Notes on Wire rope, Construction/type of wire rope, Testing of wire rope, Application of wire rope, Safety factor, Examination of wire rope, Care & Maintenance, Rope splicing, Tucking, Rope Capel, Reliance Capel, Deterioration of rope, Maximising the life of rope behalf of mining

1. INDEX
A. Wire rope
B. Construction/typeof wirerope
C. Testing of wirerope
D. Application of wire rope
E. Safety factor
F. Examination of wirerope
G. Care & Maintenance
H. Rope splicing
I. Tucking
J. Rope Capel
K. Reliance Capel
L. Deterioration of rope
M. Maximising the life of rope

2. WIRE ROPE
A. WIRE ROPE : A wire rope is an important item of engineering materials in mining & many
other engineering industries. Wire ropes are made from steel wires of plain carbon steel having
high tensile strength.
 A wire rope consists of many individual wires laid into a number of strands which are, in
turn, laid around a central core.
 The type and size of the wires used, the number of wires in the strand, the type of core
and the rope constructions determine the characteristic and strength of the wire rope
and its use.
B. CONSTRUCTION OF WIREROPES :-
Types of wire rope:
1. On the basis of operation of wire rope:-
a. Stationary wire rope, &
b. Running wire rope.
2. On the basis of construction of wire rope:-
a. Stranded wire rope, &
b. Non-stranded wire rope.
2.a Types of stranded wire rope :-
i. Round strand wire rope,
ii. Flattened strand wire rope, &
iii. Multi strand wire rope.
i. ROUND STRAND WIRE ROPE: They are of two types :
a. Ordinary lay wire ropes :-
 It is also known as Regular lay wire rope.
 The direction of the strand coiled is opposite to
the direction of individual lay of wires in the
strand.
 Because of this opposite constructional
characteristics, the rope does not spin.

3.  Each individual strand has six wires which are wound against a central wire.
 These strands are then coiled against a central hemp rope.
 This type of rope is used in shaft sinking operations.
b. Lang's lay rope :-
 The strands are coiled over the central hemp rope in the same direction as the direction
of six wires in the individual strand.
 The construction is more compact.
Advantages :-
 The wear due to friction is even and therefore the rope is durable.
 This rope can be used in rope haulages.
 Easy to examine visually.
 Fairly wide range of flexibility.
Disadvantages :-
 This rope has a spinning tendency.
 This rope is not used in shaft sinking, hoist drums.
 Tendency to twist as load changes.
 Rather vulnerable to external wear.
ii. FLATTENED STRAND ROPE :-
 The central portion of the core of the strand is at triangular
shape.
 The triangular shape is given by assembling many thin wires.
Advantages :-
 This is more durable than the other types of ropes.
 This is used in big haulages and shaft sinking also.

4. iii. MULTI STRAND ROPE :-
 The strands are coiled in two or more layers on the central core.
 The direction of the coil of the second layer is opposite to the
direction of the first one.
Advantages :-
 These ropes are non-rotating and flexible.
 These are strong and more durable.
 These ropes are used in deep shaft winding and koepe system of
winding.
2.b Types of non-stranded wire rope :-
i. Locked coil rope, &
ii. Half locked rope.
i. LOCKED COIL ROPE :-
 There are no wire strands.
 It is non-rotating type of rope.
 The wires of first layer are laid along a central core in the same direction. Another layer
of wires is laid in the opposite direction.
 Final layer of wires is of special construction such that neighbouring wires interlock
between themselves.
Advantages :-
 These are more stronger than the other ropes of the same diameter.
 They are non-spinning type.
 The smooth external surface gives greater resistance to wear by abrasion. Hence, the
ropes are more durable.
 The elastic and the permanent stretching of rope is much less than that of the stranded
type.
 Resistant to external wear.
 This rope can work under higher radial pressure than any other type of rope.
 This rope is particularly suitable as winding rope for large loads and where the rope
twist can not be tolerated.
Disadvantages :-
 It is less flexible than any other rope.
 Broken wires can not be located easily.

5.  The internal portion of the rope can not be lubricated.
 These ropes can not be spliced.
 Large size some times tend to distort.
ii. HALF LOCKED ROPES :-
 The locking action of the outer wires is designed to ensure that any broken wires (which
may develop during use) are held in position in the rope such that they will not interfere
with free running of the cage or skip.
 They offer a smooth wearing surface to the cage shoe or rubbing plate and contain very
large section of wires to give best possible wear characteristics.
GUIDE ROPES :-
 They are made of wires or rods of large diameter.
 The diameter of the rope is upto 50 mm.
There are three forms of guide ropes :-
a. A single strand of six around one.
b. A compound strand of nine around six around one.
c. Locked coil rope to give maximum wearing surface and smooth running.
C. TESTING OF WIRE ROPES :-
The wire is subjected to following tests :-
1. Tensile test,
2. Torsion test,
3. Bending test,
4. Wrapping test, &
5. Looking test.
1. Tensile test :-
 The specified length of wire is subjected to a stretching force in a testing machine until
the rope may break.
2. Torsion test :-
 A specified length of wire rope is stretched and its both ends are gripped into vice. One
of each is twisted until is is break.

