इंटरनेट मानक

Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न' 5 तरफ”

Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 3973 (1984): Code of practice for the selection,

installation and maintenance of wire ropes [MED 10: Wire
Ropes and Wire Products]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”

है”
ह
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
(Reaffirmed 2001)
UDC 677'72'005'006'76 IS :‘3973 - 1984

/naYian Standard

CODE OF PRACTICE FOR THE

SELECTION, INSTALLATION AND MAINTENANCE OF WIRE ROPES

( First Revision )

1. Scope - Relates to the selection, installation, maintenance and usage of common types of
wound strand wire ropes
Note - It is not intended that this code of practice be preferred to the statutory rules and regulations wherever
they exist. It IS intended only as a guide for the convenience of the rope user in proper selection, installation and
maintenance of wire ropes.

!. Terminology - For the purpose of this standard, the definitions given in IS : 2363-1965
‘Glossary of terms relating to wire ropes’ shall apply.
8. Information Helpful in Selecting a Wire Rope
3.1 Ordering a Wire Rope - The five principal characteristics are required to be described while
specifying a wire rope. These are:
a) dimensions,
b) rope construction,
c) grade,
d) galvanized or ungalvanized, and
e) core and lay.
Appendix A lists the information to be given with the enquiry or order.
3.1.1 Dimensions - The dimensions to be specified in ordering wire rope include not only the
length but also the diameter of the wire rope.
3.1.1.1 Length - The length to be ordered is dependent on the requirements of the service
to which the wire rope is put specifying a reel of rope or a coil of rope is not sufficient as thereare
no standard length reels or coils for a wire rope. The required length should be specifically men-
tioned with the enquiry or order.
3.1.1.2 Diameter - The diameter of the wire rope is that of the smallest circle enclosing it.
The diameter shall be measured over each pair of opposite strands at each of three places at least
I m apart with a suitable device, such as a rope caliper as shown in Fig. 1A. Care should be taken
to avoid getting an incorrect measurement as shown In Fig. IB where measurement has been obtain-
ed over two pairs of opposite strands instead of one pair.
The actual diameter of a new rope is usually slightly larger than the nominal diameter.
3.1.2 Rope construction - A wire rope is made up of strands and a strand is made up of one or
more layers of wires ( see Fig. 2 ). The rope construction refers to the number and arrangement
of strands and wires and the type of core used, and it is the means of adopting the rope to the
particular work that will be required of it. Appendix B gives details of rope construction
designation. Typical examples to designate wire rope construction have been given in Table 4.
3.1.2.1 Number of strands - The number of strands denotes the number of groups of wires
that are laid over the central core. Most wire ropes are composed of 6 strands although the
number varies depending upon the particular application.

3.1.2.2 Number ofwires in fhe strand - The number of wires in the strand is generally 7,
19 or37.

Adopted 25 May 1994 @ November 1987, BIS Or10

I I

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

i
1s : 3973 - 1984

1’
I

1A CORRECT

16 INCORRECT

FIG. 1 MEASURING OF DIAMETER OF WIRE ROPE

FIG. 2 CONSTRUCTION OF WIRE ROPE

 IS : 3973 - 1984

3.1.2.3 Arrangement of wires in the strand - The arrangement of wires, also called strand
construction, refers to the grouping of the various sizes of wires used in the strand. Wires may be
.arranged in the strand in various ways to meet certain conditions. Basically, there are two strand
constructions or’ arrangements of wires, namely, equal laid or parallel laid construction and the
-cross laid construction.
a) ‘Equal /aid’ or ‘parallel laid’ construction - In the equal laid construction, all the wires
making up the strand are laid in one operation, with the result that each covering layer of
wires has the same length of lay or pitch as the underlaying layer, thereby eliminating any
crossing of the wires in the strand. The various types of equal lay are sometimes called,
Seale Lay, Filler Seale Lsy and Warrington Lay, depending upon the relative numbers and
sizes of wires in the layers. The greatest advantage of this type of construction is that the
wires are continuously supported by being in continuous contact with other wires and,
therefore, are not so liable to fail in fatigue due to secondary bending. Another advantage
is the avoidance of nicking between crossing wires. However, this lay is less flexible than
cross lay because it is more compact. Also there are less spaces left for lubricant
because of its compactness with the result that under the same conditions of service,
internal corrosion is rather more likely to occur.
b) Gross /aid construction -All the wires in a strand are more or less of the same diameter.
The wires of each covering layer have a longer lay than the underlaying layer of wires with
the result that wires in a covering layer, although spiralling in the same direction as the
wires in the underlaying layer will repeatedly cross over the inner wires.

3.1.2.4 Rope lay - This refers to the manner in which wires are helically laid into strands and
strands into rope. If in the rope, the strands coil in the same direction as a right-hand screw
-thread then the rope is said to be of the right-hand lay, also called the Z lay. If the strands coil
around the rope in the same direction as a left-hand screw thread then the rope is said to be of
,left-hand or S lay. If the wires in a strand coil in the same direction as the strand, then the rope
is a Lang!s lay and if the coil in the opposite direction to that of the strand then the rope is in
regular or ordinary lay. Thus a rope can be either “right-hand Lang’s lay or left-hand Lang’s lay”
( right-hand regular lay or left-hand reguler lay ) ( see Fig. 3 ). When the kind of lay wanted is not
mentionod in the order it is customary to supply regular lay and when the direction of lay is not
mentioned, right-hand lay is always supplied. Thus, if information regarding lay is omitted alto-
gether, it is customary to supply right-hand regular lay.

Ordinary Lay-Wires Lang’s Lay-Wires Ordinary Lay-Wlres Lang’s Lay-Wires

in Strand Spiral in Strand Spiral in Strand Spiral in Strand Spiral
to Left to Right to Right to Lett

FIG. 3A RIGHT-HAND (Z) LAY, STRAND IN FIG. 3B LEFT-HAND (S) LAY, STRANDS IN
ROPE SPIRAL UPWARDS TO THE RIGHT ROPE SPIRAL UPWARDS TO THE LEFT
IS : 3973 - 1984

3.1.2.5 Preformed or non-preformed - The wires or strands or both in a rope may be pre-
shaped to conform to the helical shape which they take in the finished rope so as to make them lie
dead in the rope without any tendency to unlay themselves while the rope is in the unloaded
condition. In this case the wire rope is said to be preformed. It is recognizable as a rope which
remains more limp and neutral than an ordinary rope, and in which the strands or wires will not
untwist or fly apart when the rope is cut without being siezed at the ends.

3.1.2.6 Core - The central part of a wire rope or,a strand is called the core of rope or strand
core respectively. This may be of fibre, wire or synthetic material. When no mention is made of
the type of core in the order for wire rope, a fibre core is always used for the rope and wire core
for the strand.
4 Fibre cores - Fibre cores are made of vegetable fibre ropes, namely, sisal, jute, hemp,
phormium or cotton. The fibre core is very flexible and very suitable for all conditions
except those in which the rope is subjected to severe crushing ( working under high load
on very small pulleys and drums. coiling on top of itself on numerous layers on a drum,
etc ). Jute and cotton cores are not permitted in man riding ropes and cotton fibre ropes
are used as fibre cores only in small diameter wire ropes.

b) Wire cores - The main core of a stranded rope may also be of a single straight strand of
fairly soft wires ( wire main core or WMC also called wire strand core or WSC ) or even
a small wire rope made up of strands of very small wires ( independent wire rope core or
IWRC ). The wires of the core are generally of lower tensile strength than those of the
strand to obviate the possibility of the wire cores indenting the wire ropes. Wire cores are
specified where the wire rope has to strand severe heat or crushing conditions. The rope
with the independent wire rope core is more flexible than rope with a wire main core and
is only slightly less flexible than a rope with a fibre core,

cl Plastic cores - Plastic cores are also used in the case of special purpose wire ropes. It
may be a plastic impregnated fibre core, plastic covered fibre core or a solid plastic core.
In a plastic impregnated fibre core, the individual fibres of the core ( generally sisal fibre )
are impregnated with PVC during the fabrication of the fibre core. The plastic covered
fibre core is essentially a sisal fibre core over which a specified thickness of PVC has been
extruded. Solid plastic cores are PVC rods of specified hardness.

