On-Site Assessment Report: Lomé Container Terminal S.A. Route A3 D'akodessewa (Zone Portuaire) 09 BP 9103 Lomé, Togo

On-site assessment report
Lomé Container Terminal S.A.

Route A3 d’Akodessewa (Zone Portuaire)
09 BP 9103 Lomé,
1 Togo
06-04-2018
Introduction
On the 9th of January 2018 Vermeulen Europoort was contacted by the TiL Group regarding an issue on
the STS cranes at their location in Lomé, Togo. With this document Vermeulen Europoort offers to
investigate the issues on the location in Lomé and therewith providing the TiL Group with an advice on
installation activities, advice on rope selection , instructions to increase the rope life time and on –site
training.
Since the 1950’s the family business Vermeulen Europoort is active in the supply of steel wire rope, fiber
rope, lifting materials and ship rigging equipment. The specialist knowledge has been transferred from
father to son for already 4 generations now.
Vermeulen Europoort is certified by multiple organizations like, Lloyds, Bureau Veritas etc., for carrying
out inspections, proof loading and repairing of cable configurations and lifting equipment. At multiple
shipyards, container- and bulk unloaders, petrochemical companies and companies within the light- and
heavy industry (on- and off shore) Vermeulen Europoort facilitates the periodical inspection and
maintenance of the cranes, hoists and other lifting equipment.
The following activities are part of the daily business for Vermeulen Europoort:
- Reeving of cranes, bridges and locks

- Periodical inspection of lifting equipment, cranes, bridges and locks
- Certification of lifting equipment and cranes by proof loading with a test-bench, test weights
and/or load cell on-site
- Installation of cable configurations, lifting equipment or other tools
On site inspection
In calendar week 13 Vermeulen Europoort performed a three day on-site inspection at the LCT terminal
located at Lomé, Togo. The inspection was performed following the agenda as displayed below:
Day 1 - Introduction of Vermeulen Europoort

27-03-2018 Presentation on wire rope basics
Discussion with LCT employees
Inspection of wire rope stock
Inspection of wire rope storage
Day 2 - Discussion with LCT maintenance planner

28-03-2018 Inspection of STS crane 07
Watching STS cranes in operation
Day 3 - Inspection of RTG 6

29-03-2018 Discussion with RTG operator
Discussion with STS operator (trainer)
The findings of the on-site inspection are reported within this document.
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Content
Introduction................................................................................................................................................... 2
On site inspection .......................................................................................................................................... 2
Wire rope processes ...................................................................................................................................... 5
1 – Purchasing ............................................................................................................................................... 6
1.1 – Current situation .............................................................................................................................. 6
1.2 – Purchasing – Points of improvement ............................................................................................... 8
2 – Quality control of incoming wire ropes ................................................................................................. 10
2.1 – Current situation ............................................................................................................................ 10
2.2 – Quality control incoming wire ropes – Points of improvement ..................................................... 10
3 – Storage................................................................................................................................................... 11
3.1.1 – Inside storage location ............................................................................................................ 11
3.1.2 – Outside storage location ......................................................................................................... 13
3.2 – Storage – points of improvement................................................................................................... 15
3.3 – Quality of the LCT inventory ............................................................................................................... 16
4 – inspection .............................................................................................................................................. 18
4.2 – Inspection – Points of improvement ............................................................................................. 20
4.2.1 – Additional points of inspection ............................................................................................... 20
4.2.2 – Additional tools for inspection ................................................................................................ 21
4.2.3 – Change the wire rope grease................................................................................................... 22
4.2.4 – inspection intervals ................................................................................................................. 23
4.2.5 – Updated inspection forms ....................................................................................................... 23
5 – Wire rope installation (reeving operations) .......................................................................................... 24
5.2 – Wire rope installation (reeving operations) – Points of improvement .......................................... 26
5.2.1 – Installation drum preparation ................................................................................................. 26
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6 – STS crane 07 inspection ......................................................................................................................... 28
6.1 – Condition of the wire ropes ............................................................................................................ 28
6.2 - Condition of the drums ................................................................................................................... 29
6.3 – Condition of the sheaves ................................................................................................................ 30
6.4 – Condition of the rollers................................................................................................................... 31
6.5 – Condition of the wire rope protection ........................................................................................... 32
7 – RTG 06 inspection .................................................................................................................................. 33
7.1 – Condition of the wire ropes............................................................................................................ 33
7.2 – Condition of the drums................................................................................................................... 33
7.3 – Condition of the sheaves ................................................................................................................ 34
7.4 – RTG problem assessment with operator ........................................................................................ 35
7.4.1 – Possible causes and solutions.................................................................................................. 36
8 – Conclusions and recommendations ...................................................................................................... 37
8.1 – Recommended wire ropes ............................................................................................................. 38
8.1.1 – STS cranes – recommended wire ropes .................................................................................. 38
8.1.2 – RTG cranes – recommended wire ropes ................................................................................. 41
8.2 – Recommended wire rope lubricant................................................................................................ 42
9 – Attachments .......................................................................................................................................... 43
1 – Quality control form – incoming wire ropes ..................................................................................... 43
2 – STS inspection form – Main hoist wires ............................................................................................ 45
3 – STS inspection form – Trolley wire ropes .......................................................................................... 50
4 – STS inspection form – Catenary wire ropes....................................................................................... 55
5 – STS inspection form – Boom wire rope ............................................................................................. 60
6 – RTG inspection form – Wire ropes .................................................................................................... 65
7 – STS 07 inspection report .................................................................................................................... 70
8 – RTG 06 inspection report................................................................................................................... 87
9 – BelRay wire rope lubricant – Data sheet ........................................................................................... 96
10 - Presentation – Vermeulen Europoort & Wire rope basics .............................................................. 111
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Wire rope processes
During the three days of on-site inspections the Vermeulen team discussed, witnessed and/or inspected
multiple processes related to the use of wire ropes on the LCT terminal:
- Purchasing
- Quality control of incoming wire ropes
- Stock and storage
- Wire rope inspection
- Wire rope installation
For each process the current situation, based on the information gathered by the Vermeulen team, will
be described within the following chapters. Recommendations to improve the processes will be included
within the upcoming chapters.
Finally, within the conclusions of this report, Vermeulen will propose wire ropes and an wire rope
lubricant.
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1 – Purchasing
Having a controlled/standardized wire rope purchasing process is of great importance for ensuring a
consistent performance of the LCT operational assets (STS/RTG). When consumables of a consistent
quality are used it is much easier to accurately schedule wire rope changes and prevent LCT from
unnecessary downtime.
1.1 – Current situation

LCT is currently purchasing all their wire rope at CABLERIES NAMUROISES who will supply wire rope in
accordance with the purchase order as provided by LCT.
Purchase orders are created by LCT based on the by KONE/ZPMC provided factory wire rope
specifications, however, both the purchase order and specifications do not contain all information to
ensure orders of consistent quality.
Vermeulen has reviewed the wire rope certificates which are provided with the supply by CABLERIES
NAMUROISES and found that on none of the certificate a wire rope manufacturer is specified, only the
cable suppliers name is specified. Discussion with the LCT employees learned that they where under the
impression that all the cables that where ordered where actually produced by CABLERIES NAMUROISES
which is not the case.
Wire ropes are now ordered based on the type (6x36), diameter and length, which allows the cable
supplier (CABLERIES NAMUROISES) to sell 6x36 wire rope of any manufacturer and quality. For the cable
supplier this provides an opportunity, he can now supply any 6x36 wire rope of a certain diameter and
length. It is likely that the supplier chooses to ship the wire ropes on which he benefits the most, it could
even happen that the supplier ships 6x36 of different brands and qualities in one shipment.
The pictures below show two wire ropes, both 20mm, both 6x36, both the same length and both for the
same application (RTG hoisting wire ropes), but they clearly differ in the type and amount of wire rope
lubricant and color. It could therefor be that the wire ropes are produced by different manufacturers and
therefor of a different quality.
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For LCT this situation is highly undesirable. Wire ropes of different manufacturers and qualities are now
being used in the STS’s and RTG’s, herewith making it hard to create a reliable inspection and
maintenance schedule. In a worst case scenario it could even happen that four different wire ropes are
installed within the hoisting system (spreader) of an RTG. Since all manufactures have their own
production methods and facilities there is a difference between the behavior of one and the other
manufacturer, even when it is the same type of cable (6x36):
- Quality of wires
- Elongation
- Elasticity
- Closing force
- Type of grease
- Surface protection
Due to these differences, problems can occur when wire ropes of a different quality and/or
manufacturer are used in one system, for example spreaders could be unbalanced.
Problems like this where also described by the RTG operator who was interviewed by Vermeulen.
Vermeulen also discovered that the MBL as specified on the ZPMC factory wire rope specifications are
not in accordance with the wire ropes as supplied by CABLERIES NUMUROISES.
Furthermore it is noted that wire ropes are now supplied with no surface protection, this is not ideal,
especially not on sea side locations.
A copy of a typical certificate as received by LCT as part of the delivery of the wire rope, not stating the
wire rope manufacturer and a MBL that is not in accordance with ZPMC specifications:
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1.2 – Purchasing – Points of improvement
Having a consistent quality of wire ropes will lead to the following advantages for LCT:
- Increased expected life time of wire ropes

- More accurate predictions on wire rope lifetimes
- Inspections become more reliable
- All STS’s are equipped with the same wire rope
- All RTG’s are equipped with the same wire rope
In order to achieve a consistent quality of wire ropes Vermeulen advises the following:
Detailed purchase orders

When ordering a wire rope the specification on a purchase order should always consist of the following:
Date: DD-MM-YYYY
Order number: …………………….
Reference to standard EN 12385-4
Quantity: ……………………
Construction: …………………..
Grade: 1770 N/mm2 OR 1960 N/mm2
MBL: …………………….kN
Length: …………………….Meters
Diameter (Nominal) …………………….mm
Lay direction and type: sZ or zS or sS or zZ
Wire finish: Galvanized
Lubrication: …………………….
Preformation: …………………….
Wire rope manufacturer: …………………….
(after discussion and agreement with supplier)
The information as stated above is also the information that you may expect on the wire rope
certificates, when one of the parameters is missing you cannot say anything about the quality with a
100% certainty
Reliable/expert wire rope supplier:

