRE TO WIRE ROPE
using Casar Powerplast as an example
entrance control
wire stock
Length
in m
for 1000 m
of wire rope
spooling spooling spooling spooling spooling 408 000
stranding stranding stranding stranding stranding 37 800
quality quality quality quality quality

control control control control control
compacting compacting compacting compacting compacting 37 800
quality quality quality quality quality

control control control control control
spooling spooling spooling spooling spooling 37 800
closing
1 050
of rope core
quality
control
plastic extrusion 1 050
closing
1 050
of rope
final
quality control
spooling 1 050
finishing
9
BREAKING LOAD
How do Casar Special Wire Ropes

achieve their high breaking loads?
Conventional steel wire rope constructions can meet a requirement

for higher breaking loads only by increasing the tensile strength of
the individual wires.
Casar Special Wire Ropes are already designed for the highest
breaking loads by a combination of various technologies:
● A large number of strands increases the metallic area of the rope.
● Parallel lay leads to a more compact rope construction.
● A plastic layer reduces internal stresses.
● Compacting of the strands increases the fill factor

of the rope elements.
● The tensile strength of the wires is chosen according

to the requirements.
The high breaking loads of Casar Special Wire

Ropes offer the user the following advantages:
● Design advantages by reducing the sheave and drum diameters

and the size of motor and gearbox.
● Longer service life due to lower specific stress on the rope.
● Increased safety.
10
DIAGRAMS: BREAKING LOAD
0.75 0.75
0.70 0.70
0.65 0.65
fill factor [ – ]
fill factor [ – ]
0.60 0.60
CASAR Powerplast
Rammbolift
CASAR Quadrolift
CASAR Powerlift
CASAR Stratoplast
CASAR Turboplast
CASAR Superplast
0.55 0.55
CASAR Multilift F
CASAR Eurolift
CASAR Turbolift
CASAR Superlift
CASAR
CASAR Starlift
CASAR Stratolift
CASAR Multilift
8 x 19 FC
0.50 0.50
6 x 36 IWRC
36 x 7
18 x 7
0.45 0.45
0.40 0.40
BREAKING LOAD 1: Comparison of the fill factors of non BREAKING LOAD 2: Comparison of the fill factors of rotation-
rotation-resistant ropes. The fill factors of Casar Special Wire resistant ropes. The fill factors of Casar Special Wire Ropes are
Ropes are considerably higher than the fill factors of conventional in general considerably higher than the fill factors of conventional
ropes. ropes.
120 10
breaking load on swivel [% of minimum breaking load]
to 110%
to 110%
to 110%
to 110%
to 110%
to 110%
2P
100 8
90%
90%
90%
90%
90%
90%
reduction of breaking load [ % ]
80 6 18 x 7
6-strand rope P P
to 80%
8-strand rope
60%
CASAR Rammbolift
CASAR Powerplast
60
CASAR Quadrolift
4
CASAR Powerlift
6-strand rope to 60%
8-strand rope to 60%
CASAR Eurolift
CASAR Starlift
40%
40%
2P
40 2
18 x 7
20 1
10 20 30 40
D/d [ – ]
BREAKING LOAD 3: Breaking loads of steel wire ropes tested BREAKING LOAD 4: Breaking loads of steel wire ropes when
with a swivel. The breaking loads of 6-strand and 8-strand ropes tested on sheaves, depending on the ratio sheave diameter/rope
decrease considerably, whereas the rotation-resistant Casar diameter. The factors of safety cover the reduction of the breaking
Special Wire Ropes achieve values in the range of their minimum loads.
breaking loads.
220
200
Pdyn = k • P
180
tensile strength [ kp/mm2 ]
L k = 1 + 1 + (2 • H • M • E )
160 P•L
P
H
140
P
120 Pdyn = dynamic load
P = static load
L
100 L = rope length
H = height; slack
M = metallic area rope
80 E = modulus of elasticity rope
P
[°F] 200 400 600 800 1000 1200
60
0 [°C] 100 200 300 400 500 600 700
temperature [ °C ]
BREAKING LOAD 5: Tensile strength of steel wires as a function BREAKING LOAD 6: Formula to determine the dynamic load
of temperature (exposure time 10 min., cooled in air). Tempera- caused by a falling weight. Dynamic loads are not covered by the
tures up to 300°C (~600°F) reduce residual stresses, higher safety factor and should be avoided at all costs.
temperatures reduce the tensile strength drastically.
11
FILL, WEIGHT AND SPIN FACTORS
r
cto
*
tor
s
nd
t fa
tor
t
fa c
an
tra
fac
igh
is t
in
ds
er
re s
we
sp
fill
ay
cte
ge
ge
ge
cl
ion
a
mp
era
era
sti
era
tat
pla
co
av
av
av
ro
0,653 0,90 0,77
0,748 0,86 0,79
0,710 0,91 0,84
0,608 0,92 0,87
0,661 0,87 0,86
0,688 0,86 0,84
0,660 0,89 0,86
0,730 0,85 0,84
0,755 0,85 0,84
0,650 0,89 0,86
0,755 0,85 0,84
0,660 0,90 0,88
0,655 0,90 0,90
0,627 0,90 0,82
0,663 0,85 0,83
0,566 0,90 0,86
0,477 0,94 0,85
0,684 0,86 0,84

