Wire Rope Maintenance en

FATZER AG Wire Ropes Salmsacherstrasse 9 CH-8590 Romanshorn Switzerland
Phone +41 71 466 81 11 Fax +41 71 466 81 10

info@fatzer.com www.fatzer.com

Guidelines for Rope Maintenance

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Doc. 11-346: Guidelines for Rope Maintenance Rev. 04: 30.09.2008 Page 2 of 12

Content

1 Basic Lubrication by the Manufacturer ................................................................................. 3
2 Cleaning.................................................................................................................................... 3
2.1 Cleaning Stranded Ropes .................................................................................................. 4
2.2 Cleaning Full Lock Coil Track Ropes ................................................................................. 4
3 Relubricating / Maintenance................................................................................................... 5
3.1 Frequency of Relubricating................................................................................................. 5
3.1.1 Frequency of Relubricating Stranded Ropes (bright and galvanized) ............................ 5
3.1.2 Frequency of Relubricating Track Ropes........................................................................ 5
3.1.3 Frequency of Relubricating Tension / Counterweight Ropes.......................................... 5
3.2 Selection of Lubricant ......................................................................................................... 6
3.3 Quantity of Lubricants......................................................................................................... 6
3.4 Applying the Lubricant ........................................................................................................ 7
3.4.1 Stranded Ropes.............................................................................................................. 7
3.4.2 Track Ropes.................................................................................................................... 9
3.4.3 Drying Time..................................................................................................................... 9
3.5 Special Rope Areas.......................................................................................................... 10
3.5.1 Splices .......................................................................................................................... 10
3.5.2 Area of Bollard / Reel for Track Rope Reserve............................................................. 11
3.5.3 Roller Chain Area.......................................................................................................... 11
3.5.4 Saddle Areas of Track Ropes ....................................................................................... 11
3.5.5 Tension / Counterweight Ropes.................................................................................... 12

Special credit for support, revision and correction is given to
Bruno Mannsberger, P. Eng., Technical Director of the Resorts of the Canadian Rockies

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1 Basic Lubrication by the Manufacturer
Steel ropes for use in ropeways, whether they are made of either bright or galvanized wire are
lubricated during production, and are either partially or completely filled with lubricant.

This initial lubrication has the following functions:

Lubrication:
reduces the internal friction created by dynamic load (between the individual wires and
layers of wire)

Protection:
protects ropes against corrosion
prevents water from getting into the core of the rope

Correct lubrication during manufacturing, which means lubrication suited to the use of the rope, is
one of the most important steps to ensure reliable operation and a long and useful life.

2 Cleaning
During the installation of the wire rope, it may collect dirt and debris. As well, the first time the rope
is tensioned, excess lubricant will most likely come out of the rope. As a result, the rope should be
cleaned before being put into service.
Clean excess lubricant and other impurities resulting from the installation of track ropes.
Clean any impurities resulting from the installation of stranded ropes.

Example of wiping a track rope (left) and cleaning a stranded rope (right)

Rope must be cleaned before relubricating!
Only clean ropes can be checked visually!

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Warning when Cleaning Ropes:
No detergents or any other aggressive cleaners shall be used.
Solvents may only be used in small quantities and for localized cleaning of the rope surface.
Avoid mechanical damage to the rope by brushes.
Ensure that there is no build up of heat between the cleaning device and the surface of the
rope as a result of friction.
Do not use copper brushes. Remains of the bristles may increase the rate of surface
corrosion.

2.1 Cleaning Stranded Ropes
Cleaning should be carried out with a standard cleaning device, in dry and preferably cool weather.
Rope cleaning should be carried out at a slow rope speed (about 1m/s) and with empty carriers.

Cleaning device for stranded ropes

2.2 Cleaning Full Lock Coil Track Ropes
Cleaning should be carried out with a special cleaning device or using a flexible cable sling
wrapped around the rope. Cleaning should be carried out at a slow operating speed (about 0.3 -
1m/s) and with empty carriers.

Cleaning track ropes with mechanically-driven brushes:

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Cleaning track ropes with a flexible cable sling:

Surface corrosion can be partly removed with a flexible cable sling, wound three times around the
track rope and loaded with a dead-weight at the trailing end.

This method is not recommended for very dirty ropes, as the dirt would only be smeared in.

Caution:
Special safety precautions have to be taken for this method of cleaning (for example,
special precautions must be taken to prevent fouling on structural features such as tower
saddles, or tearing off of the cable sling).

