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U.M. CE rev.8 July 2015

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Contents

I. USE MANUAL OF COMPONENTS ................................................................................................................... 4

ROPE COMPONENTS ........................................................................................................................................... 4

1. FIELD OF APPLICATION .................................................................................................................................. 4

2. CONDITION OF USE AND SAFETY – APPLICABLE STANDARDS .......................................................... 4

3. GENERAL INFORMATION ................................................................................................................................ 6

3.1. MEASURED ROPE DIAMETER ........................................................................................................................... 6 3.2. WIRE ROPE ELONGATION ( CARRY – HAULING ROPE ONLY) ............................................................................ 6 3.3. MODULUS OF ELASTICITY ............................................................................................................................... 6 3.3.1. HAUL ROPES, CARRY – HAULING ROPES, SPLICED EVACUATION AND RECOVERY ROPES ................................. 6 3.3.2. FLAR CARRYING ROPES .................................................................................................................................. 6 3.3.3. TENSION ROPES ............................................................................................................................................... 7 3.3.4. RECOVERY ROPES ........................................................................................................................................... 7 3.3.5. SIGNAL ROPES WITH ELECTRIC CONDUCTORS OR OPTICAL FIBRES ................................................................... 7 3.4. SAFETY FACTORS ............................................................................................................................................. 7 3.5. ROPE TENSION ................................................................................................................................................. 7 3.6. BENDING RADIUS ............................................................................................................................................. 7 3.7. GRIPS ............................................................................................................................................................... 7 3.8. LINERS ............................................................................................................................................................. 7 3.9. END CONNECTION ............................................................................................................................................ 7 3.9.1. FIXING DRUM FOR TRACK ROPES...................................................................................................................... 7 3.9.2. EVACUATION AND RECOVERY ROPES, SIGNAL ROPES, TENSIONING ROPES – END FIXINGS ............................... 8 3.10. ROPE LENGTH .................................................................................................................................................. 8 3.11. ROLLERS AND SHEAVES GROOVE DIMENSION AND SHAPES .............................................................................. 8 3.11.1. SHEAVES ..................................................................................................................................................... 8 3.11.2. SHEAVES GROOVES DIAMETER AND ANGLE SPAN:....................................................................................... 9 3.11.3. LINE ROLLERS GROOVE DIAMETER AND ANGLE SPAN: ................................................................................ 9 3.11.4. SHEAVES AND WINCH DIMENSIONS (FOR RECOVERY & EVACUATION ROPE IF NOT SPLICED, & TENSIONING

ROPE) : 10

4. TRANSPORTATION AND STORAGE ............................................................................................................ 12

4.1. FACTORY PACKING ........................................................................................................................................ 12 4.2. ROPE IDENTIFICATION AND SHIPMENT .......................................................................................................... 12 4.3. ROPE DELIVERY AND UNLOADING ................................................................................................................ 12 4.4. STORAGE ....................................................................................................................................................... 13

5. ROPE INSTALLATION ..................................................................................................................................... 14

5.1. WORKING AREA ............................................................................................................................................ 14 5.2. REEL POSITIONING AND STANDING ............................................................................................................... 14 5.3. PULLING ROPES AND ROPE INSTALLATION .................................................................................................... 14 5.3.1. EVACUATION AND RECOVERY ROPES INSTALLATION: .................................................................................... 15 5.3.2. SIGNAL ROPES INSTALLATION: ...................................................................................................................... 15 5.4. ROPE CUTTING ............................................................................................................................................... 16 5.4.1. STRANDED ROPES: ......................................................................................................................................... 16 5.4.2. SPIRAL STRAND ROPES AND FLAR ROPES: ................................................................................................... 17 5.4.3. SIGNAL ROPES WITH OPTICAL CORE (OPTICAL FIBRES): ................................................................................. 17

6. WIRE ROPE MAINTENANCE ......................................................................................................................... 18

6.1. RE-LUBRICATION ........................................................................................................................................... 18 6.1.1. INTRODUCTION .............................................................................................................................................. 18 6.1.2. LUBRICANTS USED DURING THE ROPE’S PRODUCTION: TYPE AND QUALITY ................................................... 18 6.1.2.1. CARRYING ROPES (FLAR AND ERCOLE ROPES): ....................................................................................... 18 6.1.2.2. TOWING ROPES FOR SKY TOW, FIX ROPES, TENSION ROPES: ....................................................................... 18 6.1.2.3. GALVANISED AND UNGALVANISED CARRY-HAULING ROPES FOR FIXED AND DETACHABLE GRIPS

INSTALLATIONS, HAUL ROPES FOR AERIAL ROPEWAY AND SURFACE SYSTEM .............................................................. 18


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6.1.2.4. SIGNAL ROPE, EVACUATION & RECOVERY ROPES ON WINCH WITH OR WITHOUT ELECTRIC CONDUCTORS &

OPTICAL FIBRES ............................................................................................................................................................ 18 6.1.3. RE-LUBRICATION OF IN USE ROPES: INDICATIONS AND PRODUCTS ................................................................. 19 6.1.4. RE-LUBRICATION FREQUENCY ....................................................................................................................... 19 6.1.5. INSTRUCTION FOR THE LUBRICANT APPLIANCE .............................................................................................. 20 6.2. ROPE RELOCATIONS ....................................................................................................................................... 21 6.2.1. TRACK ROPE .................................................................................................................................................. 21 6.2.2. SIGNAL ROPES. .............................................................................................................................................. 21 6.3. GRIPS FOR BICABLE AERIAL ROPEWAYS AND FUNICULARS ............................................................................ 22 6.4. FIXED GRIPS OF MONOCABLE AERIAL ROPEWAYS .......................................................................................... 22 6.4.1. GRIP INSTALLATION....................................................................................................................................... 22 6.4.2. RELOCATION OF GRIPS .................................................................................................................................. 22

7. WIRE ROPE REPAIR......................................................................................................................................... 24

7.1. ROPE LOOP SHORTENING ............................................................................................................................... 24 7.2. FULL LOCKED COIL ROPE REPAIR ................................................................................................................. 24 7.3. STRANDED ROPES REPAIR .............................................................................................................................. 24

SPLICE COMPONENTS...................................................................................................................................... 25 1. FIELD OF APPLICATION ............................................................................................................................... 25 2. CONDITION OF USE AND SAFETY – APPLICABLE STANDARDS .................................................................. 25 3. TENSIONING AND FIRST SPLICING (APPLICABLE FOR STRANDED ROPES ONLY) ........................................ 26 3.1. GENERAL INFORMATION ABOUT THE TENSIONING ......................................................................................... 26 3.2. SPLICING PRELIMINARY TENSIONING ............................................................................................................. 26 3.3. SPLICING POSITION ........................................................................................................................................ 26 3.4. SPLICING DIMENSION ..................................................................................................................................... 26 4. WARM UP AND ELONGATION MEASUREMENTS ................................................................................... 27 4.1. FIRST OPERATING SERVICE AND “L0” MARK .................................................................................................. 27

SOCKET COMPONENT ...................................................................................................................................... 28 1. FIELD OF APPLICATION ............................................................................................................................... 28 2. CONDITION OF USE AND SAFETY – APPLICABLE STANDARDS .................................................................. 28 3. SOCKETING..................................................................................................................................................... 29

II. WIRE ROPE INSPECTION RECOMMENDATIONS.................................................................................... 30

1. FIELD OF APPLICATION ............................................................................................................................... 30 2. CONDITION OF USE AND SAFETY – APPLICABLE STANDARDS .................................................................. 30 3. POST INSTALLATION CHECK ..................................................................................................................... 31 4. DAILY INSPECTION....................................................................................................................................... 31 5. MONTHLY INSPECTION ............................................................................................................................... 31 6. ANNUAL INSPECTION .................................................................................................................................. 32 7. SPECIAL INSPECTION ................................................................................................................................... 32 8. INSPECTION OF PARTICULAR ROPES: SIGNAL ROPES AND RECOVERY ROPES ........................... 32 8.1. SIGNAL ROPES: .............................................................................................................................................. 32 8.2. RECOVERY ROPES (NOT SPLICED AND THAT WORKS ON WINCH): ................................................................... 32

The purpose of this manual is to supply to the final user the prescription for a safe use and maintenance of the ropes supplied by Redaelli S.p.A..

All the indications shown in this manual are in references and according to the European Standards (see also “Condition of use and safety” – Applicable Standards”).