* rope diameters up to 40 mm, 1770 N/mm2
12
BENDING FATIGUE
Why do Casar Special Wire Ropes

attain the longest service lives?
Conventional rope designs often do not meet the requirements of

modern reeving systems. Shorter service lives result. Casar Special
Wire Ropes offer various design advantages which lead to longer
service lives.
● A larger number of strands increases the number of contact areas

within the rope and on sheaves and drums.
● Parallel lay prevents the crossover of strands and improves

the contact conditions within the rope.
● A plastic layer reduces the danger of structural damage

and internal wire breaks.
● Compaction of the strands improves the contact conditions

within the rope and on sheaves and drums.
● A large number of strands with smooth surfaces increases

the flexibility of the rope.
The long service lives of Casar Special Wire Ropes

offer the user the following practical advantages:
● Reduced downtime due to fewer rope changes.
● Reduced costs for rope changes.
● Minimised rope costs.
● Optimum price/performance ratio.
13
DIAGRAMS: BENDING FATIGUE
300 000 150 000
[ – ] until discard and break

D/d = 20 D/d = 20
load proportional to load proportional
minimum breaking load to minimum
breaking load
200 000 100 000

CASAR Stratoplast
CASAR Turboplast
CASAR Stratolift
CASAR Turbolift
100 000 50 000
number of cycles
number of cycles
6 x 36 IWRC
Powerplast
6 x 36 FC
Quadrolift
Powerlift
CASAR
CASAR
CASAR
CASAR
CASAR
Eurolift
Starlift
18 x 7
0 0
BENDING FATIGUE 1: Comparison of numbers of cycles until BENDING FATIGUE 2: Comparison of numbers of cycles for
discard and break for non rotation-resistant ropes. Under the rotation-resistant ropes. Under the same test conditions, Casar
same test conditions, Casar Special Wire Ropes achieve much Special Wire Ropes achieve much higher numbers of cycles than
higher numbers of cycles than conventional ropes. conventional ropes.
400 000 300 000

D/d = 20
load proportional to
minimum breaking load
300 000
CASAR Stratolift (ungalvanized)
200 000
CASAR Stratolift (galvanized)
200 000
CASAR Powerplast
CASAR Powerplast
CASAR Starlift
100 000
number of cycles
number of cycles
100 000
18 x 7
CASAR
Starlift
18 x 7
0 0
on steel sheave on plastic sheave
BENDING FATIGUE 3: Comparison of numbers of cycles until BENDING FATIGUE 4: Comparison of numbers of cycles until
discard and break for ungalvanized and galvanized ropes, in discard and break on steel sheaves and on plastic sheaves. On
both cases lubricated. Under the same test conditions, the plastic sheaves, the fatigue life is higher, but the residual life (%)
galvanized rope achieves higher numbers of cycles. between discard and break is lower.
A B C
[ – ] until discard
max.
[–]
break
nominal rope diameter + 6%
number of cycles
A B C
number of cycles
groove diameter =
discard
CASAR Stratolift
optimum
180 190 200 210 220 230 240
tensile strength [ kp/mm2 ] groove diameter
BENDING FATIGUE 5: Comparison of numbers of cycles until BENDING FATIGUE 6: Rope life as a function of the groove
discard and break for ropes of different tensile strength under diameter of the sheaves. The optimal groove diameter is nominal
constant load. rope diameter plus 6% (B). For larger groove diameters, the
service life decreases steadily (C), for smaller groove diameters
it decreases rapidly (A).
14
DIAGRAMS: BENDING FATIGUE
30 100
D/d = 20
load proportional to
50
numbers of broken wires 30 x d [ – ]
25 minimum breaking load
log. number of broken wires [ – ]

20
20
tensile strength 200 kp/mm2
load 111 %
15 10
tensile strength 180 kp/mm2
load 100 %
5
10
C A B
5 2
0 1
0 30.000 60.000 90.000 120.000 5.000 10.000 20.000 50.000 100.000 200.000 500.000
number of cycles [–] log. number of cycles [–]
BENDING FATIGUE 7: Number of visible broken wires depend- BENDING FATIGUE 8: Number of broken wires depending on
ing on the number of cycles in a bending fatigue test. The number the number of cycles. Rope A: Casar Stratolift. Rope C: (compe-
of wire ropes breaks increases steadily according to a power- tition) fatigues too early. Rope B: (test rope) is dangerous,
function. because the discard criterion is reached shortly after the first wire
is broken.
200
lubricated + relubricated
[%]
150
[%]
100
actual breaking load
lubricated
number of cycles
100
50
unlubricated
~ 100%
0 0
0 discard break 100 200 300 400 500
number of cycles [%] tension [ N / mm2 ]
BENDING FATIGUE 9: Breaking load of running steel wire ropes BENDING FATIGUE 10: Number of cycles until discard for
depending on the number of cycles. Normally, the actual break- unlubricated, lubricated (= 100%) and relubricated steel wire
ing load increases during the first half of the service life. When the ropes. Relubrication during service life considerably, increases,
discard criterion is reached, the rope can still achieve its mini- lack of lubrication reduces the service life drastically.
mum breaking load.
1 000 000 2 000 000
900 000 1 800 000
800 000 1 600 000