It is of great importance to have a wire rope supplier that can supply wire ropes of a consistent quality
and manufacturer. It is important that your supplier can guarantee that it will always be capable to
deliver the selected wire ropes on time and in a decent manner.
Secondly, your supplier should not only supply you the wire ropes but should also be able to provide you
with guidance and advise about the wire ropes in combination with your applications and equipment.
Furthermore a wire rope supplier that knows what is going on in your facility can help you with the
organization of your wire rope supply. For example the wire rope supplier could already attach labels on
your reeled wire ropes, making it easy to see which wire rope has to go where when unloading the
received container. For a willing supplier this is a small effort, but this can save significant time when
unloading all wire ropes and storing then within the designated storage locations.
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Control on incoming goods:
To ensure a consistent quality of the ordered wire ropes you have to make sure that the quality is in
accordance with your requirements when you receive the wire ropes, chapter 2 will provide more
information about this subject.
Within the current situation at LCT this is of great importance. Since wire ropes of different qualities are
received it is important that wire ropes of the same manufacturer and quality are sorted and stored
together.
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2 – Quality control of incoming wire ropes
To ensure that the incoming wire ropes are in accordance with your requirements, that the quality of the
wire ropes is in accordance with your expectations and that the wire ropes not have been damaged
during transport the control of incoming wire ropes is of great importance.

By discussing with multiple LCT employees Vermeulen Europoort learned that there is currently no
control of the incoming goods. Wire ropes are delivered to LCT per container, the container is unloaded
and the wire ropes are stored on multiple storage locations.
During this process the wire ropes are not checked against the purchase order specifications nor are they
checked on damages. The first time that a wire rope is actually unpacked from its protection is when the
wire rope is required for installation into the STS or RTG, when at this point damage, quality issue, grease
issue or length issues is discovered it is already to late.
The figure below shows 6 reels of wire rope (reels with the blue protection material around the wire
rope) which were delivered to LCT in a wrong length, but this was only discovered when they where
being installed into a crane, a significant period later than they had been received. Since the reels now
already had been stored (outside) for a period of time they could no longer be returned to the wire rope
supplier.
2.2 – Quality control incoming wire ropes – Points of improvement

To prevent issues as described in chapter 2.1 Vermeulen advises to control every each and every ordered
reel of wire rope directly after receipt on the LCT terminal.
Attachment 1 provides a template form that can be used for the quality control of each received reel.
This form can be stored together with the wire rope certificate and a copy on the reel itself.
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3 – Storage
In order to keep wire ropes in a good condition storage is an important aspect to consider.

Currently there are two storage locations for wire ropes at the LCT terminal, one inside location located
within the workshop building, one outside location located at a corner of the LCT premises.
3.1.1 – Inside storage location

The inside storage location offers a limited space for the storage of wire ropes, however the location is
completely indoors and can be fully closed down. Although the space is limited, the storage location is
used for the storage of more than wire ropes only. The wire ropes are located in the far end of the room
and in front of them are big pieces of (broken) glass/windows making the wire ropes hard to reach by
foot and impossible to reach by forklift or any other equipment.
The wire ropes are stored with the reels lying on one of the flanges, reels are than stacked onto each
other. Currently it is hard to identify what rope is stored on what reel, there are no clear markings
attached on the reels and/or wire ropes.
In a conversation with Paterson Simons (LCT sub contractor for wire rope installation) Vermeulen
learned that it sometimes occurs that a cable with al length that is significantly to long (possibly a cable
for a new STS crane) is prepared for installation into a old STS crane. This could be an issue related to the
poor storage control/labeling.
Despite that the storage location is inside the building, due to the climate in which Lomé is located the
inside storage room is still quite hot.
On the next page some pictures are stated in order to display the current status of the inside storage
location.
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3.1.2 – Outside storage location
The outside storage location is located at the corner of the LCT terminal premises and consists of a
facility that is constructed with supporting beams and a roof.
Although the facility has a roof it offers limited protection against environmental elements such as; wind,
rain, sand, salt, heat, wild life. As a result of the limited protection offered by the facility a high level of
deterioration of the reels, protection materials and the wire ropes themselves.
(An indication of the wire rope quality of the wire ropes stored within this location and an advise on how
to proceed with these cables is provided in chapter 3.3 of this document.)
Inspection of the outside storage location learned that where multiple types of cables stored, some of
them dated back to 2014 (Originally supplied by ZPMC with the STS cranes). It is likely that new wire
ropes have already been purchased while there still was wire rope available on stock.
On the next page some pictures are displayed to indicate the current situation at the outdoor storage of
the LCT terminal and to display what the consequences can be if wire rope is not stored properly.
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3.2 – Storage – points of improvement
Storage is important for the preservation of the wire ropes in stock. The ISO 4309 provides some simple
standardized guidelines for storage which should also be applied at the LCT terminal:
“Ropes should be stored in a cool, dry building and should not be allowed to be in contact with the floor.
They should not be stored where they are likely to be affected by chemicals, chemical fumes, steam or
other corrosive agents.
If outdoor storage cannot be avoided, ropes should be covered so that moisture cannot induce corrosion.
Ropes in storage shall be checked periodically for any signs of deterioration such as surface corrosion
and, if deemed necessary by a competent person, dressed with a suitable preservative or lubricant which
is compatible with the rope manufacturing lubricant.
In warm environments, the reel should be periodically rotated one half-turn to prevent drainage of
lubricant from the rope.”
Furthermore Vermeulen advises to:
- Keep the storage facility structured and clean

- Accurately label all reels and wire ropes in accordance with their specifications as stated on the
wire rope certificates (see also chapter 1.2 of this document)
- Always store reels horizontally (Presentation - wire rope handling - attachment 10)
- Store all the wire ropes on one location
- Store in accordance with the first in first out principle
(The wire rope that came first in stock will be the first to be installed within a STS/RTG)
- Store cables for high STS’s, low STS’s and RTG’s on different area’s within the same storage
facility
Consequences ISO 4309 and Vermeulen advice for storage at LCT:

The indoor storage location of LCT is in many points in accordance with the ISO 4309 and the Vermeulen
advices. When all items other than the wire ropes are removed from the location the reels that are
currently stored inside can be stored in a decent and structured way.
In order to achieve this all reels should be clearly labeled and sorted within three category’s:
- RTG
- High STS
- Low STS
Due to the climate in Lomé it is not likely that the wire ropes will be stored in a cool building like the ISO
4309 specifies, therefor it is advised to rotate a coil 180 degrees every 6 months.
The outdoor storage is in it’s current state not a suitable location for the storage of wire ropes, however,
when LCT decides to empty the current facility and install side walls on al sides there is a great space
available for storage of all wire ropes.
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3.3 – Quality of the LCT inventory
During the on-site inspection Vermeulen was asked to take a look at the quality of the current inventory
at the LCT terminal.
At this moment the wire ropes are stored at two locations, one outdoor location and one indoor location
(For more details reference is made to chapter 3.1). Since the inventory of both locations differs a lot an
quality indication of the wire ropes will be provided per location in the section below:
Quality of the wire ropes stored inside:

Although the wire ropes seem to differ from quality and manufacturer (chapter 1) in general we can say
that the wire ropes that could be checked were in a good condition and are ready for use.
Although the condition of the wire ropes is in good order this says nothing about the quality of the wire
ropes. Without knowing by who a wire rope is manufactured it is harder to say anything about a wire
ropes quality, especially when they are coiled and packaged. The wire ropes that could be closely
inspected showed outer wire strands that were closed quite loosely around the wire ropes core, also on
some reels at the wire rope end the core or the wire rope crawled out of the strands indicating a possible
default in the production process.
The indoor stored wire ropes are ready for use but Vermeulen would like to emphasize that LCT should
make sure that cables of the same manufacturer and quality will be installed within a STS or RTG cranes.
When different brands and qualities are installed into a crane this could lead to undesirable behavior of
equipment.
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Quality of the wire ropes stored outside:
The quality of the wire ropes stored outside can be generally stated as bad.
Due to the problems with the outside storage as described in chapter 3 there are currently multiple
problems with the quality of the cables stored within this facility.
Some of the cables seem to be stored at the outside location from 2014 until this the date of this
document. Due to environmental influences (salt water/wind/rain/heat/wildlife) reels are deteriorated
until the point that they can no longer support the weight of the wire rope and protection materials have
been damaged.
Vermeulen advises the following for all wire ropes currently stored within the outdoor facility:
- When a reel shows damages or deterioration reel the wire rope onto a new reel
- if the wire rope is dried out and (light)corrosion occurs due to damaged packaging, clean the
rope section and apply new layer of lubricant.
- Check the complete length of each wire rope on damages and corrosion.
- Place the wire ropes in a inside location.
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4 – inspection
Standardized and efficiently scheduled inspections can provide LCT with the option of planned wire rope
replacement and prevent the terminal from unscheduled down time.
The actual inspections of a STS crane and a RTG by Vermeulen are reported within chapters six and seven
of this document.