6. 3. Bending test :-
 One of the wire is fixed in vice with specially rounded laws and the wire bend towards
and backward through 180° over the jaws until break.
4. Wrapping test :-
 in wrapping test the wire is heated and one end is wrapped tightly at other usually for
eight turns.
5. Looping test :-
 The end of short piece are taken one on each hand & stress generate on the rope by
rounding in forward & backward direction.
 Repeat this process until the wire break.
D. APPLICATION OF WIREROPE:-
A. IN OPEN CAST MINES :
1. Dipper shovel ropes :-
 Dipper hoist ropes : For 32mm & smaller size, 6×25 filler langs lay with IWRC. & For
35mm to 68mm size, 6×41 seale filler wire langs lay with IWRC.
 Crowd & retract ropes : For 58mm & smaller size, 6×41 seale filler wire langs lay with
IWRC.
 Boom hoist ropes : 6×25 filler wire langs lay with IWRC. (for 30mm size)
2. Dragline hoist rope :-
 6×25 filler wire langs lay with IWRC (for 32mm to 58mm size)
3. Dozer :-
 6×25 filler wire regular lay with IWRC.
4. Mobile cranes :-
 Main hoist rope : 6×25 filler wire regular lay with fiber core.
 Boom hoist rope : 6×25 filler wire regular lay with IWRC.
B. IN UNDERGROUND MINES :-
1. Winding ropes:- following constructional wire ropes can be used for winding purpose:
 6×7 lang lay,
 6×19 seale regular or Lang lay, fiber core

7.  6×21 Filler wire regular or Lang lay, Fiber core,
 6×25 Filler wire regular or Lang lay, Fiber core,
 6×27 Flattened strand lay fiber core,
 6×30 Flattened strand lay fiber core,
 Locked coil hoist rope.,
2. Winding rope for shaft sinking :-
 19×7 non rotating regular lay or locked coil hoist ropes.
3. Haulage rope :-
 Wire rope used for haulage construction should be 6×7 & 6×19 ,seale construction
either regular lay or langs lay.
4. COAL CUTTING MACHINE :-
 Wire rope used in coal cutting machine construction should be 6×37 regular lay with
IWRC.
E. FACTOR OF SAFETY OF WIREROPES :-
 Factor of safety of wire rope is the ratio of ultimate normal breaking strength of rope to
the maximum static load.
FOS = Normal breaking strength
Maximum static load
Factors influencing factorof safety in winding rope :-
FACTORS :-
1. STATIC LOAD :-
 With higher static load, the factor of safety decreases. The static load is the sum of the
weight of the rope, cage attachment, full load tub etc.
2. DYNAMIC LOAD :-
 Consists of forces due to acceleration and the effect of the kinetic shock load. Severe
shock loads may be caused due to
a. starting with slack cage or bridle chains.
b. Friction from shaft guides when they are out of alignment.
c. Incorrect setting of the valve geared engine.
d. Out of balance forces by steam winders.

8. e. Lifting of shaft gates giving a direct impact load.
f. Rapid action of the weight loaded brake system.
g. Sudden stopping of the skip with simultaneous loading of material etc.
3. DEPTH OF WIND :-
 In deeper shaft the length and diameter of the rope and hence the weight increases. But
capacity to resist kinetic shock is roughly proportional to its length and hence lower
factor of safety is permissible in deeper shaft.
4. CONSTRUCTION OF ROPE :-
 Locked coil ropes are stronger with than the stranded rope due to higher space factor.
Hence, these ropes can be used in place of larger diameter stranded ropes.
5. CONDITION OF USE :-
 With new rope, safety factor is more than the rope in use. Wire rope in upcast shaft,
exposed to moisture and temperature has reduced factor of safety.
6. BENDING STRESSES :-
 CMR has stipulated the size of the pulley sheave etc. to be 120 times the diameter of
the rope. If the diameter is less, the bending stresses reduce the safety factor.
7. MAN OR MATERIAL WINDING :-
 Wire rope in use for material winding have reduced safety factor than the rope used in
man-winding work.
F. EXAMINATION OF WIREROPE:-
1. During construction :-
a. Composition of 0.01 :
 Carbon - 0.5
 Silica - 0.11
 Manganese - 0.48
 Sulphur - 0.033
 Phosphorus - 0.014
b. Standard construction
2. During testing :-
 Tensile test,