3.7.3 Gra<e - Ropes

_ are classified according to the . tensile strength of the wire which is used
in the manufacture of the rope and according to the finish of the wire.

3.1.3.1 Tensile grade - The following ranges of tensile strength for the wires used in the,
wire rope construction are specified in IS : 1835-1976 ‘Specification for steel wire for ropes
( third revision )‘.

Tensile Designation Tensile Strength Range

N/mm2
1 230 1 230 to 1620
1 420 1 420 to 1810
1 570 1 570 to 1960
1 770 1 770 to 2150
1 960 1 960 to 2340

Note - The tensile range depends on the wire diameter. The values given in the table correspond to the tensile
range for wire below 0.5 mm. For coarser wire the range is narrower.

The wires used for making the wire rope should be selected from within one of these ranges
taking into account the service conditions under which the rope has to operate. A wire of higher
tensile strength is of course stronger than wire of the lower tensile range but it is also rather more
sensitive than wire of lower tensile range to the effects of any service irregularities which may be
present or which may appear in service, such as scratches on the wire surface.

3.1.3.2 Finish - The rope may be made from galvanized wire or bright wire. In the case of
galvanized wire, it may be supplied with one of the recognized types of finish, that is, Type A, AB.
or B conforming to IS : 1837-1976 ‘Round steel wire for ropes ( third revision )‘. Type B wires have
a lighter zinc coating but are required to comply with higher mechanical properties than wires of
Type A.

4
3.2 Choice of a Wire Rope

3.2.1 Wire ropes have to meet the following requirements to various extent. Before deciding on
the construction of a rope or before making a change in the present construction, these various
conditions should be carefully weighed to determine whether one particular factor should be
favoured above others:

a) strength,
b) abrasion resistance,
c) fiexibility,
d) resistance to crushing,
e) fatigue or endurance strength, and
f ) corrosion resistance.

3.2.2 Tensile strength - The tensile strength of a wire rope primarily depends on the tensile
strength of the wire constituting a wire rope and the effective metal cross-sectional areas of the
rope. Use of a wire core in the place of fibre rope increases the strength of the wire rope to a
certain extent but decreases flexibility.

3.2.3 Abrasion - Where abrasion from the rope dragging through gritty material or across
stationary objects is the governing factor, large outer wires in the strand are necessary, 6 x 7
construction offers the best abrasion resistance. Lang’s lay ropes offer better resistance to abrasive
wear than regular lay ropes.

3.2.4 Flexibility - Where sheaves are small or where the rope makes a great many bends in
proportion to the wear present, a special flexible rope is called for. Flexibility increases with the
number of outer wires for a given rope diameter. Lang’s lay is slightly more flexible than regular
lay and where it can be applied, it increases the life of a rope. Preforming enables the rope to
stand more bending, thus giving the rope a better chance to withstand wear abuse where small
sheaves are-present. Wire strand cores result in ropes which are not as flexible as fibre core ropes.
However, IWRC ropes are nearly as flexible as fibre-cored ones.

Note - Experiments with wire ropes coated with polyamide ( nylon type ) resins have shown that these coated
ropes have a bending endurance strength nearly five to six times that of the uncoated rope. (See Addendum to
the document 372/C.L.E. 8 issued by Association Des lndustriels De Belgique, 29, Avenue Andre Drouart,
Bruxelles 16 ).

3.2.5 Resistance to crushing - When a rope is subjected to over-winding on drums or to other

abuses that tend to crush or distort the shape of the rope, a wire main core makes it more resistant
to crushing than a rope with that of fibre core but unfortunately it also makes it less flexible. An
independent wire rope core makes the rope resistant to crushing without greatly reducing its
flexibility. A construction which employs much oversize wires also helps in meeting this condition.

3.2.6 Corrosion - see 6.1.2.

3.2.7 Fatigue - see 8.1.3.

3.2.8 Lay selection -The lay of the rope to be selected depends on the following overall
considerations:
a) Regular lay rope - The balance resulting from the opposite direction of the lay of the
strands to that of the wires together with the shorter length of exposed wires gives:
1) more structural stability,
2) greater resistance to crushing and distortion,
3) less tendency to rotate under load,
4) less likelihood of kinking, and
5) greater ease in handling during installation.
b) Lang’s lay ropes - In a Lang’s rope, the lay of the strands and that of the wires are in the
same direction. This, while unbalancing the structure, does result in the outer wires
being bent on a larger arc of a circle and so exposes a longer length of the wire to wear
and give Lang’s lay ropes.
Note - Greater wearing surfaceand, therefore, increases resistance to abrasion and results in less wear on
ropes, sheaves and drums; and

Greater flexibility and, therefore, increases resistance to fatigue.

5
IS : 3973 - 1984

However, Lang’s lay ropes are:

1) very difficult to handle and install due to the inherent characteristics of their
construction;
2) liable to link if allowed to become slack;
3) less resistant to crushing and distortion and so, unsuitable where there is poor wind-
ing or severe overload; and
4) liable to untwist unless both ends are permanently fastened and hence, not recom-
mended for single part hoist, free ends, swivel terminals, etc.
The above shortcomings of Lang’s lay rope can, however, to a certain extent, be reduced by
performing.
4. Installation - Ropes prior to installation require careful handling to ensure that the lay lengths
are not disturbed. The rope shall preferably received on reels and kept on reels as late as possi-
ble prior to installation. Care shall be exercised when making fast this rope to ensure that the entire
cross-section of the rope is firmly secured in order to avoid the core drawing from the rope end and
the surface length of the core protruding in the rope.
4.1 Holding Capacity of the Reels - The rope capacity L (m), of a reel, in any size and length may
be calculated by the following formula:
L_- (A+B) XAXC
1 000 dz
where
f - rope capacity of reel (m),
H-B
A - depth of rope layer (mm), = -2,

B= diameter of reel barrel (mm),

C = width between reel flanges (mm),
d* - rope diameter (mm), and
H- diameter of the drum (mm) as measured over the outermost layer filling the drum.
This forumla is based on assumption of uniform rope winding and will not givecorrect results
if rope is not wound uniformly in a reel.
4.2 Unreeling and Uncoiling Wire Ropes
4.2.1 Unreeling - During installation, the rope should be mounted on a reel if not supplied on
a reel. The reel should be mounted on a horizontal shaft so that it is free to turn. One method is
to put a shaft through the centre of the reel and jack it up so that the reel will revolve freely. The
rope is pulled straight ahead keeping it taut to prevent it from loosening up on the reel. A board
held against one flange may be used as a brake to keep the reel from revolving too fast
( see Fig. 4 ).
The other method to fix the reel on shaft and mount shaft on bearing so that reel with shafting
will revolve. In this method, a brake can be fixed on the shaft by the reel to see that the rope is
tight during installation.
4.2.2 Uncoiling - When the rope is supplied in coils, the uncoiling can be done in the following
way:
The ties are removed and the the coil is rolled along the ground so that the rope lies straight.
Care should be taken that there is no twist or kink in the rope while uncoiling ( see Fig. 5 ).
4.3 Kinking
4.3.1 Kinking of wire rope can be avoided if ropes are properly handled and installed, Kinking is
caused by the rope taking a spiral shape as a result of unnatural twist in the rope. One of the most
common causes for this twist is improper unreeling and uncoiling.
Kinking may also occur in a rope in use if slack rope is allowed and is pulled before carefully
coiling up the slack.
4.3.2 Figure 6A shows the start of a kink. At this stage, no harm will be done if the loop is
immediately thrown out to prevent further kinking.
4.3.3 Figure 6B shows the effect of kinking. The rope has been kinked and is permanently
injured.