During the on-site inspection Vermeulen learned that inspection and replacement of wire ropes is
performed by sub-contractor Paterson Simons who is in all their tasks supported by local LCT personal.
Vermeulen deems Paterson Simons as a knowledgeable partner with a lot of experience in wire rope
installation and maintenance.
Scheduled inspections
Although Paterson Simons is a experienced party they are currently managed by the LCT management
and therefor actions are mostly re-active. For a long time inspections were only carried out after LCT
reported a wire rope related issue, often this will be to late.
After a conversation with the LCT maintenance planner it became clear that since a short period of time
periodic maintenance was scheduled (every 250 running hours), special forms therefor were created,
filed and stored (Forms were only used twice at the moment of the inspection). Standardized periodical
inspection is a step in the right direction, chapter 4.2 provides more information to improve this step
even more.
What is inspected
The inspections that are currently performed by Paterson Simons / LCT are completely focused on the
wire rope itself, other wire rope related components are not part of the inspection.
The wire rope is visually checked on damages and the diameter is measured; sheaves, rollers, drums and
wire rope protection are not part of the inspection and are therefor also not mentioned on the
inspection forms.
The visual inspection of the wire rope is made almost impossible due to the huge amount of grease that
is applied to both the STS and the RTG wire ropes (see pictures on the next page).
Tools for inspection

At this moment the only tool that is used during the inspection of a wire rope is the wire rope inspection
form. There are no special tools for measuring sheave/drum groove radiuses and there was no de-
greaser available during the Vermeulen STS inspection. Especially with the amount of grease that is
currently applied onto the cables a de-greaser is of great importance to be able to check the quality of
the installed wire rope.
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4.2 – Inspection – Points of improvement
A standardized wire rope inspection and inspection schedule can prevent the LCT from unscheduled wire
rope replacements and unscheduled downtime of operational assets.
4.2.1 – Additional points of inspection

As stated in the chapter before the performed inspections are not covering all wire rope related
components, therefor Vermeulen added the following components to the inspection form:
- Sheaves
- Drums
- Rollers
- Wire rope protection (structural damages)
A short explanation on why these components are an important factor to include within the wire rope
inspection is provided below:
Sheaves and drums

Especially in container loading/unloading operations wire ropes run to multiple sheaves. When a groove
of a sheave is worn-out the radius of the groove becomes to small causing deformation and damages to
the installed wire ropes. Furthermore it can occur that the wire rope imprints it’s outer layer pattern into
the sheave which will cause extensive damage to a newly installed wire rope.
During the inspection of STS crane 07 this was something that was (lightly) visible on the sea side
sheaves on the end of the boom (for full STS inspection report and photos reference is made to chapter
6 of this document)
Rollers
Rollers are installed to a crane in order to support the wire rope and prevent the wire rope from hitting
the steel crane structure. When a roller is used for a long time it gets worn out by the wire rope and
creates a groove that causes similar damages as a sheave with a to small groove radius. When a roller is
completely worn out the risk is created that the wire rope will be in direct contact with the steel crane
structure.
During the inspection of STS crane 07 this was something that was visible on some of the rollers installed
(for full STS inspection report and photos reference is made to chapter 6 of this document)
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Wire rope protection (structural damages)
When there are visible damages to the crane structure close to a wire rope this indicates that when the
crane is in operation the wire ropes hits the crane structure. When this is the case the wire rope will get
damaged due to steel to steel contact. When structural damages are noted it is likely that more
protective measures will have to be taken in order to prevent further damages.
During the inspection of STS crane 07 this was something that was visible at the back end of the engine
room (for full STS inspection report and photos reference is made to chapter 6 of this document).
4.2.2 – Additional tools for inspection

In order to be able to perform a adequate wire rope inspection Vermeulen advises to use the following
tools:
Calibrated digital caliper

In order to accurately measure the remaining diameter of the
installed wire rope a calibrated digital caliper is required.
During inspection the measured wire rope diameter can than
be compared to the minimum allowable diameter as stated on
the inspection forms.
Sheave gauges
Vermeulen has included the sheaves and drums to the periodic
inspections, in order to check whether or not the groove radius of a
sheave is still acceptable sheave gauges are required. Sheave gauges
allow to precisely measure the radius of a sheave, during the
inspection the measured radius can be compared with the minimum
and maximum allowable value as stated on the inspection forms.
De-greasing agent
In order to be able to properly inspect the installed wire rope a de-greasing agent is required. During the
inspection the noted amount of wire-breaks can than be compared to the maximum allowable amount
of wire breaks as stated on the inspection form. Especially with the amount of grease that is currently
applied to the wire ropes a de-greasing agent is of great importance (for the advised de-greasing agent
reference is made to chapter X). After inspection an new layer of wire rope lubricant has to be applied to
the inspected wire rope section.
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4.2.3 – Change the wire rope grease
During multiple inspections Vermeulen witnessed a enormous amount of grease applied on wire ropes,
drums and sheaves of both the STS and RTG cranes. The grease applied is thick and sticky and in some
cases completely closes the wire ropes completely, making it almost impossible to inspect.
Wire ropes require a wire lubricant that penetrates the cable in provides a lubrication of not only the
outside of the wire rope but also the inside of the wire rope.
Further investigation learned that the grease that is currently applied is “Total CERAN AD PLUS” which is
a common purpose grease which is used within multiple different heavy industries and has no
penetrating characteristics what so ever.
Although the data sheet states that the grease can be used on steel wire ropes, this type of grease is not
the correct choice for the applications at the LCT terminal.
Using this type of grease not only is not only making wire rope inspections near to impossible but also
causes dangerous situations since walking platforms and hand rails are becoming slippery and unsafe.
Furthermore the grease was even located at the operator cabins herewith blocking his view on the
vessels.
Within chapter 8 of this documents Vermeulen

Proposes a wire rope lubricant that is specially
Designed for the applications and wire ropes
as present on the LCT terminal.
The proposed wire rope lubricant is commonly

used on similar terminals within the Rotterdam
port area and also useable in high temperature
climates.
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4.2.4 – inspection intervals
Vermeulen advises the following inspection intervals when a new wire rope in combination with the
advised wire rope lubricant is installed:
- Daily inspection crane operator/maintenance engineer:

Visual swift inspection of wire ropes and all related components. Findings are communicated to
the technical department which asses whether or not further actions are required.
- Inspection one week after installation:

Full inspection of the newly installed wire rope section in accordance with the prescribed
inspection forms (based on ISO 4309 & 16625).
- First full crane inspection (after 2 Months)

Extensive and full crane in section in accordance with the prescribed inspection forms (based on
ISO 4309 & 16625).
The findings of this inspection determine the intervals for the upcoming inspections. When wire
breaks and damages are detected, the next inspection adjusted shorter period. This period shall
be determined by a competent person. When no findings are reported the next inspection shall
take place after 2 months.
Remark: Boom hoist wires only have to be inspected every 6 months.
4.2.5 – Updated inspection forms

In order to gather standardized information during inspections Vermeulen would like to refer to the ISO
4309 which is specially designed for the maintenance, inspections and discard criteria of wire ropes.
Vermeulen has included the by the ISO 4309 prescribed inspection points and discard criteria into the
updated inspection forms.
Vermeulen has added the inspection of sheaves and drums to the periodical inspections and the
inspection forms. Vermeulen here for uses the ISO norm 16625 which provides guidelines for the
inspection of drums and sheaves. Vermeulen has included the by the ISO 16625 prescribed inspection
points and discard criteria into the updated inspection forms.
LCT already started with the use of inspection forms for periodical inspection, which are now completed
by Vermeulen and are attached to this document:
- Wire rope inspection form - STS Main hoist Attachment 2

- Wire rope inspection form - STS Trolley Attachment 3
- Wire rope inspection form - STS Catenary Attachment 4
- Wire rope inspection form - STS Boom hoist Attachment 5
- Wire rope inspection form - RTG Hoisting wires Attachment 6
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5 – Wire rope installation (reeving operations)
During the on-site inspection at LCT it was unfortunately not possible to witness the reeving/un-reeving
of a wire rope into a STS crane or RTG what makes it hard to provide any improvements related to the
reeving operations.
Despite that a reeving operation could not be witnessed Vermeulen learned about these operations by
dialog and discussion with the personnel of LCT and Paterson Simons.

The installation of wire rope into a STS crane or an RTG is performed by Paterson Simons who is in all it’s
operations supported by LCT personal. During the Vermeulen presentation the following information
was gathered:
Time required for installation of a wire rope:
Main hoist wire rope Trolley wire rope

2 x 8 persons 2 x 8 persons
2 x 12 hours 2 x 12 hours
At first sight this looks like quite some time to reeve a wire into a STS crane, 24 hours of downtime is a
lot, especially when it is unscheduled.
For reference purposes:
A experienced rigging team in the Rotterdam port area can replace a hoisting or trolley wire rope in 12
hours with a team of 6 people.
24
Further discussion learned that the 24 hours includes the preparation of the drum for installation of the
wires into the crane, a short summary of the steps taken when a wire rope has to be replaced is provided
below:
1. LCT informs Paterson Simons that a wire rope has to be replaced (scheduled or unscheduled)
2. LCT takes the correct wire rope from the wire rope storage and reels it onto the installation
drum
(12 hours STS downtime)
3. Paterson Simons uses the by LCT prepared installation drum for reeving the wire rope into the
STS crane
4. STS crane can be taken back into operation
Total STS downtime: 24 hours
The second step of the summary above could completely be removed from the list when LCT would
prepare the wire rope installation drums in an earlier stage. During the site visit multiple installation
drums were seen on the terminal, these could be used for preparation (see 5.2.1)
Furthermore it was understood that the reeving operations are carried out with limited tools and
equipment.
Also, during the inspection of STS crane 07 (for the full inspection report reference is made to chapter 6
of this document) the Vermeulen team noted an enormous amount of grease on all wire rope systems.
This amount of grease will also negatively affect the required time for wire rope installation.
25
5.2 – Wire rope installation (reeving operations) – Points of improvement
Installation of wire ropes into a operational asset is a costly operation, especially on a terminal that is in
operation 24/7; It is important to install the wire ropes as efficient as possible.
5.2.1 – Installation drum preparation

On the previous page it is established that four steps are taken when a rope is replaced, with the
preparation of the installation drum as step 2:
2. LCT takes the correct wire rope from stock and reels it onto the installation drum
(12 hours)
This is a step that, with the necessary attention, can completely be removed from the wire rope
installation sequence.
Off course the preparation of the installation is a step that has to be taken, but it can be done in
advance, before a wire rope needs to be replaced.
Vermeulen advises to keep a installation drum of each wire rope in stock at all times, resulting in the fact
that when a wire rope needs replacement the installation drum is immediately available, reducing the
wire rope installation time (and STS down time) with 12 hours.
When the advise of Vermeulen is followed the following amount of installation drums should always be
prepared and stored:
Amount of Diameter Length