The changes of the manual are underlined: The additions, in cursive underlined The removals, through a vertical line, on the side of the

page, in the point of the removal


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I. USE MANUAL OF COMPONENTS

ROPE COMPONENTS

1. FIELD OF APPLICATION Haul ropes, carrying – hauling ropes, locked coil carrying ropes, towing and fix ropes, recovery and evacuation ropes, tension ropes and signal ropes for cableways installations designed to carry persons.

“Hercules” ropes are not included in the EN 12927. CE marking does not apply on “Hercules” ropes. “Hercules” ropes shall only be selected to replace similar ropes on existing installations.

2. CONDITION OF USE AND SAFETY – Applicable standards If not otherwise specified in this document the applicable standards are:

DIN 21258:1986 Preservative compounds for Keope friction drive winding ropes mining – Safety requirements and testing

DIN 53521 Determination of behaviour of rubber and elastomers when exposed to fluids and vapours

DM 1175 Disposizioni per le verifiche e prove per l’accettazione delle funi metalliche destinate ai pubblici servizi di trasporto effettuati mediante impianti funicolari aeree e terrestri” (N.B. this standard is applicable for Ercole ropes only)

EN 10264-1 Steel wire and wire products – Steel wire for ropes – Part 1: General requirements

EN 10264-2 Steel wire and wire products – Steel wire for ropes – Part 2: Cold drawn non-alloyed steel wire for ropes for general applications

EN 10264-3 Steel wire and wire products – Steel wire for ropes – Part 3: Cold drawn and cold shaped non-alloyed steel wire for heavy duty applications

EN 12385-1 Steel wire ropes – Safety – Part 1: General requirements

EN 12385-2 Steel wire ropes – Safety – Part 2: Definitions, designation and classification

EN 12385–3 Steel wire ropes – Safety – Part 3: Information for use and maintenance

EN 12385-4 Steel wire ropes – Safety – Part 4: Stranded ropes for general lifting applications

EN 12385–8 Steel wire ropes – Safety – Part 8: Stranded Hauling and carrying-hauling ropes for cableway installation designed to carry persons

EN 12385–9 Steel wire ropes – Safety – Part 9: Locked coil carrying ropes for cableway installation designed to carry persons

EN 12397 Safety requirements for cableway installations designed to carry persons – Operation

EN 12408 Safety requirements for cableway installations designed to carry persons – Quality assurance

EN 12927-1 Safety requirements for cableway installations designed to carry persons – Ropes – Part 1: Selection criteria for ropes their end fixings

EN 12927-2 Safety requirements for cableway installations designed to carry persons – Ropes – Part 2: Safety factors

EN 12927-3 Safety requirements for cableway installations designed to carry persons – Ropes – Part 3: Long splicing of 6 strand hauling, carrying-hauling and towing ropes

EN 12927-4 Safety requirements for cableway installations designed to carry persons – Ropes – Part 4: End fixings

EN 12927-5 Safety requirements for cableway installations designed to carry persons – Ropes – Part 5: Storage, transportation, installation and tensioning

EN 12927-6 Safety requirements for cableway installations designed to carry persons – Ropes – Part 6:


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Discard criteria

EN 12927-7 Safety requirements for cableway installations designed to carry persons – Ropes – Part 7: Inspection, repair and maintenance

EN 12927-8 Safety requirements for cableway installations designed to carry persons – Ropes – Part 8: Magnetic rope testing (MRT)

EN 12929-1 Safety requirements for cableway installations designed to carry persons - General requirements - Part 1: Requirements for all installations

EN 12929-2

Safety requirements for cableway installations designed to carry persons - General requirements - Part 2: Additional requirements for reversible bicable aerial ropeways without carrier truck brakes

EN 12930 Safety requirements for cableway installations designed to carry persons – Calculations


EN 13107 Safety requirements for cableway installations designed to carry persons – Civil engineering works

EN 13223 Safety requirements for cableway installations designed to carry persons – Drive system and other mechanical equipment

EN 13243 Safety requirements for cableway installations designed to carry persons – Electrical equipment other than for drive system

EN 13411-1 Terminations for steel wire ropes – Safety – Part 1: General purpose steel thimbles

EN 13411-2 Terminations for steel wire ropes – Safety – Part 2: Spliced eyes

EN 13411-3 Terminations for steel wire ropes – Safety – Part 3: Ferrule secured eyes

EN 13411-4 Terminations for steel wire ropes – Safety – Part 4: Metal and resin socketing

EN 13411-5 Terminations for steel wire ropes – Safety – Part 5: U-Bolt wire rope gripped terminations

EN 13411-6 Terminations for steel wire ropes – Safety – Part 6: Asymmetric wedge socket clevis

EN 13411-7 Terminations for steel wire ropes – Safety – Part 7: Symmetric wedge socket clevis

EN 13796-1 Safety requirements for cableway installations designed to carry persons – Carriers – Part 1: Grips, carrier trucks, on-board brakes, cabins, chairs, carriages, maintenance carriers, tow-hangers

EN 13796-2 Safety requirements for cableway installations designed to carry persons – Carriers – Part 2: Slipping resistance tests for grips

EN 13796-3 Safety requirements for cableway installations designed to carry persons – Carriers – Part 3: Fatigue testing

EN 1709 Safety requirements for cableway installations designed to carry persons – Pre-commissioning inspection, maintenance, operational inspection and checks

EN 1907 Safety requirements for cableway installations designed to carry persons – Terminology

EN 1909 Safety requirements for cableway installations designed to carry persons – Recovery and evacuation

EN 444 Non-destructive testing – General principles for radiographic examination of metallic material by X – and gamma rays

ISO 2592 Determination of flash and fire points – Cleveland open cup method

EN 1908 Safety requirements for cableway installations designed to carry persons – Tensioning device

ISO 4308-1:2003 Cranes and lifting appliances – Selection of wire ropes - General

DIN 15061 teil 1 Rillenprofile fur seilrollen

DIN 1501 teil 2 Rillenprofile fur Seiltrommeln


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3. GENERAL INFORMATION

3.1. Measured Rope diameter

The measured diameter of ropes shall be in accordance with the standard, EN 12385-4(for towing, signal ropes, recovering rescue ropes, tension rope), EN 12385–8 for haul and carry – hauling ropes, The Redaelli general diameter production tolerance shall be +1% / +5% of the nominal diameter of the wire rope.

The measured diameter of the Full Locked Coil Ropes and Ercole shall be in accordance with the standard EN 12385-9 (± 2% of the rope nominal diameter).

Different tolerances can be agreed with the customer during the commercial and technical discussion before the issue of the order confirmation

IMPORTANT: the diameter measurements shall be taken in accordance of EN 12385-1

3.2. Wire Rope Elongation ( carry – hauling rope only)

The indicative elongation values of the non pre-tensioned stranded wire ropes are indicated below:

0,20 % in the first 500 hours of use 0,30 % in the first 1500 hours of use 0,60 % in the life of the cable

The experiences confirm that the pre-tensioned ropes show a reduced elongation values than the ones above indicated for the non pre-tensioned ropes (close to 50% less than the standard values indicated). The real values depend by different factors and mainly by: correct rope installation and its over tensioning before the splicing operation (see chapter “Splice Component” paragraph 10), number of bending cycles, tensioning, working temperature, etc.

THE GALVANISED ROPES SHOW MORE ELONGATION DURING ITS SERVICE LIFE DUE TO THE DEFORMABILITY OF THE ZINC COATING. FOR THIS MATTER THE VALUES LISTED ABOVE SHALL

BE INCREMENTED OF 0.05% AT LEAST.

FOR MORE DETAILS ABOUT THE WIRE ROPE ELONGATION CONTACT THE TECHNICIANS OF REDAELLI S.P.A. .

3.3. Modulus of Elasticity

The modulus of elasticity indicated below are refereed to values determinate after the initial trial

stage. During the rope lifetime these values will increase significantly.

3.3.1. Haul ropes, Carry – hauling ropes, spliced evacuation and recovery ropes

For six strands wire ropes with fibre core, the value of the modulus of elasticity (after a certain period of use) is:

E = 125 kN/mm2 ± 4%

For seven strands wire ropes with fibre core, the value of modulus of elasticity (after a certain period of use) is:

E = 114 kN/mm2 ± 4%

3.3.2. FLAR carrying ropes

For the track rope the indicative value of the modulus of elasticity is:

E = 140 kN/mm2 ± 4% for Ercole rope type E = 155 kN/mm2 ± 5% for Full Locked Coil rope type


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3.3.3. Tension Ropes

For the tension ropes the indicative value of the modulus of elasticity is:

E = 110 kN/mm2 ± 4%

3.3.4. Recovery Ropes

For the recovery ropes with metallic core the indicative value of the modulus of elasticity is:

E = 120 kN/mm2 ± 4%

3.3.5. Signal ropes with electric conductors or optical fibres

For the signal ropes the indicative value of the modulus of elasticity is:

E = 170 kN/mm2 ± 4% for Spiral Strand ropes E = 120 kN/mm2 ± 4% for stranded ropes

If the actual measured value of “E” is to be known, it should be determined experimentally on an appropriate wire rope specimen.

