When crawler cranes are used on high-lift job sites they generate unique operating conditions that result in unique wire rope deterioration. This session features four leading industry experts who will share their insights on the behavior of wire rope in such circumstances and provide you with guidelines for inspection, repair, or replacement. Moderator: Tony Fastuca, Vice President, ASC/Python America Panelists: Justin Brown, Product Manager, Unirope Limited Mario Hartl, Teufelberger Wire Rope Dave Sleightholm, Manager, Customer Technical Support, Bridon Bekaert

2. LIVE POLL
What is needed to achieve
a perfect spooled multi-
layer drum without major
rope issues?

3. LIVE POLL
Which of the following
factors DOES NOT
influence the stability of
hook blocks?

4. LIVE POLL
Which of the following
reeving configurations is
the least stable against
block rotation?

5. LIVE POLL
What is the most important
consideration relating to
the safe operation of the
boom hoist rope?

6. Wire Rope Challenges for
Crawler Cranes
Tony Fastuca

7. Panelists
Mario Hartl Justin BrownDave
Sleightholm

8. Wire Rope Challenges for Crawler Cranes
Hartl Mario
Head of Field Engineering, Teufelberger Wire Rope
September, 2017
Multi-layer spooling
“What is needed to achieve a perfect spooled rope on a multi-layer
drum without major issues” …for “high-lift jobs” on crawler-cranes

9. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
Multi-layer spooling
“What is needed to achieve a perfect spooled rope on a multi-layer drum
without major issues” …for high-lift jobs on crawler-cranes
 Proper Correlation Multi-layer Drum & Wire Rope
 High Performance Rotation Resistant Steel Wire Rope
 Proper Rope Installation

10. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Correlation Multi-layer Drum & Wire Rope

11. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Correlation Multi-layer Drum & Wire Rope
Play = Pitch– act. Rope-Ø
Pitch Multi-layer drum: 105% nom.Rope-Ø
act. Rope-Ø ~ 103.5 – 104.5% nom.Rope-Ø

12. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Correlation Multi-layer Drum & Wire Rope Play  0

13. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Correlation Multi-layer Drum & Wire Rope
Excessive play (Gap)

14. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Correlation Multi-layer Drum & Wire Rope
Influence of the fleet angle on the spooling behavior
Min-Max – fleet angle acc.to. ISO 16625:
Rotation Resistant Ropes 0,5° to 1,5°- max. 2,0°
Non-Rotation Resistant Ropes 0,5° to 3,5°- max. 4,0°
Fleet angle ≤0,5°
 Rope climbs up the flange

15. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 High Performance Rotation Resistant Steel Wire Rope
…for high-lift jobs on crawler-cranes
 15-18 Outer Strands (high rotation resistance)
 Compacted Outer Strands (high wear resistance)
 High Resistance Against Radial Deformation
 Dimensional Stability (Rope-Ø) Under Lateral Pressure
 High Flexibility and Efficiency
 Use lang’s lay to minimize the wear (multi-layer application)

16. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 High Performance Rotation Resistant Steel Wire Rope
…for high-lift jobs on crawler-cranes
35x7- WSC - RHRL

17. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 High Performance Rotation Resistant Steel Wire Rope
…for high-lift jobs on crawler-cranes
35x7- WSC - RHRL

18. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Rope Installation
„Wire ropes may only be installed by technical experts or trained persons
under competent supervision“
…….Incorrect wire rope installation may be hazardous to those involved with installation and subsequent
operation. Further incorrect handling can have unchangeable negative consequences to the rope and its lifetime.

19. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Rope Installation
 Back-Tension During Installation
apply a minimum of 2½ - 5% of the MBL with
- a traction winch
- a break disc on a spooling device or reel
- or at least use a auxiliary break (wood) or tighten the first layer by hammering

20. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Rope Installation
 Back-Tension During Installation
apply a minimum of 2½ - 5% of the MBL with
- a traction winch
- a break disc on a spooling device or reel
- or at least use a auxiliary break (wood) or tighten the first layer by hammering
 No Counterbends
try to stick to the bending direction of the reel
 Fleet- angles
Minimize fleet angle and stick to the regulations acc. ISO 16625
 Train the rope before max. SWL

21. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Rope Installation
Loose spooling of safety wraps
High loading of the second layer

22. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
 Proper Rope Installation
High loading of the 2nd and 3rd layer
Loose spooling of safety wraps

23. Wire Rope Challenges for Crawler Cranes – Multi-layer spooling
Multi-layer spooling

24. Multi-layer spooling
“What is needed to achieve a perfect spooled rope on a multi-layer drum
without major issues” …for “high-lift jobs” on crawler-cranes
a) a regular lay rotation resistant rope
b) an uncompact rotation resistant rope
c) actual rope-Ø should be 1% smaller than the drum pitch
d) fleet angles ≥2° for rotation resistant ropes