Lay
drums (mm) (m)
New STS crane
Main hoist rope 2 30 683 Right lay
Trolley rope 1 22,4 345 Right lay
boom hoist rope 1 32 1417 Right lay
Catenary rope 1 16 210
Old STS crane

Main hoist rope 2 30 645 Right lay
boom hoist rope 1 32 1330 Right lay
RTG
Hoisting rope 2 20 - Right lay
Hoisting rope 2 20 - Left lay
26
When a installation drum is always available the steps for replacing a wire rope will be in accordance
with the list below:
Preparation:
1. LCT takes the correct wire rope from the wire rope storage and reels it onto the installation
drum.
Wire rope installation:

1. LCT informs Paterson Simons that a wire rope has to be replaced (scheduled or unscheduled)
2. Paterson Simons uses the by LCT prepared installation drum for reeving the wire rope into the
STS crane
3. STS crane can be taken back into operation
Total STS downtime: 12 hours
The required time for installation has now decreased from 24 hours to 12 hours, which according to
Vermeulens expertise is a time you may expect considering the climate, experience, amount of applied
grease and limited amount of tools and equipment.
27
6 – STS crane 07 inspection
This chapter provides a summery of the full inspection of STS crane 07, the full report can be found as
attachment 7 of this document.
6.1 – Condition of the wire ropes
Diameter
The diameter of all installed wire ropes was checked and all were found within the specified bandwidth.
The trolley and hoisting wire ropes were installed only one month ago and therefor a decrease in
diameter was not expected.
Wire breaks and damages

Main hoist wire ropes:
Due to the fact that the wire ropes were only used for a short period of time there were no visible wire
breaks discovered during the inspection.
Besides the relatively new wire ropes the amount of grease applied to all components of the crane it was
near to impossible to check the wire rope for wire breaks or any other damages.
Although the main hoist wire ropes are only one month
old there was already corrosion detected during the
inspection of the crane. The corrosion was occurring at
the point where the wire rope was fixated to the crane
structure as indicated within the figure below. The
corrosion started at the fixed ends (unloaded part) but
was already creeping into the wire rope core and into the
loaded part of the wire rope (see pictures below).
Furthermore there were wire rope clamps mounted onto

the wire rope that were very lose or not fixated at all (see
pictures below).
28
Trolley wire ropes:
Trolley wire ropes were inspected against the ISO criteria and were found, besides the enormous
amount of grease applied, in good order.
Catenary wire ropes:

Catenary wire ropes were inspected against the ISO criteria and were found, besides the enormous
Boom hoist wire rope:

Boom hoist wire ropes were inspected against the ISO criteria and were found, besides the enormous
6.2 - Condition of the drums

All accessible drums where checked on:
- Minimum/maximum groove radium

- Minimum drum diameter
- Correct wire rope lay direction for the drum
Since the cranes are only in operation for four years problems with the drums were not expected, all
grooves are within the allowable bandwidth and the drum diameters are all bigger than the advised
minimum. On all accessible drums a wire rope with the correct lay direction was installed.
Remark: At the drum locations a enormous amount of grease is applied which is a major
problem at all locations in the crane. Grease is found literally everywhere, this is not only
bad for the wire ropes but also causes safety issues since handrails and platforms
become slippery and dangerous (see pictures below).
29
6.3 – Condition of the sheaves
During discussion with the personal of LCT and Peterson Simons Vermeulen learned that the sheaves are
not part of the inspections performed at the LCT terminal, these are now included within the proposed
and attached inspection forms.
In general it can be said that al sheaves are in good order, the grooves are within the prescribed
bandwidths and the diameters are in correspondence with the installed wire rope.
During the inspection of STS crane 07 two sheaves were discovered that showed the first symptoms of
wear. The two sheaves (as indicated on the picture below) started to show a worn in wire rope pattern
and a decreased groove radius.
Remark: Despite the fact that the sheaves seem to be in good order the remark has to be placed
that the enormous amount of grease applied makes it very hard to inspect the wire
ropes and sheaves. Vermeulen is of the opinion that not only to much but also the wrong
type of grease is applied.
Issues like this are exactly the reason why Vermeulen proposed to include the sheaves into the periodical
inspections, worn out sheaves can cause sever damage to installed wire ropes.
30
6.4 – Condition of the rollers
Some of the rollers on STS crane showed already some signs of wear and tear, Vermeulens advise is to
replace rollers in a early stage in order to prevent unnecessary wire rope damages. When a roller is worn
it creates a narrow path in which a wire rope easily damages, in the worst case scenario a roller is
completely worn out and steel to steel contact occurs.
The photos below show some rollers that are starting to show signs of wear.
31
6.5 – Condition of the wire rope protection
During a crane inspection Vermeulen is always looking whether or not there is sufficient protection
between the wire ropes and the crane structure.
During the inspection three critical points related to wire rope protection where discovered:
- Exit point of the main hoist wire ropes out of the machine/drum room (photo below, left) :
At the exit point it was clearly visible that the wire ropes came in direct contact with then steel
engine room walls. When steel to steel contact occurs it is likely that the wire ropes will damage
at the point of contact. Further more the risks of martensite increases due to the steel to steel
contact.
- Steel protection frame with protection material (photo below, middle):

The protection frame should prevent the wire rope from getting damaged, however the bottom
layer of protection material is almost completely worn out and should be replaced in order to
prevent steel to steel contact.
- Support beam on trolley (photo below, right):

The support beam should prevent the wire rope from getting damaged, however the layer of
protection material is almost completely worn out and should be replaced in order to prevent
the wire rope from touching the steel crane structure.
Issues as stated above are the exact reason why Vermeulen advises to include the subject wire rope
protection into the periodical inspections.
32
7 – RTG 06 inspection
This chapter provides a summery of the full inspection of RTG crane 06, the full report can be found as
attachment 8 of this document.
7.1 – Condition of the wire ropes
Diameter
The diameter of all installed wire ropes was checked and all were found within the by the ISO norms
specified bandwidth.
Wire breaks and damages

The amount of grease applied to all components of the crane it was near to impossible to check the wire
rope for wire breaks or any other damages.
During the inspection no wire breaks were detected.
Remark: At all wire ropes locations a enormous amount of grease is applied which is a major
become slippery and dangerous.
7.2 – Condition of the drums

All accessible drums where checked on:
- Minimum/maximum groove radium

- Minimum drum diameter
- Correct wire rope lay direction for the drum
Since the RTG’s are only in operation for four years problems with the drums were not expected, all
grooves are within the allowable bandwidth and the drum diameters are all bigger than the advised
minimum. On all accessible drums a wire rope with the correct lay direction was installed.
Remark: At the drum locations a enormous amount of grease is applied which is a major
become slippery and dangerous (see pictures below).
33
7.3 – Condition of the sheaves
During discussion with the personal of LCT and Peterson Simons Vermeulen learned that the sheaves are
not part of the inspections performed at the LCT terminal, these are now included within the updated
inspection forms.
In general it can be said that al sheaves are in good order, the grooves are within the prescribed
bandwidths and the diameters are in correspondence with the installed wire rope.
During the inspection of STS crane 06 two sheaves were discovered that showed the symptoms of
damaged bearings. The sheaves can be moved diagonally more than they should, you can hear them
moving around.(see indication of sheave location in the picture below). When sheaves bearings are
damaged the sheaves are no longer centered which can lead to damaged wire ropes.
Issues like this are exactly the reason why Vermeulen proposed to include the sheaves into the periodical
inspections, unbalanced sheaves can cause sever damage to installed wire ropes.
34
7.4 – RTG problem assessment with operator
During the inspection of RTG 06 the Vermeulen team had the change to talk to a RTG operator,
Vermeulen learned a lot from this conversation.
Working with the original ropes

The RTG operator had been working on the LCT terminal from the early beginning and could therefor tell
his experiences over the years. The operator emphasized that when he was working with the RTG the
first few months there were no problems with handling the spreader in loaded an unloaded condition,
this was with the wire ropes that had been originally been supplied by Kone cranes. After the
replacement of the original wire ropes problems started to occur .
RTG wire rope problems