[–]
[–]
700 000 1 400 000
600 000 1 200 000

number of cycles
number of cycles
500 000 1 000 000
400 000 800 000
300 000 600 000
200 000 400 000
100 000 200 000
0 0
10 12 14 16 18 20 22 24 26 28 30 200 240 280 320 360 400 440 480 520 560 600
rope diameter [ mm ] sheave diameter [ mm ]
BENDING FATIGUE 11: Number of cycles until discard (lower BENDING FATIGUE 12: Number of cycles until discard (lower
curve) and break (upper curve) depending on the nominal rope curve) and break (upper curve) depending on the sheave dia-
diameter. For every combination of sheave diameter and line pull meter. The service life of a wire rope increases with increasing
there is an optimum rope diameter. sheave diameter.
15
WHICH ROPE FOR WHICH APPLICATION?
Tower crane
Hoist rope
Container crane
Hoist rope
Tower crane
Boom hoist rope
Container crane
Boom hoist rope
Tower crane
Trolley rope
Floating crane
Hoist rope
Tower crane
Installation rope
Floating crane
Boom hoist rope
Tower crane
Pendant rope
Electrical hoist
Hoist rope
Mobile crane
Hoist rope
Ladle crane
Hoist rope
Mobile crane
Boom hoist rope
Floating grab
Holding- and closing rope
Mobile crane
Pendant rope
Floating grab
Pendant rope
Deck crane
Hoist rope
Shovel
Hoist rope
Deck crane
Boom hoist rope
Shovel
Crowd line
Offshore crane
Hoist rope
Shovel
Boom line
Offshore crane
Boom hoist rope
Dragline
Hoist rope
Grabbing crane
Holding- and closing rope
Dragline
Drag rope
Grabbing crane
Pendant crane
Dragline
Boom hoist rope
Grabbing crane
Boom hoist rope
Cable crane
Hoist rope
Bulk handling rope
Hoist-, closing-, grab rope
Cable crane
Trolley rope
Bulk handling rope
Trolley- and compensation rope
Scraper
Traction and haulback rope
Elevator
Hoist rope
Scraper
Boom hoist rope
CASAR DRAHTSEIL-
WERK SAAR GMBH
Casarstraße 1 • 66459 Kirkel
Postfach 187 • 66454 Kirkel
Telefon: (0 68 41) 80 91 - 0
Teletex: 68 41 972 Casar
Telefax: (0 68 41) 86 94
16
17
ROTATION
Why are Casar Special Wire Ropes

so rotation-resistant?
Conventional wire ropes try to untwist under load. Stability can often
only be achieved by overloading the core of the ropes.
Rotation-resistant Casar Special Wire Ropes are stabilized against

rotation by various technologies.
● A wire rope core, closed in the opposite direction of the outer

strands, creates a stabilizing moment.
● A compacted core increases the rotational stability.
● A favourable ratio of the metallic areas leads to stability without

overloading the core.
The high rotational stability of Casar Special Wire

Ropes offers the user the following advantages:
● No block rotation even with great lifting heights.
● Long service life because of an untwisted rope structure.
● Great safety in crane operations.
18
DIAGRAMS: ROTATION
0.12 0.12
0.10 CASAR Stratoplast