6
 IS : 3973 - 1984

FIG. 4A CORRECT WAY OF UNREELING

FIG. 48 INCORRECT WAY OF UNREELING

4.3.4 Figure 6C shows the result of a rope that has been kinked. Strands and wires are out of
position, which results in unequal tension and brings excessive wear on this part of the rope.

4.3.5 Even though the kink may be straightened so that the damage appears to be slight - the
relative adjustment between the strands will have been disturbed and the rope cannot give proper
service. A kinked rope is liable to fracture without warning.

4.4 Preparing the Wire Rope for Use

4.4.1 Storage of the wire ropes - Wire rope is a steel product and as such is subject to rust and
corrosion. Therefore, all precautions should be taken in storing both new and used ropes to ensure
that the deterioration is minimum. The rope should be stored under cover, protected from rain
and moisture. Used wire rope should be kept coiled up, lubricated and kept free of twists-and
kinks.

4
7
 +4 I

FIG. 5A CORRECT WAY OF UNCOILING

FIG. 58 INCORRECT WAY OF UNCOILING

6A 6B

6C
FIG. 6 KINKING OF WIRE ROPE
 IS:.3973 - 1984

4.4.2 Economical lengths of ropes - Highly important is the economical length of the wire rope
to be cut off the reel or coil. It should neither be very short as nothing will be left for cutoffs at
the drum end to permit shifting the rope, nor should it be too long as the excess length will pile
up in the multiple layers on the drum which cuts down service materially.

4.4.3 Cutting a wire rope - A wire rope can be cut at a desired point by any suitable method
which does not disturb the wires. Special care has to be taken in the case of percussive or shear-
ing methods to ensure that the seizing or the rope lay is not disturbed. Oxy-acetylene cutting
should not be employed as it is likely to affect the wire and lubrication.

4.4.4 Seizing - A seizing is a wrapping of wire laid around a rope to prevent its wires from
‘kinking’ or moving to slacken themselves when the rope is cut between two adjacent seizings.
Before cutting a wire rope, seizing should be placed on each side of the place.where the rope is to
be cut to prevent unlaying of the strands. The length of the seizing and the diameters of the
wires used for seizing depend on the rope diameter. One of the methods of seizing is as
follows:

a) The seizing wire is wound on the rope by hand, keeping the coils together with a consi-
derable tension on the wire. The application of not less than 8 or more than 10 wraps of
seizing wire for each seizing made, is recommended.

b) The ends of the wire are twisted together counter-clockwise by hand, so that the twisted
portion of the wire is near the middle of the seizing.

c) Using rippers, the ends of the wire are gripped just above the first twist. The twist is
continued just enough to take up the slack. No attempt should be made to tighten the
seizing by twisting.

d) The seizing is tightened by prying the twist away from the axis of the rope with the
cutters.

e) The twist is again tightened as in operation (c). Operations (d) and (e) are repeated as
often as is necessary to make the seizing tight. Ends of the seizing wires are cut off and
the twist is pounded flat against the rope. The appearance of the finished seizing should
be as in Fig. 7.

4.4.5 Attachments - Since wire rqpe is ?o safer than its attachments, fitting should be selected
with care and attached properly to obtain the desired strength. The fittings could be attached to
the wire rope by splicing, swaging, wedge socketing by means of molten metal or by the use of
grips and socketing clamps. The efficiency of the attachments depend on the type of attachment
and the care with which it is attached. Zinc and white metal filled sockets develop 100 percent of
the rope’s breaking strength when properly attached, but the socket attachment efficiency can drop
as low as 25 percent if babbit metal or lead is used in place of zinc or white metal, In the case
of the swaged fittings 100 percent efficiency could be expected. In the case of wedge type sockets
with a rope looped around the wedge 70 to 80 percent efficiency could be expected, In the case
of wire rope clips, the efficiency is dependent upon the arrangement, care in tightening and the
number of clips used. With properly attached U-bolts 70 to 80 percent efficiency could be expected
and 50 percent efficiency with knot and clip attachment. When wires break from fatigue near the
attachment, clips or wedge sockets are preferable to metal filled sockets inspite of their lower
efficiency in strength tests. Clips shall be placed with the U-bolt over the dead end of the rope
and the base against the live end.

4.5 Correct Spooling of Rope on Drums

4.5.1 Sintile layer winding

4.5.1.1 Flat or smoothface drums - If a rope is fitted incorrectly to a smooth surface drum,
it may coil badly forming open or widely spaced coils instead of closely packed coils. When a rope
is wound into a drum, any tendency of the rope to twist when the tension is released will be in
a direction which would untwist the rope at the free end. The advantage of applying rope of proper
direction ot lay is that when the load is slacked off, the several coils on the drum will be together
and maintain on even layer. The proper direction of rope lay to give best results is shown in Fig, 8.
This applies to either regular or Lang’s lay rope.

On new equipment and also on existing equipment, where possible, the drum anchorages
shall be so positioned so as to favour right-hand lay rope since left-hand lay rope is not always
available from stock.

9
IS : 3973 - 1984

Fl6. 7 SEIZING A WIRE ROPE

Overlap Left to Right Use Underlap Right to Left

Right Lay Rope Use Right Lay Rope

Overlap Right to Left Use Underlap Left to Right

Left Lay Rope Use Left Lay Rope
Observer Standing Behind Drum and Looking Towards the Direction of the
Rope Travel
FIG. 8 SELECTION OF PROPER DIRECTION OF ROPE LAY

10
i
 IS:3973- 1984

4.5.1.2 Drums with spiral grooving - For drums with spiral grooving direction of coiling is
fixed and the ropes should be used to suit the grooving as follows:
A right-hand rope for a groove corresponding to a left-hand groove screw thread and
vice versa.
4.5.2 Multilayer winding - Although it is advisable to resort to singlelayer winding as far as
possible, there are cases where multilayer winding cannot be avoided and in such cases, great care
shall be taken to ensure that cross-winding between layers does not occur.
4.6 Fleet Angle
4.6.1 Where a wire rope leads over a sheave and on to a drum, the rope will not remain in
alignment with the sheaves but will deviate to either side depending on the width of the drum and
its distance from the first fixed sheave.
4.6.2 The angle between the vertical plane of rotation of the sheaves and the rope leading to
the drum is called the fleet angle ( see Fig. 9).

-4 FLEET I--
FIG. 9 FLEET ANGLE

4.6.3 To avoid excessive wear to the sheave and to prevent excessive chafing of the oncoming
rope against previous wraps on the drum, it is desirable to keep the fleet angle as small as
possible.
4.6.4 Where space is unrestricted, fleet angle is sometime as small as half a degree. This is
equivalent to a distance of aporoximately 155 mm between the drum and the first fixed sheave for
each millimetre of the drum width. It represents the minimum below which the rope will not pro-
perly wind back from the drum flange after completing only a layer. Most installations do not
permit this much distance between the drum and the sheave and for average conditions, it is
considered good practice to keep the fleet angle within the following limits:
Mining installations 1” 30’
Cranes and other hoisting equipment 5”
4.7 Drums, Pulleys and Sheaves - Sheaves and drums should be of proper size, free running and
properly grooved for most economical wire rope service.
4.7.1 Diameters of the drum and pulleys - The purposes for which the rope may be used vary
considerably and it is, therefore, not possible to recommend minimum sizes of drums and
pulleys suitable for all purposes. Reference should, therefore, be made to relevant standards or
statutory regulations which specify requi.rements of drum, pulley or sheave diameter. In the
absence of such requirements, the diameter of a drum or sheave shall not be less than that given
in Table 1.