The RTG operator specified three major problems related to the wire ropes used in the RTG.
Unbalanced spreader:
According to the operator problems with an unbalanced spreader are according a lot. As stated within
the section above the problem started to occur after the replacement of the wire ropes as originally
supplied by Kone cranes
Bouncy spreader:
A second issue as described by the RTG which occurred after the replacement of the original wire rope is
the high level of up and down movement (bouncing) of the spreader.
Grease:
Just as Vermeulen already indicated within this document before, the operator also pointed out that the
enormous amount of grease on the RTG’s was something that was not originally the case. Grease is
found everywhere, even on the operator cabin herewith blocking the view to the containers.
35
7.4.1 – Possible causes and solutions
Based on the Vermeulen expertise the following possible causes and solutions are provided:
Unbalanced spreader:
As indicated in chapter 1 of this document it is likely that wire ropes of different qualities are being
purchased and used within the LCT terminal.
Each manufacturer has it’s own production method and facility, therefor there is a difference between
the behavior of one and the other manufacturer, even when it is the same type of cable (6x36). Due to
the differences in wire rope characteristics it can be expected that RTG spreaders behave unexpected
when wire ropes of multiple qualities and/or manufactures are installed.
This explanation is supported by the statement of the operator regarding the occurrence of the
problems after the original wire rope had been replaced.
Furthermore Vermeulen expects that old and new wire ropes are used in a RTG simultaneously, for
example when one of the four wire ropes is damaged, only the damaged one will be replaced. Kone
cranes explicitly states the following*:
“
Always Replace All Four Hoist Ropes
The hoist ropes on an RTG crane must always be replaced as a complete set of four new ropes. The
stretch characteristics of the new ropes are not the same as the old ones that have been in use on the
crane for a period of time. This applies, even if the new rope Is supplied from the same original drum as
the old rope.
Never replace just hoist rope, even if only one rope is damaged!
“
Bouncy spreader:
As stated above each wire rope has it’s own characteristics. When the quality of a wire rope is lower
than the wire rope that was originally supplied it is possible that a wire rope is more elastic. This can be
caused by the use of lower grade wire rods during the production or perhaps the wire rope is closed with
lesser force.
Vermeulen would like to emphasizes once more that having a consistent quality of wire ropes is of great
importance.
*Information from document: VOL2_11_R16WA_EN / Rev. 1 / 17.06.2010
36
8 – Conclusions and recommendations
Achieving a longer wire rope lifetime and decreasing the amount of downtime due to wire rope
replacements cannot be achieved by solely looking at the quality of the used wire ropes. It is not
guaranteed that when a wire rope with the highest quality and price, produced by worlds best wire rope
manufacturer, the wire rope lifetime will increase as well; This is also the case at LCT.
Therefor this report has covered all relevant wire rope processes and provides points of improvement for
all these processes. Vermeulen Europoort is confident that the combination of improving the wire rope
processes and using fit for purpose wire ropes will help to extent the lifetime of the wire ropes. and
prevent LCT from any unscheduled downtime.
Furthermore Vermeulen would like to emphasize that it is more than willing to support LCT with their
future wire rope related processes. Vermeulen is used to closely cooperating with clients and customers
in order to ensure reliable operational relationship. When wire ropes are supplied by Vermeulen we are
able to facilitate within the following wire rope processes:
- Purchasing
- Quality control
- Labeling (clearly indicating for which crane a rope should be used)
- Technical support
37
8.1 – Recommended wire ropes
Currently 6x36 common purpose wire ropes of unknown manufactures and qualities are purchased,
installed and used within the operational assets of LCT. Vermeulen is always looking for a fit for purpose
wire rope that fits the clients applications but that also makes sense economically.
It is not always required to change the typology of a wire rope, life time improvements can already be
expected when using a consistent quality.
Vermeulen has specified all recommended wire ropes with a galvanized wire rope finish. Currently this is
not the case at LCT. Especially at sea side locations this is highly recommended.
Based on the three days of on-site inspection and the years of experience of Vermeulen Europoort
hoisting and trolley wire ropes are recommended in the section below.
8.1.1 – STS cranes – recommended wire ropes

Vermeulen Europoort recommends the following wire ropes for the 9 STS cranes at the Lomé Container
Terminal.
Phase 1 – Implementing advises & increasing performance

As a first step to increasing the wire rope lifetime and performance Vermeulen advises to implement all
improvement points as stated within this report. With the current status of the wire rope related
processes and the grease issue, it would be (both economically an operationally) unwise to purchase and
install a more sophisticated wire rope. Vermeulen expects that a consistent and higher quality of 6x36
wire rope (as offered by Vermeulen) and implementation of all points of improvement together will
result in a better wire rope performance.
Main hoisting wire rope:
Manufacturer : Drumet
Construction : 6x36
MBL : 628kN
Grade : 1960 N/mm2
Diameter : 30 mm
Surface protection : Galvanized
When the first phase is completed Vermeulen expects to further optimize the wire rope performance in
the second phase as stated on the following page.
38
Trolley hoisting wire rope:
Construction : 6x36
MBL : 340kN
Grade : 1960 N/mm2
Diameter : 22.4 mm
Catenary wire rope:
Manufacturer : Drumet Drumet

Construction : 6x36 6x36
MBL : 179kN 100kN
Grade : 1960 N/mm2 1960 N/mm2
Diameter : 16 mm 12 mm
Surface protection : Galvanized Galvanized
When the first phase is completed Vermeulen expects to further optimize the wire rope performance in
the second phase as stated on the following page.
39
Phase 2 – Wire rope performance optimization
When Phase 1 is implemented and competed and when the first improvements in wire rope
performance are accomplished Vermeulen and LCT can together try to further optimize the wire rope
life time and performance by changing the wire rope typology.
The reason that this is has not been proposed directly is that Vermeulen expects that it will take some
time to get not only all wire rope related processes in order but also to get the STS cranes a correct
condition to facilitate a more advanced wire rope.
Now that phase 1 is completed, wire rope processes are in order, STS cranes are in optimal condition and
the correct wire rope lubricant is used Vermeulen suggests a main hoist wire rope further optimize the
wire rope performance.
Main hoist wire rope - 6 or 8 strand compacted:

A compacted wire rope offers a number of benefits that are also valid for the container loading/off-
loading industry:
- Higher breaking load

- Higher flexibility
- Better rope- to sheave contact
- Increased resistance to abrasion
- Increased resistance to corrosion (due to outer sealing of the strand)
- Increased resistance to mechanical damages / vibrations
- Increased resistance to shock loading and whipping
- Reduction of mechanical stress on both the rope and the sheave, thus extending the life of both
the sheave and the winch drum.
Which compacted wire rope will be selected can be determined after evaluation and close cooperation
with the client.
40
8.1.2 – RTG cranes – recommended wire ropes
Vermeulen Europoort recommends the following wire ropes for the RTG cranes at the Lomé Container
Terminal.
Having seen the application and the condition of the wire ropes installed within the RTG cranes,
Vermeulen does not think that changing the typology of the wire rope is required to get better wire rope
performance.
When LCT makes sure that wire ropes of a consistent and good quality are purchased and installed, all
four hoisting wire ropes are of the same wire rope manufacturer, all four wire ropes are replaced at
once, the correct type of wire rope lubricant is being applied and inspections are in accordance with the
ISO requirements Vermeulen expects to see a increase of the life time of the RTG wire ropes.
Main hoisting wire rope:
Construction : 6x36
MBL : 279 kN
Grade : 1960 N/mm2
Diameter : 20
41
8.2 – Recommended wire rope lubricant
As stated within this report multiple times LCT currently has a problem with the lubrication of the
installed wire ropes. Although the wire ropes are lubricated regularly it is being done with the wrong
kind of lubrication. The lubricant that is now used at LCT is not actually a lubricant, it is a grease. The
consequences of using this grease are clearly visible on each RTG or STS crane, the grease is literally
everywhere.
As a replacement of the “Total CERAN AD” grease Vermeulen recommends “BelRay wire rope lubricant”
(see attachment 9 for full data sheet)
The BelRay wire rope Lubricant is specially formulated for ropes requiring a penetrating lubricant. Wire
Rope Lubricant Low Viscosity’s penetrating action draws the lubricant to the core, coating the inner
strands, protecting them from rubbing wear and corrosion. Wire Rope Lubricant Low Viscosity exhibits
superior water displacement to provide a positive film, even on wet ropes. The anti-wear and anti-
corrosion properties protect the wire rope inside and out, as well as protecting sheaves and drums.
Vermeulen Europoort is using the BelRay lubricant within their own facility and at the operational assets
of numerous clients within the port of Rotterdam.
The lubricant can easily be applied onto a wire rope by spraying the complete length of the wire rope.
Remark: The BelRay lubricant will have no effect on wire ropes which already have been covered
with the Total CERAN AD grease.
Vermeulen advises that when a new cable has to be installed the complete wire rope
system will be cleaned (drums/sheaves) before the new wire rope is installed. Only then
the BelRay lubricant will positively effect the life time of the new wire ropes.
42
9 – Attachments
1 – Quality control form – incoming wire ropes
43
Lomé Container Terminal - Incoming wire rope inspection
General information:
Date received: ……………………………………………
Reel number: ……………………………………………
Wire rope certificate: ……………………………………………
Ordered diameter: ……………………………………………
Ordered length: ……………………………………………
Ordered construction: …………………………………………… Lay direction:………………………
Wire rope for application: High STS – Low STS – RTG (cross what is not applicable)
--------------------------------------------------------------------------------------------------------------------------
Quality control wire ropes:
Measured diameter: …………………………………
Construction:…………………………………………….
Is the measured diameter in accordance with the ordered diameter?
Yes  Wire rope is ready for storage

No  Contact the wire rope supplier when the measured
diameter is to small
--------------------------------------------------------------------------------------------------------------------------
Is the packaging of the rope in a good condition?

No  Asses if the wire rope at the location of the damaged packaging is
damaged, if so, make pictures and contact your supplier.
--------------------------------------------------------------------------------------------------------------------------
Weight of the supplied reel:……………………………………………
Is the weight of the reel in correspondence with the length (indication)?

No  Contact the supplier to check if the correct length has been supplied
--------------------------------------------------------------------------------------------------------------------------
Roll out the first 10 meter of wire rope, is the wire rope fairly straight when lying on the
floor?
No  Make a picture and contact supplier
2 – STS inspection form – Main hoist wires
45
Lomé Container Terminal Main hoist wire rope
WIRE ROPE INSPECTION

Date: ……………………………………………
Forman: ……………………………………………
Technician: ……………………………………………
STS Crane number : ……………………………………………
A: STS operational hours: …………………………………………… (previous inspection)

B: STS operational hours: …………………………………………… (current inspection)
Hours operated between

inspection: …………………………………………… ( = B - A )
Wire rope information:
Date installed: ……………………………………………

Brand name: ……………………………………………
Construction: ……………………………………………
Grade: ……………………………………………
Lay direction: ……………………………………………
Nominal diameter: ……………………………………………
Length: ……………………………………………
Reference diameter:
(measured before installation) ……………………………………………
Main hoist wire rope

Nominal diameter: 30 mm.
5 6
Amount of wire ropes: 2 (B1 & B2)
6
5
3
3
1
4
1
1
4
1
2
2
2
2
Wire rope diameter measurements
Location B1 B2 % decrease
1 ….…mm ….…mm ……………...%
2 ….…mm ….…mm ……………...%
3 ….…mm ….…mm ……………...%
4 ….…mm ….…mm ……………...%
5 ….…mm ….…mm ……………...%
6 ….…mm ….…mm ……………...%
% Wear Action
Calculation: < 3.5% Very low -
3.5% – 4.5% Slight -
(Dia. Reference* - Dia. Measured) 4.5% – 5.5% Medium -
----------------------------------------------- X 100% 5.5% – 6.5% High Monitor
30 mm 6.5% – 7.5% Very high Monitor
> 7.5% To high Replace rope
* Reference diameter = Measured wire rope diameter before installation, if not available use nominal diameter
(30mm)
Wire breaks
Location Amount of wire breaks on Amount of wire breaks on

180mm rope 900mm rope
B1 B2 B1 B2
1
2
3
4
5
6
Are there more than 9 wire breaks on a length of 180mm?
No  Continue using the rope

Yes  Replace the rope

Wire rope damages
Does the wire rope looks like the pictures below?