0.08
opening moment
0.08
torque factor [ – ]
untwisted closed
0.04
0.06
CASAR Stratoplast
CASAR Turboplast
CASAR Superplast
0
CASAR Stratolift r
CASAR Turbolift r
CASAR Superlift r
CASAR Alphalift r
CASAR Multilift F
CASAR Starlift
0.04
CASAR Multilift
closing moment
CASAR Quadrolift
CASAR Powerlift
-0.04
0.02
0 -0.08
1000 500 0 500 1000
spec. rope twist [ deg mm/m ]
ROTATION 1: Torque factors for different Casar Special Wire ROTATION 2: Torque factors of Casar Stratoplast and Casar
Ropes. The torque factor is defined as the moment of the rope Powerlift against the rope twist (forcible twist). The high torque of
under a given load, divided by the load and the rope diameter. Casar Powerlift under forcible twist guarantees a high resistance
against rotation of the load.
0.16 0.10
40°/m 0.08
0.14 40°/m
20°/m 0.06
twisted
0.04 20°/m
0.12
10°/m
0.02 10°/m
twisted
0.10 0°/m 0
untwisted -10°/m
0.02
0.08 -20°/m
0.04
CASAR Stratoplast
-10°/m
untwisted ø 19/180
-20°/m 0.06
0.06 -40°/m
-40°/m CASAR Starlift
0.08 ø19/180
0.04 0.10
0 20 40 60 80 100 120 140 0 20 40 60 80 100 120 140
load [ kn ] load [ kn ]
ROTATION 3: Torque factor of Casar Stratoplast depending on ROTATION 4: Torque factor of Casar Starlift as a function of the
the load for different levels of rotation. For higher loads, the load for different levels of rotation. The forcible twist influences the
forcible twist does not influence the torque factor very much. torque factor of the rope considerably. Any rotation of the load
creates a high moment in the opposite direction, stabilizing the
system.
40 000
8 x 36 IWRC
Stratoplast e
30 000 D•e
k<
spec. rope twist [ deg mm / m ]
4,8 • h • d
d
D
h h >> D
20 000
k = torque factor
D = rope spacing at block
Superplast e = rope spacing at top
10 000 d = nominal rope diameter
Quadrolift
h = length of fall
Powerplast
Starlift
Eurolift
Powerlift
0
0 10 20 30 40 50 60 70
load [ % of minimum breaking load ]
ROTATION 5: Specific rope twist as a function of the load. When ROTATION 6: Formula to determine the stability of a block. If the
tested on a swivel, 6-strand and 8-strand ropes untwisted under conditions of the formula are met, the block will be stable (static
very low loads. Casar Powerlift, Casar Starlift and Casar Power- situation). The formula can also be used to determine the mini-
plast only started untwisting at high loads. mum rope spacing or the greatest stable length of fall.
19
EFFICIENCY
Why are Casar Special Wire Ropes

so flexible?
● Modern machines demand flexible wire ropes.
Casar Special Wire Ropes are designed to provide maximum flex-

ibility. The high flexibility is achieved by a combination of different
technologies.
● A larger number of wires and strands allows easier bending.
● Intensive lubrication in all stages of production reduces

the internal friction.
● The smooth surfaces of the compacted strands prevent

indentations and allow easier relative motion of the elements.
● Cold-resistant lubricants and cold-elastic plastics guarantee

good flexibility at low temperatures.
The high flexibility of Casar Special Wire Ropes

offers the user the following advantages:
● Improved running properties due to lower friction losses.
● Reduction of motor capacity.
● Easy handling during installation.
● Excellent spooling on the drum.
20
DIAGRAMS: EFFICIENCY
100 100
CASAR Eurolift CASAR Quadrolift
CASAR Starlift
CASAR Stratolift r
98 98
CASAR Stratoplast r CASAR Turbolift r CASAR Powerlift
6 x 37 + Fe CASAR Powerplast
efficiency [ % ]
efficiency [ % ]
96 96
94 94
92 92
90 90
0 0.5 1.0 1.5 2.0 0 0.5 1.0 1.5 2.0
load [ % of minimum breaking load ] load [ % of minimum breaking load ]
EFFICIENCY 1: Efficiencies of rotation-resistant steel wire ropes EFFICIENCY 2: Efficiencies of rotation-resistant steel wire ropes
on sheaves with roller bearings for low loads. Casar Special Wire on sheaves with roller bearings for low loads. Most rotation-
Ropes show higher efficiencies than conventional steel wire resistant wire ropes show lower efficiencies than non rotation-
ropes. D/d = 20 resistant wire ropes.
100.0 100
30 x d
20 x d
10 x d
CASAR Powerlift
99.5 90
efficiency [ % ]
efficiency [ % ]
18 x 7
99.0 80
CASAR Starlift
CASAR Starlift ungalvanized
98.5 70
0 10 20 30 40 0 0.5 1.0 1.5 2.0
EFFICIENCY 3: Efficiencies of rotation-resistant steel wire ropes EFFICIENCY 4: Efficiency of a steel wire rope on sheaves with
on sheaves with roller bearings for high loads. Casar Special Wire roller bearings against load for different sheave diameters. The
Ropes show higher efficiencies than conventional steel wire efficiency decreases considerably with decreasing sheave di-
ropes. D/d = 20 ameter.
100 100
CASAR Powerlift -40°C (-40°F) CASAR Starlift 20°C (70°F)
CASAR Starlift galvanized
98 CASAR Starlift ungalvanized
CASAR Powerplast 20°C (70°F) 90

efficiency [ % ]
efficiency [ % ]
96
CASAR Powerplast -40°C (-40°F)
94
80
92
90 70
0 0.5 1.0 1.5 2.0 0 0.5 1.0 1.5 2.0
EFFICIENCY 5: Efficiencies of steel wire ropes on sheaves with EFFICIENCY 6: Efficiencies of galvanized and ungalvanized
roller bearings against load for different temperatures. The influ- steel wire ropes on sheaves with roller bearings for low loads.
ence of low temperatures is minimized by the use of special Galvanized ropes show lower efficiencies. D/d = 20
lubricants and plastics. D/d = 20
21
LEFT HAND OR RIGHT HAND LAY ROPE?
The choice of the correct direction of lay is essential for the proper functioning of a reeving
system. A wrong direction of lay leads to torque build-up, to spooling problems and to structural
damage to the rope.
One layer spooling

