Index

1.
1.1
1.2
2.
3.
3.1
3.1.1
3.1.2
3.2
4.
4.1
4.2
4.3
4.4
5.
5.1
5.2
5.3
5.4
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
7.4
8.
9.
10.
10.1
10.2
11.
11.1
11.2
11.3
11.4
12.
12.1
12.2
12.3
12.4
13.
13.1
13.2
14.
14.1
14.2
14.3
15.

The company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drahtseilwerk Dietz sole manufacturer of DIEPA Special Wire Ropes . . . . . . . . . . . . . . . .
The DIEPA philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What makes DIEPA Special Wire Ropes so special ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic information about ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rope strands - wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structural design of a steel wire rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The outer strands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Easy rope selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview rotation resistant DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a rotation resistant DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview non-rotation resistant DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a non-rotation resistant DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . .
Which direction of lay is appropriate right- or left-handed ? . . . . . . . . . . . . . . . . . . .
General recommendations for DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simple method for the selection of optimum direction of lay of the rope . . . . . . . . . . . . . . . . . .
Right- and left-handed ropes working in pairs or multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling (joining) non-rotation resistant ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single layer coiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The advantages of DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-layer coiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How many outer strands ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The advantages of DIEPA Special Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grooves their diameter and their radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The ropes swivle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Order data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of a specified DIEPA Special Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of a DIEPA Special Wire Rope as an alternative to other specified rope . . . . . . . . . . . . . .
Handling, inspection and in-service maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting the rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting a DIEPA Secial Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unwinding from a reel or coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the rope under load in a multy-layer coiling system . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shortening the rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When is the rope to be inspected ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What needs to be inspected ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The most important discard criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2
2
4
7
7
7
8
8
13
14
15
16
17
18
18
21
21
22
23
23
23
24
25
25
26
27
29
30
31
32
32
32
33
33
33
34
35
36
36
36
38
40
41
41
42
43
43
43
44
48

1.

The company

1.1 Drahtseilwerk Dietz sole manufacturer of DIEPA Special Wire Ropes

The company Drahtseilwerk Dietz was founded in Germany in 1873, initially
as a manufacturer of fibre ropes. Later on, as markets developed and requirements changed, it decided to concentrate its efforts on the manufacture of steel
wire ropes. From the beginning, the earlier owners recognised the need to develop new types of
ropes for special applications and instituted their
own in-house research and development programs. The company Drahtseilwerk Dietz was
granted its first patent covering ropes produced
in double parallel lay in 1936 and the brand name
DIEPA (= Dietz Patent) was born nowadays a
synonym for high performing steel wire ropes.
Figure 1 Aerial view of company

In 1943 the development of a new generation of rotation-resistant ropes began and in 1951 ropes incorporating a plastic insert were
introduced to meet the ever-increasing performance requirements of machinery
manufacturers and end users.
Nowadays, DIEPA Special Wire Ropes are manufactured around the clock by
approximately 340 specialists operating in 15 production halls. With the continuous modernisation and expansion of its machinery and facilities,
Drahtseilwerk Dietz is well placed to meet the ever-increasing demand for its
DIEPA Special Wire Rope products.
1.2

The DIEPA philosophy

Different applications place different demands

on the rope, particularly as far as breaking
force, abrasion, and in some cases, resistance
to rotation are concerned. A rope that meets all
the demands for every application rarely
exists. Indeed, the most appropriate rope is, in
reality, a compromise of the different characteristics that best meet the specific demands and
expectations for a given job.

Figure 2 Simple bending machines

Figure 3 Horizontal bending machine

It is important, therefore, for tests to be conducted that not only evaluate the rope for
its breaking force and resistance to bending, but also assess its resistance to abrasion, rotational behaviour and structural
stability. These tests should be designed to
evaluate the behavioural characteristics
throughout the rope's service life and the
company Drahtseilwerk Dietz has built,
and operates, a large number and variety of
testing facilities and equipment that are
devoted to this purpose.

Figure 4 Testing tower simulating actual working conditions

2. What makes DIEPA Special Wire Ropes so special ?

Special design

Recognizing that many jobs require a unique design

of rope, the number of available rope designs in the
DIEPA manufacturing program is almost as varied as
the number of different types of lifting appliances.

Calculated with most up to date computer technology and based on decades of experience
Figure 5
Rotation resistant special wire rope

New CAD and other computer software programs

provide the rope design specialist with the tools to calculate and determine the optimal dimensions of each single wire as it fits in the rope. To assist
in this process, account is also taken of the decades of manufacturing and
field experience.

High quality wire

A meal is only as good as the ingredients used in the recipe. The same principals apply to rope-making. Only high quality wires are used in the manufacture of DIEPA Special Wire Ropes. Our proven and reliable suppliers
have continued to provide us, over the decades, with the best materials.

Lubricant

The lubricant is an important component of the rope that is often underestimated. The use of a rope without sufficient lubricant, or, indeed, with
the wrong type of lubricant will inevitably lead to premature fatigue failure and/or internal corrosion of the rope.

Plastic insert

DIEPA uses only high quality polyamide-12, which has proven to be more mechanically efficient and robust than other more common and cheaper lower grade
polymers.

Figure 6 Non-rotation resistant special wire rope DIEPA PZ 371 with

plastic insert

Modern equipment and machinery

The manufacturing of a wide variety of ropes over a large size range requires different types and sizes of machines. Our very own in-house engineering department has the expertise and skills to design and build equipment and machines that enables each DIEPA Special Wire Rope to be produced on the most appropriate machine. As an example, right-handed and
left-handed ropes of the same type are closed on mirror-imaged machines
in order to obtain identical quality.

Figure 7 New spinning machines ...