3.4. Safety factors

They shall comply with the EN standards if not otherwise specified. A lower safety factor could be adopted only for rope’s installation purpose. For this specific situation refer to specific instruction of the rope manufacturer if available

3.5. Rope tension

It shall comply with the EN standards if not otherwise specified. If the rope needs to be spliced, the installation’s manufacturer shall notify in advance the value of the minimum rope tension (or the value of maximum safety factor) to the rope manufacturer and the organization in charge for the splice so to evaluate the right splice length ad design following the EN standards

3.6. Bending radius

The minimum bending radius depends by the rope type and construction. The allowable values shall comply with the EN 12927-2 or specific standards and / or rope’s manufacturer indications (see par. 3.11) In same cases, using special rope constructions (7 strands rope for example), the minimum bending radius may be lower allowing to use smaller rollers, sheaves etc. The minimum bending radius selection can be addressed by the rope manufacturer. A sharp bending may permanently damage the rope.

3.7. Grips

They shall comply with the EN standards if not otherwise specified.

Their grooves must comply with the rope diameter. The closing force must be as specified by the manufacturer. The max admissible transversal pressure on the rope is 35 N/mm2 (referred to the nominal rope diameter); see SS1 Technical Documentation released by Redaelli. After the releasing of the clamping force, the rope shall not stay permanently deformed.

3.8. Liners

They shall comply with the EN standards if not otherwise specified.

3.9. End connection

They shall comply with the EN standards (En 12927-4, EN 13411 for example) if not otherwise specified.

3.9.1. Fixing drum for track ropes

The storage of the spare cable and the winding of the suspension cables on drums shall be carried out by running out the end of the cable along the route and placing it in the correct position as the operation proceeds.


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It is important that the cables are placed in position without having been rotated, as this may create anomalies. To do this, the pitch should be checked in the section immediately in front of the departure and arrival stations, extending the check to the intermediate zones if any difference in the lay length is noted. The excess lengths of cable (storage rope) must be coiled or wound on drums having a diameter equal or larger than 30 times the rope nominal diameter. The direction and the diameter of the coiling must be the same of those of the anchor drum.

3.9.2. Evacuation and recovery ropes, signal ropes, tensioning ropes – End fixings

The connection of the evacuation and recovery ropes, signal ropes and tensioning ropes shall be performed accordingly with the EN 12927-4 and EN13411 or specific National standards where applicable and request. The “end fixing” in the main cases is an EC component and as indicated before each possible or chosen type of end fixing shall be comply and respect the proper EN or local (if request by the local authority) standards and subjected to an EC conformity evaluation by an authorized notify body. The indicated standards give the minimum indication and parameters for the end fixing characteristics, dimensioning and safety – strictly parameters can be adopted. Possible main end fixings that can be use and take in consideration during a people transportation installation design are (see EN 12927-4 also):

Filled and Clamp Socket:

Splice

Drum

Wedge socket

Spliced eyes

Ferrule secured eye

etc The end fixing efficiency indicated in the EN standard shall be take in account during the installation design and calculation. All the developed end fixing or in line connection shall not damage the rope and its components (for example optical fibres, cupper electric wires etc, metallic core etc.) Special connection could be design but shall be communicate to the rope manufacture in order to verify that the rope will be not subjected to any damage or important reduction in safety and if requested must be subjected to the EC conformity procedure.

FOR SIGNAL ROPES WITH OPTICAL FIBRES THE FINAL CONNECTION AT THE FINAL ELECTRICAL BOARD SHALL BE PERFORMED BY COMPETENT / SPECIALIZED PERSONS AND ADEQUATE AND

PROPER TOOLS MUST BE USE SO TO AVOID ANY COMPONENT DAMAGE AND FAILURE THAT CAN RESULT IN A SAFETY REDUCTION

3.10. Rope length

The length of each rope depends by :

The rope tension (depending by the force, the rope metallic area and the E modulus)

The rope stretch (depending by the type of rope, its core, rope pre-stretching)

The environmental temperature [depending by the factor 12 mm/(km x °C)].

3.11. Rollers and sheaves groove dimension and shapes

In order to reduce and avoid any rope rotation that could compromise the rope in service life time and then ensure its best behaviours during the service, all the systems where the rope pass through shall have the correct dimension and shape to avoids its lateral and transversal compression that are one of the causes of its rotation. The sheave and groove of the line rollers and the drive and bull sheaves shall be meet at least the dimension indicated in the next sub paragraphs.

3.11.1. Sheaves

They shall be comply with the EN standards if not otherwise specified.

The lining material shall be compatible with the rope lubricant and the lubricant used for the rope re-lubrication


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FOR FURTHER INFORMATION READ CHAPTER 1 PARAGRAPH N° 6 “WIRE ROPE MAINTENANCE” OF THIS USE AND MAINTENANCE MANUAL.

The groove diameter must be higher than the rope diameter (see 3.11.2 and 3.11.3 also) For the recovery and evacuation rope if are not spliced and are install on winch, particular attention to the installation design (sheaves and drum) need to be take in account.(see3.11.4 also)

3.11.2. Sheaves grooves diameter and angle span:

Bicable installation (reversible aerial ropeway, 2S,3S, Funifor etc.): the groove angle span (α) shall be: α ≤ 60°. The new groove diameter shall be at least: 1.05d ≤ d ≤ 1.10d where d =nominal rope diameter. In presence of wear groove its diameter shall be at least d wear groove ≥ d actual rope diameter

Gondola lifts, chairlifts, ski-tow: the groove angle span (α) shall be a least 80° ≤ α ≤

140° with optimal angle span of 120°. The groove diameter after 200 working hours shall be at least d groove 200h ≥ d actual rope diameter

In presence of lining material with M.E. ≤ 5000 N/mm2 small groove diameter than the ones above mentioned could be allowed but shall be respect the actual dimension after 200 working hours

200h: d groove 200h ≥ d actual rope diameter

3.11.3. Line Rollers groove diameter and angle span:

the groove angle span (α) shall be α ≤ 120° with optimal angle span of 120°. The new

groove diameter shall be at least: 1.05d ≤ d ≤ 1.10d where d =nominal rope diameter. In presence of wear groove its diameter shall be at least d wear groove ≥ dactual rope diameter..

In presence of lining material with M.E. ≤ 5000 N/mm2 small groove diameter than the ones above mentioned could be allowed but shall be respected the actual dimension after 200 working hours

200h: d groove 200h ≥ d actual rope diameter

The following sketch put in evidence the difference between the angle span and the envelope angle”. The span angle shall be calculated taking as reference the angle between to two lines starting from the roller / sheave centre, and tangent to the circle that simulate the rope diameter + 10% (figure below on the left) For flat rollers the span angle is due to the roller / sheave side flanges inclination


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Redaelli suggest as optimal dimension of the groove:

D = dn x 1.10

Where: D = groove diameter [mm] dn = nominal rope diameter [mm]

A REGULAR CONTROL OF THE GROOVES DIMENSION AND THEIR REGULAR MAINTENANCE AVOID POSSIBILE DAMAGE ON THE ROPE. DIAMETERS AND SHAPES LESS THAN THE MINIMUM

TOLERANCES INDICATED ARE NOT ALLOWED AND REDUCE DRASTICALLY THE IN SERVICE ROPE LIFE.

3.11.4. Sheaves and winch dimensions (for recovery & evacuation rope if not spliced, & tensioning rope) :

Sheaves: The groove dimension for the sheaves shall be at least 1.05d and not more

than 1.10d ( where d = nominal rope diameter), with optimal dimension of 1.108d when new (see ISO 4308-1:2003 also). The construction material shall be choose in order to support the rope pressure on it under working condition so to avoid fast and dangerous groove wear. For the pressure calculation see table below. The sheave diameter must be ≥25d (where d= nominal rope diameter) and the open span angle must be not less than 30° and not more than 60°included (see ISO 4308-1:2003 also). The maximum allowed fleet angle is 1.5%. Different value not included in the above indication shall be communicate to the rope manufacturer for evaluation and in use admissibility;

Winch: the winch must be design to allow a perfect rope wind on it. The drum diameter

shall be at least 30d (where d = nominal rope diameter), while the drum width must be design in order if will work in a single or multi layer and if the drum will be smooth or grooved. The dimensions shall be develop to avoid any wrap cutting and or incorrect rope winding. For grooved winch the groove’s pitch shall be 1.06 d and the groove diameter equal to 1.05d (where d = rope nominal diameter) and in any case respect how indicated in the ISO 4308-1:2003 or DIN 15061. The max allowed fleet angle is 1.5°. During the first installation the rope shall be wind on the drum with appropriate back tension (see par 5.4).