For drums with one layer, the direction of lay has to be chosen according to the following
rule:
right hand drum - left hand lay rope
left hand drum - right hand lay rope
Multiple layer spooling

With multiple layer spooling, the direction of the spooling changes from layer to layer. So the
direction of lay of the rope would also have to be changed from layer to layer. Here the direction
of lay should be chosen for the layer which is working the most.
right hand layer - left hand lay rope

left hand layer - right hand lay rope
Multiple-part reeving
In a multiple part reeving system very often the influence of the fleet angles between the sheaves
is greater than the influence of the drum. In this case, the direction of lay of the rope should be
chosen depending on the direction of the reeving.
right hand reeving - left hand lay rope

left hand reeving - right hand lay rope
And here is how you determine the direction of the winding of the drum or reeving system:
Place yourself at the fix point ( ⊗) of the rope on the drum (at the reeving system) and follow the
turns of the rope with your finger.
⊗ ⊗ ⊗ ⊗
☞ ☞ ☞ ☞
⊗ ⊗ ⊗ ⊗
☞ ☞ ☞ ☞
right hand drum - left hand lay rope left hand drum - right hand lay rope
If you move your finger clockwise, the drum If you move your finger counterclockwise, the
(reeving system) is right hand, and needs a drum (reeving system) is left hand, and needs
left hand lay rope. a right hand lay rope.
22
ELASTICITY AND ELONGATION
What gives Casar Special Wire Ropes

the best stress-strain behaviour?
Conventional steel wire ropes often have insufficient modulus of

elasticity and too high permanent elongations.
Casar Special Wire Ropes are optimized with regard to their stress-
strain properties by various features:
● The full steel construction provides a high modulus of elasticity.
● The compact rope structure guarantees minimal permanent

elongations in the working range.
● The homogeneous load distribution on all rope elements creates

high elongations at break.
● The plastic layer absorbs dynamic energy.
The balanced stress-strain properties

of Casar Special Wire Ropes
offer the user the following advantages:
● High rigidity of suspended structures.
● Less retentioning for suspended structures and positioning

machines.
● High safety against dynamic failure.
23
DIAGRAMS: ELASTICITY AND ELONGATION
1.3 1.3
modulus of elasticity [ x 105 N/mm2 ]

1.2 1.2
1.1 1.1
CASAR Quadrolift
1.0 1.0
CASAR Stratoplast
CASAR Superplast
CASAR Turboplast
CASAR Technolift
CASAR Starlift
CASAR Stratolift
CASAR Turbolift
CASAR Superlift
CASAR Alphalift
Rammbolift
Powerlift
Powerplast
0.9
CASAR
CASAR
0.9
CASAR
Eurolift
CASAR
0.8 0.8
ELASTICITY 1: Moduli of elasticity for non rotation-resistant ELASTICITY 2: Moduli of elasticity for rotation-resistant Casar
Casar Special Wire Ropes. The modulus of elasticity of a steel Special Wire Ropes. The modulus of elasticity of a steel wire rope
wire rope is about half the modulus of plain steel. (Average values is about half the modulus of plain steel. (Average values from a
from a great number of tests) great number of tests)
4.5 4.5
4.65
4.72
elongation at break [ % ]
elongation at break [ % ]
4.0 4.0
CASAR Turbolift
CASAR Rammbolift
CASAR Powerplast
CASAR Turboplast
CASAR Stratolift
CASAR Alphalift
CASAR Eurolift
3.5 3.5
Stratoplast
Superplast
Quadrolift
Technolift
CASAR
Superlift
Starlift
CASAR
CASAR
CASAR
CASAR
CASAR
Powerlift
CASAR
3.0 3.0
ELASTICITY 3: Elongation at break for non rotation-resistant ELASTICITY 4: Elongation at break for rotation-resistant Casar
Casar Special Wire Ropes. The elongations at break range from Special Wire Ropes. The elongations at break range from 3.1 to
3.2 to 4.7 percent. (Average values from a great number of tests) 4.7 percent. (Average values from a great number of tests)
1.2 0.75
CASAR Stratolift
1.0
permanent elongation [ % ]
8 x 19 FE 0.50
0.8
8 x 19 FE
0.6
0.25
CASAR Stratolift
0.4
0.2 0
0 20 40 60 80 100 0 10 20 30 40 50
previous load [ % of minimum breaking load ] previous load [ % of minimum breaking load ]
ELASTICITY 5: Modulus of elasticity depending on the previous ELASTICITY 6: Permanent elongation depending on the previ-
load for Casar Stratolift and a conventional rope with fibre core. ous load for Casar Stratolift and a conventional rope fibre core.
The modulus increases with increasing load. Casar Stratolift The permanent elongation increases with increasing load. Casar
shows a much higher modulus. Stratolift shows a much lower elongation.
24
DIAGRAMS: ELASTICITY AND ELONGATION
1.00
500
450
elongation after unloading [ % ]