Figure 8 ... in new manufacturing halls

Qualified specialists

Many modern machines are computer controlled; but at DIEPA, ropemaking craft skills and experience are equally regarded as key requirements. Low fluctuations in the workforce at Drahtseilwerk Dietz creates
the optimal mix of young dynamic enterprising forces and those having
long years of experience who are able to pass on their knowledge to the
younger generation.

Availability and punctual delivery

Figure 9 Wire warehouse

Figure 10 Rope warehouse

A wire and a rope warehouse, each storing several thousand tons of product, facilitates punctual delivery and allows for timely responses to the
needs and wishes of our valued customers.

High quality certified in accordance with EN ISO 9001.

3.

Basic information about ropes

3.1. Rope strands wires

3.1.1 Structural design of a steel wire rope
As the term steel wire rope implies, the rope is made up of a large number of steel wires (1). These are twisted together to form strands (2a and
2b), following which some of these strands (2b) are used to form the core (3)
of the rope. In the final manufacturing operation a layer of strands, known
as outer strands (2a), is closed over the core to complete the rope.
Some types of ropes also have a plastic insert (4). This is usually in the
form of a plastic coating applied to the core in a special process. Naturally,
lubricant is also applied to the interior of the rope.

(1) Wires
(4) Plastic insert

(2a) Outer strands

(2b) Core strands
(3) Core

Figure 11 Structural formation of a steel wire rope

3.1.2 The outer strands

The number of load-bearing wires in the outer strands is used to determine the individual discard criteria for visible broken wires. The so called filler wires of a strand design such as 1-5-5F-10 or 1-6-6F-12 are not counted. As an example, a rope with 8 outer strands and each strand with a
design 1-6-6F-12 wires, i.e. 8x25F, is considered to have 152 load bearing
wires for the purposes of discard.
3.2

Basic terms and definitions

Direction of lay:
The direction of lay of the rope corresponds to
the direction of lay of the helix of the outer
strands. The direction of lay is either righthanded, denoted Z (figure 12) or left-handed,
denoted S (figure 13). Strands also have a
direction of lay, denoted z for right-handed lay
and s for left-handed lay.

Right-handed
sZ
Figure 14 Ordinary lay

Left-handed
zS

Figure 12
Right-handed

Right-handed
zZ
Figure 15 Lang lay

Figure 13
Left-handed

Left-handed
sS

Ordinary (regular) lay:

The direction of lay of the wires in the strands is opposite to that of the
strands in the rope (figure 14).

Lang lay:
The direction of lay of the wires in the strands is the same as that of the
strands in the rope (figure 15).

Rotation resistance:
A steel wire rope is rotation resistant if the rope does not, or barely,
rotates around its longitudinal axis
while lifting an unguided load or if
its end termination does not turn or
turns very little. This characteristic
results from the fact that the direcFigure 16 Opposite torque moments in a rotation
resistant rope
tion of lay of the core is opposite to
the direction of lay of the rope itself. When a rotation resistant rope is
under load, the torque generated by the core is opposite to that generated
by the outer strands, thus creating an equalizing effect.

Tension free:
A steel wire rope is considered tension free if the wires do not, or barely,
jump out of their structural position when the rope is cut and is not served.

Low tension:
A steel wire rope is considered as low tension if the wires barely lose their
structural position when the rope is cut and is not served.

Free of twist:
A steel wire rope is regarded as being free of twist if it does not exhibit any
twist when it is laid out or when being installed. Every rope should be free
of twist. Being free of twist is sometimes confused with rotation resistance.
To ensure that every DIEPA Special Wire Rope is absolutely free of twist

to allow for trouble-free handling during installation, every DIEPA Special

Wire Rope is laid out, prior to shipment, on a 100 metre long table.

Figure 17 Bench for releasing twist

Compacted strands
A compacted strand is a strand of regular round wires with a diameter that is
reduced compacted by passing the strand through a die or roller, or by swaging it. Before being compacted the strand has a larger diameter, requiring the
use of thicker wires. Therefore, size for size, a compacted strand has a higher
fill factor, and hence, a higher breaking force than a conventional strand of
round wires.

Round wire strand

before compacting
Figure 18 Compacted strand

10

Compacted strand

Round wire strand with

same diameter

Especially in a multi-layer coiling system,

the outer strands of a rope with conventional strands will interface with those of a
neighbouring layer (figure 19) and suffer
high abrasion of the surface. The smooth
cylindrical surface of a compacted strand
offers greater resistance to abrasion and
crushing forces than a conventional strand.
Compacted ropes
Compacted ropes are made of either regular
strands of round wires or of compacted
strands. After the rope is closed, its diameter is reduced compacted by passing the
rope through a die or a roller, or by swaging
it. Such ropes have a particularly smooth,
cylindrical surface and are designed and
produced to perform especially well under
the extreme radial pressures to which a
rope is subjected in a multi-layer coiling
system.

Figure 19 Interference of round wire

strands

Figure 20 Contact between compacted

strands

A compacted rope has a higher metallic cross-sectional area than a conventional rope, resulting in a particularly high breaking force.

11

Figure 21 Interference of ropes with outer

strands of round wires

Figure 22 Contact between ropes with compacted outer strands

12

4.

