AS 2759-2004

1 - AS 2759-2004 STEEL WIRE ROPE-USE, OPERATION AND MAINTENANCE
4 - PREFACE
5 - CONTENTS
8 - SECTION 1 SCOPE AND GENERAL
8 - 1.1 SCOPE
8 - 1.2 APPLICATION
8 - 1.3 INNOVATIONS
8 - 1.4 REFERENCED DOCUMENTS
9 - 1.5 DEFINITIONS
10 - SECTION 2 SELECTION
10 - 2.1 GENERAL
10 - 2.2 PHYSICAL PROPERTIES
11 - 2.3 TEMPERATURE
11 - 2.3.1 High temperature effects
11 - 2.3.2 Low temperature effects
11 - 2.4 WORKING LOAD LIMIT
11 - 2.4.1 General
12 - 2.4.2 Design factors
13 - SECTION 3 STORAGE AND HANDLING
13 - 3.1 STORAGE
13 - 3.2 UNCOILING AND HANDLING (see Figure 3.2)
16 - SECTION 4 CUTTING AND FITTING
16 - 4.1 ROPE END PREPARATION
16 - 4.2 SEIZING
16 - 4.2.1 Purpose
16 - 4.2.2 Seizing materials
17 - 4.2.3 Length
17 - 4.2.4 Cutting
20 - SECTION 5 ROPE FITTINGS AND THEIR EFFICIENCIES
20 - 5.1 SELECTION OF FITTINGS AND END ATTACHMENTS
20 - 5.2 TYPES OF FITTINGS
20 - 5.2.1 General
20 - 5.2.2 Hand-spliced eyes
20 - 5.2.3 Ferrule-secured rope attachments
21 - 5.2.4 Swaged end fittings
21 - 5.2.5 Poured sockets
21 - 5.2.6 Wedge grip capels
21 - 5.2.7 Wedge-type sockets
21 - 5.2.8 Wire-rope grips
25 - SECTION 6 POURED SOCKETS
25 - 6.1 GENERAL
25 - 6.2 QUALIFYING AND QUALITY CONTROL
25 - 6.2.1 Personnel
25 - 6.2.2 Poured socket systems
25 - 6.2.3 Type testing
26 - 6.2.4 Proof testing
26 - 6.3 SPECIFICATIONS FOR SOCKETS
26 - 6.3.1 General purpose sockets
26 - 6.3.2 Sockets for strand and higher capacity wire rope
26 - 6.3.3 Reuse of sockets
26 - 6.3.4 Inspection of sockets prior to socketing
26 - 6.4 SOCKETING MATERIAL
26 - 6.4.1 Resin socketing
26 - 6.4.2 Metal socketing
26 - 6.4.3 Lift applications
27 - 6.5 PREPARATION OF WIRE ROPE OR STRAND AND SOCKET READY FOR FITTING
27 - 6.5.1 Temporary seizing
27 - 6.5.2 Permanent seizing
27 - 6.5.3 Cutting the wire rope
28 - 6.5.4 Forming the brush
28 - 6.5.5 Cores
28 - 6.5.6 Degreasing
28 - 6.5.7 Hooking
29 - 6.5.8 Position of wires in socket
29 - 6.5.9 Preparation procedures
30 - 6.6 RESIN SOCKETING
30 - 6.6.1 Resin systems
30 - 6.6.2 Resin socketing procedure
30 - 6.7 METAL SOCKETING
30 - 6.7.1 Socketing metals
30 - 6.7.2 Containers
31 - 6.7.3 Metal socketing procedure
31 - 6.8 INSPECTION
32 - 6.9 IN-SERVICE INSPECTION ADVICE
32 - 6.10 FLOW CHART PRESENTATION OF SOCKETING PROCEDURES FOR STRANDED STEEL WIRE ROPES
36 - SECTION 7 SPLICING
36 - 7.1 SPLICING TOOLS
37 - 7.2 TUCKING LENGTHS FOR EYE SPLICES
37 - 7.3 NUMBER OF TUCKS FOR EYE SPLICES
37 - 7.3.1 Cores of the rope
37 - 7.3.2 Le Blanc splices
38 - 7.3.3 Ordinary lay-Slings, anchorages and standing rigging
38 - 7.3.4 Ordinary lay-Crane ropes
38 - 7.3.5 Lang's lay ropes
38 - 7.4 PREPARATION OF ROPE FOR SPLICING AN EYE
41 - 7.5 TUCKING METHOD
41 - 7.5.1 General
42 - 7.5.2 First set of tucks
42 - 7.6 TUCKING SEQUENCE FOR FIVE°TUCK EYE SPLICES
42 - 7.6.1 Different methods
44 - 7.6.2 Method No. 1
48 - 7.7 LONG SPLICING
48 - 7.7.1 General
48 - 7.7.2 Length of splice
49 - 7.7.3 Method of splicing
56 - 7.7.4 Long splices in wire rope cored or steel strand cored ropes
57 - 7.7.5 Long splices in flattened strand ropes
58 - SECTION 8 DIMENSIONS OF SHEAVES, DRUMS AND ANCHORAGES
58 - 8.1 GROOVES FOR SHEAVES AND DRUMS
58 - 8.1.1 Round grooves
58 - 8.1.2 Traction drive V-grooves
58 - 8.2 DIAMETER OF SHEAVES AND DRUMS
58 - 8.3 DIAMETER OF DEAD EYES OR END ANCHORAGES
59 - 8.4 RADIAL BEARING PRESSURES
59 - 8.4.1 General
59 - 8.4.2 In a crane or hoist
59 - 8.4.3 Other than in a crane
61 - SECTION 9 ROPES USED ON DRUMS
61 - 9.1 ARRANGEMENT OF ROPE ON DRUMS
62 - 9.2 ROPE ANCHORAGES
64 - 9.3 FLEET ANGLES
64 - 9.4 DRUM CAPACITY
68 - SECTION 10 ROPE ROTATION
68 - 10.1 GENERAL