400 0.75
load 80 % of minimum breaking load
350
load [ kN ]
300
0.50
250
200
150 0.25
100
50
0 0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 1 min 5 min 30 min 60 min 24 h
elongation [ % ] time after unloading
ELASTICITY 7: Load-elongation diagram (Casar Powerplast). ELASTICITY 8: Permanent elongation after unloading depend-
During the test, the computer determines the increase of the ing on the time. The effect prestressing disappears to a great
modulus of elasticity, the total and permanent elongation, the extend with increasing time. Here 6-strand rope as an example.
energy absorption, the elongation at break, the diameter change
and other required data.
100 12
rope diameter [ % of actual rope diameter ]
absorbed specific energy [ Nm/(m mm2) ]
Superlift 10
at 80% of minimum breaking load
99 8
CASAR Turboplast Kr
CASAR Turbolift Kr/L
CASAR Turboplast L
CASAR Dragplast L
CASAR Rammbolift
Starlift
CASAR Powerplast
CASAR Stratoplast
CASAR Quadrolift
CASAR Technolift
Eurolift
CASAR Powerlift
CASAR Stratolift
Stratolift
CASAR Eurolift
CASAR Starlift
Turboplast r
98 Stratoplast l
4
Turbolift r
Powerlift
2
Stratoplast r
6 WKP
97 0
0 10 20 30 40 50 60
ELASTICITY 9: Rope diameter of a new rope depending on the ELASTICITY 10: Absorbed energy at 80% of the minimum
load in a break test. During service, the rope diameter is of cause breaking load for Casar Special Wire Ropes. Langs lay ropes
reduced by additional factors, e. g., abrasion. have a higher energy absorption than regular lay ropes, ropes
with an internal plastic layer have a higher energy absorption than
full steel ropes.
12 200
CASAR Dragplast
specific energy [ Nm /( m • mm2 ) ]
10 rope wire strand wire rope

CASAR Stratoplast l
A 150
A: energy input
8
stress [ kp/mm2 ]
B: energy output
C: energy converted into permanent
6 deformation and heat
100
B
4 undrawn
steel
C 50
2
0 0
0 20 40 60 80
load [ % of minimum breaking load ] elongation [ % ]
ELASTICITY 11: Specific energy of Casar Special Wire Ropes. ELASTICITY 12: Comparison of the stress-elongation- curves of
steel, rope wire, strand and wire rope.
25
ELONGATION CURVES
The knowledge of the elongation properties of a 2.0

steel wire rope can be of great importance to the
1.8
equipment manufacturer or user. Therefore we
present the load-elongation diagrams of the most 1.6
important Casar Special Wire Ropes, here.
1.4
The upper curves show the total elongations CASAR Powerlift
elongation [ % ]
depending on the load. The lower curves show 1.2
CASAR Starlift
the permanent elongations remaining in the rope
after unloading depending on the previous load. 1.0
0.8
The diagrams show the average values of a
great number of cyclical loading and unloading 0.6
tests performed with ropes of different diameters
and tensile strength. The diagrams are inde- CASAR Powerlift
0.4
pendent of the rope diameter. The influence of CASAR Starlift
the tensile strength is negligible. 0.2
Please note: setting in the end fitting can cause 0

additional elongation. 0 20 40 60 80
R = Regular Lay; L = Langs Lay elongation curves 1
2.0 2.0
1.8 1.8
CASAR Powerplast CASAR Stratolift R
1.6 1.6
CASAR Turbolift R
1.4 1.4
CASAR Eurolift
elongation [ % ]
elongation [ % ]
1.2 1.2
1.0 1.0
0.8 0.8
CASAR
Stratolift R
0.6 0.6
CASAR CASAR
Powerplast Turbolift R
0.4 0.4
CASAR
Eurolift
0.2 0.2
0 0
0 20 40 60 80 0 20 40 60 80
elongation curves 2 elongation curves 3
26
ELONGATION CURVES
2.0 2.0
1.8 1.8
CASAR Superplast L
1.6 1.6
CASAR Turboplast R/L CASAR Superplast R
1.4 1.4
CASAR Stratoplast R/L
elongation [ % ]
elongation [ % ]
1.2 1.2
1.0 1.0
0.8 CASAR 0.8

Turboplast L CASAR Superplast L
CASAR
0.6 Stratoplast R/L 0.6
CASAR
Superplast R
0.4 0.4
0.2 0.2
CASAR Turboplast R
0 0
0 20 40 60 80 0 20 40 60 80
2.0 2.0
1.8 1.8
CASAR Technolift
1.6 1.6
1.4 1.4
CASAR Douzeplast CASAR Superlift R
elongation [ % ]
elongation [ % ]
1.2 1.2
1.0 1.0
0.8 0.8 CASAR

CASAR Douzeplast Quadrolift
0.6 0.6
CASAR Technolift
0.4 0.4
CASAR Superlift R
0.2 0.2
CASAR Quadrolift
0 0
0 20 40 60 80 0 20 40 60 80
27
DIAGRAMS: GENERAL
650 16
15
Brinell hardness HB 30 [ kp/mm2 ]
specific surface [ mm2/ mm • mm ]