9.  Torsion test,
 Bending test,
 Wrapping test, &
 Looking test.
3. During uses:-
 Flexibility,
 Shockedload,
 Wateryplace,
 Hot place,&
 Stationary& rotatingrope.
G. CARE& MAINTENANCE:
Care of wire ropes during storage anduse:
The following points should be kept in mind during the storage and use of wire rope :-
 Avoid use of rope with fibre core, when the rope is subject to heat, fumes and extreme
pressure.
 Buy right construction of rope suitable for the job.
 Corrosion can be delayed by using galvanised rope.
 Don't load the rope beyond its safe working load.
 Ensure that the rope is strongly seized before it is cut.
 Flexibility of rope should be suitable to the size of drums and pulleys, and diameter of
rope to grooves.
 Grease the rope and cover properly before storing in a dry ventilated shed.
 Handle the rope carefully while transporting and uncoiling to avoid kinks.
 Inspect the rope periodically and lubricate with acid-free lubricant.
 Judge the safe life of the rope for the conditions under which it has to work and replace
it in proper time.
H. ROPESPLICING :-
METHOD OF SPLICING :-
 Decide the length for splicing of Rope.
 After deciding the length of the splice, the ends of the rope are brought nearer and
overlapped for the length of the splice.

10.  Beyond the overlapping length, the thin binding wire is lightly coiled and the rope is
seized.
 The strands are now opened out up to the płace of binding and the centre hemp rope
piece is cut.
 The alternate strands near the binding are cut such that 0.3m length are cut out, from
the binding.
 The places of both binding of ropes are brought face to face and the strands are
arranged in such that the long strand of one rope are opposite the short/cut strand of
the other rope.
 The opened out strands of left hand rope are tied temporarily to the strand of the right
hand rope.
 Strand of one rope is run over the place vacated by the out-coming strand of the other
rope. The strands are laid in correct bed till all except 0.3 m of the strand is remaining.
 Cut off the extra strand (came out) to keep an equal length & tie the strands temporarily
in its place.
 This process is repeated for the balance 2 pair of strands but stopping the pair at
predetermined equi-distance places.
 Repeat the process for the other rope strands til the spliced length, gives an appearance
of 6 pairs of tails coming out at crossing.

12. I. TUCKING :-
 The spiral formations of the tail strands are straightened.
 The rope is untwisted with the help of the vice and clamp at the crossing. The core rope
is cut and pulled out and the tail rope is cut & pulled out and the tail rope is inserted in
the space occupied earlier by core rope.
 Other tail end is also similarly inserted.
 This tucking is repeated at the next pair of tail rope.
J. ROPE CAPEL :-
Following types of capels are in use :-
1. Bent back wire cappel (used for haulage ropes.)
a. Split capel with rivets, &
b. Coned-socket type of capel.
2. Conical capel with white metal:-
a. Open type socket, &
b. Closed type socket.
3. Conical capel with zinc cone and tail strand - open type socket.
4. Inter locking wedge capel.
METHOD OF CAPPING :-
1. BENT BACK WIRE CAPPEL :-
1.a SPLIT CAPEL WITH RIVETS:-
 The length of the rope for fixing to the rope cappel is ascertained, depending on the
length of the capel.
 A thin binding wire is wound on the end of the decided length. .
 The wires are then opened. Hemp-rope is cut & the opened wires are straightened.
 The opened wires are bent back over the wire and the binding wire is coiled so as to
make a tapered cone.
 The length of the tapered cone is minimum eight times that of the diameter of the rope.
 The cone is now kept in between the jaws of the cappel and the jaws are hammered,
closing each other.
 Two or three rivets are hammered across the Jaws cone and the rope.
Advantage :-
 It is used for haulage purposes.