INCORRECT SYSTEM DESIGN OR SMALLER DIMENSION THAN THE ONES INDICATED ABOVE CAN RESULT IN RAPID AND UNEXPECTED ROPE DETERIORATION WITH A SAFETY DRASTICAL

REDUCTION


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Maximum acceptable specific pressure P table for different sheave construction material

Sheaves material construction Cast Iron Fe410 C45 36NiCrMo4

Sheaves material hardness [HB] >100 >160 >235 >465

Max admissible rope pressure [N/mm2] 35 60 90 170

Note values for 6 strand ropes only

Formula for rope / sheaves pressure calculation

Where:

P = effective pressure on the sheave’s groove [N/mm2] (P due to the rope slide and contact)

F = force applied on the rope [N]

D = sheave diameter [mm]

d = rope nominal diameter [mm]

λ = shape coefficient - depends by the rope type, sheave and groove conditions, etc.

“λ” values for a 6 strands ropes with IWRC

New groove, without fleet angle and right groove diameter 0.50

Wear sheave with max 1.5° of fleet angle 0.25

smooth drum or sheave with groove diameter higher (more than 1.10d) than rope diameter 0.25

Rope on the cross over point in the multi layer drum / winch 0.10

Dxdx

FP

2


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4. TRANSPORTATION AND STORAGE

4.1. Factory Packing

The Redaelli S.p.A. – Wire Ropes supplies all Haul ropes, carrying – hauling ropes, locked coil carrying ropes, towing and fix ropes, recovery and evacuation ropes, tension ropes and signal ropes for cableways installations designed to carry persons; in reels packed according to the Client’s specification, if any. .

Only short lengths of tensioning rope can be packed in coils. The rope identification tag is firmly fixed to the reel in a readable position.

4.2. Rope Identification and Shipment

The wire rope shall be recognized and identified by means of the identification’s tag applied to the reel and on the rope.

Normally the tag (Redaelli one) is filled with the following details :

CE Marking followed by the last two numbers of the rope production year and the notified body number that released the CE certification;

Rope Manufacture name and address

Customer;

Installation name;

Rope Identification;

Customer Order Number;

Reel number;

Rope Designation;

Rope Length;

Gross weight;

Net weight;

Tare;

Year of manufacture;

The order number confirmation is written in the rope CE declaration also. For the FLAR ropes the reel number is write in the rope CE declaration too.

If the reel is shipped via sea, it will be suitably protected or placed in a container to prevent damage during handling, transportation and storage phases. Specific agreement about the transportation and tags can be discussed and required with the customer.

4.3. Rope Delivery and Unloading

At the beginning of the shipment all the delivery documents are sign by the carrier and at the arrival by the person in charge to the delivery receiving. Copy of the rope’s identification tag must be keep with all the delivery documents by the customer job site representative. During transportation the reel shall be placed in a horizontal position and suitably anchored by restrains. The reel shall be handled using suitable and certified lifting devices inserting a proper shaft throughout the centre hole’s shaft of the reel. The reel must be unloaded using the appropriate equipment avoiding:

no direct contact between the lifting slings and the wire rope happens;

Shocks. Jerks, falls etc…The reel shall not be dropped or subjected to any shock, jerk, knock etc. which may cause damage to the rope or the structure of the reel itself. This may adversely affect the uncoiling operation and any braking action;

Reel roller. The reel should not be rolled over the floor. If this cannot be avoided, ensure that the flanges are not damaged and that the outer layer of the rope does not touch the ground. If inclined plane is used a continuously and correct control of the reel must be adopt


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4.4. Storage

If not otherwise agreed, the supplied protection of the reels is only provided for the duration of the transport (maximum 2 months). If the rope needs to be stored for a longer period, an adequate protection shall be adopted in relation to the storage site also. It’s better to store the reel in a safe well covered place and avoid that the rope is expose and goes in contact with rain, humidity, dust, dirt, chemical agents or chemical vapour, corrosive environments. Under good storage conditions, a reel of rope could be stored for an unlimited period of time. Preferably, the reel should be stored with horizontal axis.

In case of hot climates or hot environments the lubricant on the rope may leak out. In this case, the reel must be rotated half a revolution (at least every six months) in order to prevent migration and dripping of the original lubricant. Care should also be taken to preserve intact the protection applied by the manufacturer.

The condition of the cable-reel assembly must be assessed at the start and at the end of the storage period, and the results written on the identification tag. For rescue rope and signal rope with electric conductors and / or optical fibres if long storage is required attention shall be take for the rope’s ends also. A proper and adequate seal must be adopt so to avoid water or humidity penetration, damages due to incorrect handling etc. of the optical core.

IMPORTANT: for further information refers to the European standards EN 12385-3 and EN 12927-5


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5. ROPE INSTALLATION

5.1. Working Area

Whatever techniques are adopted, which may vary according to the availability of equipments or factors linked to the site layout, the company responsible for the preparation and erection works must provide for:

- A horizontal platform with the necessary anchors points for fixing the reel on the pay-off system; - The installation of the pay-off equipment, winches or pulling devices, shall comply with all safety

requirements and shall be designed to ensure the regular and uniform tensioning of the rope; - Supplementary supports for running-out the rope (supports, guide rollers, pulleys, etc.) shall be

installed according to the ground configuration, to prevent the rope from coming into contact with the ground or any other obstacles.

It is discouraged to use wooden timbers to prevent contact with the ground (to prevent rope rotation, lubricant removal and possible accidents).

The deviation rollers shall be laid-out in such a way to prevent fleet angle, sharp bending or bends on not allowed reduced diameter.

The installation company shall use the necessary site equipment in accordance with the procedures previously accepted by the cableway constructor and by the rope manufacturer.

FAIL IN THE ABOVE INDICATIONS CAN RESULT IN A PERMANENT AND IRREPARABLE ROPE DAMAGE

5.2. Reel Positioning and Standing

The reel shall be placed on a suitable stand, which allows the reel control and its freely rotation, the uncoiling speed control to allow the keep the designated tension in the cable by of an appropriate braking system. The stand shall be secured to ensure its stability during all the uncoiling phases.

Prior to start each run-out, the installation company shall ensure that it has obtained all the necessary authorisations.

THE REELS WHERE THE ROPES ARE WOUND ARE DESIGNED ONLY FOR THE TRANSPORTATION PURPOSE. THEY CAN NOT ACCEPT A DIRECT PULLING OF THE ROPE UNDER A TENSION HIGHER

THAN ”1t” FOR REEL MADE IN STEEL. FOR HIGHER PULLING FORCE, THE ROPE SHALL BE

SPOOL USING A SUITABLE TENSIONING DEVICE (capstan for example). WOODEN REEL ARE NOT ABLE TO SUPPORT DIRECT PULL

5.3. Pulling Ropes and Rope Installation

The dimensioning of the messenger wire and pulling ropes shall be carried out considering the proper safety coefficients.

Before pulling, it is advisable to run-out 20 – 30 metres of rope to check any tendency to twist and measure the rope lay length. Some ropes are provided with a painted longitudinal strip. The stripe helps in detecting any rope rotation which may occur during installation.

The connection between the ropes shall be made using a suitable connection system (short splice or Chinese fingers for six strands rope, socket terminal or clamps for multi-strand, Spiral Strand Ropes, FLAR etc).

In case of connection by short splice, the diameter ratio between the messenger wire and the rope, shall be > 0.5.

To prevent rope rotation, the lay direction of the ropes used shall be the same.