Yes  Replace the wire rope
Sheave and drum grooves
OK =
Rmin = 15.75mm
Rmax = 16.50mm
# Radius # Radius # Radius # Radius

1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
Are there radius measurements smaller than 15.75 or bigger than 16.50?
No  Continue using sheave / drum

Yes  Replace the sheave / drum
Condition rollers & wire rope protection
Are there rollers worn-out (Grooves within the rollers)
No  Continue using the roller

Yes  Replace the roller
Is there a risk of wire rope to steel contact?

3 – STS inspection form – Trolley wire ropes
50
Lomé Container Terminal Trolley wire rope

Date: ……………………………………………
Forman: ……………………………………………
Technician: ……………………………………………
STS Crane number : ……………………………………………


inspection: …………………………………………… ( = B - A )
Date installed: ……………………………………………

Brand name: ……………………………………………
Construction: ……………………………………………
Grade: ……………………………………………
Lay direction: ……………………………………………
Length: ……………………………………………
Reference diameter:
Trolley wire rope

Nominal diameter: 22.4 mm. 5
5
Amount of wire ropes: 2 (B1 & B2) 6
1 6
1
4
3
4
3
1 ….…mm ….…mm ……………...%
2 ….…mm ….…mm ……………...%
3 ….…mm ….…mm ……………...%
4 ….…mm ….…mm ……………...%
5 ….…mm ….…mm ……………...%
6 ….…mm ….…mm ……………...%
% Wear Action
Calculation: < 3.5% Very low -
3.5% – 4.5% Slight -
(Dia. Reference* - Dia. Measured) 4.5% – 5.5% Medium -
----------------------------------------------- X 100% 5.5% – 6.5% High Monitor
22,4 mm 6.5% – 7.5% Very high Monitor
(22,4mm)
Wire breaks
Location Amount of wire breaks on Amount of wire breaks on

B1 B2 B1 B2
1
2
3
4
5
6


Wire rope damages

Sheave and drum grooves 9

10
OK =
Rmin = 11.70mm
1
Rmax = 12.30mm
2
7
5
8
6
3
4
# Radius # Radius # Radius

1 5 9
2 6 10
3 7
4 8



4 – STS inspection form – Catenary wire ropes
55
Lomé Container Terminal Catenary wire rope

Date: ……………………………………………
Forman: ……………………………………………
Technician: ……………………………………………
STS Crane number : ……………………………………………


inspection: …………………………………………… ( = B - A )
Date installed: ……………………………………………

Brand name: ……………………………………………
Construction: ……………………………………………
Grade: ……………………………………………
Lay direction: ……………………………………………
Length: ……………………………………………
Reference diameter:
Catenary wire rope

Nominal diameter: B1 & B2 = 12 mm // B3 & B4 = 16 mm 3
Amount of wire ropes: 4 (B1 & B2 B3 & B4) 4 3
4
1 3 4
B1 4
1
3
2
B2
2 2
B3
2
1
1
B4
Location B1 B2 B2 B2
1 ….…mm ….…mm ….…mm ….…mm
2 ….…mm ….…mm ….…mm ….…mm
3 ….…mm ….…mm ….…mm ….…mm
4 ….…mm ….…mm ….…mm ….…mm
Calculation:
% Wear Action
(Dia. Reference* - Dia. Measured) < 3.5% Very low -
----------------------------------------------- X 100% 3.5% – 4.5% Slight -
(B1 & B2 =12mm) OR (B3 & B4 =16mm) 4.5% – 5.5% Medium -
5.5% – 6.5% High Monitor
6.5% – 7.5% Very high Monitor
(B1 & B2 = 12mm) OR (B3 & B4 = 16mm)
Wire breaks
Location 72mm 360mm 96mm 480mm

B1 B2 B1 B2 B3 B4 B3 B4
1
2
3
4
5
6
B1 & B2 are there more than 9 wire breaks on a length of 72mm?




Wire rope damages


OK =
B1 & B2 B3 & B4
Rmin = 6.30mm Rmin = 8.40mm 7
4
8
Rmax = 6.60mm Rmax = 8.80mm
1
1
2
v 5
6
B1 & B2 B3 & B4
# Radius # Radius
1 5
2 6
3 7
4 8
Are there radius measurements for B1 & B2 smaller than 6.30 or bigger than 6.60?
Are there radius measurements for B3 & B4 smaller than 8.40 or bigger than 8.80?



5 – STS inspection form – Boom wire rope
60
Lomé Container Terminal Boom wire rope – Every 6 months

Date: ……………………………………………
Forman: ……………………………………………
Technician: ……………………………………………
STS Crane number : ……………………………………………


inspection: …………………………………………… ( = B - A )
Date installed: ……………………………………………

Brand name: ……………………………………………
Construction: ……………………………………………
Grade: ……………………………………………
Lay direction: ……………………………………………
Length: ……………………………………………
Reference diameter:
Boom hoist wire rope

Amount of wire ropes: 1
10
1 9
12 8
7
2
6
5
4
11 3
1 ….…mm ….…mm ……………...%
2 ….…mm ….…mm ……………...%
3 ….…mm ….…mm ……………...%
4 ….…mm ….…mm ……………...%
5 ….…mm ….…mm ……………...%
6 ….…mm ….…mm ……………...%
7 ….…mm ….…mm ……………...%
8 ….…mm ….…mm ……………...%
9 ….…mm ….…mm ……………...%
10 ….…mm ….…mm ……………...%
11 ….…mm ….…mm ……………...%
12 ….…mm ….…mm ……………...%
Calculation: % Wear Action

(Dia. Reference* - Dia. Measured) < 3.5% Very low -
3.5% – 4.5% Slight -
----------------------------------------------- X 100%
4.5% – 5.5% Medium -
32mm 5.5% – 6.5% High Monitor
(32mm)
Wire breaks
Amount of wire breaks on Amount of wire breaks on

Position Position Position Position
1 7 1 7
2 8 2 8
3 9 3 9
4 10 4 10
5 11 5 11
6 12 6 12


Wire rope damages


11, 12, 13, 14, 15, 16,
OK =
Rmin = 16.8mm
10
Rmax = 17.6mm
1 9
12 8
7
17, 18, 19, 20, 21 6

2 5
4
3
11
# Radius # Radius # Radius # Radius # Radius # Radius

1 5 9 13 17 21
2 6 10 14 18
3 7 11 15 19
4 8 12 16 20



6 – RTG inspection form – Wire ropes
65
Lomé Container Terminal RTG – Wire ropes

Date: ……………………………………………
Forman: ……………………………………………
Technician: ……………………………………………
RTG Crane number : ……………………………………………
A: RTG operational hours: …………………………………………… (previous inspection)

B: RTG operational hours: …………………………………………… (current inspection)

inspection: …………………………………………… ( = B - A )
Date installed: ……………………………………………

Brand name: ……………………………………………
Construction: ……………………………………………
Grade: ……………………………………………
Lay direction: ……………………………………………
Length: ……………………………………………
Reference diameter:
RTG hoist wire rope

Amount of wire ropes: 4
Location Diameter Location Diameter

1 ……...…mm 9 ……...…mm
2 ……...…mm 10 ……...…mm
3 ……...…mm 11 ……...…mm
4 ……...…mm 12 ……...…mm
5 ……...…mm 13 ……...…mm
6 ……...…mm 14 ……...…mm
7 ……...…mm 15 ……...…mm
8 ……...…mm 16 ……...…mm
Calculation: % Wear Action

< 3.5% Very low -
(Dia. Reference* - Dia. Measured) 3.5% – 4.5% Slight -
----------------------------------------------- X 100% 4.5% – 5.5% Medium -
20 mm 5.5% – 6.5% High Monitor
(20mm)
Wire breaks
Amount of wire breaks on Amount of wire breaks on

1 9 1 9
2 10 2 10
3 11 3 11
4 12 4 12
5 13 5 13
6 14 6 14
7 15 7 15
8 16 8 16


Wire rope damages


OK =
Rmin = 10.50mm
Rmax = 11.00mm 18 17
15
16
# Radius # Radius # Radius # Radius # Radius

1 5 9 13 17
2 6 10 14 18
3 7 11 15
4 8 12 16



7 – STS 07 inspection report
70
Visit Report nr: STS 07
Information
Visit at : Lome Container Terminal

Visit on : CW 13
Reason for visit : on site problem assessment
Attendees : Jan Schaap – Adriaan Sluiter – Sander Barnhoorn
The Crane
Type : ZPMC
Lifting Capacity : 75T
Capacity / h :-
Outrigger : 67 meters
Hoisting height : 70 meters
The Reeving System for the trolleys – Boom - hoisting – wire
NAAM : Lome Container terminal – STS 07 Page 1 of 16

REV. : 01
DATUM : CW 13 - 2018
Rope Data Main hoist Trolley Catenary Boom hoist
Rope Diameter : 30 mm 22.4 - 32 mm

Producer : unknown unknown` unknown unknown
Rope Construction : 6X36 6X36 6X36 6X31
Core : IWRC IWRC - IWRC
Hardness : 1910 1770 - -
Wire Surface : - - - -
Lay direction : Right lay Right lay Right lay Right lay
Rope Length : 2x 645 1x 485 1x335 - 1417
Reference diameter : unknown unknown` unknown unknown
Inspection
1. Engine room / Drums
a. Quality of drums
Main hoist drums: Boom hoist drums: trolley drums:
12
11
4 3 2 1
Trolley drums were not
accessible during the
time of the inspection
All inspected drums are in good condition, drums are only four years old, it is not
expected to see any extensive wear.
Remark:
Enormous amount of grease applied on all drums, grease is therefor literally
everywhere in the engine room.