600
total surface of all elements

10
550
500
5
outer surface
450 π
surface of steel bar
400 0
160 180 200 220 240 260 3 6 9 12 15 18
tensile strength [ kp/mm 2 ] number of outer wires [ – ]
GENERAL 1: Brinell hardness HB 30 of the wire surface depend- GENERAL 2: Surface of a seale strand, divided by the strand
ing on the tensile strength of the wire. diameter and the strand length, depending on the number of
outer wires. The outer (exposed) surface is only slightly larger
than the surface of a steel bar, the total surface is much larger.
1.0 100
percentage of metallic area [ % ]
0.9 80
outer layer
fill factor [ – ]
0.8 60
0.7 40
inner wires
0.6 20
0.5 0
0 10 20 30 40 3 6 9 12 15 18
number of wires [ – ] number of outer wires [ – ]
GENERAL 3: Fill factor of a seale strand depending on the total GENERAL 4: Percentage of the total metallic area for the outer
number of wires. The fill factor increases steadily with the number and inner wires of a seale strand depending on the number of the
of wires. core increases steadily, and the percentage of the outer wires
decreases steadily with increasing number of outer wires.
24
22 16
12
10
1/3/3 1/4/4 1/5/5 1/6/6 1/7/7 20
8
angle of lay [ deg ]
18 6
16
1/8/8 1/9/9 1/10/10 1/11/11 1/12/12
14
12
1/13/13 1/14/14 1/15/15 1/16/16 1/17/17
10
6 7 8 9 10 11 12
lay length factor [ – ]
GENERAL 5: Seale strand 1+N+N, for N=3 to N=16. With GENERAL 6: Angle of lay depending on the lay length factor for
increasing N, the diameter of the center wire is increasing while 6-, 10-, 12-, and 16-strand ropes.
the diameter of the outer wires is decreasing.
28
DIAGRAMS: GENERAL
100 100
90 90
80 80
remaining metallic area [ % ]
remaining metallic area [ % ]

70 70
60 60
50 50
s
40 40
30 30
d
20 20 h d
10 10
0 0
0 0.2 0.4 0.6 0.8 1.0 0.8 0.6 0.4 0.2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
ratio s/d [ – ] ratio h/d [ – ]
GENERAL 7: Reduction of the metallic area by abrasion. Re- GENERAL 8: Reduction of the metallic area by abrasion. Re-
maining metallic area of the outer wire depending on the ratio of maining metallic area of the outer wire depending on the ratio of
the width of the abrasion ellipse s vs. the wire diameter d. the remaining height of the wire h vs. the wire diameter d.
18 30
16
number of required torsions [ – ]
number of required bends [ – ]
14
12 20
10
6 10
4
R = 1.75
R = 3.75
R = 2.5
R = 7.5
R = 10
R = 15
R=5
0 0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
wire diameter [ mm ] wire diameter [ mm ]
GENERAL 9: Quality control for rope wire according to DIN 2078. GENERAL 10: Quality control for rope wire according to DIN
Number of required bends in a bending test depending on the 2078. Number of required torsions in a torsion test depending on
wire diameter. R = radius of bend. Tensile strength 1770 N/mm2 . the wire diameter. Tensile strength 1770 N/mm2 .
weight of the zinc coating per surface unit [ g/m2 ]
260
[ mm ]
thikness of
zinc coating
0.035
240
220 heavy galvanized
0.030
200 b = reel wide
Da = flange diameter
180 0.025 Da Di Di = barrel diameter
160 d = rope diameter
L = rope length
140 0.020
120
drawn galvanized
0.015
100 b
80
0.01
60
40
π . ( Da2 - Di2 ) . b
<L< π . ( Da2 - Di2 ) . b . 2
0.005
4 . d2 4 . d2
20
0
0 1.0 2.0 3.0 4.0
wire diameter[ mm ]
GENERAL 11: Quality control for rope wire according to DIN GENERAL 12: Formula to calculate the rope length on a reel.
2078. Required weight of the zinc coating per surface unit and
thickness of the coating for drawn galvanized and heavy galva-
nized wires depending on the wire diameter.
29
THE DRUM
The drum is an important element of a hoisting system. We distinguish between

grooved and ungrooved drums, and between single and multiple layer drums. In
order to guarantee good spooling on the drum, the following rules should be
considered:
Single layer drum

● The direction of layer of the rope has to be chosen opposite to the direction
of winding on the drum.
Multiple layer spooling