3 Relubricating / Maintenance
Correct relubrication at proper intervals will maintain the initial lubrication of the rope and prolong
its serviceable life considerably. The lubricant used must be compatible with the initial lubricant
applied by the rope manufacturer, and with all materials in contact with the rope or used in the
splice. The lubricant must not negatively affect the operating conditions of these components.

Failure to relubricate regularly and appropriately will reduce the useful life of the rope.

3.1 Frequency of Relubricating
3.1.1 Frequency of Relubricating Stranded Ropes (bright and galvanized)
We recommend dressing strand ropes for the first time after about 30,000 bending cycles
1
or at the
very latest, after 3 years of operation, whichever occurs first.
Yearly relubrication is recommended from then on.
3.1.2 Frequency of Relubricating Track Ropes
In the case of full lock coil track ropes, relubrication has the purpose of protecting the bare rope
surface against increased corrosion.
We recommend relubricating track ropes regularly until a protective coating has built-up. After that,
yearly relubrication is generally sufficient. Relubrication should be carried out after a visual
inspection.
3.1.3 Frequency of Relubricating Tension / Counterweight Ropes
In the case of tension ropes, relubrication has the purpose of ensuring that the wires can move.
Tension and counterweight ropes have to be relubricated at least every three months. During the
required visual or non-destructive inspections, the type of lubrication and the frequency of
relubrication may need to be adjusted.

1
Bending cycles: one turn around a drive or deflection bullwheel
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Caution:
In special rope areas (see point 3.5) or in the case of special environmental conditions, for
example high humidity, the lubricant type and frequency of relubrication may need to be
reviewed and adjusted.

3.2 Selection of Lubricant
For every initial lubricant (see rope certificates) there is a corresponding lubricant for re-lubrication.
Most lubricants are the same as the initial lubricants, but do contain solvents. The compatibility of
the relubricant with the initial lubricant cannot be guaranteed if it is from a different manufacturer
and therefore needs to be checked.

Requirements for lubricant of stranded ropes:
The relubricant must comply with the requirements of EN 12385-8, appendix A.
Friction coefficient at 20C: > 0.22 (DIN 21258)
Flash point: > 55 C (ISO 2592)
Acidity: < 0.5 mg KOH/g (DIN 21258)
Reduction of liner hardness: < 10 Shore A
Modification in volume filler material: < 20% (DIN 23521)
Adhesive strength and plasticity in compliance with DIN 21258

The compatibility must be confirmed by the lubricant supplier and by the rope manufacturer. Data
sheets for the initial lubricants used by FATZER are available on request.
Lubricants with excessive solvents can affect the initial lubricant or can wash it out. Excessive
dilution should therefore be avoided.

Requirements for lubricant of Track Ropes:
Lubricants must be compatible with the basic lubricant.
The compatibility must be confirmed by the lubricant supplier and by the rope manufacturer. Data
sheets for the initial lubricants used by FATZER are available on request.

Warning:
For ropeways equipped with track rope brakes, relubricants must be chosen in accordance
with the ropeway manufacturers requirements for the minimum friction coefficient between
the track rope and the braking surfaces.

3.3 Quantity of Lubricants
When applying the lubricant, irrespective of the method of application, the correct amount must be
applied. Too little lubricant has no effect and too much of it will cause problems such as soiling of
the station, line equipment and carriers as well as damaging the bullwheel liners, interfering with
the friction coefficient on the drive bullwheel, or polluting the environment, etc.
Depending on requirements and frequency, the quantity of lubricant for stranded ropes should not
exceed 30 g/m
2
of rope surface for track ropes and it should never be more than 15 g/m
2
of rope
surface (lubricant not counting solvent content).

The following diagram shows the approximate quantity of lubricant to be applied (not counting
solvent content) for each 1,000m of rope, depending on the rope diameter, and for different
quantities per square meter of rope.
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The basic principle is: apply smaller quantities of lubricant, but lubricate more frequently.
Where there is a lack of experience with a particular installation, it is recommended that a
trial be conducted on a 100 m section of the rope before the actual relubrication, in order to
determine the right quantity and the drying time, therefore avoiding the danger of excessive
lubrication and any problems arising from this.

3.4 Applying the Lubricant
3.4.1 Stranded Ropes
Ropes should only be relubricated when they are dry and under warm weather conditions.