11
1s : 3973 - 1984

TABLE 1 RATIO OF DRUM AND SHEAVE DIAMETER TO ROPE DIAMETER

( Clause 4.7.1 )

-
Purpose Construction
-I Minimum Ratio*

Mining installation Winder 100

Haulage
up to but excluding 50 kW 50
100 kW and above 60
lZlass lf Class 2 d 3t Class 4t
Cranes and allied holst- 6 x 37
ing equipment 8x 19 15 17 22

8 x 19
8 x 19 Seale 17 18 24
34 x 7 Non-rotating

6 x 19 Filler wire 18 20 23

6 x 19
17 x 7 Non-rotatlng 19 23 27
18 x 7 Non-rotating

6 x 19 Seale 24 28 35

*The ratio of the diameters specified are valid for rope speeds up to50 m/min. For higher speeds, the
drum or sheave diameter should be increased pro rata by 8 percent for each additional 50 m/min of rope
speid where practicable. Larger ratlo shall be used particularly for non-rotating ropes.
tSee IS : 807-1976 ‘Code of practice for design, manufacture, erection and testing ( structural portion)
of cranes and hoists ( first revision )‘.

4.7.1.1It should be appreciated that the diameters recommended are minimum ratios and it
is never advisable to allow the sheave and drum diameters to come below these values. Diameters
larger than those recommended will give increased rope life and consequently more economical
service.

4.7.2 Pulley or sheave grooves - Where requirements for pulley and sheave grooves are not
specified in the standard for a particular equipment, grooves shall comply with the following
requirements given in 4.7.2.1 and 4.7.2.2.

4.7.2.1Groove depth and flare - The depth and flare of the groove shall be so chosen as to
ensure that the rope is not rubbing against the flange of the sheave when entering or leaving a
groove. The bottom of the groove shall be a circular are over an angle of not less than 120°C and it
is recommended that the sides of the groove shall be flared with an included angle of 30 to 45°C.

The pulley or sheave shall be grooved to a depth at least equal to l-5 times the diameter of the
rope and the groove shall be smoothly finished and free from surface defects liable to injure the
rope. The edges shall be rounded.

4.7.2.2 Groove diameter - The groove diameter of the pulley or sheaves should always be
larger than the actual diameter of the rope but if the groove is too large, the rope will tend to
flatten. On the other hand, too small a groove will cause rope distortion in the opposite direction,
namely, pinching of the rope.

As the rope is bent around a sheave, the strands and wires lie upon each other slightly in an
effort to adjust themselves to this curvature. When the rope is pinched in an undersize groove the
strands and wire bind against each other which not only increase the abrasion and internal and
external wear but also hinder the readjustment of the rope under the load and forces some of the
wires and strands to carry more than their share. In order to prevent the deteriorating effects of
oversized or undersized grooves, it is recommended that the groove diameter be maintained within
the limits shown in Table 2.

12
 IS: 3973 - 1984

TABLE 2 TOLERANCES ON PULLEY OR SHEAVE GROOVE DIAMETERS

( Clause 4.7.2.2 )

Nominal Diameter Minimum Clearance Before Minimum Clearance or

of the Rope Sheave Replacement or New or Remachined Groove
Remachining of Groove

mm mm mm

8 to 8 0’40 0’80

10 to 20 0.80 1.80

22 to 29 1’20 2.40

32 to 38 1’60 3’20

41 to 57 2’40 4’00

Above 57 3’20 4-80

4.7.3 Drum grooves

4.7.3.1 The grooved drums are recommended in preference to smooth drums as the grooves
furnish better support for the rope than the flat surfaces of the smooth drums and the more uniform
winding results in less abrasive wear on the rope. Annularerconcentric grooves should not be
greater in. depth than IO percent of the rope diameter. Deeper grooves will cause undue distortion
of the rope at the points of cross-over from one groove to the next.

4.7.3.2 Clearance between adjacent turns of rope - The grooves on the drum shall be pitched
so that there is clearance between neighbouring turns of rope on that drum and also there is clear-
ance between the part of the rope leading on to, or leaving the drum and the adjacent coil.

The following clearances are recommended for annular or concentric grooves:

Rope Diameter Clearance
-~-,,-_h,--- __-_ -=.
Yrom Up to and including
mm mm mm
12 1’5
12 2% 2.5
28 38 3’0

Allowance should be made for the permissible 5 percent oversized tolerance and the permissi-
ble misalignment up to 1 in 12.

The following clearances are recommended for helical type grooves:

Rope Diameter Clearance

---h, --------7
Yro m Up to and Including
mm mm mm
32 1’5
32 44 2’5
44 51 3’0
5. Wire Rope in Use
5.1 Proper Working Load for Wire Ropes

5.1.1 Safety Factors - The factor of safety for steel wire rope is defined as the ratio of breaking
strength to safeworking load which is the maximum static load met in service, Laboratory findings
and practical investigations have shown that in addition to the provision of satisfactory static
safety factor, it is necessary to take into account not only kinetic stresses but the effect of bending
in considering rope service. In general terms, it has been found that where the combined effect of

4
13
IS : 3973 - 1984

static, kinetic, and bending stress exceed 25 percent of the nominal breaking load of rope then the
satisfactory rope life cannot be expected. The safety factors recommended in Table 3 are for
normal conditions. When conditions are more rigorous, for example, when the wire ropes undergo
more than two windings or undergo reverse bends, it is recommended that these factors be
suitably increased.

TABLE 3 FACTORS OF SAFETY FOR WIRE ROPES

Rope Application Factor of Safety

Not Less Than
1. Mining Ropes
a) For shafts of varying depths
Up to 300 m 10
300 to 500 m 9
500 to 700 m a
700 to 1 000 m 7
1 000 to 1 500 m 6
Over 1 500 5
b) Haulages 7

2. Wire ropes used on the cranes and other hoisting Statutory Authority
equipment Class l* Class2&3* Class 4*
Fixed guys
Unreeved rope bridles of jib cranes or anciilary
appliances, such as lifting beams 3.5 4.0 4’5
Ropes which are straight ibetween terminal
flttings

Hoisting, luffing and reeved bridle systems of

inherentlv flexible cranes t for example.
mobile, crawler tower, guy‘ derrick, stiff’leg
4’0 4.5 5’5
derrick) where jibs are supported by ropes or
where equivalent shock absorbing devices are
incorporated in jib supports
Cranes and hoists in general hoist blocks 4.5 5’0 6’0

Aerial ropeways In accordance with the values speci-

fled In relevant standards
Slings In accordance with the values specl-
fied in IS : 2762-1964 ‘Specification
for wire rope slings and sling
legs’,

*See IS : 807-1976 ‘Code of practice for design, manufacture, erection and testing ( structural portion ) of
cranes and hoists ( first revision )‘.

5.2 Breaking in Period

5.2.1 The many moving parts in the wire rope shall work together, Experience has proved that a
short breaking-in period and gradual loading and slow speed adjust the moving parts amongst each
other, This breaking-in period results in better spooling, more efficient performance and longer rope
life.

