Manual For Wire Ropes PDF
Manual For Wire Ropes PDF
CMD-III/1855/1 MANUAL
DATE OF ISSUE 17 MARCH 2008
MANUAL FOR
WIRE ROPES AS PER
INDIAN STANDARD SPECIFICATIONS
( 1855,1856,2266,2365,2581,2762,13156 )
(First Issue)
1
TABLE OF CONTENTS
TITLE PAGE NO
FOREWORD
3
SECTION II SPECIFICATIONS
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FOREWORD
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The manual has been divided into following sections :
Section II Specifications
Section VI Annexes
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SECTION I
Wire ropes are composite construction of strands of fibre or steel or both, bunched to form a
core surrounded by stranded and twisted cores . A wire rope is designated by the over all
diameter, the number of strands, number of wires per strand, the cores, the type of lay and the
length etc.
The Glossary of Terms relating to Wire ropes are covered in the Indian Standard IS 2363 : 1977
Glossary of Terms relating to wire ropes ( first revision). The IS 6594:2001 Technical
Supply Conditions for Steel Wire ropes and Strands ( Second Revision) is an important adjunct
to this manual.
To understand the construction and technical requirements of a wire rope the following
definitions are important and are suitably explained by the accompanying illustrations.:
DIMENSIONS 1. Length
2. Diameter ( in mm )
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TENSILE DESIGNATION - 1420 / 1570 / 1770 / 1960
ARRANGEMENTS OF WIRES IN STRAND
The typical designation for a rope through connecting symbols is given below :
The connecting symbols used are : - / : + x
For example, as per IS 1855: 2003, Wire ropes for use in mines shall be of round, multi strand,
rotation resistant or flattened strand type . The core can be of fibre or steel. The wire ropes for
general purposes as per IS 2266 : 2002 specifies the type, construction, rope grades and the
range of sizes.
Wire ropes can be supplied as black or galvanized depending upon customer requirements.
Joints are also permitted depending upon the applications. Pre-formed wire ropes are generally
used as they have superior flexibility and have better bending resistance.
The wire ropes unless properly protected against oxidation tend to corrode fast and result in
fatigue failures. Therefore the wires and the ropes are galvanized unless otherwise demanded. In
order to reduce friction, wire ropes are well lubricated The lubrication requirement is dependent
on the application of the wire rope. In case of ropes for general engineering purposes ,
the grease used shall be fee from solvents, acidity, alkalinity, moisture or any other aromatic
compound.
Fibre cores are normally of Manila ropes, jute fibre or any other suitable fibre. Of late, synthetic
fibres ( popularly termed as Nylon ) made of polythene, polypropylene etc are being used in
place of natural fibres due to their easy availability and higher wear out capabilities.
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Major reasons of failure :
Wire ropes are affected by heat, corrosion, fatigue or any other damages. The resultant effects
are extension of strands, loss of surface metal, potential internal ruptures due to heat, loss of
shape of rope and hence more friction losses. The improper jointing can also result in primitive
failures.
Wire ropes acquire their characteristics due solely to the proper and correct manufacturing
practices which comprise of proper selection of raw materials, heat treatment facilities, method
of cleaning of scales after heat treatment, pickling, galvanizing (Hot dip / electro),core
preparation and closing. Extra care is taken when natural cores of fibre are used in construction
like proper storage under humidity controlled conditions,
The strength of a rope depends on diameter for a specific tensile designation of steel and type of
construction.
Abrasive resistance- it is higher for ropes with larger diameter outer wires and hence should
be preferred where potential for abrasive usage is higher.
Flexibility is higher with larger number of wires/ strand and should be preferred where
flexibility is required.
Preformed wires are safer, easier, better workability, greater resistance for fatigue
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SECTION I I
IS 1855 : 2003 Stranded Steel Wire Ropes For Winding and man-riding Haulages
Mines Specification
This standard covers the general requirements for stranded steel wire ropes for winding and
man riding haulages used in mines. The wires used shall conform to Grades 1,2 and 3 of
IS 1835 :1976 - Round steel wires for ropes ( third revision). The cores can be of fibre or
steel . The wire ropes shall be as far as possible joint free. However, if jointed, the total
number shall not exceed 3 in any length of rope. The grade of ropes shall be 1420 ( only for
multi strand rotation resistant) 1570, 1770 and 1960.