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Special care must be taken to:

Prevent injuries during the rope cutting. Generally the ropes are not fully preformed : the wires or the strands may unwind during cutting operations (see par. 5.4 also)

Prevent the cables from touching sharp edges. Support rollers must be placed at the points where the cable could come into contact with the ground or other;

Prevent the cable from rotating. The connection point must be ballasted using a lever system to prevent twisting in the cable. Where the cable is run-out over snow, suitable measures must be taken to prevent the cable from burying itself in the snow;

If the run-out is performed under tension, pulling forces up to approximately one ton (for steel reel) could be applied directly to the reel. Forces greater than one ton require the use of special equipment designed specifically for the purpose (see point 5.2);

Ensure that communications between the operators during the running-out operations is safe and secure (visual, direct, voice connection, etc.);

Ensure that the appropriate precautions are taken during storms and in the presence of lightning or unconformable environments conditions;

Ensure that, if there are any interruptions in the running-out operations, the cables is safely immobilised, taking into account any forces and live loads which may intervene during the stoppage;

Never heat the cable (fire, torch, welding, etc.) and never use the cable as an earth wire or earth connection during welding;

FOR FURTHER INFORMATION REFERS TO THE EUROPEAN STANDARD EN 12927-5 AND DQ19 02 REV_1 “WIRE ROPES FOR PEOPLE TRANSPORTATION – ROPE INSTALLATIONS

RECOMMENDATIONS“ EDIT BY REDAELLI

5.3.1. Evacuation and recovery ropes installation:

This rope, if not spliced and will be used on specific winch, shall be installed following some specific rules:

Rope back tension: the rope shall be wind on the drum (first installation) with a back tension equal to 2% of the rope Fmin or 10% of the SWL (safety working load). Smaller values of back tension could be accepted, but during the first working operation the rope behaviour shall be constantly verified in order to avoid dangerous localized rope squeezing or deformation due to the inadequate initial rope back tension.

The original reel used for the rope delivery is not able to support the installation back tension, so appropriate capstan or device able to ensure the right back tension without damage the rope must be used;

During the rope installation attention shall be adopt to avoid any rope rotation and rope damage;

Particular attention must be carry out during the rope’s winding on the drum in order to verify that each wrap is close to the previous one. In case of multi layer winch attention must be carry out in the layer change points also, so to verify the proper rope winding.

IF THE ABOVE INDICATIONS ARE NOT FOLLOWED THE ROPE PERFORMANCE AND SAFETY CAN BE REDUCED

5.3.2. Signal ropes installation:

For this specific ropes the same attentions indicated above for the other ropes shall be take in account and observed so to avoid any rope damage and failure. In addition particular attention shall be adopted in order to avoid the optical core damage:

Not allow to bend the rope on sheaves, roller etc with a diameter smaller than 20d;

During the rope’s installation operations not apply a tension over 15% - 20% of the rope Fmin;

No pre-stretch the rope

Avoid any rope rotation / twisting

Apply all the attention and precautions against the rope and optical core failure


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5.4. Rope cutting

The rope cutting is a dangerous and delicate operation that require to follow some basic attentions and must be carry out by competent person so to avoid operators injuries and ropes / thing damages

MISTAKES OR SUPERFICIAL ATTENTION DURING THE CUTTING CAN RESULT IN A OPERATORS INJURIES AND ROPE DAMAGE

Generally the ropes are not fully preformed : the wires or the strands may unwind during cutting operations. For this a proper rope’s extremity seizing / blocking to avoid uncontrolled wires / strand unwind shall be carry out. The distance between the two seizing on both sides of the cutting point must be equal 2d.

5.4.1. Stranded ropes:

Normally two seizing equal 2d in length and 10d distant (where d = nominal rope diameter) on each end are enough to ensure the rope stability and avoid any wires / strands loosening. The following sketches is an example of the correct way as carry out rope seizing and cutting. For further information see ISO 4309:2004 also


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5.4.2. Spiral Strand Ropes and FLAR ropes:

For the Spiral Strand ropes and FLAR ropes longer servings than ones indicated in the par 5.4.1 are requested to ensure the rope’s elements stability and avoid any wires loosening and unhook. Redaelli suggest at least 3 servings >3d in length distant at least 2d each one.

5.4.3. Signal ropes with optical core (optical fibres):

For the signal ropes with optical core particular attention shall be take during the cutting to avoid damage and failure of the optical core itself Normally the optical fibres are located in the rope core (centre) and are contained inside to an aluminium tube. As for the previous ropes before to proceed to the rope’s cutting a proper seizing shall be perform. On depending to the type of rope (stranded, Spiral Strand ropes or FLAR etc.) the corresponding serving shall be carry out (see par. 5.4.1, 5.4.2, 5.4.3), then is possible to proceed to cut the rope following the next indications:

With a grinder cut the external and inner steel wires layers doing attention to not cut the aluminium core hose;

After cut the steel wires and the aluminium hose is visible proceed to cut it on its circumferences by with hand saw. Attention shall be take so to avoid to cut the optical fibres inside the aluminium hose;

When the aluminium hose is cut and take out is possible to proceed to cut the optical fibres with the specific fibres cutter or if not available with a scissor. At this step and the previous one tools with flame or tools that generate heat cannot be used.

IF THE ABOVE INDICATIONS ARE NOT FOLLOWED DAMAGE ON THE OPTICAL CORE CAN HAPPEN AND THE OPTIMAL AND CORRECT ROPE PERFORMANCE IS NOT ENSURED

IF NECESSARY FOR FURTHER INFORMATION ABOUT ROPE CUT CONTACT THE ROPE MANUFACTURER


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6. WIRE ROPE MAINTENANCE

6.1. Re-lubrication

6.1.1. Introduction

The internal lubrication of steel wire ropes should be carried out during fabrication with the correct lubricants / greases selected to suit the rope’s final application. The lubricants meet the in force standards for the final rope’s application (EN12385-8 for example). Benefits of lubricating a rope internally include: lubrication helps the wires slipping during rope bending,

Lubrication helps to preserve the potential degrading of the “natural” fibre core and reduces the possibility of the internal rope being oxidised. (PP core does not degrade when subjected to humidity, chemical elements etc. and so core lubrication is not strictly required)

Actually during the stranding operation specific developed (in collaboration with Kluber) lubricant, Redaelli 9R100, is used. Redaelli 9R100, has great lubricant performances, no effect on the lining materials (in conformity to EN 12385-8). After the lubrication with this lubricant, the rope surface appears dry and clean, and doesn’t drop off in huge quantity from the rope during the first working hours avoiding problems to the in line grips controls and other automatic control devices present in the stations and in line. If solid and sticky lubricant / grease is used is important to know that the quantity of lubricant used during the stranding operations is normally more than the effective quantity that the rope could keep after its initial period of adjustment. It is possible that during the first working hours some lubricant will leak from the rope. The lubricant that leaks will rest on the outer rope’s surface and protects the rope from the external oxidation during the first few hours of the ropes operation.

6.1.2. Lubricants used during the rope’s production: type and quality

6.1.2.1. Carrying ropes (FLAR and Ercole ropes):

The rope lubrication, starting from the second last round wire’s layer of the spiral strand core is carried out using ELASKON SK-V MOS2. These lubricants are applied using a special pump which allows application without heating.

6.1.2.2. Towing ropes for sky tow, fix ropes, tension ropes:

For the core, made by PP fibres, the lubrication is limited at 2 fibres each strand that compose the core itself. The lubricant utilised is ELASKON 30. In case of metallic core the lubrication is carry out during the stranding operation with the same lubricant utilised for the outer strands

Towing ropes (following UNI 7169), fix ropes, tension ropes: the lubrication is carry out during the stranding operation with ELASKON 20 BB or with NYROSTEN T 55-13-20510 BS or with Redaelli 9R100

Towing ropes (following EN12385-4): the lubrication is carry out during the stranding operation with Redaelli 9R100

6.1.2.3. galvanised and ungalvanised carry-hauling ropes for fixed and detachable grips installations, haul ropes for aerial ropeway and surface system

For the core, made by PP fibres, the lubrication is limited at 2 fibres each strand that compose the core itself. The lubricant utilised is ELASKON 30. The rope lubrication is carry out during the stranding operation with Redaelli 9R100

6.1.2.4. signal rope, evacuation & recovery ropes on winch with or without electric conductors & optical fibres

For this type of ropes the lubrication is carry out during the standing operation with Redaelli 9R100. The conductors and optical fibres are sealed and are not directly in contact with the rope’s lubricant.


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IT IS POSSIBLE USE DIFFERENT LUBRICANTS THAN THOSE MENTIONED ABOVE, HOWEVER THIS MUST BE AGREED PRIOR TO CONTRACT AWARD WITH OUR COMMERCIAL OFFICE AND

TECHNICAL DEPARTMENT. COMPATIBILITY TEST BY LUBRICANT - RUBBER LINING OF THE ROLLS SHALL BE CARRY OUT

BEFORE THE ROPE PRODUCTION IN CONFORMITY TO EN 12385-8 .