Easy rope selection

The most important decision to make when selecting a wire rope is:
Which type do I choose a rotation resistant or a non-rotation
resistant rope?
This decision must be made very carefully. There is no room for error.
Short rope life, changes to the structure of the rope, abrupt and unexpected failure of the rope, etc., could result
from an incorrect choice.
A rotation resistant rope must be selected when:

Lifting an unguided load on a single fall

Lifting an unguided load on several falls at a great

lifting height

Figure 23 Rotation resistant

rope

 see page 14 Selecting a rotation resistant DIEPA Special Wire Rope

Rotation resistant ropes can work with or without a swivel.
A non-rotation resistant rope must be selected when

Lifting a guided load

Lifting an unguided load on several falls at a small lifting height (e.g. Electric Overhead Travelling Cranes)

Lifting loads with right-handed and left-handed ropes

operating in pairs

Figure 24 Non-rotation
resistant rope

 see page 16 Selecting a non-rotation resistant DIEPA Special

Wire Rope
Non-rotation resistant ropes must not be used with a swivel

13

4.1 Overview rotation resistant DIEPA Special Wire Ropes

non-compacted outer Strands

DIEPA D 1315
DIEPA D 1315 C

Ordinary lay
Lang lay
Figure 25 DIEPA D 1315 C

compacted outer Strands high breaking force

DIEPA D 1315 Z

Ordinary lay

DIEPA D 1315 CZ

Lang lay

DIEPA D 1315 ZP

Ordinary lay
with plastic insert
Lang lay
with plastic insert

DIEPA D 1315 CZP

Figure 26 DIEPA D 1315 CZ

compacted outer Strands very high breaking force

DIEPA B 60
DIEPA B 63

Ordinary lay
Ordinary lay
with plastic insert

DIEPA B 65

Lang lay
Figure 27 DIEPA B 65

DIEPA B 68

Lang lay
with plastic insert

DIEPA D 915 CZ

Lang lay
for tower cranes
Figure 28 DIEPA D 915 CZ

14

4.2 Selecting a rotation resistant DIEPA Special Wire Rope

All DIEPA Special Wire Ropes listed in page 14 can be used
universally and therefore can be employed in many different types of lifting appliances requiring a rotation resistant rope. It simplifies selecting the rope.
Examples: Hoisting rope for mobile cranes, telescopic cranes, crawlers, offshore cranes, EOTs with a single fall, ship deck cranes, etc..
For single-layer coiling
on the drum:

DIEPA D 1315
DIEPA D 1315 Z
DIEPA B 60

For multi-layer coiling

on the drum:

Every rotation resistant rope listed in

page 14, whereby ropes in Lang lay
and/or with compacted outer
strands have a longer service life

For tower cranes:

DIEPA D 915 CZ
DIEPA D 1315 CZ
DIEPA B 65

The final decision in selecting a rope from one from the above three groups
shall be made based on the required breaking force.
For specific application
(if necessary contact us):

DIEPA
DIEPA
DIEPA
DIEPA
DIEPA
DIEPA
DIEPA

Super 3
Super 4
D 1200 Z
D 1318 Z
D 1318 CZ
D 1318 ZP
D 1318 CZP

15

4.3 Overview non-rotation resistant DIEPA Special Wire Ropes

non-compacted outer strands

DIEPA P 825
DIEPA S 321

Ordinary lay
with plastic insert
Ordinary lay
in hot environments

Figure 29 DIEPA P 825

compacted outer strands high breaking force

DIEPA PZ 371

Ordinary lay
with plastic insert

DIEPA SKZ 8
DIEPA SKZ 8P

Ordinary lay
Ordinary lay
with plastic insert

Figure 30 DIEPA PZ 371

compacted outer strands very high breaking force

DIEPA H 50

Ordinary lay

DIEPA H 53

Ordinary lay
with plastic insert
Figure 31 DIEPA H 50

Every non-rotation resistant rope can also be manufactured in Lang lay.

Please contact us.

16

4.4 Selecting a non-rotation resistant DIEPA Special Wire Rope

All non-rotation resistant DIEPA Special Wire Ropes listed in page 16 can
be used universally and therefore can be employed in many different
types of lifting appliances which require a non-rotation resistant rope. It
simplifies selecting the rope.
For single-layer coiling
on the drum:
Examples: Indoor cranes, overhead
travel cranes, floating dredges,
mills work cranes, etc.

For multi-layer coiling:

Example: Boom hoist rope

DIEPA P 825
DIEPA S 321 (in hot environments)
DIEPA PZ 371
DIEPA SKZ 8P

DIEPA
DIEPA
DIEPA
DIEPA

PZ 371
SKZ 8
H 50
H 53

The final decision in selection the rope in one of the above two groups shall
be made based on the required breaking force.
For specific applications
(if necessary contact us):

DIEPA K 114
DIEPA PZ 299
DIEPA S 417
DIEPA ZV 831
DIEPA SKZ 12

17

5.

Which direction of lay is appropriate right or left handed ?

5.1 General recommendations for DIEPA Special Wire Ropes

During coiling onto the drum the rope is bent and receives a slight twist.
A drum whose grooves are pitched to the right will induce twist into a
left-handed lay rope. A right-handed lay rope will be untwisted by the
same drum grooving. When the rope exits the drum the added twist
or untwist is not always fully released from the rope and as the number
of lifts increases a certain amount of twist remains and builds up in the
rope.
Non-rotation resistant DIEPA Special Wire Ropes are specially designed
and manufactured to resist the additional twist so that at the end there is
usually no, or very little, residual twist. The amount of residual twist, if any,
is so small that it has no adverse influence on the performance of the rope.
DIEPA Special Wire Ropes with a plastic insert will usually resist the
un-twist expected when the rope used is of the wrong direction of lay as
dictated by the direction of the pitch of the drum.
A small amount of twist can be sufficient to negatively influence the structure of a rotation resistant rope. Such ropes are more sensitive to any
type of twist because the direction of lay of the core is laid in the opposite
direction to that of the outer strands. For this reason it is not advisable to
use a rope with the same direction of lay as the pitch of the drum when
single layer coiling.
Just as when the rope is wound onto the drum the rope also suffers
bending when threaded. If the direction of the pitch of the drum differs
from that in which the rope will be threaded, the direction of the pitch
of the drum determines the direction of lay of the rope. The reason is that
the drum usually has the greater influence on the rope. In certain
circumstances one selects a rope with a direction of lay better suited for
the threading rather than be suitable for the direction of the pitch of the
drum.