REV. : 01
DATUM : CW 13 - 2018
b. Drum diameter
Drums are in accordance with the minimum drum diameter (ISO 16625)
c. Quality of drum grooves
Main hoist drum grooves should be between:
Rmin = 15.75
Rmax = 16.5
Measured groove radiuses:
1 = 16 3 = 16
2 = 16 4 = 16
All measurements are within the specified bandwidth
Boom hoist drum grooves should be between:
Rmin = 16.8
Rmax = 17.6
11 = 17
12 = 17
d. Correct lay in combination with grooves
On all inspected drums a wire rope with the correct lay direction is installed

REV. : 01
DATUM : CW 13 - 2018
e. Pictures

REV. : 01
DATUM : CW 13 - 2018
2. Wire rope (fill out inspection form)
a. Broken Wires - ISO 4309
Construction: 6x36
Maximum amount of wire breaks =
6*d = 9
30*d = 18

No wire breaks detected during the inspection, wire ropes are only 1 month in
use, wire breaks are to be expected.
Detecting wire rope breaks is almost impossible due to the enormous amount of
grease applied.
Trolley wire ropes:

No wire breaks detected during the inspection.
grease applied.
Boom hoist wire ropes:

grease applied.
Catenary wire ropes:

grease applied.

REV. : 01
DATUM : CW 13 - 2018
b. Diameter decrease - ISO 4309
Maximum decrease = 7.5%
[(dref-dmes)/d(nominal)]*100
Nominal diameter: 30mm

reference diameter: Unknown (30,5 mm has been therefor used within the
calculations, this was the highest measured value)
lowest allowable percentage of decrease: 7.5%
Measured values:
Di a % decr ease
5 30 1. 66%
6 30 1. 66%
7 30 1. 66%
8 30 1. 66%
9 30. 2 1%
10 30. 1 1. 33%
11 30. 1 1. 33%
12 30. 1 1. 33%
13 30. 3 0. 66%
14 30. 5 0%
15 30. 4 0. 3%
16 30. 3 0. 66%
Wire rope is in good condition and the wear can be specified as: very low

REV. : 01
DATUM : CW 13 - 2018
Trolley wire ropes:
Nominal diameter: 22.4mm

reference diameter: Unknown (22,4 mm has been therefor used within the
calculations)
Measured values:
Di a % decr ease
I 22 1. 8%
II 22. 2 0. 9%
III 22. 2 0. 9%
IV 22. 2 0. 9%

REV. : 01
DATUM : CW 13 - 2018
Boom hoist wire rope:
Nominal diameter: 32 mm
reference diameter: Unknown (32 mm has been therefor used within the
calculations)
Measured values:
Di a % decr ease
12 31. 9 0. 3%
11 31. 8 0. 6%
1 31. 8 0. 6%
2 31. 6 1. 25%
3 31. 7 0. 9%
4 32 0
5 31. 8 0. 6%
6 31. 6 1. 25%
7 31. 7 0. 9%
8 32 0
9 31. 6 1. 25%
10 31. 8 0. 8%
c. Construction
Main hoist wire rope: 6x36

Trolley wire rope: 6x36
catenary wire rope: 6x36
boom hoist wire rope: 6xp31
d. Deformation
no deformation was detected

REV. : 01
DATUM : CW 13 - 2018
e. Corrosion
Main hoist cable:
Although the main hoist wire ropes are only

one month old there was already corrosion
detected during the inspection of the crane.
The corrosion was occurring at the point
where the wire rope was fixated to the
crane structure as indicated within the figure
below. The corrosion started at the fixed
ends (unloaded part) but was already
creeping into the wire rope core and into the
loaded part of the wire rope (see pictures below).
Furthermore there were wire rope clamps mounted onto the wire rope that were
very lose or not fixated at all (see pictures below).

REV. : 01
DATUM : CW 13 - 2018
3. Sheaves (Fill out inspection form)
a. Min/max groove radiuses according to ISO 16625)
Main hoist wire rope sheaves:
Groove diameter Ømin 0,525 x 30 x 2 = 31.5 (r=15.75)

Groove diameter Øopt 0,5375 x 30 x 2 = 32.25 (r=16.12)
Groove diameter Ømax 0,550 x 30 x 2 = 33 (r=16.5)
Radi us
5 16
6 16
7 16
8 16
9 16
10 16
11 16
12 16
13 16
14 16
15 16
16 16
All sheaves are within the prescribed bandwidth
General remark: The sheaves are covered in a enormous amount of

grease

REV. : 01
DATUM : CW 13 - 2018
Trolley wire rope sheaves:
Groove diameter Ømin 0,525 x 22.4 x 2 = 23.52 (r=11.76)

Groove diameter Øopt 0,5375 x 22.4 x 2 = 24.08 (r=12.04)
Groove diameter Ømax 0,550 x 22.4 x 2 = 24.64 (r=12.32)
Measured values:
Radi us
I 12
II 12. 5
sheaves are within the prescribed bandwidth, however sheaves I&II show the first
signs of wear and should therefore be inspected more frequently.
Sheave I shows the most signs of wear, also the groove radius has already
decreased with 0.5 mm when compared with sheave II.

grease

REV. : 01
DATUM : CW 13 - 2018
Boom hoist wire rope sheaves:
Groove diameter Ømin 0,525 x 32 x 2 = 33.6 (r=16.8)

Groove diameter Ømax 0,550 x 32 x 2 = 35.2 (r=17.6)
Measured values:
Radi us
1 17
2 17
3 17
4 17
5 17
6 17
7 17
8 17
9 17
10 17
All sheaves are within the prescribed bandwidth

grease (see pictures below)

REV. : 01
DATUM : CW 13 - 2018
4. End connections / sockets
a. Type talurit, welded point, socket, threaded end
Not applicable on LCT cranes
5. Wire rope routing / Wire rope protection
a. Sharp edges
Exit point of the main hoist wire ropes out of the machine/drum room (photo
below).
At the exit point it was clearly visible that the wire ropes came in direct contact
with then steel engine room walls. When steel to steel contact occurs it is likely
that the wire ropes will damage at the point of contact. Further more the risks of
martensite increases due to the steel to steel contact.

REV. : 01
DATUM : CW 13 - 2018
b. Protection
During the inspection two critical points of attention related to protection were
noted:
- Steel protection frame with protection material (photo below, left):
The protection frame should prevent the wire rope from getting damaged,
however the bottom layer of protection material is almost completely worn
out and should be replaced in order to prevent steel to steel contact.
- Support beam on trolley (photo below, right):
The support beam should prevent the wire rope from getting damaged,
however the layer of protection material is almost completely worn out and
should be replaced in order to prevent the wire rope from touching the
steel crane structure.
- Rollers:
Rollers are important for the protection and support of the installed wire
ropes. Some of the installed rollers are starting to show signs of wear.
Rollers should be included within the periodical inspections at the LCT
terminal.

REV. : 01
DATUM : CW 13 - 2018
6. Wire rope installation / optimisations
a. Removal of old wire rope
During the inspection it was noted that the de-installation drums with reeled
old/used wire ropes where still stored within the engine/drum room.
In order to speed up the installation of a new wire rope, these drums should
already have been brought down therewith providing space for the unreeving of a
wire when required.
b. Pictures

REV. : 01
DATUM : CW 13 - 2018
7. Fleet angle
a. At sheaves and drums
There were no abnormalities noted related to the fleet angle from sheaves to
drums.
8. Summery
In general STS crane 07 is in a good condition. However, everything that was
inspected was covered in a enormous layer of grease, this is something LCT
should try to solve.
Within the Vermeulen problem assessment report a wire rope lubricant is

proposed in order to solve this issue.

REV. : 01
DATUM : CW 13 - 2018
8 – RTG 06 inspection report
87
Visit Report nr: RTG 07
Information
Visit at : Lome Container Terminal

Visit on : CW 13
Reason for visit : on site problem assessment
Attendees : Jan Schaap – Adriaan Sluiter – Sander Barnhoorn
The Crane
Lifting Capacity : 40T

Capacity / h :-
Outrigger :-
Hoisting height :-
The Reeving System for the trolleys – hoisting – closing – wire
NAAM : Lome Container terminal – RTG 07 Page 1 of 8

REV. : 01
DATUM : CW 13 - 2018
Rope Data Hoist Hoist
Rope Diameter : 20 mm 20 mm
Rope Construction : 6X36 6x36
Core : IWRC IWRC
Hardness : 1960 1960
Wire Surface : - -
Lay direction : ZS SZ
Rope Length : 114 114
Reference diameter : unknown unknown` unknown unknown
Inspection
1. Engine room / Drums
a. Quality of drums
All drums are in a good condition
Remark:
Enormous amount of grease applied on all
drums, grease is therefor literally everywhere
in the engine room.
b. Drum diameter
Drums are in accordance with the minimum drum diameter (ISO 16625)

REV. : 01
DATUM : CW 13 - 2018
c. Quality of drum grooves
Main hoist drum grooves should be between: 3 4

1 2
Rmin = 10.5
Rmax = 11
1 = 10.5 3 = 10.5
2 = 10.5 4 = 10.5
All measurements are within the specified bandwidth
d. Correct lay in combination with grooves
On all inspected drums a wire rope with the correct lay direction is installed

REV. : 01
DATUM : CW 13 - 2018
e. Pictures

REV. : 01
DATUM : CW 13 - 2018
2. Wire rope (fill out inspection form)
a. Broken Wires - ISO 4309
Construction: 6x36
Maximum amount of wire breaks =
6*d = 9
30*d = 18
Hoist wire ropes:

grease applied.