6.1.3. Re-lubrication of in use ropes: indications and products

The greases used for rope re-lubrication shall be select in order to ensure their compatibility with the lubricant that has been used in rope production (original lubricant), and the rubber lining of the rollers and sheaves present in the installation. The lubricant shall meet the requirements indicated in the used standards (EN 12385-8 for example).

There are many different lubricants on the market, with different characteristics for the same application. Before using new products, in particular if they contain solvent, specific test should be carried out to shows the compatibility of the lubricant with the rollers and sheaves lining material and with the original lubricant also, or this information needs to be asked and confirmed by the lubricant / grease manufacturers. As general information the re-lubricants, apart what above, needs to ensure the following:

Stranded ropes: good fluidity so to ensure a better penetration in the rope components (strands, wires), absence of mineral oils, good anti oxidation / corrosion properties, no effect against the steel and or its surface protection (galvanization for example)

Track ropes (FLAR): o External / surface re-lubrication: absence of mineral oils, good oxidation / corrosion

properties, no effect against the steel and or its surface protection (galvanization for example)

o On saddles / shoes: specific lubricant that allow reduce / limit the rope wear and corrosion under particular condition. This lubricant normally contains special compounds (MoS2 , graphite etc.) that enable the lubricant to maintain its specific characteristics and properties under heavy cyclic pressure conditions

FOR ANY SPECIFIC APPLICATION OR IN CASE OF DOUBTS TO THE IN USE RE-LUBRICANT ALWAYS CONTACT THE LUBRICANT MANUFACTURER OR THE ROPE MANUFACTURER BEFORE

TO USE / APPLY IT ON THE ROPE

6.1.4. Re-lubrication frequency

The frequency of rope re-lubrication will depend by many factors including local climate, bending cycles, owner preferences, etc. The main aim of the re-lubrication is to protect the rope surface from the external oxidation, mainly during the installation shutdown (after the winter season), and reduce the internal strands wires friction.

If one rope is constantly in use, then re-lubrication is not essential to protect it from the external oxidation because continuous contact with the rolls inhibits possible oxidation, but is recommendable so to reduce the internal strands wires friction and so ensure a longer rope lifespan. Nevertheless, to the installation and service characteristics, we suggest the following re-lubrication frequencies:

1. Stranded ropes (carrying-hauling, hauling, tensioning ropes): a. Whole rope

i. At least every 1000 –1500 working hours or 15000 – 20000 single bending cycles (choosing the restricted one)

ii. At least every 600 – 900 working hours or 9000 – 12000 single bending cycles (choosing the restricted one), in presence of critical aggressive environmental conditions

b. Specific rope areas: i. Splice: Only the tucks and the tucked tail ends of a long splice, should be intensively

re-lubricated at least monthly after each regular visual inspection. The specific area


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lubrication shall be done after the splicing, shortening or repair activities also and limited to the involved area only

ii. Filled socket area: only the specific area close to the socket neck were the rope goes into the socket should be re-lubricated at least monthly after each regular visual inspection

iii. Clamp socket, chapeau de gendarme, bolted clamp, drum, grips, any other end connection: following the specific end connection’s designer indications and remarks.

iv. Tensioning rope: It is recommended that the flexed rope area be re-lubricated at least monthly after the regular inspection

2. Carrying ropes

For this ropes the in line periodical re-lubrication is not strictly necessary, but can be implemented in case of specific situations, like environmental working conditions for example. The re-lubrication is recommendable for specific areas:

a. Saddles / shoes: i. Metallic saddles / shoes (steel, stainless steel, brass etc): at least every six months,

or less in depends by the installation working time, environmental conditions etc, restricted to the contact and slide point so to maintain and ensure the correct friction and allow the proper sliding ropes movement, and also to avoid any direct contact between the rope and the saddle material that can result in a premature rope damage and failure (fretting problems for example)

ii. Specific self-lubricant materials (like Ultra High Molecular Weight Polyethylene type Polizene 1000, Cestilite or similar): the periodical rope re-lubrication is not strictly necessary due to the specific material characteristics. For the saddle maintenance refers to the manufacturer indications also

b. Roller-chain: It is recommended that the rope area flexed over a roller chain be lubricated on a frequent basis, preferably continuously. If no continuous lubrication device has been installed, it is recommended that the flexed rope area is re-lubricated during operation at least monthly after the regular inspection.

c. Bollards: Care should be taken to ensure that the rope part wrapped around the bollard remains inspectable and is always covered with lubricant in order to avoid corrosion mainly if the environmental conditions are

6.1.5. Instruction for the lubricant appliance

The rope’s re-lubrication shall be carried out following the next general rules:

The re-lubrication shall be carry out when the weather is dry and sunny. The rope shall be perfectly and completely dry (inside also). For example if the weather conditions are not satisfactory (i.e.: rain, wet weather etc.) the re-lubrication of a rope is not recommended.

Clean the rope surface from the old and dry grease, powder, rubber particles etc, with special spatulas or special devices that are not able to damage the rope. For the cleaning operation is not allowable use products that contain chemical and solvent elements.

THE LUBRICANT MUST STICK TO THE CLEANED SURFACE OF THE ROPE. THE LUBRICANT WILL NOT STICK TO THE ROPE IF IT IS APPLY ON DIRTY SURFACE.

If the lubricant contains solvent, it must be mixed continuously during application on the rope. This avoids the possibility that the solvent only goes in contact with the rope and therefore the mixing will prevent any damage that may otherwise occur. After its application is better not move the rope to give time to the solvent to evaporate..

The lubricant must be apply on the rope in small quantities and uniformly to create a thin layer on the rope. Application using this method will ensure that the rope will be perfectly lubricated allowing visual inspection of the rope to take place without the need for re-cleaning. After applying the lubricant, it is


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recommended that the rope is not used for a few hours to ensure that the lubricant is fully dry. The formula below provides an indication of the quantities of lubricant that should be used for re-lubrication:

P = 0.2 d L where: P = lubricant quantity [kg] d = rope nominal diameter [mm] L = rope total length [km]. The result takes into account loss that will occur to a lesser or greater extent. These loss depends on the devices used and application method. If oil lubricant (Redaelli 9R100 for example) is used for the re-lubrication the lubricant quantity must be 50% of the quantity resulted by the above formula.

If is necessary or is planned already to change the rollers / shave rubber lining material, it is better to carry out this operation after the re-lubrication

IF THE ABOVE RE-LUBRICATION INDICATIONS ARE NOT FOLLOWED, THE LUBRICANT WILL NOT WORK PROPERLY AND THIS COULD BE DANGEROUS FOR THE ROPE.

FOR FURTHER INFORMATION READ EN 12929-1 and OITAF Book 28 General recommendations for the manufacturer’s lubrication and the re-lubrication of steel wire ropes used in ropeway installation

for passengers - edition 2014 ALSO

6.2. Rope relocations

The support points and contact points of the cables must be moved periodically as follows:

6.2.1. Track rope

Relocation of the track ropes has a great influence on the safety.

Redaelli Tecna SpA recommends carrying out periodical rope relocations.

If applicable the minimum relocation time is listed in the standard EN 12927-7 or National standards where applicable and request, tacking in account the restrictive one. The rope manufacturer can supply more information for setting the proper relocation time depending by the plant configuration. The plant designer should be contacted on this matter also. This is particularly true for modern plant lay out (2S, 3S etc.type), where Redaelli suggest to relocate the rope at least every 3 years

6.2.2. Signal ropes.

Redaelli recommends to carry out periodical rope relocations of the signal ropes, if this is possible and spare cable length is available. Suggested relocation time:

at least every 5 - 10 years if no rope damages are detached during the normal rope inspections (see chapter 2 also)

in case wires break are found close to the fixed points (clamp, drum etc) and is necessary to move the damaged section in a dead/ waiting position so to avoid more breaks in the involved area avoiding in this way the necessity of rope change;

RELOCATION OF THE ROPES HAS GREAT INFLUENCE ON THEIR SAFETY AND LIFETIME


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6.3. Grips for bicable aerial ropeways and funiculars

The translation of the fixed grips of the vehicles on the hauling rope must be carried out moving them in the direction of travel of a distance equal to at least 30 times the diameter of the rope. In the case of two-way cableways, this translation must always be in the same direction. The frequency of the translation must be according to the EN 12927-7 and by the constructor of the plant instruction, and must be in relation with the installation parameters /type, weight of cabin, length of cables, etc.)

6.4. Fixed grips of monocable aerial ropeways

The correct coupling between grips and cable is of prime importance for the operational life of the rope. Experience has shown that lang lay ropes behave better than regular lay ropes under the effect of transverse pressures.