13. Disadvantage:-
 Its strength and reliablity depends on the workmanship of the person making the rope
capel.
 These capels are forbidden to be used in the winding ropes.
1.b CONED-SOCKETTYPE CAPPEL :-
 Clamp the rope temporarily by a thin binding wire before cutting of the old cappel.
 Thread the socket on the rope and push it along.
 Seize (bind) the rope tightly with soft iron binding wire at the length decided, which is
e
q
u
a
l
t
o
t
h
e
length of the tapered portion of the socket.
 Build up short cone of the seizing wire. This cone should be made of 2 to 3 layers of
wires and should have about the same taper as the inside of the socket.
 Open out and straighten the wires and divide them into three equal groups so that each
group is spaced evenly around the rope.
 Leave one group full length, cut the second group to 2/3 of the full length and cut the
last group to 1/3 of the full length.
 Bend the shortest wire on the conical seizing and arrange them evenly around the rope.
Seize them tightly over its length by the binding wire.
 Bend the next short wires in the same way and seize them tightly over the whole length.
 The longer remaining wires are bent in the same way and seize them over the whole
length.
 Cut the fibre core where it leaves the end of the cone.
 Draw the socket on to the capel and drive the tapered plug into the stump. The plug is
of wrought iron or mild steel.
 Only 3 to 4 rope diameter in length, conical in shape with its large and slightly bigger
than the fibre core.

14.  Put some thick grease into the socket to keep out water.
AIM :-
The alm in making a bent back wire cappel is to get a tight solid core of wires at the end of the
rope. It is squeezing of bent back wires against the ropes which holds the rope in the socket.
2. CONICAL CAPPEL WITH WHITE METAL :-
In this type of capel, a cone of while metal is made which fits tightly into the barrel of
the capel.
CAPPING METHOD :-
 Deducting twice the rope diameter from the length of the tapered portion of the
CAPPEL.
 A place is marked on the rope.
 The rope is seized at a length of twice diameter of the rope at this determined place.
 The socket is now pushed over the rope and the rope beyond the seizing is opened.
 The central hemp rope is cut. The wires are opened individually and made to form a
brush shape.
 These wires are cleaned with the help of kerosene or diesel oil or petrel. (Water
soluble degreasing fluid or non inflammable organic solvent is preferred. Paraffin in
not recommended).
 The wires are now cleaned with dry cotton.
 Pull the brush through the capel such that the brush remains Inside its conical
portion.
 Clamp the cappel complete with the the rope in place such that the rope is vertical
for a length of at least 24 times of its diameter.
 Seal the junction of the rope and cappel with asbestos yarn or moist clay to prevent
escape of molten metal.

15.  Heat the socket evenly upto 100 degree centigrade with the help of blow lamp (not
permitted in underground coal mines). When the socket is hot, powdered resin is
sprinkled over the rope brush in the capel.
 White metal is heated upto 365°C and is poured in the molten form in the conical
hole of the capel.
 The metal is allowed to cool gradually till the capel cools down to the atmospheric
temperature.
CONICAL CAPPEL WITH ZINC CONEAND TAIL STRAND :-
 This type is also D.G M.S approved.
 The cones are ready made with the fixed length tail rope.
 At one end of the tail rope a zinc cone is made.
 This capel can only be used in the ropes with central hemp rope.
 The capping process is very simple and heating process is completely eliminate. So, it
can be safely used in underground gassy mines.
METHOD OF CAPING :-
 The rope is seized with the help of binding wire at a length equal to the length of the tail
rope +.12.5 mmm The end of the rope is also seized similarly.

16.  The socket is threaded over the rope and is placed at a distance.
 Remove the serving from the rope end and unlay three neighbouring strands for a
length of approximately 75 mm more than the length of the tail unit.
 Measure of the from the rope end, the length of the cone and the tail unit +10mm.
 Remove the rope core upto this position and cut it.
 Insert the tail strand in place of removed core and relay the opened strand to reform the
rope.
 Place the strands one in each of the grooves provided on the cone in natural lay of rope.
 The strand should protrude over the end of the cone.
 Bind the rope tightly at the small end of the cone using a fine wire of a size which will
allow the rope to pass through the small end of the socket.
 Draw the socket into the position by applying a load equal to the working load .
 After the socket ing is completed a trial run should be made followed by an examination
of the rope socket.
K. INTER LOCKING WEDGE CAPEL :-
It is also RELIANCE CAPEL.
Description of the capel :-
 It has two interlocking wedges which are placed between the tapered split socket.
 There are five outer pressure rings (clamps) to press the socket inwards.
 The length of the tapered portion of the wedges is equal to 24 times of the rope
diameter.
 At the end of the rope in the socket, is a tapered conical white metal block.
 A small distance is kept between the conical block and the wedges so as to give an
indication in the event of rope slippage in the socket.
 The rope is firmly held in position with the capel because of the friction of the
interlocking tapering design of the wedges.
RECAPING OF RELIANCE CAPPEL :-
 3 to 6 rope clamps are kept ready for clamping purpose.