18

Thus the following is imperative:

For a grooved drum having a right-handed pitch a left-handed lay rope is
recommended. Consequently, for a grooved drum having a left-handed pitch a
right-handed lay rope should be used, as stated in DIN 15 020, part 1, para 5.6
Direction of lay and ISO 4308, Annex C.

Coiling on a single layer with a rotation resistant DIEPA Special Wire

Rope:

The above recommendation must be strictly adhered to. Failure to do so

could result in permanent
changes to the structure of
the rope, such as the formation of a birdcage, protrusion of the core between
the outer strands, etc.

Figure 32 Single layer coiling

Coiling on a single layer with a non-rotation resistant DIEPA Special

Wire Rope:

DIEPA Special Wire Ropes with an internal plastic insert have an exceptionally
high degree of compactness and robustness. This special property of DIEPA Special Wire Ropes allows, on certain occasions, the use of a rope with the apparent
wrong direction of lay according to the general recommendations, such as when a
rope with the specified or proper direction of lay may not be readily available.

Multi-layer coiling:

The direction of coiling at the drum changes from layer to layer. A drum
with left-handed pitch grooves wraps the first layer of the rope with a pitch
to the left and the second layer with a pitch to the right. Therefore, it is
generally not possible to select a rope with an optimum direction of lay.

19

Figure 33 Multi-layer coiling

For rotation resistant and non-rotation resistant DIEPA Special Wire

Ropes it is recommended that the direction of lay be determined by the
pitch of the grooves in the drum (i.e. the first layer). The reason for this is
that the rope will fit better and form a better base and support for the overlying layers. Experience has shown that if a rope with the proper direction
of lay is not readily available, one can, on certain occasions, deviate from
this rule.
In some cases it is even advantageous to select a rope with a direction of
lay required by that layer of rope that is more often wound onto and off
the drum.

Twin lifting appliances:

When both ends of the rope have to be affixed to

the drum, one of the ends will be wrong according
to the recommendations relating to the optimal
direction of lay. Thus it makes no difference which
direction of lay applies to the rope.
In twin lifting appliances up to a limited lifting
height, it is possible to employ a non-rotation
resistant DIEPA Special Wire Rope. At higher
heights, the bottom block is likely to twist and the
rope falls tangle. This is sometime referred to as
cabling.
Figure 34 Double drum lifting appliance

20

Rotation resistant ropes cannot be used because of the possibility of structural deformation due to both ends of the rope being coiled and fixed. In
this case one must select a rope specifically designed for such applications
such as the DIEPA Super 4. This type of rope, however, has a lower resistance to bending than a rotation resistant rope. Please contact DIEPA
when selecting a rope for this type of application.
R

5.2 Simple method for the selection of

optimum direction of lay of the rope
One stands in front of the drum and
points with the thumb towards the flange of the drum in which the rope is affixed while the index finger points in the
direction that the rope exits the drum.

If done with the right hand then a

right-handed rope is recommended.
See figure 35. In this case the pitch
of the drum grooving is left-handed.

Figure 35 Right hand = right-handed rope

Pitch of the drums grooves = left-handed
L

If done with the left hand then a

left-handed rope is recommended.
See figure 36. In this case the pitch
of the grooving is right-handed.

5.3 Right- and left-handed ropes working in pairs or multiples

right-handed
rope

left-handed
rope

Figure 37 Ropes used in pairs

Figure 36 Left Hand = left-handed rope

Pitch of the drums grooves = right-handed

When two or more ropes work simultaneously, in pairs, in parallel, on a lifting appliance, both right- and left-handed ropes must be
used. The build up of torque within each
rope is balanced out as they oppose each
other in opposite directions. This prevents
rope tangle (i.e. twisting or cabling of the
falls of rope).

21

The lifting height has no significance when DIEPA Special Wire Ropes are
used, because right- and left-handed ropes will have the same equalizing
amount of torque. One must make sure that the ropes used are of the same
type.
5.4 Coupling (joining) non-rotation resistant ropes
Only ropes of the same type and diameter may be coupled (joined) together,
otherwise one rope will untwist (unlay) the other.
Only ropes of the same direction and type of lay may be coupled (joined)
together, otherwise the torque generated when the ropes are loaded will
result in serious untwisting/unlaying of both ropes where the ropes are
joined, leading to structural deformation (such as birdcaging) of the rope
and a significant loss in breaking force, etc.
right-handed
rope

left-handed
rope

right-handed
rope

left-handed
rope

left-handed
rope

left-handed
rope

right-handed
rope


right-handed
rope

Figure 38 Coupling (joining) non-rotation resistant ropes

22

6.

Single layer coiling

6.1 General
The principal demand placed on a rope by drive systems with single-layer
coiling, is resistance to reverse bending.
Additionally, and from a safety standpoint, it is preferable that the rope
exhibits deterioration on the outside of the rope as opposed to hidden internal deterioration that might otherwise go unnoticed.
That is why every DIEPA Special Wire Rope designed for this type of operation has a high performance core, in some cases optimized with a plastic insert.
6.2

Test results

DIEPA Special Wire Ropes are designed and manufactured to outperform

conventional ropes. Although they cost more to produce, they will prove
to be more cost effective overall when taking everything into account,
such as downtime and cost of replacement.

DIEPA P 825

8x19F+SE

6x36+SE

Figure 39 Service life of the rope up to the discard criteria

23

The longer the length of rope required or the more complex is the application,
the better DIEPA Special Wire Ropes compare. The diagram (figure 39)
clearly demonstrates their improved performance characteristics.
6.3 The advantages of DIEPA Special Wire Ropes
When used in single-layer coiling, DIEPA Special Wire Ropes offer the following advantages:

24

High resistance to bending

Smooth surface to protect sheaves and drum
Less elongation every DIEPA Special Wire Rope is pre-stretched
Higher structural stability to counter the effects of the larger fleet
angles
Special lubricant
Extended safe service life resulting from high performance core containing a large number of single wires

7.