The specification is covering the general requirements except for man riding purposes like
lifts and escalators. The three grades recommended are tensile designation of 1570,1770 and
1960. The diameter of ropes covered range from 8,13 to 40 mm. Where fibre core is used it
shall be of soft jute fibre.
IS 2266: 2002 Steel Wire ropes for General Engineering Purposes Specification
specifies steel wire ropes for use in cranes, excavators and other general engineering
purposes. The tensile designated are 1570,1770 and 1960 . The type of ropes shall be round,
oval and flattened. The oval type is restricted to sizes from 8 to 40 mm. The flattened strand
is for special applications and ranges from 13 to 48 mm sizes.
1S 2365: 1977 Specification for Steel wire Suspension ropes for lifts, escalators and
hoists
This standard specifies the steel wire ropes for suspension purposes predominantly used for
lifts, escalators and hoists. The ropes cannot be used for winding purposes in mines. The
core shall be only of fibre. Joints are permitted only in case of wires of 0.5 mm diameter or
smaller.
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IS 2581: 2002 Round Strand galvanized steel wire ropes for shipping purposes-
Specification ( Fourth revision ) (derived from ISO/R 346:1963 - Ship
building details- Galvanized Steel wire ropes )
This standard is meant for round steel wire ropes, galvanized exclusively for shipping
purposes. Wire ropes are used extensively standing, rigging, mooring, towing hawser, cargo
gearing and also life boat drops The types covered are both round stranded, multi-strand
rotation resistant types with both fibre and steel cores. The size range from 8mm to 52 mm
for round steel strands with the rope grades of 1420 and 1570 designation. However, for
multi strand ropes only 1570 tensile designation is specified and the size range is restricted to
8mm to 40 mm, the cores can be both fibre and steel.
IS 2762 : 1982 Specification for wire rope slings and sling legs ( First revision)
The above Indian Standard specifies dimensions, constructions loading, tests for two,
three and four leg slings for use with wire ropes of nominal diameter ranging from 8 mm to
44 mm. The sling legs of single part spliced, double part spliced and endless and double
part, Grommet types are covered by this Indian Standard.
Pulley blocks for wire ropes form an integral component in the usage of wire ropes. The
above Indian Standard covers the requirements of single, double and triple sheave pulley
blocks of nominal sheave sizes from 160 mm to 320 mm dia suitable for wire ropes of
nominal dia from 12 to 22 mm. While specifying the blocks the working load has to be
properly calculated . The standard specifies safe and working load of 40 k N per single part.
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SECTION III
HEAT
TREATMENT
OIL FABRICATION
PICKLING IMPREGNATION
BLACK WIRES
WIRE DRAWING
GALVANIZING
STRANDING
ROPE WINDING
CLOSING OPERATIONS
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SECTION IV
The stages of Inspection for processing of wire ropes are listed below :
SECTION IV
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TEST EQUIPMENT & TEST S
Dimensions
Diameters of round steel wires, cores and finished ropes - Vernier calipers, Micrometers,
Snaps, fabricated outside calipers
Length Metre scales, measuring tapes,
Classification of Tests
The tests for completed wire rope and stranded can be categorized into routine and type
tests:
The routine test on completed wire ropes is the Breaking force test while the Type test
carried out to prove the design would include tests for material, size, construction, core,
length, mass, minimum breaking force, lay , freedom from defects, and performing . The
rope manufacturer shall ensure that the wire manufactured meets the requirements of the
standard with regard to tensile, torsion, reverse bend, and where appropriate, galvanizing
tests. The test results shall be available for the purchaser at the manufacturers premises.
Calibration of the testing equipment and gauges is an important activity for which facilities
as far as possible should be in- house. Where gauges and tools can be calibrated by outside
agencies care must be taken to ensure that the agency is approved for such activity under
the national accreditation Sytem operated by National Accreditation Board for
Laboratories (NABL) of the Directorate of Science & Technology, New Delhi.