5.2.2 The following breaking-in routine may be followed:

a) The equipment should be in a good condition;

b) The rope should be unwound from the reel or coil such that twisting and kinking does not
occur;
c) The rope should be firmly anchored to the equipment, taking care to seize it first with wire
to prevent it from untwisting;
d) After the rope is attached and reeved around sheaves and drums, it is operated with a
light load a few times, until it is flexing easily over sheaves and winding correctly on the
drum; and
e) Gradually the speed and load are increased until the rope is operating up to its normal
loading and speed.
 IS : 3973 - 1984

TABLE 4 EXAMPLE OF ROPE CONSTRUCTION, DESIGNATION

%eneral Rope Figure Details of Construction and Designation

Construction

All the wires in the strands are of the same size except
6x7 the king or centre wire. Thelength of lay of the
outer wires is longer than that of the inners, that
is, ‘cross laid’. Each strand is constructed of
6 wires over I, or the construction is 6 x 6/l.

All the wires in the strands are of the same size except
the king or the centre wire. The length of the lay
of the outer wires is longer than that of the inners
6X19 that is, it is a ‘cross laid’ construction. tach
strand is constructed of 12 wires over 6 wires
over I, or the rope construction is 6 x 12/6/l.

Smaller wires are used for the inner layer of strands.

The length of the lay is the same for both layers,
that is, ‘equal lay’. Each strand is constructed of
6x19 9 wires over 9 wires over I, or the construction Is
Seale 6 x 9/9/l, If the same rope had been supplied wlth
the independent wire rope core, the construction
would have been designated as 6 x 9/9/l I WRC.

The length of lay is the same for both the layers,

that is, the construction is ‘equal laid’.Flller wlres
are laid in the valleys formed to the wlres by the
inner layer. Each strsnd Is constructed by 12 wires
ov r 6 wires over 1 plus 6 filler wires between the
6x19 outer and inner layers. The construction Is berlg-
Filler nated as 6 x 12/6 + 6F/l. It Is to be noted that
though the number of wires in the strand Is 25. It
is designated as 19, as the filter wires are not
taken into account in counting the number of
wires.

( Continued )
 IS : 3973 - 1984

TABLE 4 EXAMPLE OF ROPE CONSTRUCTION, DESIGNATION - Contd

General Rope Figure Details of Construction and Designation

Construction

Alternatively large and small wires are used for the

outer layer of strands. The length of lay is the
same for both layers, that is, the construction is
‘equal laid’ construction. Each strand is construc-
6X19
ted of 6 large and 6 small wires over 6 wires over
Warrington
1. The rope is designated as 6 x 6 and S/S/l.

All the wires in the strands are of the same size. Each
strand is constructed of 15 wires over 9 wires over
fibre centre. The 15 outer wires have a longer
6x24 length of lay than the 9 inners, that is, the rope Is
of ‘cross laid’ construction. This rope is designa-
ted as 6 x 15/9/Flbre.

The wires in the strands are arranged In a combina-

tion of Scale and Warrington formation. Each
strand is constructed of 14 wires of one size over
7 layers of large and small wires over 7 wires of
one size over 1. All the layers of wlres have the
6x36
same length of lay, that is, it is of ‘equal laid’
construction. This rope is designated as 6 x 14/7
and 7/7/l.

They are designated by the number of strands and

Multi-Strand by the number of wires. For example, 34 x 7 indl-
Ropes cates a multi-strand rope of 34 strands of 7 wires
each.

5.3 Operation
5a3.1 A good operation consists in the avoidance of shock loads and reverse bends and the use
of proper drums and sheaves.
5.3.2 Shock loads - Wire ropes will continue to meet with unexpected and unforeseen stresses,
but shock loads that obviously overstress the rope should be avoided. Any sudden load can deve-
lop into a shock of load. Shock loads may be avoided by:
a) making sure that there is no slack and no jerking of the rope at the start of the loading,
b) careful hoisting of load to see that there is no load beyond the rope’s proper working
load,
 IS : 39730 1984

c) preventing the rope from becoming foulded or jammed either on the drum or jumping a
sheave,
d) sudden breaking while hoisting rope, and
e) keeping the track in good condition to avoid obstructions and bumps.

5.3.3 Reverse bends - Experience and many tests have proved that reverse bending increases
the risk of failure of rope. Where reverse bending cannot be eliminated, the largest sheaves possi-
ble should be used and placed as far apart as possible. By getting the maximum distance between
the reverse bends, fatigue is reduced, thus ensuring longer service.

5.3.4 Drums and sheaves

5.3.4.1 Drums - Careless operation of equipment can be the greatest abuse of wire rope.
This often starts with ,improper spooling on the drum and will cut or crush the wires leading to
further trouble. if the rope repeatedly jumps out of the drum groove, fhe trouble may lie in letting
the drum run too free or perhaps, the rope is too soft for the job. Both the situations can be easily
corrected.

5.3.4.2 Sheaves - To get most out of the wires, the sheaves and wire ropes work together in
harmony. The sheaves should run true and should not wobble on their bearing. Sheaves shall be
free from roughness or burrs of any kind. Grooves shall be smooth and shall be larger than the
diameter of the rope to prevent pinching and excessive wear.

5.3.4.3 Reeving - When reeving up, the rope should wind evenly on the drum and run freely
through ail sheaves.

6. Maintenance - Maintenance of wire rope means two thing-shifting the points of wire by cutting
off drum ends or by changing the rope end, and ensuring adequate lubrication. Lack of lubrication
is a common neglect of rope.

6.1 Lubrication

5.1.1 In manufacture, wire ropes are fully lubricated (including fibre core and layers ) to reduce
internal abrasion, to exclude external moisture and delay corrosion. In service, the initial lubricant
will tend to dry out and, therefore, it is desirable to lubricate all ropes at regular intervals. There
are many methods of applying lubricant, such as vertical or horizontal grease boxes through which
the rope runs, application by brush, leather gloves, drip or by spraying. Lubrication will fit in at
least one of these methods and regular lubrication is a factor in prolonging the life of a wire rope.

6.1.2 Lubricant - The lubricant employed shall be similar and completed compatiable with the
lubricants that has been used during manufacture of a rope. The lubricant employed should be free
from all harmful substances, such as acids and alkalies. The lubricant should have good penetra-
bility, high film strength, good resistance to corrosion, high drop point and softening point
without beccming brittle and good water workout characteristics. The lubricants designed or
approved for rope should be able to penetrate between the wires and strands. They should be non-
soluble under the conditions where the rope operates and should have high film strength and should
resist degradation. They should preferably be of mineral origin rather than animal or vegetable
origin. For the latter tend to break down eventually and produce acids. However, lubricants based
on lanolin ( wool wax ) are permissible for use with wire ropes. The lubricant used should satisfy
the following minimum requirements as regards absence of corrosiveness:

4 The total acidity expressed in terms of SOS shall be less than 0’1 percent. The mineral or
inorganic acidity shall be nil. The organic acidity ( the difference between the above two
values ) expressed in terms of SOsshall be less than O-1 percent;
b) The ash content shall be less than 0’1 percent, and
cl A polished silver panel immersed in a bath of lubricant maintained at 120°C for 50 hours
should show no visible alteration in appearance. A polished mild steel test plate exposed
to the action of the lubricant at 120°C for a period of 50 hours should not show any trace
of corrosion.

The lubricant should be of a light grade that may penetrate between the wires and the strands
of the rope before being wiped off or absorbed by surface dirt.

6.1.3 Application -It is very desirable that the rope be clean and dry before application of lubri-
cant. A jet of air or wire brushing are some of the cleaning methods used preparatory to apply the
lubricant.