Only in cases of particularly long and tortuous routes is may be convenient to adopt regular lay ropes. The frequency of the movement of the grips varies mostly in accordance with the length and speed of the plant.

Nevertheless, in order to determinate the frequency, consideration should also be given to the profile of the plant, the number of supports (suspension and re-tensioning points) and the number of hours per day of operation.

6.4.1. Grip installation

For plants with fixed grips, it is advisable to run the plant for a full day prior to applying the grips. The chairs or drags must be fitted gradually by initially inserting every 20 positions one, and then applying the remainder when the entire ring is complete. This procedure improves the equilibrium of the cables over its entire length and prevents possible rotation between the cable and the grip.

If, after this precaution, the seats or drags are showing signs of misalignment, then the alignment and coupling between rollers and pulleys must be corrected. To do this, carefully adjust these elements both vertically and horizontally, in order to find the correct adjustment of the contact of the roller with respect to the centreline of the cable.

6.4.2. Relocation of Grips

The frequency of the movement of the grips varies mostly in accordance with the length and speed of the plant.

Nevertheless, in order to determinate the frequency, consideration should also be given to the profile of the plant, the number of supports (suspension and re-tensioning points) and the number of hours per day of operation.

The time interval between two successive movement operations, expressed in working hours, can be determined in an initial approximation using the formula in EN 12927-7 paragraph 5.3.2:

N° of working hours = (L x k) / v

where - L = length of the installation in m - v = operating speed m/s - k = 0.8 for lang lay rope - k = 0.5 for regular lay rope During the first working period, we suggest to increase the translation frequency by using the factors: - k = 0.2 for lang lay rope - k = 0.125 for regular lay rope

After the execution of the first relocations, if the visual inspection of the grips area does not show any damage, the value of k can be increased up to the values listed in the standard.

If the visual inspection detects any rope damage (broken wires, wear, wire loosening etc.) the relocation frequency must be increased by reducing the value of k.


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Ropes are also subjected to vibration stresses even when the plant is not operational. These stresses, in fact, can be added to the pressure exerted by the grips. It is therefore recommended to relocate the grips, even if the plan is closed-down, at least each two months.

The suggested grip relocation procedure is to move a certain number of grips each day, in order to be able to complete the entire operation within the time recommended.

All relocation activity, including the identification of each relocated grip, must be recorded on the plant log book.

Tightening of the grips must be carried out according to the recommendations of the plant constructor according to the need to prevent the sliding between the rope and the grip.

It is quite normal that the grips slightly move from their original position, therefore it is suggested to mark the position of some grip to evaluate their slippage in service.

EXCESSIVE GRIPS / CLAMP TIGHTENING ALSO CAUSES DAMAGE TO THE ROPE.

FOR FURTHER INFORMATION REFERS TO EUROPEAN STANDARD EN 12927-7


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7. WIRE ROPE REPAIR

7.1. Rope loop shortening

Rope shortening is required when the position of the tensioning system may exceed the allowable operating limits (considering elastic elongation of the rope and temperature) or if the geometrical rope dimensions in the splice area require its restoring (see point 10.4 also) For the purpose to determine the amount of the rope to be shortened, it is extremely important to refer to the tensioning device markings (see point 7.1). The plant responsible shall organize the site and the labour necessary for splicing.

The shortening shall be carried out by competent person following an approved procedure issued by the plant constructor or the rope manufacturer. The Redaelli splice procedure supplies all the relevant information and instruction to carry out a safe and successful work. The trained personnel of Redaelli Tecna can carry out the splice shortening accordingly with the EN 12927-3.

When the splicing is complete, the splicer and the site superintendent shall check the shape and diameter of the tuck and fill the splicing report. All the splice dimension must be in accordance with the reference standards.

FOR FURTHER INFORMATION REFERS TO EN 1292–3 AND EN 12927–6

7.2. Full Locked Coil Rope Repair

The repair work must be carried out by qualified personnel through the braze welding of lengths of similar wires to those of the cable in accordance with the procedure laid down by Redaelli S.p.A.n° P09-09B "Braze welding of the rope wires on site" or in accordance the actual in use standards (EN 12927-7): At the end of this repair work, a report must be drafted and signed by the qualified operator and the plant manager. When assessing the steel section of the cable, the repaired wires are always considered as still being broken.

7.3. Stranded Ropes repair

When the damage to a cable exceeds the limits provided for by the standards, repair work must be carried out by inserting a length of rope or individual strands through a partial splicing. Repair work is only advisable if the damage is localised and accidental, and must be carried out by personnel qualified as stated for the splicing procedures. After the repair the repaired section shall be inspected at least monthly.

For repair involving the insertion of strand follow the rules indicated in the approved in use standards (EN 12927- 3, EN 12927- 6 and EN 12927- 7) and the following conditions:

If available, to use a spare strand coming from the same rope (resulting from the first splice or from an existing spare length rope)

If not available, the strand to be inserted must have constructional characteristics same to those of the rope.


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SPLICE COMPONENTS

1. FIELD OF APPLICATION Haul ropes, carrying – hauling ropes, towing ropes, recovery and evacuation ropes for cableways installations designed to carry persons that require to be spliced for their application and working on the installation.




EN 12385-3 Steel wire ropes – Safety – Part 3: Information for use and maintenance









EN 12927-6 Safety requirements for cableway installations designed to carry persons – Ropes – Part 6: Discard criteria




EN 12929-2 Safety requirements for cableway installations designed to carry persons - General requirements - Part 2: Additional requirements for reversible bicable aerial ropeways without carrier truck brakes








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P09 rev.3 Redaelli internal splice procedure

3. TENSIONING AND FIRST SPLICING (applicable for stranded ropes only)

3.1. General information about the tensioning

In order to be able to define the positions of the counterweight (or the hydraulic tensioning piston) and the splicing position, the constructor of the plant shall supply (in written way) to the responsible for the erection and the cable supplier all the necessary information to carry out the work. In particular, the contractor shall indicate:

The name of the technician that has in charge the evaluation of the splice point and splice centre

All the needed information and sketch to be able to make an evaluation about the splice centre and the final position of the rope’s tensioning system

The installation firm that has in charge of the rope pulling, the name of the site superintendent and its telephone number, any other contact means and the access modes to the site,

FOR FURTHER INFORMATION READ AND DQ19 02 REV_1 “WIRE ROPES FOR PEOPLE TRANSPORTATION – ROPE INSTALLATIONS RECOMMENDATIONS“ EDIT BY REDAELLI

3.2. Splicing preliminary tensioning

The rope should be kept under tension (at least >15% higher than the nominal one) for at least 36 hours before splicing. Missing this action may take to abnormal rope stretch in a short time and annul the rope guarantee

3.3. Splicing position

The part of the rope which has been used for the temporary splice (for rope installation) shall be cut off (it must not to remain in the final working splice).

The splice shall be performed by competent persons following a written procedure in according to the EN 12927-3.

The Redaelli splice procedure supplies all the relevant information and instruction to carry out a safe and successful work. The trained personnel of Redaelli Tecna can carry out the splicing accordingly with the EN 12927-3 and local national standard if required and allowed

In the case of two or more splices on the same rope, each of them shall be marked (i.e. with different coloured paint) and the length of each part of the rope section recorded.

FOR FURTHER INFORMATION REFERS TO THE EUROPEAN STANDARDS EN 12927-3 AND EN 12927- 5 AND DQ19 02 REV_1 “WIRE ROPES FOR PEOPLE TRANSPORTATION – ROPE

INSTALLATIONS RECOMMENDATIONS”

3.4. Splicing dimension

The splice dimensions shall be meet the EN 12927-3 requirements about the splice and tails length, and about the knots diameter.

The rope diameter tolerances in correspondence of the tails, measured immediately after the end of splice operations and before any rope movements, must be equal - 0% / +5% of the actual rope diameter measured with the rope in tension. ,

After any rope movement the diameter on the tails area could be less than the minimum tolerances above indicated and shall be correlate to the nominal rope diameter.

IF THE MEASURED ROPE DIAMETER, IN THE TAILS AREA, IS LESS THAN 2% OF THE NOMINAL ROPE DIAMETER, THE ROPE’S USER NEED TO CONTACT THE ROPE MANUFACTURER IN ORDER

TO UNDERSTAND IF THE ROPE IS STILL IN SAFETY OR NEED TO PLAN ITS RENEWS .THIS IN


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ORDER TO AVOID ANY POSSIBLE WIRE BREAKS DUE TO THE STRANDS SIDE CONTACTS BY EACH ONE AND THE ROPE’S SAFETY REDUCTION

4. WARM UP AND ELONGATION MEASUREMENTS

After splice and rope relocation on the towers the plant shall be run for some hours (at least 15 h) in order to check eventual rollers misalignments, rope rotation and to make uniform the rope tension along the plant line (to absorb the slack between the towers).