Tensile Testing Equipment is generally calibrated once a year. The proving ring used for
calibration should be calibrated before use and duly certified by the national testing,
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approving agency. National physical Laboratory, New Delhi (NPL) has the requisite
facilities for calibrating the master proving ring gauge for calibration by the supplier of the
tensile testing machine. The calibration of the machine for testing purposes , is done by
the supplier while installation and commissioning of the testing equipment. For the
purpose of the calibration of the tensile tester in house, if carried out, it is necessary to get
the supplied ring also calibrated once in three years.
The proving ring is to be maintained in a cool and dry place to avoid exposure to
temperature/humidity variations. The tensile testing equipment, if fitted with a computer for
generation of results, through graphical analysis should, preferably be kept in a dust free,
airconditioned room. The lubrication of the fixed supports ( frame ) , moving arm,
hydraulic circuits, pressure gauges etc. should be checked before every usage of the
machine.
The grips are to be identified as per the sizes and maintained properly. In many
organizations, the testing equipment is maintained under an Annual maintenance Contract
by the Original Equipment suppliers.
Measuring Gauges - Vernier Calipers, Micrometers, dial gauges, snap gauges, measuring
tape and scales are also to be calibrated periodically. The recommended non production
equipment is once in a year. It varies with the usage of the gauge. As in the case of in
house calibration if calibrated and certified masters exist, they may be used for secondary
calibration of the gauges in- house.
Care through lubrication, dry and clean cloth for wiping etc. to be taken for proper
maintenance of the measuring gauges.
If outsourced, the calibration certificate issued by the calibrating agency will indicate the
errors, accuracy and the limits of uncertainty. Fabricated gauges if any, shall also be
checked for their accuracy of measurement.
Renowned suppliers of Tensile testing equipment are : Blue Star, FIE , Avery and KMI.
Mitutoyo is the well known brand for verniers, micrometers and dial gauges.
The calibrating agencies for all laboratory mechanical, electrical and electronic equipment
are the NPL and NTH. The measuring gauges and instruments can be calibrated at Central
Machine Tool Institute, ( CMTI) Bangalore.
SECTION V
CERTIFICATION CRITERIA
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The criteria for certification and operation is detailed in the Operating Manual for
Product Certification 2004 ( Fifth Revision ). Reference shall be made to the Manual by
the Auditors while carrying out Certification activities.
For certification of wire ropes manufactured by an enterprise, with the Standard mark
issued by BIS, it is mandatory to comply with the following requirements before submission
of the application form to BIS .
While carrying out the preliminary visit the auditor shall fill up the appropriate
proforma issued by CMD. For a proper inspection, it is preferable to have a checklist
prepared before hand by the technical auditor.
Manufacturing Facilities- The layout should be such that the whole production is carried
out simultaneously and uniformly without any hindrance
For a wire rope manufacture, procurement of right raw materials is imperative. Steel
wires , fibre for core, lubricants should be from, preferably, BIS certified sources. If not,
facilities for testing on them on receipt should be established.
Wire drawing and stranding machines , pickling tanks, annealing and lubrication
facilities should be ensured. The wires, if to be supplied after coating, galvanizing
facilities should be established.
The finishing on reels/ drums , preforming etc. should be ensured. The storage facilities
in a covered godown, marking of conforming products, storage of rejected material etc.
shall be ensured
Visual inspection for checking freedom from any defects should be done for each and
every coil received. Chemical testing for lubricant may also be carried out in any outside
laboratory as a verification of the claims of the supplier.
A laboratory shall be maintained, suitably equipped and staffed where different tests
given in the specification shall be carried out in accordance with the methods
specified.
The subjective tests for a wire rope include checking of wires for hardness, dimensions,
construction details, the type and direction of lay, tensile strength, torsion and reverse bend
tests for wires, galvanizing tests on coated wires. The rope shall be checked for visual
checks, freedom from defects, size, mass of rope, preforming, core tensile strength
and joints.
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Grant of Licence - Depending on the successful completion of preliminary visit and
approval by the technical auditor, the samples drawn by him during the processing would
be tested in an independent laboratory. As far as possible the facilities available with the
BIS laboratories shall be utilized for testing the applicant sample. The conformance to
the requirements of the specification indicated by the laboratory testing enables an
applicant to obtain the certification mark licence.
For each type of wire rope, a scheme of testing and Inspection has been established by BIS,
which would have to be agreed and maintained during the process by the licensee. A
written consent is to be obtained before hand in this regard. Whenever an amendment is
issued to the ST& I, the same shall be implemented by the wire rope licensee.