17
i
IS : 3973 - 1984

6.1.3.1 An easy and effective method of applying lubricant is to brush the lubricant on to the
rope. The brush is dipped into the lubricant and applied. In some cases a rag or piece of sheepskin
is dipped in the lubricant and used to swab the lubricant on to the rope.
6.1.3.2 The lubricant may also be applied by hand with leather gloves. Leather is preferred to
canvas, because of its greater protection and less penetration of the grease. This method is
specially good where a heavy, non-flowing lubricant is applied. It is desirable to heat fhe lubricant
slightly to get a smoother, better application.
6.1.3.3 A simple lubricating device is a wooden trough with sheave mounted on a shaft. The
rope is run over the end of the trough, under the sheave, and out the other end so that the rope
runs through the lubricant. A rag or swab held in place at the out-going end wipes off excess
lubricant. Regular inspection of the rope with frequent applications of lubricant produces better
results than heavy coatings less frequently applied.
6.1.3.4 Periodicity of lubrication - As a rule, ‘it is better to lubricate lightly and frequently
than heavily and rarely’. Though periodicity will depend upon the service conditions prevailing, yet
fortnightly schedule of lubrication is recommended, as a rule.
7. Inspection
7.1 Sheaves - Sheaves should periodically be inspected and reconditioned groove contours should
be checked for uneven wear. Sheaves that have worn out of round or have developed flat spots will
set up vibration in the rope which will result in an early fatigue failure of the metal.
The depth and flare of the groove shall be examined to make sure that the rope does not rub
against the flange of the sheave when entering and leaving the groove, Selection of proper sheave
and correction of improper characteristics by means of regrooving or replacing the sheaves is an
important function of every maintenance department, and will result in longer rope life as well as
safer operation.
7.2 Wire Ropes- The life of a steel wire rope is solely dependent on its construction, grade, the
surroundings in which it is being used and the manner of application alongwith maintenance pro-
cedure being adopted. It is possible by means of periodical inspection to increase ‘the effective
life span’ of a steel wire rope.
The wire ropes should be inspected at regular intervals depending on usable condition of the
steel wire rope; inspection includes not only visual examination but also non-destructive examina-
tions like electromagnetic testing. Close examination will not only indicate when it is time to put on
a new rope but it will also reveal many other things about the way the rope does its work and
whether it is suited to the job. For instance, wires breaking without showing wear indicate exces-
sive bending, that is, sheave and drums are too small or rope construction is too coarse. Whenever
a rope is cut for recapping, the cut off portion of the rope shall be specially examined. The findings
during the inspection can be mentioned in a ‘steel wire rope inspection card’ of which a sample is
given in Appendlx C. The effective life span of the steel wire rope to be tested is then determined
by means of the figures in the steel wire rope inspection card. By this way a better insight in the
effective life span can be had. In inspection the places where as a rasult of the usable condition
corrosion, wear and tear, fatigue or damage can be expected call for special attention. In the
inspection we should always keep in mind that by visual examination only the external faults of the
rope can be detected. Where internal faults of some significance can be expected, the wire rope
must be inspected, for example, by judiciously turning open here.
6. Discard Criteria
6.1 A steel wire rope can be discarded on following grounds:
4 wear and tear,
b) corrosion,
cl fatigue, /
d) external deformation,
e) action of heat,
f) type, position and number of wire ruptures,
9) abnormal stretching,
h) surface embrittlement,
j) core collapse,
k) fitting time, and
m) accidental damage.

18
 IS:3973-1984

8.1.1 Wear and tear - The wear and tear of a wire rope is to be distinguished for the internal and
external wear and tear by contact between the wire ropes. The condition in which a wire rope is
found is examined at the external, and consequently, visible wear and tear. The normal external
wear and tear is caused by the contact between the wire rope and the drum. Figure IO gives an
example of visible wear and tear of a cross lay wire rope and that of a Lang’s lay wire rope.

Visible Wear and Tear of Cross Lay Wire Ropes

Visible Wear and Tear of Long Lay Wire Ropes

FIG. lo

8.1.1.1 While examining the external wear and tear of a wire rope one should keep in mind
that the definite places of a wire rope show abnormally great wear and tear. This wear and tear
can more or less be caused by:
a) scrubbing of the steel wire rope along the flanges of the top disc in the loaded condi-
tion during the swerving or in the hoist disc of the load ( slanting rope pull ) or by a
very big hook of the steel wire rope with the plane perpendicular to the axis of the disc;
b) scrubbing of the steel wire rope along the parts of the implement;
c) scrubbing of the steel wire rope along the obstacle outside of the irnplement or over
the ground ( for example, along the shutter head of th.e disc); and
d) a drum with a speed too small for the rope or a disc with new grooves.

8.1.1.2 The internal wear and tear of steel wire rope consists of:
a) wear and tear of the wires common in a strand,
b) wear and tear between the strands in the same lay,
c) wear and tear between the strands of different lays, and
d) wear and tear between inner most laid strand and the steel core,
ln application of Table 5, in which judgement figures for the external wear and tear are given,
the calculation is at the szme time bound normally to anticipate simultaneously appearing internal
wear and tear as a result of friction of the strand along both, across each strand and across
the core.
For the steel wire rope in which the internal, not directly observable, part of the wlre
represents a relatively big part of the metal surface and in which many strands contacts are
present.
8.1.1.3 Under definite circumstances we should keep in mind that the internal wear and tear
can be greater than those with which calculation in Table 5 is made. This abnormal internal wear
and tear can be caused by:
a) unsuitable filling by improper construction and/or the pattern of the core,
b) corrosion of the steel core and/or the drying of the rope core, and
c) abnormally high temperature.

8.1.2 Corrosion - By the interaction of moisture, the presence of pollution in the air and the
eventual direct contact with chemicals, a steel wire rope will, during use and sometimes even
during storage, corrode. Thus corrosion is not an instantaneous effect. It is defined as the eating
away of metal from the surface by chemical or electrochemical action. It will appear as loose red
rust, dark discolouration or pitting. It results in a loss of wire area and consequently, of weight
and strength without any loss of elasticity. By galvanizing of ropes that are li,able for rusting in use
and by good lubrication at frequent intervals from the time of installations, the corrosion can be
fuel off for a long or short period, but can not be for ever. If corrosion has already appeared, It
can not be stopped by external greasing.

1 19
IS : 3973 - 1984
-
TABLE 5 JUDGEMENT OF STEEL WIRE ROPES

Visible Wire Wear and Tear on External Corrosion: External and Internal
Wires ( In Percentage of the ( Locally Corroded or Uniform
Surface Section of Wire )

Wire surface

Measured length = 30X wire rope diameter.

Method of judgement = The iudgement of a,wire rope must always be made over the worst part of wire rope. For each
of the judged length the sum of the evaluation figures should be determined.
Discarding = The sum thus fixed may be 6 for not a single judged wire rope part. Moreover none of the
evaluation figures may be separately equal to 4.
*The percentage of wire breaking has taken into account the total number of wires in the rope outside the core.

20
 IS : 39’1-3- 1984

ln the case of corrosion, a difference should be made between the external (visible) and
internal ( invisible ) corrosion. According to this, the wire rope is examined for visible corrosion.
The internal corrosion must always be taken into consideration because it may exercise great
influence on the bedding and thus on the fulfilment of the task of the wires and the strands in the
wire rope.

In case of any doubt the presence of abnormal internal corrosion, the steel wire rope should
be inspected immediately against that doubt.

A seriously corroded rope, the corrosion being external or internal or both, should be
considered for removal immedietely even if the corrosion is local and not spread to the entire
length of the rope if the corroded portion cannot be cut off and removed. Any wear and tear of
broken wire will add to the discard factor (see Table 5, col 4 ).