Multi-layer coiling

7.1 General
The different coiling systems are not discussed here in any detail, regardless
of whether they have regular grooves (figure 40) or Lebus grooves (figure 41).
Experience shows that a rope will achieve a longer service life on a multi-layer
coiling system using a drum fitted with Lebus system.

Figure 40
Drum with regular
(helical) grooving

Figure 41
Drum with
Lebus-grooving

Of special significance for optimum coiling, leading to an increased service

life, is the relationship between the diameter of the rope and the width
(pitch) of the grooves in the drum. The width of the groove is obtained by
measuring the distance occupied by ten grooves and dividing the result by
ten. (Ten grooves are measured in order to reduce or eliminate the possibility of an erroneous measurement of one width.)
pitch
distance 10 grooves

Figure 42 Determining the pitch of the grooves

25

An optimum situation occurs when the actual rope diameter is approximately 1% smaller than the width of the grooves, thus promoting compact
(close) coiling. The diameter of the rope should never be larger than the
width of the grooves, otherwise the rope would not sit correctly in the grooves, resulting in irregularities of the coil, especially along the flange of the
drum where the rope climbs from the first to the second layer.
When selecting a rope, attention should be paid to ensuring that the actual diameter of the rope is within strict limits and will remain so when the rope is
under load. The diameter of the rope should reduce in size very little as the service life progresses and it is clear that a rope should be selected that is capable
of resisting the intense crushing forces associated with multi-layer coiling and avoid
any tendency to become oval-shaped in cross
section. DIEPA Special Wire Ropes with a
18
specially constructed core and having comouter
pacted outer strands are most advantageous
strands
under these extreme operating conditions.

7.2 How many outer strands ?

The more outer strands there are in the
rope the thinner each of them will be.
Figure 43 shows a rope with 18 outer
strands having smaller strands than one
with 15. Thinner strands of the same
strand construction contain thinner individual wires, which makes the rope more
flexible and provide a higher resistance to
reverse bending. At first glance, these
characteristics appear to be advantageous as a hoisting rope is bent by sheaves
many times during its life. A flexible rope
is also more easily attached and detached

26

15
outer
strands

Figure 43 Comparison 15 outer strands to

18 outer strands

from a wedge socket and coils with fewer problems onto and off a winch drum.
Thicker outer strands of the same design, however, allow for the use of
thicker individual wires that will significantly increase the ropes resistance to abrasion, wear, mechanical damage, corrosion and the crushing
forces at the drum inherent in a multi-layer coiling system.
Rope selection is often a compromise. Only through the optimum tuning of
each and all of the different design characteristics of the crane is it possible to employ a rotation resistant rope in a multi-layer coiling system that
will result in improvements to service life.
For this reason DIEPA manufactures rotation resistant ropes with 15 outer
strands (e.g. DIEPA D 1315 CZ) that possess all of the above mentioned
characteristics. The specially designed core provides for very high flexibility and resistance to bending fatigue. An indicator of the high flexibility is
the large number of individual wires used (e.g. DIEPA D 1315 CZ has 328
single wires).
When subject to multi-layer coiling, rotation resistant ropes with 15 outer
strands, for example, have fewer points of contact between adjacent coils
in the same layer and at the cross over points on the drum than a rope with
18 outer strands; but testing and field experience have repeatedly demonstrated that this is more than compensated for by the use of ropes containing the thicker wires.
7.3 Test results
When ropes of different design are compared with one another on a multilayer coiling system it has been shown that by changing from ordinary to
Lang lay and using compacted instead of regular strands of round wires,
the service life can be significantly improved.

27

The Lang lay arrangement results in a more flexible rope, facilitating rope
installation and fitting of the rope termination. In addition, coiling at the
drum is optimised.
Compacted strands, having a smoother surface than conventional strands
of round wires, offer a greater resistance to abrasion and crushing forces.
By combining these two characteristics, additional increases in service life
can be achieved. Indeed, test results clearly show that DIEPA D 1315 CZ
with its Lang lay, compacted strands, is truly a high performance rotation
resistant special rope.

Ordinary lay
outer strands
not compacted
DIEPA D 1315

Lang lay
outer strands
not compacted
DIEPA D 1315 C

Ordinary lay
outer strands
compacted
DIEPA D 1315 Z

Figure 44 Test results in a multi-layer coiling system

28

Lang lay
outer strands
compacted
DIEPA D 1315 CZ

7.4 The advantages of DIEPA Special Wire Ropes

When used in multi-layer coiling systems, DIEPA Special Wire Ropes offer
the following advantages:

Correct and constant real diameter of the rope

High stability of diameter while under load because every rope has been
pre-stretched
High flexibility because of the large number of single wires
Example: DIEPA d 1315 CZ and DIEPA B 65 have 328 wires; DIEPA
SKZ 8 and DIEPA H 50 have 347 wires
Relatively thicker wires for better resistance to abrasion
Every rope is laid out (figure 17) prior to shipment making it significantly easier to install

29

8.

Grooves their diameter and their radius

The grooves in the drum and in the sheaves are required to provide adequate support for the rope during operation. Therefore, during their calculation or control the following must be taken into consideration:
DIEPA Special Wire Ropes in new condition have a real diameter 3 to 4 %
larger than the nominal diameter, unless otherwise agreed. In a groove
having a radius size 0.53 d (where d = nominal rope diameter), one can
expect the longest service life of a rope. If the radius of the groove is smaller, or even narrower then the diameter of the rope, then one can expect
such changes to the ropes structure as birdcaging, corkscrew, etc. If the
radius of the groove is larger, then insufficient support is provided. A groove radius of 0.55 d can result in a 20 % reduction in the service life of the
rope.
Sheaves of synthetic material must have a groove radius of a least 0.55 d.
Sheaves of synthetic material work similar to brakes and can block the
rope from sliding into the sheave, especially when the rope runs at an
angle. Sheaves of synthetic material are used primarily in cranes with a
multi-layer coiling. However, the reduction in resistance to reverse bending caused by the larger size of the groove will be of less significance as
the service life of the rope is largely affected by the more intense wear and
tear experienced in the multi-layer coiling at the drum.
The shape and size of the grooves in the drum and sheaves are
subject to wear and their exact size can be determined by the use of
gauges.