Warning:
While it is a requirement that the lubricant must be applied while operating the ropeway to
ensure that the lubricant properly penetrates between the wires, all necessary precautions
for worker safety and equipment safety must be taken into account.
Deposits of lubricant and a reduction of friction in the drive (slipping) must be avoided. The
best place to apply the lubricant is, on the outgoing side of the drive bullwheel or on the
incoming side of the return or deflection bullwheel.
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Example: Position of lubrication device for hauling ropes in cable cars

Example: Position of relubrication device for hauling rope on revolving ropeways

Example: Inefficient point of lubrication in direction of free rope area
Point of relubrication:
Before deflection
Point of relubrication:
Before last deflection in
return terminal or in drive
terminal
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Relubrication device for stranded ropes

3.4.2 Track Ropes
Ropes should only be lubricated when they are dry and under warm weather conditions with little
wind. The most important area of a track rope to lubricate is the section of the rope that is not
directly contacted by a sheave, saddle or roller chain.

Warning:
It is important to avoid deposits of lubricant on carriage sheaves. This can be achieved by
careful positioning of the spray nozzles.
Depending on the model of the lubrication device, the spray nozzles can be closed
individually.

Relubrication device for track ropes

3.4.3 Drying Time
After relubrication, the rope should not be used right away - the drying time of the lubricant must be
checked and verified before returning the installation into service.

Warning:
At least 95% of the solvent content should have evaporated before resuming operation.

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A2: Liquids with a flash point of 21 55C
A3: Liquids with a flash point of 55 100C

Warning:
Follow user instructions for lubricants with solvents. Ensure sufficient ventilation in enclosed
spaces.

3.5 Special Rope Areas
3.5.1 Splices
In the area of the splice, the tucks and tails must be inspected and relubricated every
month. Lubrication with a viscous lubricant prevents corrosion due to friction, thus
prolonging the useful life of these areas.

Warning:
It is important to apply the viscous lubricant only in the area of tucks and tails. Only
lubricate up to 10 cm to each side of these areas.
Do not lubricated the splice area with tucked-in strands more often than the rest of the rope
area.
Tails with a fully or partially collapsed strand must be repaired.

Special lubricant in spray cans is available for easy application.

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3.5.2 Area of Bollard / Reel for Track Rope Reserve
Ropes on and in the area of the bollard and on the reserve reel must be protected against
corrosion. Independent of the general relubrication of the rope, these areas require regular
application of external lubrication to ensure that no moisture damages the rope. The interval for
relubrication should be based on regular inspections of these areas and the lubricant used should
take into account any special environmental conditions.

Warning:
Should this delicate area of the rope be exposed to the elements, we recommend diligent
surveillance and maintenance of the area.

3.5.3 Roller Chain Area
The rope area on the roller chain is under particular stress. Normally, it is equipped with a
permanent lubrication device. The lubricants used in this case have a good viscosity and contain
solid lubricants.

Product Requirements for Lubricants:
Lubricants must be compatible with initial lubricant used during the manufacture of the rope.
Please have the compatibility of the relubricant confirmed by the lubricant supplier and by the rope
manufacturer. Data sheets for the initial lubricants used by FATZER are available on request.

Warning:
These viscous lubricants should only be applied in the roller chain rope area. The position
and layout of the permanent lubrication device has to cover all of the deflection area of the
track rope. Once the lubrication process is started, it must never be stopped.

Example: Permanent lubrication

3.5.4 Saddle Areas of Track Ropes
The section of the rope which rest on the saddles are also exposed to higher strain than the open
sections of the rope. Adequate lubrication between the saddle point and the rope ensures both
smooth movement of the track ropes in the saddles as well as ensures proper maintenance of the
corresponding bottom of the track rope (danger of accumulation of moisture). As an example,
lubrication of the saddles can be carried out through lubrication grooves at the saddle point, thus
guaranteeing a constant film of lubricant between the rope and the saddle.
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Warning:
The sliding and adhesion coefficient of the lubricant should be as similar as possible to
allow smooth movement of the rope.
To prevent water from entering the saddles as it runs down the track rope, a special device
can be fitted (for example drip edge).

Example: Drip edge

Warning:
Solid particles between the saddle and the rope can severely damage the rope.
Care must be taken if pneumatic/hydraulic grease pumps are used, as the steel balls of the
lubricating nipples can be pressed out.

3.5.5 Tension / Counterweight Ropes
The lubricant must be applied to the whole length of the rope. In particular, the areas of the rope
which are bent by the deflection sheave must be relubricated (total length of deflection plus 1
metre along the rope on both sides).

Ropes should be dry when being relubricated.
The transition area between the tension rope and the end sockets must be inspected regularly for
corrosion or damage and maintained accordingly.

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FATZER AG Wire Ropes Salmsacherstrasse 9 CH-8590 Romanshorn Switzerland

Phone +41 71 466 81 11 Fax +41 71 466 81 10

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