Moreover attention should be paid to the corrosives in the case of wire ropes used for a
longer period.

8.1.3 Fatigue - Fatigue is the outcome of repeated reversal of stresses on a wire due to which
the wire shows the tendency to fracture by means of a progressive crack which appears first on
the surface and progresses in inward direction. The fracture occurs at a stress much below the
ultimate tensile strength. Sharp edged surface irregularities, such as small but relatively deep
corrosion pits, narrow scratches and surface cracks encourage fatigue faiture because the
stresses at the bottom or root of the irregularity is always greater than in other parts of the
wire.

Reversal of stress occurs when rope is bent. Small radius bends have greater fatigue effect
than large. Fatigue may be prevented if precautions are taken to avoid large winding shocks, sharp
bending of the ropes around pulleys and drums of insufficient size, loosening of the lay of the rope
with consequent accentuation of secondary bending and faults in rope design. When secondary
bending is the cause of fatigue, consideration should be given to employing ropes of equal lay
because equal lay ropes do not cross over one another and, therefore, are virtually free of all
secondary bending. Figure 11 shows the stages in the breaking of a wire at a fatigue crack. While
designing a wire rope, proper consideration should be given to endurance limit of the material of
the wire being used.

FIG. 11 STAGES IN THE BREAKING OF A WIRE AT A FATIGUE CRACK

21
IS : 3973 - 1984

8.1.4 External deformation - External deformations of the wire ropes are visible changes in the
iope bends. According to appearance, most important of them can be enlisted hereunder:
a) corkscrew deformation (see Fig. 12 )
b) cage formation ( see Fig. 13 )
4 looping of wires (see Fig. 14)
d) loosening of individual wires or strands (see Fig. 15 )
e) knots ( see Fig. IS)
f) construction ( see Fig. 17 )
9) flattening ( see Fig. 18 )
h) curling
i) puffing ( see Fig. 19 )
k) kinks ( see Fig. 20 )

FIG. 12 WIRE ROPE WITH CORKSCREW DEFORMATION

FIG. 13 WIRE ROPE WITH CAGE FORMATION

FIG. 14 WIRE ROPE WITH LOOPING OF WIRES

FIG. 15 WIRE ROPE WITH WIRE LOOSENED BECAUSE OF CORROSION AND WEAR

2i
 FIG. 16 WIRE ROPE WITH KNOTS

FIG. 17 WIRE ROPE WITH CONSTRUCTION

FIG. 18 WIRE ROPE WITH FLATTENING DUE TO CRUSHING

FIG. 18 WIRE ROPE WITH PUFF

FIG. 20 WIRE ROPE WITH KINK

23
16 : 3973- 1984

Deformations also imply the loosening of the rope structure, at least in the neighbourhood
of the place of deformation.

In the case of corkscrew type of deformation, the axis of the unloaded wire rope takes the
form of a helix. This type of deformation in the first instance, does not lead to a weakening of the
wire rope. However, due to this deformation, the wire rope can run noisely. After a load period of
working this can lead to excessive wear and rupture of the wire rope. The wire rope shall be taken
out if the deformation as in Fig. 12 at the most undeformable place is one third of the rope nominal
diameter or more. The deformation shall be measured without load but with the weight of carrying
device ( supporting device ) if it is less than 30 percent of the load capacity.
Cage formation can occur in the case of wire ropes with steel filler if the outer layer of wires
are loose or the outer strands longer than the inside ones. Due to the displacement of the outer
layers of wires and strands with respect to the inner, the extra length is pushed at one plate.
Simultaneously, this can cause at another place of the wire rope an extra length of the filler with
respect to the outer strands, thus buckling the filler or making it come out of the wire rope. In the
case of cage formation, the wire rope shall be discarded.

In the case of loop formation of wires, individual wires or groups of wires come out of the
wire rope in the form of hairpins on the side opposite to the seating groove. Usually the loops
are in several strands one behind the other. If the rope binding is considerably altered due to
loop formation of the constituent wires, the wire rope shall be discarded.

If the individual wires or strands get loose the outer wires of the loaded wire rope or a few
strands can be displaced. They, therefore, do not take up their part of the load and the other wires
or strands are excessively loaded. In the running over pulleys, therefore, very high bending
stresses can be generated leading to premature rupture of the wires. If the loosening of wires is
caused by rust or wear, the wire rope should be discarded. If the loosening is due to other causes,
the rope can be discarded according to the resulting rupture of the wires.

Knots are thickenings that occur repeatedly over long stretches of wire rope. At the thickened
places the filler usually comes out of the wire rope. At the thin places the strands are supported
against each other forming an arch and this can cause rupture of the wires. When there are knots,
the wire ropes make additional movements. Wire ropes with excessive knot formation shall be
discarded.
Constrictions are reductions of the wire rope diameter over short lengths. Portions of the
rope immediately before the end fixing should be checked carefullv. oarticularlv for constrictions
which are difficult to identify at these places. If there is much of constriction, ‘the wire rope shall
be discarded.
Flattenings are permanent deformation of the rope caused by crushing and cause high
incidence of ruptures.
Curling deformation occurs when a loaded rope is drawn over an edge. Ropes with curly
deformation shall be discarded.
Puffs are deformations of the wire rope caused by the fact that an eye-shaped rope sling is
pulled in a straight line without the wire rope being able to take up the deformation by turning in
its axis. Wire rope with one or more puffs shall be discarded.

Kinks are deformations of the wire rope caused by powerful external action. Wire rope with
kinks shall be discarded.
8.1.5 Action ofheat - Wire ropes that have been exposed to excessive heat ( recognizable
externally by tempering colour ) ( oxidation tint ) shall be discarded. Wire ropes which are exposed
to severe heat, for example, in steel works or foundries can become dried out internally which leads
to a risk of internal wire rupture. In such cases the inspector should in each particular case,
preferabty after examination of similar ropes condemned earlier, determine the period for which
the rope may be allowed to remain in use.

8.1.6 Type, position and number of wire ruptures - Wire ropes are bound to deteriorate when
used and the wires do get ruptured. A wire rope should be discarded latest when at any place the
number of visible wire ruptures reaches the values specified in Table 6.

On the occurrence of nests of wire ruptures the wire rope should be discarded. If one strand
breaks, the wire rope should be immediately discarded.
8.1.7 Abnormal sfretching - This results from untwisting of the rope, resulting in parallelling
of the strand.
 IS : 3973 - 1984

TABLE 6 DISCARDING OF WIRE ROPES ON THE BASlS OF WIRE RUPTURES

( Clause 8.1.8 )

Number of Load No. of Visible Wire Ruptures When Ready for Discarding
Bearing Wires in
the Outer Strand of Ordinary Lay Lang’s Lay
the Rope
Over a length of Over a length of

n 6d 38d 6d 30d
-
up to 50 2 4 1 2
-pp
51 to 75 3 6 2 3
-
76 to 100 4 8 2 4
---
101 to 120 5 10 2 5

121 to 140 6 11 3 6
-
141 to 160 6 13 3 6

161 to 180 7 14 4 7

181 to 200 8 16 4 8

201 to 220 9 18 4 9
--
221 to 240 10 19 5 ’ 10

241 to 260 10 21 5 10

261 to 280 11 22 6 11
-_
281 to 300 12 24 6 12

Above 300 i ‘04 x n ‘08 xn ‘02 x n ‘04 x n

In the case of rope constructions with specially thick wires in the outer layer of the outer strands, for example,
round strand rope 6 x 19 Seale or round strand rope 8 x 19 Seale, the number of visible wire ruptures for discarding
shall be 2 rows lower than the table values.
Filler wires are not considered as bearing wires. In tha case of wire ropes with several strand layers, only the
outer layer strands are considered as ‘outer strands’. In tha case of wire ropes with steel filler, the filler is considered
as inner strand. The calculated numbers shall be rounded off in accordance with IS : 2 - 1960 ‘Rules for rounding off
numerical values ( revised )‘.
W is wire rope diameter.
Note - Number of broken wires above is not the only factor in discarding a wire rope.