Figure 45 Measuring the diameter of the grooves


30

9.

The ropes swivel

Basically, all rotation resistant DIEPA Special Wire

Ropes can be employed with or without a swivel. On certain cranes or for certain applications (lifts of great
heights, long periods of continuous work) the use of a
swivel (figure 46) is recommended. Rotation resistant
ropes could develop a twist (due to elongation or by the
guiding system) during operation. If the ends of a rotation resistant rope are permanently fixed without being
connected to a swivel, the rope cannot release this twist.
On reeving systems with multiple falls this twist can
lead to a turning of the bottom hook block or result in the
formation of a birdcage in the rope.

Figure 46
Rope swivel

Attention: Only rotation resistant ropes may be used in conjunction with a

swivel. Semi-rotation resistant and non-rotation resistant ropes untwist
under load when used with a swivel, resulting in a permanent change to
the structure of the rope. Furthermore, the breaking force of the rope may
be substantially reduced (figure 47).

DIEPA D 1315 CZ
rotation resistant

6-strand
non-rotation resistant
normal rope

19 x 7
semi-rotation resistant
normal rope

Figure 47 Remaining breaking force

after test to destruction when
using a swivel

31

10. Order data

10.1 Use of a specified DIEPA Special Wire Rope

Number and length of the ropes (5 x 200 m, etc.)

Type of rope (DIEPA D 1315 CZ, DIEPA 321, etc.)

Nominal diameter of the rope (20 mm, etc.)

Direction of lay (right- or left-handed)

Nominal tensile strength grade of the wires (1770 N/mm2, etc.)

Surface finish of the wires (bright, galvanized, etc.)

Lubrication (with or without lubricant)

Type of rope end or termination (plain, fused, solid thimble, etc.)

10.2 Use of a DIEPA Special Wire Rope as an alternative to other specified rope
If a DIEPA Special Wire Rope is being selected for the first time and is to
be used as an alternative to an existing rope with a view to improving rope
performance, no exact designation of the rope is needed (e.g. DIEPA S 321,
etc.). Instead the following information is necessary:

Type of rope used until now and its designation (e.g. DIN 3064
6 x 36 + SE, DIN EN 12385, etc.)

Double check if according to page 13, a rotation resistant rope or a nonrotation resistant rope is required.

State whether the system is single- or multi-layer coiling

State the required minimum breaking force

With this information we will be able to recommend a DIEPA Special Wire

Rope or offer you one from our warehouse.

32

11.

Handling, inspection and in-service maintenance

11.1 Inspection on delivery

The condition of the rope and/or its packing should be inspected on the delivery truck or when down loaded. Any mechanical damage to the rope or
damage caused during transportation can then be recorded on the delivery
document.
11.2 Transporting the rope
Damage to the rope can result from incorrect or careless handling techniques. Contact with sharp objects or the edges of the
arms of a forklift invariably result in damage to the rope (figures 48
and 49).

Figure 48 + Figure 49 Transportation damage caused by forklifts

A better means of transport is through

the use of a bar through the middle hole
or axle of the reel (figure 50). The reel can
then be lifted with a forklift or directly
with a sling attached to a crane (figure
51).
Figure 50 Proper method with the help of a bar

33

If the arms of the forklift are long enough it is

possible to lift the reel directly with the forklift by
placing the arms underneath both flanges of the
reel (figure 52).
Textile slings can be used effectively when lifting
coils (figure 53).

Figure 51 Proper method with the help

of a sling




Figure 52 Proper method with the help of long arms

Figure 53 Proper method with the

help of a textile sling

11.3 Storage
Ropes should be stored in dry, dust free and, if possible, slightly
heated rooms and protected against any potential mechanical damage.
Any wet packing material must be removed. The identification markings of
the rope should not be misplaced. They assist the management in quality
control.
Storage in the open for short periods of time is possible under certain conditions. Direct contact with the ground should be prevented, e.g. by using
a pallet. Covering with a plastic foil requires continuous control and regular inspections of the foil for ruptures, which could allow water to penetrate or lead to a build up of condensation.

34

It is possible for a film of rust to develop on the rope surface after a

rope has been stored for a long period of time in a hot or humid area.
The rust will normally be limited to the outer layer, and more often
than not, will only be an indication of a red pigmentation of the
lubricant. Scratching the surface of the rope with a fingernail will
show if the wires have been affected. If the surface of the wires
are not scarred by the rust, the rope can than be used without
restrictions. This optical feature can easily be eliminated by the
use of regular oils and grease or commercially available rope care products.
11.4 Cutting a DIEPA Special Wire Rope
When cutting a DIEPA Special Wire Rope, the following points must be
adhered to in order to prevent damage or changes to the structure of the
rope:
All non-rotation resistant DIEPA Special Wire Ropes are specially preformed. Thus, for ropes with smaller diameter it is sufficient to wrap with
tape the area where the cut will take place; for rope of larger diameter this
should be done as shown in figure 54.
Rotation resistant DIEPA Special Wire Ropes must be prepared for cutting as shown in figure 54.

Point of cut

Length of serving =
5 x nominal diameter of rope
Figure 54 Serving the area where a DIEPA Special Wire Rope will be cut.