MARKING FEE
A royalty fee for using the standard mark of BIS has to be paid by the wire rope licensee
which varies according to the production of certified quantity during a year. To compute the
fee payable, it is obligatory to furnish quarterly details in a prescribed format by the
licensee to BIS.
A mandatory item for use in mines, any complaint of certified material is to be considered
on priority and actions for preventive measures are to be initiated with detailed
investigation on the nature of complaint . A root cause analysis is to be carried out to
prevent recurrence and also any occurrence later.
If the performance is not satisfactory during the year, BIS would initiate actions to defer/
cancel the licence,, ,pending review, with appropriate actions.
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CERTIFICATE OF TEST
With each coil or reel of completed wire rope the manufacturer shall supply a certificate
of Test as per Annex C of IS 6594 : 2001 Duly certified and signed by the competent
person , this certificate will cover the following :
Certificate No,. Reel/ Coil No., Name and address of the manufacturer, particulars of
rope, grade of rope, date of test, breaking force ( Aggregate/Actual), name and address
of test house making the test and examination, any other details.
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LIST OF VALID LICENCES
( As on 1 Dec 2005)
IS 1855 : 2003 Stranded Steel Wire Ropes For Winding and man-riding Haulages
Mines Specification
17
IS 2266: 2002 Steel Wire ropes for General Engineering Purposes Specification
18
12. 9167287 Usha Martin Ltd,
Dharamshala road,
Hoshiarpur,Punjab
IS 2365: 1977 Specification For Steel Wire suspension Ropes for Lifts, Elevators
And Hoists ( First revision)
IS 2581: 2002 Round Strand Galvanized Steel Wire Ropes For Shipping Purposes
- Specification
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APPROVED LABORATORIES FOR TESTING WIRE ROPES
* Charges for testing Fibre core as per IS 1804 and the lubricant as per IS 6594 will be
extra
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SCHEDULE OF MARKING FEES
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LIST OF INDIAN STANDARDS RELEVANT
TO WIRE ROPE SECTOR
Sl. No IS No & Year Title
6. 1855: 2003 Stranded Steel Wire ropes for Windings and Man
riding Haulages in mines Specification ( Second
revision)
8. 1875: 1978 Carbon steel billets, blooms, slabs and bars for forgings
( Fourth revision)
10. 2266: 2002 Steel Wire ropes for general Engineering Purposes-
Specification ( Fourth Revision)
( Derived from ISO 2408:1975 Steel wire ropes for
general purposes- Characteristics )
11. 2315: 1975 Specification for thimbles for wire ropes ( First
revision)
12. 2363: 1981 Glossary of Terms relating to wire ropes (First revision)
13. 2365: 1977 Specification for Steel wire Suspension ropes for lifts,
escalators and hoists
14. 2581: 2002 Round Strand galvanized steel wire ropes for shipping
purposes- Specification ( Fourth revision)
(derived from ISO/R 346:1963 - Ship building details-
Galvanized Steel wire ropes )
15. 2758: 1969 Specification for mild steel point hooks for use with
wire ropes ( First revision)
16. 2759: 1969 Specification for higher tensile steel point hooks for use
with wire rope thimbles
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17. 2760: 1972 Specification for mild steel chain slings
18. 2762: 1982 Specification for wire rope slings and sling legs
( First revision)
19. 3121: 1981 Rigging screws and stretching screws (First revision)
20. 3815: 1969 Point hooks with shanks for general engineering
purposes
23. 6594: 2001 Technical supply conditions for steel wire ropes and
strands ( Second revision)
25. 13917: 2003 Stranded wire ropes for mine hoisting Technical
Delivery requirements
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MANDATORY CERTIFICATION OF WIRE ROPES
IS 1855 : 2003 Stranded Steel Wire Ropes For Winding and man-riding Haulages
Mines Specification
In accordance with the BIS Rules and ( Certification ) Regulations, the following are to be
notified in the Official Gazette.
While gazette notification for the standard mark and the marking fee rates shall be prepared
by the central marks department the gazette notifications shall be prepared by the individual
Branch office every month, consolidated by CMD and sent for gazetting under the signatures
of Competent authority.
CMD shall maintain a register for recording the details and immediate gazetting .
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