8.1.8 Surface embrittlement - The surface embrittlement refers to the embrittlemenf of the worn
surfaces of the outer wires of a rope. It may be due to work hardening of the wire surface also
known as ‘plastic-wear embrittlement’ or due to the formation of .a martensitic skin. When a
moving rope rubs heavily or some hard object, the resulting friction heat can bring the outer surface
of each rope wire above the temperature of the martensite formation. When the rubbing stops, the
surface will be suddenly cooled as the remainder of the wire taking the heat away. This causes a
very thin layer of martensite of the order of about 3 microns to be formed on the rubbed crowns of
the wire. First time the wire is bent, the martensitic surface will develop a series of cracks along or
near the base central line, each mark running across the worn crown of the wire. These cracks are
perfect examples of sharp edged surface irregularities and they will certainly become fatigue
cracks, it is only a matter of time. Further the cracks are formed in the wire itself, nof in an
overhanging fin as in the case of plastic-wear cracks and, consequently, the wire is certain to
break in fatigue when the fatigue crack has extended far enough into the depth of the wire. This
martensitic embrittlement is an extremely dangerous form of deterioration. Fortunately it does not
often affect winding ropes, because they do not normally rub against obstructions, but is relafively
common in haulage ropes.
8.1.9 Core collapse - This seems to be of infrequent occurrence. An incipient sign would be the
departure from circular shape of a rope when bent. An advanced sign would be a depressed
strand. The first calls for investigation, the second for discard if the rope cannot be repaired by
replacing the collapsed core.

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IS : 3973 c 1984

8.1.10Fittingtime - If sufficienf experience is available it is possible to predict the time when

the rope will require to be replaced. However, the time of replacement is determined by the
criteria given in 8.1.1 to 8.1.9 explained above.

8.2 Discarding a Wire Rope - No rope should remain in service when it is considered that:

a) The factor of safety has become too low ( when the reserve of strength is no longer
sufficient to ensure that the rope can safely withstand the repeated shock loads, bends,
etc ).
b) The loss in rope strength due to wear, corrosion, or both is approaching one-sixth or 16
percent of the original strength ( or any lower value set by the concerned engineer ).
c) The loss in rope strength due to fatigue, corrosion-fatigue, or surface embrittlement or
due to cracked or broken wires of any kind, is approaching one tenth of the original
strength ( or any lower value set by the concerned engineer ).
d) The outer wires have lost about one third of their depth as a result of any form of
deterioration.
e) The outer wires are becoming loose and displaced for any reason.
f ) The rope has become kinked or otherwise deformed, distorted or damaged, and the affec-
ted part cannot be cut out.
g) The rope has been subjected to a severe overwind or overload or to severe shock loading,
as a result of an accident if the portion of the rope so subjected cannot be cut off ( as in
the case of overwind above banking level ).
h) The examination of the rope leaves any doubt to its safety on any grounds.
j) A rope, which is still in good condition, reaches the maximum life for its type prescribed
by the manufacturer or as laid down in Regulations, if any,

APPENDIX A

( Clause 3.1 )

INFORMATION TO BE GIVEN WITH THE ENQUIRY OR ORDER

A-l. The following particulars should be given with the enquiry or order:

a) Lengths and exact points between which the measurement is made ( in the case of rope
with terminal fittings );
b) Diameter;
c) Construction of rope;
d) The type of galvanizing required;
e) Preformed or non-preformed;
f) Tensile strength of wire;
g) Breaking strength of rope;
h) Whether ordinary lay or Lang’s lay, right-hand or left-hand;
j) Particulars of ends and fittings, whether spliced, socketed or plain, with dimensioned
sketches if limiting conditions apply;
k) Particulars of inspection and tests required;
m) Whether to be delivered on reels or in coils; and
n) No. of Indian Standard.

A-2. If the purchaser is uncertain about any of these particulars, reference should be made to the
rope maker, giving detail of the use to which the rope will be put.

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 IS : 3973 - 1984

APPENDIX B
( Clause 3.1.2 )

DESIGNATION OF WIRE ROPE CONSTRUCTlON

B-l. A wire rope is made up of strands and a strand is made up of one or more layers of wire. The
rope construction refers to the number and arrangement of strands and wires and a type of core
used and is the means of adopting the rope to the particular work that will be required of it, The
method discribed in B-2 has been adopted in designating the wire rope construction in Indian
Standards.
B-2. Wire rope is generally designated by the number of strands and by the number of wires in the
strand. ( The filler wires are not taken into account in 6 x 19 construction ), It is not usual to
indicate the core of the wire rope unless it is the wire main core or the independent wire rope core
when the abbreviation WMC or IWRC are given after the wire rope designation. The number of
strands and the number of wires are separated by a multiplication sign. Many times it is not
sufficient if the number of wires in the strand ara given but details of the strand construction
is also required. In this case, the following procedure is adopted:
After the multiplication sign, the number of wires in each layer of the strand are given,
separated by oblique sign. If the filler wires are there in the strand the number of filler
wires is also indicated by separating it from the number of wires in the outer layer to that of
the filler wires by a plus sign and following the number of filler wires with the letter ‘F’. If
the Warrington construction is used ( alternatively large and small wires are used for the
outer layer of the strands ) the numbers indicating the number of wires in different layers
are separated by word ‘and’. A few examples are given in Table 4 to illustrate the procedure
employed to designate the wire rope construction.

APPENDIX C
( Clause 7.2 )

STEEL WIRE ROPE INSPECTION CARD

Implement Application

construct ions : Date of use:

MO& of lay pattern : right/left/cross/Lang’s Date of discarding:
lay
Nominal diameter:
Tensile designation: True:
White/galvanized/galvanized and traced: Breaking load:
Core material: Workina load:
Well/not pre-formed or post formed:
Rope wire length: Measured diameter:
Finish of rope ends: With a load of:

-
Visible Wear Corro- Decrease Measured Total Damage Date Initials
Wire and sion of and Evalua- and
Breaking Tear Wire Rope Observed tion Defor-
of Diameter Place mation
External (3
Wire

Supplier: No. of fwist:

Remarks: Reason for discarding:
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IS : 3973 - 1984

E XPLANATORY NOTE

Wire ropes find extensive application in industry for hoisting, haulage, material handling,
power transmissjon and other uses.
_ To suit the work . .which
. is. expected of -. the wire rope it.. is
._
necessary that the proper type ot wire rope is selected and to ensure etticient service, It IS
necessary that these wire ropes are installed and maintained properly.

Originally this standard was published in 1967 covering recommendations on the selection,
installation and maintenance of round strand wire ropes. In the the original standard discarding
factors were not explained properly which are of paramount importance in proper functioning and
maintenance of wire ropes. This revision is mainly to overcome this shortcoming along with few
other changes based on the revision of referred standard.

In the preparation of this standard, considerable assistance has been derived from the
following publications:
a) The Ropeman’s Hand Book, published by the National Coal Board of United Kingdom
b) DIN 15020 14 Blatt 2 April 1974 ‘Principles relating to rope drives, supervision during
operation’ issued by Deutsches lnstitut fiir Normung.
c) NEN 3233-1968 ‘Discarding of steel wireropes’ issued by Nederlandse Norm.

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