35

12. Installation and operation

12.1 Inspection of the drive system
It is recommend that the various components of the drive system are inspected before installing the rope. Special attention must be given to the
condition of the sheaves and the drum, which should be within normally
accepted limits. (See chapter 8. Grooves their diameter and their radius)
12.2 Unwinding from a reel or coil
Every length of DIEPA Special Wire Rope is laid out prior to being shipped
(figure 17). This ensures that they are supplied completely free of twist and
do not need to be laid out again prior to installation. The following steps
must be followed on site:
a) Unwinding from a reel
To prevent the formation of kinks the supply reel should be set up as
shown in figure 55. The rope shall never be pulled from a reel which is
laying on its side (figure 56).


Figure 55 Reel supported by stands

Figure 56 Wrong uncoiling from reel

Wooden boards should be used on one or both sides of the reel flange(s)
(figure 57) for use as a brake(s) (figure 58) to prevent the rope from
running loose and forming loops on the reel, which could become
damaged (figure 59) or displaced over the flange of the reel.

36


Figure 57 Braking of reel

Figure 58 Slack rope on reel

Figure 59 Rope damage after forming loops

b) Unwinding from a coil

There are two possibilities. The coil
can be placed on a turning block
(swift) and the rope pulled (figure
60), or in the case of smaller coils,
the rope can be rolled out (figure
61). In no circumstances shall the
rope be pulled from a coil that lays
on its side (figure 62), otherwise the
rope will form loops and be kinked
(figure 59).

Figure 60 Swift turntable


37

Figure 61 Uncoiling on the floor

Figure 62 Wrong uncoiling of wraps

12.3 Installing the rope

When the rope is unwound from a reel it is advantageous to maintain the
direction of bending as it leaves the reel, thus avoiding any reverse bending
of the rope (figure 63 and 64).

Reel
Drum

Figure 63 Wrong direction of bending

Reel

Drum

Figure 64 Right direction of bending

There are two ways to change a rope: either the old rope is removed and
the new rope is fed on by hand; or, the old one is used as a lead rope to pull
the new one through the reeving system.
In the latter case it is necessary to ensure that there is a good connection
between both ropes.

38

The connection should not be rigid, otherwise any twist present in the old
rope will be transferred to the new one. Connecting both ropes with a
Chinese finger (figure 65) is, therefore, preferable. When using a Chinese
finger ensure that it is firmly secured and unable to slide. Remove any
restrictions, such as rope guards, that might affect the smooth passage of
the rope through the system before installing the new rope.

Figure 65 Chinese finger

For lead ropes use only rotation resistant ropes (semi-rotation resistant
ropes) or ropes with the same direction of lay as the rope being installed.
If welded attachments (figure 66) are fitted to facilitate installation, they
should be attached to a thinner strand or rope of sufficient strength to withstand the forces that will be induced during installation. The distance between the two ropes should be long enough in order for the connecting strand
or rope to take up any twist that might be present.

Figure 66 Welded link becket

39

12.4 Installing the rope under load in a multi-layer coiling system

The installation of a rope on a multiple-layer coiling system must be carried out very carefully. The high flexibility of DIEPA Special Wire Ropes,
due to their large number of wires, can only be advantageous. Particular
attention must be paid to ensure that the rope sits properly in the bottom
of the grooves immediately after leaving the flange or barrel of the drum.
This area presents a special problem in that it is where the rope switches
from the second to the third layer. If the rope does not sit properly it will
suffer an over proportional amount of fatigue in this area.
The rope should be installed under as much load (back-tension) as
possible, the required amount being approximately 2% of the minimum
breaking force of the rope. If the site conditions do not permit this kind of
value then the supply reel or mounting reel should receive as much
braking as physically possible (figure 57).
It is also advantageous to thread the rope through the bottom hook block
as many times as possible so that the rope can be driven out as far as the
last couple of coils. Afterwards, several lifts should be carried out alternatively with loads and without loads attached to the bottom hook block. This
will help the rope adjust to the reeving system, to the bends in the guiding
system and especially to the spooling arrangement at the drum.

40

13.

Service

13.1 Re-lubrication
DIEPA Special Wire Ropes are originally delivered lubricated with a special
corrosion preventing lubricant that is highly adhesive and has good film coating characteristics. The lubricant does not only cover the outer surface of
the rope, it also fills every space within the rope. This simplifies the servicing of DIEPA Special Wire Rope.
Under certain conditions, blank spots may appear on the surface
of the rope. In this case, the rope needs to be lubricated again.
A timely re-lubrication can have positive effects on the service life of the
rope.
Re-lubrication can be done with commercially available rope lubricants
or with regular oils and greases.
Lubricants used in re-lubrication barely
penetrate the interior of the rope (figure 67
and 68); therefore, excessive application
should be avoided. Excessive amounts of
lubricant remaining on the surface of the rope
make detection of wire breaks more difficult.
A fallacy is widely held that galvanized ropes
are not required to be re-lubricated or, even
more bizarre, that they are manufactured
without a lubricant. This is totally untrue.
Where metal slides on metal (the wires slide
against each other each time the rope bends
over a sheave) a lubricant is necessary to reduce friction. Nobody would contemplate the
idea of galvanizing the pistons of the engine of
a car and then drive away without any engine
oil. The same applies to steel wire ropes.

Figure 67 + Figure 68
Re-lubricating with extreme amounts does not solve
the corrosion problems in the interior of the rope

41

13.2 Shortening the rope

Sometimes, very long lengths of rope in a single layer coiling
system suffer must of the wear and tear in areas associated with rope
that most often bends over the guiding sheaves and/or at the drum.
By shortening the rope at the rope anchorage (not at the end in the
drum) in a timely manner, the affected areas will be re-positioned,
thus promoting a longer service life for the rope.