4.1. First operating service and “L0” mark

As soon as the cable has been installed in its final position and after the splicing check, the plant shall run at a reduced speed (max 2 m/s) to start the running-in period. After at least some complete turns (or better one hour time), the position of the tensioning device shall be marked in an indelible manner on the slide, indicating the number “0” and the date.

Same marking shall be done after the first 100 working hours of the plant indicating the number of hours and the date. All the data regarding rope stretch must be recorded on the installation log book and kept available for any future investigation.


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SOCKET COMPONENT

1. FIELD OF APPLICATION Haul ropes, locked coil carrying ropes, fix ropes, recovery and evacuation ropes, tension ropes and signal ropes for cableways installations designed to carry persons that require to be connected by socket to the system.




EN 12385-3 Steel wire ropes – Safety – Part 3: Information for use and maintenance














EN 12929-2 Safety requirements for cableway installations designed to carry persons - General requirements - Part 2: Additional requirements for reversible bicable aerial ropeways without carrier truck brakes










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P08 rev.3 Redaelli internal procedure for the socketing operations

3. SOCKETING The connection of the rope end by socketing shall be performed accordingly with EN12927-4 and EN13411-4 or local and national standard (DM n°2672 – 31/08/37 for example) if requested and approved by the customer responsible

In order to obtain a perfect connection the following key points must be adopted:

The working area must be protected against adverse environmental conditions.

The surface of the wires shall be perfectly clean

The melting point of the alloys shall be respected

The shell (socket) in which the alloy is to be poured shall be properly pre-heated

The casting must be kept protected and securely fixed during natural cooling of the socketing mean.

Before inserting the cone into the socket, the feed-head (if existing) shall be removed. The surface of the cutting point shall be refined by file and sand paper.

The cast terminal shall be visually inspected by disassembling or extracting the cone from the socket. The cone shall not show any significant piping or air bubbles or blowholes. The resin shall be used if is request and necessary carry out the socketing of ropes with optical fibres or electric conductors so to not damage them with the high temperature necessary to mould the white metal.


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II. WIRE ROPE INSPECTION RECOMMENDATIONS

1. FIELD OF APPLICATION Haul ropes, carrying – hauling ropes, locked coil carrying ropes, towing and fix ropes, recovery and evacuation ropes, tension ropes and signal ropes for cableways installations designed to carry persons.

Inspection of the cable and the splicing during operation is fundamental for the safety of the plan. Visual inspection, together with a few measurements, is of prime importance, even when magneto-inductive testing is regularly performed.

The scope of visual inspection is:

Find any abnormal situation related to ropes (aspect, waviness, broken wires, corrosion, wear, diameter variations, core protrusion, variations in the rope lay length etc.)

Find any abnormal situation related to the installation (vibrations, unexpected noise, noise changes etc)

All the results of the inspections must be recorded in the applicable log book. Following the rope examination the actions to be taken depend by the type and amount of the found damages. The rope manufacturer or a competent person must be involved in the evaluation of the rope damage and in proposing eventual remedial actions.

Any broken outer wire in a full locked coil rope requires a specific planned check in order to assess the extent of its propagation. If the distance between the two ends are more than 2 cm, or there are more than 2 broken wires in one lay length, repairs must be carried out immediately.




EN 12385–3 Steel wire ropes – Safety – Part 3: Information for use and maintenance












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EN 12929-1 Safety requirements for passenger transportation by rope – General requirements – Part 1: Requirements applicable to all installations

EN 12929-2 Safety requirements for cableway installations designed to carry persons – Ropes – Part 2: Additional requirements for reversible bicable aerial ropeways without carrier truck brakes

EN 13223 Safety requirements for cableway installations designed to carry persons – Drive system and other mechanical equipment

EN 13243 Safety requirements for cableway installations designed to carry persons – Electrical equipment other than for drive system






The minimum inspection frequencies and the discard criteria are listed in the European standards: EN 12927-6, EN 12927-7, EN 12927-8 – EN 1709-:2004 also. If request and applicable National Standards rules can be used as reference for the periodical inspection frequencies. In alternative to the above EU standards requirements Redaelli on its ropes suggest the inspection frequencies as indicated in the next paragraphs. Special inspection could be determined by the customer or rope constructor in presence of particular rope conditions also.

3. POST INSTALLATION CHECK After rope installation and before the installation opening the rope and the elements (rollers, lining etc) which are in contact with the rope itself must be checked to search:

possible damage;

lubricant deterioration;

frictional properties of the rope (braking rest);

grips / rope coupling;

proper roller and sheave groove size for the installed rope;

Optical fibres and electric conductor of the signal and recovery ropes must be checked properly to verify the signal continuity

4. DAILY INSPECTION The daily visual inspection must be carry out on:

singular points where previously exams put in evidence a critical situation that requires the daily inspection – see next paragraph 7 also;

in case of thunderstorms, acts of good, icing muff, whiplash etc. or other critical situations that can result in rope damage.

5. MONTHLY INSPECTION Monthly the operator carried out, at specific points of the cable (sockets, clamps and grips, shoes, splicing, anchor drum, coupling drum etc. ) visual inspection to ascertain any indication of instability due to slippage,


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corrosion, deformation or brakeage. The inspection result must be communicated to the technical responsible that will determine if the rope still has the in service suitability.

6. ANNUAL INSPECTION They shall be carried out on the full length of the cable and at singular points. This inspection includes:

Surface visual check, examination of the external appearance of the cable: condition of the lubrication, possible corrosion, general wear and tear and possible abrasions, broken wires, loose or bent wires, local deformation, abnormal wear

Geometric checks: diameter, pitch length, waviness)

Checking of the rope’s end

Signal continuity of the Optical fibres and electric conductor positioned in the stranded rope

7. SPECIAL INSPECTION Special inspections must be carried out when:

when it can be reasonably assumed that there has been some damage on the cable following after an incident, cable overrun, slippage of a pulley, whiplash, slipping grips or any particular meteorological conditions.

in presence of particular working conditions that requires a specific inspection plan to ensure the safety. Below are reported some example of special application;

8. INSPECTION OF PARTICULAR ROPES: SIGNAL ROPES AND RECOVERY ROPES

8.1. Signal ropes:

Redaelli suggest to carry out at least a yearly visual control of the fixed points present in the installation line ( on the line towers for example) and close to the end connections also. The inspection is necessary to verify the rope’s condition and put in evidence eventual wires break or other rope damage / deformation that can result in a safety reduction Decrease in the time between one control and the following must be take in account in case wires break are found during one inspection. The entity of reduction in time must be evaluated by the technical responsible and / or competent person involved in the evaluation itself. Signal ropes with optical fibres or electric conductors shall be subjected to specific control in order to verify the right and good performance of this special elements.

8.2. Recovery ropes (not spliced and that works on winch):

specific inspection time shall be planned to:

Control of the cross over point on the drum (for multi layer winch only) – at least every two months. In case of rope damage or recognized problem on the rope the control must be carry out after each working cycle.

Control of the winch groove dimensions (for grooved drums only) – at least every 6 months. In case of detached problems in the groove’s dimension the rope manufacturer must be advise and the rope behaviour must be checked during each working cycles;

Control of the sheaves grooves (dimension and wear) - at least every 6 months - For the right groove dimension see chapter 3.11.4. – In case of evident wear or / and reduction in the groove diameter the sheave must be change fast as possible. Until the sheaves are not changed the rope must be checked and verified after each working cycle;

Control of the end fixing (connection to the recovery vehicle) – at least every six months in order to verify that no slides or unexpected rope slide, no rope or connection end damage are present

IF REDUCED SHEAVES DIMENSION ARE USED AND IS NOT POSSIBLE TO CHANGE THEM, THESE MUST BE COMMUNICATE TO THE ROPE MANUFACTURER SO TO VERIFY THEIR ADMISSIBILITY

AND IF NECESSARY DEVELOP AND RELAESE SPECIFIC INSTRUCTION FOR THE SAFETY INSPECTION AND MAINTENANCE


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SEE CHAPTER1 USE MANUALS PARAGRAPH 6 “WIRE ROPE MAINTENANCE” OF THE PRESENT MANUAL ALSO FOR FURTHER INFORMATION ABOUT THE WIRE ROPES MAINTENANCE

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