68 - 10.2 SWIVELS
68 - 10.2.1 Bottom hook application
68 - 10.2.2 Dead end application
68 - 10.3 HEIGHT OF LIFT AND MULTI-PART REEVING
69 - SECTION 11 INITIAL OPERATION
70 - SECTION 12 LUBRICATION OF WIRE ROPES IN SERVICE
70 - 12.1 GENERAL
70 - 12.2 CLEANING
70 - 12.3 APPLICATION OF LUBRICANTS
71 - 12.4 TYPE OF LUBRICANT
72 - 12.5 CHARACTERISTICS OF LUBRICANTS
73 - SECTION 13 ROPE INSPECTION
73 - 13.1 REGULAR INSPECTION
73 - 13.2 SPECIAL INSPECTION
74 - 13.3 FREQUENCY
74 - 13.4 MEASURING DIAMETER
75 - 13.5 INSPECTION LOG
75 - 13.6 POSITIONS
75 - 13.7 INTERNAL INSPECTIONS
76 - 13.8 NON-DESTRUCTIVE TESTING
80 - SECTION 14 ROPE DISCARD
80 - 14.1 GENERAL
81 - 14.2 CONSTRUCTION
82 - 14.3 FRACTURED STRANDS
82 - 14.4 BROKEN WIRES
82 - 14.4.1 Number of wire breaks
88 - 14.4.2 Rate of increase of wire breaks
88 - 14.4.3 Wire breaks at terminations
88 - 14.4.4 Localized groupings of wire breaks
88 - 14.4.5 Tensile breaks
88 - 14.4.6 Abrasion breaks
89 - 14.4.7 Fatigue breaks
89 - 14.4.8 Martensitic failures
89 - 14.5 PLASTIC DEFORMATION
90 - 14.6 PHYSICAL DAMAGE
91 - 14.7 HEAT OR ELECTRIC ARCING
91 - 14.8 CORROSION
95 - 14.9 WEAR
97 - 14.10 STRETCH
98 - 14.11 REDUCTION OF ROPE DIAMETER
98 - 14.12 DECREASED ELASTICITY
99 - 14.13 DEFORMATION
99 - 14.13.1 General
99 - 14.13.2 Flattened portions (see Figure 14.13.2)
99 - 14.13.3 Bends (see Figure 14.13.3)
99 - 14.13.4 Kinks (see Figures 14.13.4(a) to 14.13.4(c))
102 - 14.13.5 Local diameter decrease (see Figure 14.13.5)
102 - 14.13.6 Local diameter increase
102 - 14.13.7 Scuffing (see Figures 14.13.7(A), 14.13.7(B) and 14.13.7(C))
102 - 14.13.8 Core dislodgement (see Figure 14.13.8)
102 - 14.13.9 Birdcaging (see Figures 14.13.9(A) to 14.13.9(E))
103 - 14.13.10 Waviness (see Figures 14.13.10(A) and 14.13.10(B))
108 - 14.14 DAMAGE WHILE ON DRUMS
109 - 14.15 DAMAGE CAUSED BY SHEAVES
110 - APPENDIX A - GLOSSARY OF TERMS RELATING TO STEEL WIRE ROPES AND THEIR APPLICATION
118 - APPENDIX B - STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS
119 - APPENDIX C - WROUGHT ALUMINIUM ALLOY FERRULES (BASED ON DIN 3093.1 AND DIN 3093.2)
119 - C1 SCOPE
119 - C2 TYPES OF FERRULES
120 - C3 DESIGNATION
120 - C3.1 Flat oval tube and ferrule blanks (Types A and B)
121 - C3.2 Ferrules for the preparation of cylindrical-conical swage joints (Type C)
121 - C4 DIMENSIONS AND TOLERANCES
122 - C4.1 Wall thickness
123 - C4.2 Straightness of flat oval tubes
123 - C4.3 Twist of flat oval tubes
124 - C5 MATERIAL PROPERTIES
124 - C5.1 Composition
124 - C5.2 Strength properties
124 - C6 MANUFACTURE
124 - C7 TESTING
124 - C7.1 General
124 - C7.2 Batch sampling
125 - C7.3 Additional testing
125 - C8 MARKING
125 - C9 SELECTION OF FERRULE BLANKS FOR A GIVEN ROPE
125 - C9.1 General
125 - C9.2 Fill factor
125 - C10 STANDARD DIMENSIONS FOR SWAGED FERRULES
125 - C10.1 Selection of ferrule size
127 - C10.2 General
128 - C11 PREPARATION OF THE ROPE FOR PRESSING
130 - C12 PRESSING OF THE ROPE FERRULE
130 - C12.1 General
130 - C12.2 Strength properties
131 - C13 APPLICATION TEMPERATURES
131 - C14 TESTING
131 - C15 INSPECTION
131 - C16 TYPE TESTING OF TERMINATIONS
131 - C16.1 General
131 - C16.2 Special wire ropes
131 - C16.3 Proof testing of terminations

Specifies procedures for the selection, storage, handling, maintenance, use, inspection and discard of helically laid steel wire ropes.

This Standard describes recommended procedures for the selection, storage, handling, maintenance, use, inspection, and discard of helically laid steel wire ropes.

Originated as AS MB1-1968.
Previous edition AS 2759-1985.
Second edition 2004.