● Wedges should be provided to help the rope to climb into the second
and third layer.
● The first layers must be installed under tension.
● The direction of lay of the rope should be chosen according to the rules
(see page 22).
In the second and higher layers, adjacent wraps are no longer separated by the
walls on the drum, so that the wraps can form indentations. In order to avoid
premature rope destruction, the following rules should be observed in selecting the
correct type of rope:
● In Langs lay rope, indentations between outer wires do not occur. So Langs lay
rope should be preferred to regular lay rope.
● In rope with compacted outer strands, indentations between outer wires do not
occur. So rope with compacted outer strands should be preferred to conven-
tional rope (see page 31).
● Eight strand rope should be preferred to six strand rope (see page 31),
because it has a more closely circular cross- section.
Under the pressure of the overwinding layers, the rope of the lower layers is subject
to high radial forces which might cause structural damage.
● Ropes with an internal plastic layer show excellent results because of their high
structural stability.
30
Conventional outer strands: Compacted outer strands:
Between conventional outer strands of adja- The outer wires of compacted outer strands
cent rope wraps, there is danger of mutual cannot form indentations. This is why ropes
indentations of the outer wires. The indenta- with compacted outer strands are so suitable
tions can lead to severe external damage to for multiple layer spooling.
the ropes.
Six strand ropes: Eight strand and ten strand ropes:
Six strand ropes can form deep indentations, Eight strand and ten strand ropes do not form
because they have deep valleys between the deep indentations, because their cross- sec-
outer strands. The indentations can lead to tion is very round. This is why eight strand
severe external damage to the ropes. ropes and ten strand ropes are so suitable for
multiple layer spooling.
CONVERSION FACTORS
Length 1m = 1000 mm = 3,28 ft = 39,37 inch
Force 1 kN = 101,97 kp = 0,10197 t metric-f = 224,8 lbs-f
Tensile Strength 1 N/mm2 = 0,10197 kp/mm2 = 145,04 p.s.i. = 10 bar
Cross Section 1 mm2 = 0,00155 sq.inch
Weight 1 metric t = 1000 kg = 1,102 short t = 0,9842 long t= 2204,6 lbs
Weight per Length Unit 1 kg/m = 0,672 lbs/ft.

© Copyright 1991/1997 CASAR Drahtseilwerk Saar GmbH, content subject to alterations.
Technical author: Roland Verreet, WRTA Wire Rope Technology Aachen.
Realisation, Layout and Typesetting: PR Werbeagentur u. Verlag GmbH, Aachen.
31
®
;;;;
;;;;
;;;;
;;;;
;;;;
;;;; CASAR DRAHTSEILWERK SAAR GMBH
;;;;
;;;;
;;;; Casarstraße 1 • D-66 459 Kirkel
Postfach 18 7 • D-66 454 Kirkel
Phone ++ 49-68 41/ 80 91-0
Fax ++ 49-68 41/ 86 94
Sales Dept.
Phone ++ 49-68 41/ 80 91-39/44
Fax ++ 49-68 41/ 80 91-29
http://www.casar.de

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Introduction and table of contents ....................................................................... 2

A steel wire rope is a complex machine part and consists of

Based on a wide range of empirical data and test results,

LEFT HAND LAY

RIGHT HAND LAY

Some of the Casar Special Wire Ropes

conventional strand compacted strand

In order to produce a compacted strand, a conventional strand made out of round

In a cross (non-parallel) lay strand all wires have different

cross (non-parallel) lay parallel lay

The geometrical design

The plastic layer ...

acts as a cushion prevents internal

stabilizes the rope prevents

seals in lubricant absorbs dynamic energy

prevents interstrand nicking stabilizes the rope structure

... solves rope problems !

using Casar Powerplast as an example

spooling spooling spooling spooling spooling 408 000

stranding stranding stranding stranding stranding 37 800

quality quality quality quality quality

compacting compacting compacting compacting compacting 37 800

quality quality quality quality quality

spooling spooling spooling spooling spooling 37 800

plastic extrusion 1 050

How do Casar Special Wire Ropes

Conventional steel wire rope constructions can meet a requirement

● A large number of strands increases the metallic area of the rope.

● Parallel lay leads to a more compact rope construction.

● A plastic layer reduces internal stresses.

● Compacting of the strands increases the fill factor

● The tensile strength of the wires is chosen according

The high breaking loads of Casar Special Wire

● Design advantages by reducing the sheave and drum diameters

● Longer service life due to lower specific stress on the rope.

reduction of breaking load [ % ]

8-strand rope to 60%

0,748 0,86 0,79

0,710 0,91 0,84

0,608 0,92 0,87

0,661 0,87 0,86

0,688 0,86 0,84

0,660 0,89 0,86

0,730 0,85 0,84

0,755 0,85 0,84

0,650 0,89 0,86

0,755 0,85 0,84

0,660 0,90 0,88

0,655 0,90 0,90

0,627 0,90 0,82

0,663 0,85 0,83

0,566 0,90 0,86

0,477 0,94 0,85

0,684 0,86 0,84

Why do Casar Special Wire Ropes

Conventional rope designs often do not meet the requirements of

● A larger number of strands increases the number of contact areas

● Parallel lay prevents the crossover of strands and improves

● A plastic layer reduces the danger of structural damage

● Compaction of the strands improves the contact conditions

● A large number of strands with smooth surfaces increases

The long service lives of Casar Special Wire Ropes