17.  As shown in the sketch, the rope is seized at two places with binding wire.
 The length of this binding is twice the length of the metal
block.
 The pressure rings/clamps are threaded over the ropes in
correct sequence.The conical block is threaded at the end.
 A clamp is clamped in the position.
 The binding of the rope end is opened and the wires are
separated to form brush.
 The hemp rope inside the brush is cut, and the wires are
cleaned of grease or lubricant.The clamp C is taken out for
a while and the upper conical block is brought down on the
brush.
 The clamp, the brush and the rope is held vertically in
position and white metal is poured into this cone.
 After cooling down of the white metal, the rope clamp C
and the binding under beneath is opened.
 The grease and other lubricant over the rope equal to the
length of the capel is cleaned.
 The interlocking wedges are also similarly cleaned.
 The wedges are kept 1/2" above the conical block and the
wedges are kept in the 'U' shaped outer sockets.
 Now, the pressure rings are pushed over the socket one by
one.
 The capel is kept vertical on a hard floor & the pressure
rings are tightened in their correct order. This is how
recaping is done for reliance cappel.
L. CAUSES OF DETERIORATION OF ROPES :-
The main causes of deterioration are as follows :-
1. Wear,
2. Corrosion, &
3. Fatigue.
1. WEAR :-
 It is due to friction of the rope with drums and pulleys and due to differential internal
movements of internal wires and strands.
 The wear is partly abrasive due to removal of metal from the outer wire.

18.  The plastic wear renders the rope brittle.
 Wear is minimised paying attention to the design, layout and lubrication of the moving
pulleys and alignment of track etc.
2. CORROSION :-
 The external corrosion is due to contact of acidic or alkaline water.
 A small corrosion is worst to produce failure than a considerable amount of rusting.
 The internal corrosion is worst in presence of moisture together with the acids liberated
by the lubricant or by disintegration of fibre core.
 Corrosion can be minimised by proper lubrication and by the use of rope of galvanised
wires.
3. FATIGUE :-
 Fatigue is the physical change in the condition of a rope after repeated applications of
stress.
 The stress below which fatigue does not occur is called the Fatigue Limit.
 The rope should not be exposed to repeated loading greater than about 1/4 of the
breaking strength.
 The fatigue of the winding rope is likely to occur near the capel.
 Because of various vibrations, kinetic stresses and shocks are arrested and reflected at
this point.
Fatigue can be reduced by
a. Correct installation and regularity in winding, &
b. Cutting of 3 meter length of rope at each recapping.
CORROSION FATIGUE :-
 When the rope is subjected simultaneously to both corrosion and repeated stressing,
much more deterioration occurs.
 Moreover, there is no fatigue limit under corrosive conditions.
 The most characteristic evidence of corrosion fatigue is presence of multiple cracks, any
of which may cause fracture.
M. PRECAUTIONS TO BE TAKEN FOR MAXIMISING THELIFE OF THE ROPE :-
USE AND CARE OF ROPES :
1. STORAGE AND HANDLING :-
 The rope should be stored in dry place in a shelter in a little high place on the ground.

19.  The air should move freely below the rope. Fibre rope slings should be used for lifting
the rope.
 For uncoiling the rope, the rope reel should be mounted on the spindle. While opening
out a rope, kink should be avoided which injures the wires permanently.
2. DRUMS AND PULLEYS :-
 Recommended size of the drum and pulleys should be used.
 For winding rope drums and pulleys should be between 80 to 120 times the diameter of
the rope.
 For haulage ropes this ratio is minimum 80 times.
3. LUBRICATION :-
 Lubricants are applied to each wire and strands during manufacture to prevent and
minimise corrosion and reduce friction between wires and strands.
 During the use of the rope, lubricant should be applied regularly to the external parts of
the ropes, weekly or monthly accordingly to the condition.
 Before lubricating, the ropes should be cleaned and dried in air and accumulated dust
should be removed by a wire brush.
4. AVOIDANCE OF KINETIC SHOCKS :-
 The kinetic shock is due to the slack rope at the beginning of the upward wind. This
should be avoided.
 The lifting of heavy gates at the surface or badly aligned rigid guides result in shocks
leading to deterioration of the rope by fatigue.
5. RECAPING :-
 The rope must be recapped every six months and the 3 meter length of the rope is cut.
 So that the same portions are not subjected to the worst condition for too long a time.
6. EXAMINATION :-
 Regular examination of the rope is essential.
 DAILY EXAMINATION :- To detect visible faults, broken wires, excessive wear, loosening
of the strands etc.
 MONTHLY EXAMINATION :- Selected cleaned portions of the rope are very minutely
inspected for wear, corrosion and fatigue cracks.
 At each recapping, the internal condition of the rope is examined strand by strand and
wire by wire.