Wear area

Figure 69 Wear area

crossover zones

42

In a multi-layer coiling system, the rope

wears out mainly at the so-called crossover
zones (S shaped form assumed by the rope).
To offset this wear it is sometimes possible to
shorten the rope at the drum end. It is
recommended that a length equivalent to
approximately one third of the circumference
of the drum is cut off. This will have the effect
of displacing the concentrated areas of wear at
the cross over zones, significantly improving
the service life of the rope. Depending on the
rope length, it may be possible to repeat this
action a second time. A longer rope life is the
reward for this action.

14.

Inspection

14.1 When is the rope to be inspected ?

Wire breaks

Wire ropes do wear out and must be inspected at regular intervals by

qualified (competent) personnel. The intervals between inspections should
be scheduled so as to allow for timely identification of deterioration and
damage. A daily visual inspection is recommended. Be aware that broken
wires will not necessarily increase at a rate proportional to the time in
service.
For example: a rope that shows five broken wires after 100 days in service
may have many more than ten broken wires after 200 days in service.

Time in service
Figure 70 Development of wire breaks

14.2 What needs to be inspected ?

When ropes operate in single layer coiling systems, special attention
should be given to those portions of the rope that are bent the most by the
sheaves and/or the drum. Another critical area of the rope is that portion
that is bent in the sheaves and/or drum when the load is picked-up.

43

On multi-layer coiling systems the areas of rope that require greater

attention are those that come into contact with the flanges of the drum
and the cross-over areas (figure 69) where the top layer crosses over the
underlying layer.
The inspection procedures should be conducted in accordance with
DIN 15 020, part 2, or ISO 4309 : 2004.
14.3 The most important discard criteria
Following is a condensed description of the most important discard
criteria
Wire breaks
This is the most commonly used discard criteria.
DIN 15 020, part 2, and ISO 4309 : 2004 list the number of breaks in
the load bearing wires in outer strands needed to determine the discard
criteria. This information is also included in our catalogue for each different type of rope. According to DIN EN 12385-2, the ropes description
is to be taken from the works certificate, which also includes other
information relating to the rope.
The number of visible broken wires are to be counted in that area
of the rope where most of them are present. The length of the
area has been determined to be 6d (= 6 x nominal rope diameter) and
30d.
The rope must be discarded whenever the number of broken wires counted, in 6d or 30d, is equal to, or greater than, those listed in the standards. A qualified person can determine whether the rope can remain
in operation until the end of the shift.
Many tests conducted by the company DIEPA, as well as decades of
practical experience, show that the number of wire breaks listed in the
standard for some types of ropes are very conservative, giving away precious service life. The principal mode of deterioration for a rope in a
multi-layer system occurs through abrasion of its surface. The core of

44

the rope does not have the chance to wear out. Still, according to the
standards, the rope must be discarded.
Broken strand
When a strand breaks, the rope must be immediately discarded.

Reduction of the ropes diameter (interior wear)

When the real diameter of the rope is reduced by 15 % from the
nominal diameter as result of internal wear, then the rope has
reached discard criteria. DIEPA Special Wire Ropes have a very high
metallic cross-sectional area and, therefore, their diameter is very
stable. Thus, this criteria is not very relevant to DIEPA Special Wire
Ropes.

Abrasion (outer wear)

The rope has reached discard criteria when its diameter has reduced by
10 % from the nominal diameter due to abrasion of the surface of the
rope. Just as in the case with the above criteria reduction of the ropes
diameter, the discard criteria for abrasion seldom needs to be applied
to DIEPA Special Wire Ropes.

Deformation of the rope

DIEPA Special Wire Ropes are structurally very stable; hence, the
criteria described below seldom needs to be applied:

Corkscrew


Figure 71 Corkscrew

When the amount of deformation x as shown in the picture is, or

exceeds, one third of the nominal diameter of the rope, the rope
must be discarded.

45


Bird-caging

Figure 72 Bird-caging

The rope must be discarded whenever a bird-cage develops.

Looped wires

Figure 73 Looped wires

Extreme deformation of the rope in the form of looped wires is a

reason for discard.

Flattening of the circumference, mechanical damage, and kinks

Figure 74 Flattening

Flattening of the circumference and/or mechanical damage are

permanent deformations caused by crushing and depending upon
the extent, may be a reason for discard.

46

Figure 75 Kink

Kinks will occur when a rope forming a loop is pulled

tight.

Bend

Figure 76 Bend

Bends are angular deformations of the rope caused by external

influence.
Every inspection of the rope should be documented. An example of this
record is included in page 48.

47

15. Enclosure
Simple example of an Inspection Record
Type of crane / Crane number:

............................................

Type of rope:

............................................

Length of rope [m]:

............................................

Rope nominal- [mm]:

............................................

Actual- of the rope in new condition [mm]: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of lay / Direction of lay:

............................................

Nominal tensile strength [N/mm2]:

............................................

Type of wire surface:

............................................

Date rope was installed:

............................................

Operating hours / Number of lifts:

............................................

Max. allowable number of broken wires

in 6 x d

in 30 x d
............

Location on
the rope:

48

Number of broken wire:

6xd
30 x d

............

Ropes actual- Additional observations

Discard criteria met:

Date / Signature

YES / NO

.........................................

TZ & SOHN
IE
D
.
H
IC
R
T
AUGUS
nfseilwerk
Draht- und Ha
KG
GmbH & Co.
bei Coburg
t
d
ta
s
u
e
N
6
5
D-964

DIEPA
Drahtseilwerk Dietz
GmbH & Co. KG
Damaschkestrae 30
D-96465 Neustadt bei Coburg
Postfach 1167
D-96456 Neustadt bei Coburg
Phone +49 (0) 9568 924-0
Fax +49 (0) 9568 924-101
E-mail info@diepa.de
www.diepa.de
Rev. 02/07
(1000 02/07)

Extracts can be used only when the publisher is referenced or with the explicit consent
of the company DIEPA Drahtseilwerk Dietz, Neustadt bei Coburg