REV. : 01
DATUM : CW 13 - 2018
b. Diameter decrease - ISO 4309
Maximum decrease = 7.5%
[(dref-dmes)/d(nominal)]*100
Nominal diameter: 20mm

reference diameter: Unknown (20 mm has been therefor used within the
calculations)
Measured values:
Di a % decr ease
1 19. 60 2%
2 19. 30 3. 5%
3 19. 50 2. 5%
4 19. 30 3. 5%
5 19. 60 2%
6 19. 20 4%
7 19. 80 1%
8 19. 30 3. 5%
9 19. 80 1%
10 19. 50 2. 5%
11 19. 80 1%
12 19. 50 2. 5%

REV. : 01
DATUM : CW 13 - 2018
c. Construction
Hoist wire rope: 6x36
d. Deformation
No deformation was detected, deformations are also hard to detect due to the
enormous amount of grease applied.
e. Corrosion
No extensive corrosion was detected during the inspection.
3. Sheaves (Fill out inspection form)
a. Min/max groove radiuses according to ISO 16625)
Main hoist wire rope sheaves:
Groove diameter Ømin 0,525 x 20 x 2 = 21 (r=10.5)

Groove diameter Ømax 0,550 x 20 x 2 = 22 (r=11)
Radi us
5 10. 5
6 11
7 10. 5
8 10. 5
9 10. 5
10 11
11 10. 5
12 10. 75
All sheaves are within the prescribed bandwidth, most of the sheaves are at
the lower limit and should be part of the usual inspection.

grease

REV. : 01
DATUM : CW 13 - 2018
4. End connections / sockets
a. Type talurit, welded point, socket, threaded end
Not applicable on LCT cranes
5. Wire rope routing / Wire rope protection
No abnormalities were noted during the inspection
6. Wire rope installation / optimisations
None
7. Fleet angle
No abnormalities were noted during the inspection
a. At sheaves and drums
There were no abnormalities noted related to the fleet angle from sheaves to
drums.
8. Summery
In general RT crane 06 is in a good condition. However, everything that was
inspected was covered in a enormous layer of grease, his is something LCT
should try to solve.
Within the Vermeulen problem assessment report a wire rope lubricant is

proposed in order to solve this issue.

REV. : 01
DATUM : CW 13 - 2018
9 – BelRay wire rope lubricant – Data sheet
96
SAFETY DATA SHEET
SECTION 1: Identification of the substance/mixture and of the company/undertaking

1.1. Product identifier
Trade name or Wire Rope Lubricant Low Viscosity
designation of the mixture
Product code 66700
SDS number 6977
Registration number -
Synonyms Wire Rope Lubricant
Issue date 14-December-2011
Version number 8,0
Revision date 19-May-2016
Supersedes date 05-April-2016
1.2. Relevant identified uses of the substance or mixture and uses advised against
Identified uses Not available.
Uses advised against None known.
1.3. Details of the supplier of the safety data sheet
Bel-Ray Company, LLC
P.O. Box 526
Farmingdale, NJ 07727
United States of America
+1 732 938 2421
CHEMTREC: 800-424-9300 (USA)
CHEMTREC: +1 703-527-3887 (outside USA - call collect)
Bel-Ray Company, LLC Calumet Sales Company, Inc.

Pa Monument Chemical BVBA
Haven 1972, Ketenislaan 3
B-9130 Kallo (Keildrecht)
Belgium
+32 3 570 25 20
Europe Emergency: 112
customerservice@belray.com
www.belray.com/msds_search
SECTION 2: Hazards identification

2.1. Classification of the substance or mixture
The mixture has been assessed and/or tested for its physical, health and environmental hazards and the following classification
applies.
Classification according to Regulation (EC) No 1272/2008 as amended
Physical hazards
Flammable liquids Category 3 H226 - Flammable liquid and
vapour.
Health hazards
Specific target organ toxicity - repeated Category 1 H372 - Causes damage to organs
exposure through prolonged or repeated
exposure.
Aspiration hazard Category 1 H304 - May be fatal if swallowed
and enters airways.
Material name: Wire Rope Lubricant Low Viscosity SDS EU

66700 Version #: 8,0 Revision date: 19-May-2016 Issue date: 14-December-2011 1 / 14
Hazard summary WARNING
FLAMMABLE LIQUID AND VAPOR.

May be ignited by heat, sparks or flames. May be fatal if swallowed and enters airways. Irritating
to respiratory system. Causes damage to organs through prolonged or repeated exposure.
2.2. Label elements
Label according to Regulation (EC) No. 1272/2008 as amended
Contains: Stoddard solvent
Hazard pictograms
Signal word Danger

Hazard statements
H226 Flammable liquid and vapour.
H304 May be fatal if swallowed and enters airways.
H372 Causes damage to organs through prolonged or repeated exposure.
Precautionary statements
Prevention
P210 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources. No smoking.
P233 Keep container tightly closed.
P240 Ground/bond container and receiving equipment.
P241 Use explosion-proof electrical/ventilating/lighting equipment.
P242 Use only non-sparking tools.
P243 Take precautionary measures against static discharge.
P260 Do not breathe mist or vapour.
P264 Wash thoroughly after handling.
P270 Do not eat, drink or smoke when using this product.
P280 Wear protective gloves/eye protection/face protection.
Response
P301 + P310 IF SWALLOWED: Immediately call a POISON CENTER/doctor.
P331 Do NOT induce vomiting.
P303 + P361 + P353 IF ON SKIN (or hair): Take off immediately all contaminated clothing. Rinse skin with
water/shower.
P314 Get medical advice/attention if you feel unwell.
P370 + P378 In case of fire: Use appropriate media to extinguish.
Storage
P403 + P235 Store in a well-ventilated place. Keep cool.
P405 Store locked up.
Disposal
P501 Dispose of contents/container in accordance with local/regional/national/international regulations.
Supplemental label None.
information
2.3. Other hazards None known.
SECTION 3: Composition/information on ingredients

3.2. Mixtures
General information
Chemical name % CAS-No. / EC REACH Registration No. INDEX No. Notes
No.
Stoddard solvent 30 - < 40 8052-41-3 - 649-345-00-4

232-489-3
Classification: Flam. Liq. 3;H226, Asp. Tox. 1;H304, STOT RE 1;H372 P
1,2,4-Trimethyl benzene 1-<3 95-63-6 - 601-043-00-3 #

202-436-9
Classification: Flam. Liq. 3;H226, Skin Irrit. 2;H315, Eye Irrit. 2;H319, Acute Tox. 4;H332, STOT SE
3;H335, Aquatic Chronic 2;H411
Other components below reportable levels 60 - < 70

List of abbreviations and symbols that may be used above
CLP: Regulation No. 1272/2008.
DSD: Directive 67/548/EEC.
M: M-factor
vPvB: very persistent and very bioaccumulative substance.
PBT: persistent, bioaccumulative and toxic substance.
#: This substance has been assigned Community workplace exposure limit(s).
Composition comments The full text for all R- and H-phrases is displayed in section 16. IP 346: < 3.0% DMSO extract for
all base oil substances.
SECTION 4: First aid measures

General information Take off all contaminated clothing immediately. If you feel unwell, seek medical advice (show the
label where possible). Ensure that medical personnel are aware of the material(s) involved, and
take precautions to protect themselves. Wash contaminated clothing before reuse.
4.1. Description of first aid measures
Inhalation Move to fresh air. Call a physician if symptoms develop or persist.
Skin contact Take off immediately all contaminated clothing. Rinse skin with water/shower. Get medical
attention if irritation develops and persists.
Eye contact Immediately flush eyes with plenty of water for at least 15 minutes. Remove contact lenses, if
present and easy to do. Continue rinsing. Get medical attention if irritation develops and persists.
Ingestion Call a physician or poison control centre immediately. Rinse mouth. Do not induce vomiting. If
vomiting occurs, keep head low so that stomach content doesn't get into the lungs. Never give
liquid to an unconscious person.
4.2. Most important Dizziness. Aspiration may cause pulmonary oedema and pneumonitis. Irritation of eyes and mucous
symptoms and effects, both membranes. Irritation of nose and throat. Skin irritation. Prolonged exposure may cause chronic
acute and delayed effects.
4.3. Indication of any Provide general supportive measures and treat symptomatically. Thermal burns: Flush with water
immediate medical attention immediately. While flushing, remove clothes which do not adhere to affected area. Call an
and special treatment ambulance. Continue flushing during transport to hospital. Symptoms may be delayed.
needed
SECTION 5: Firefighting measures

General fire hazards Flammable liquid and vapour.
5.1. Extinguishing media
Suitable extinguishing Water fog. Foam. Dry chemical powder. Carbon dioxide (CO2).
media
Unsuitable extinguishing Do not use water jet as an extinguisher, as this will spread the fire.
media
5.2. Special hazards arising Vapours may form explosive mixtures with air. Vapours may travel considerable distance to a
from the substance or source of ignition and flash back. During fire, gases hazardous to health may be formed.
mixture
5.3. Advice for firefighters
Special protective Self-contained breathing apparatus and full protective clothing must be worn in case of fire.
equipment for
firefighters
Special fire fighting In case of fire and/or explosion do not breathe fumes. Use standard firefighting procedures and
procedures consider the hazards of other involved materials. Move containers from fire area if you can do so
without risk.
Specific methods Use standard firefighting procedures and consider the hazards of other involved materials.
SECTION 6: Accidental release measures

6.1. Personal precautions, protective equipment and emergency procedures
For non-emergency Keep unnecessary personnel away. Keep people away from and upwind of spill/leak. Keep out of
personnel low areas. Eliminate all ignition sources (no smoking, flares, sparks, or flames in immediate area).
Wear appropriate protective equipment and clothing during clean-up. Do not breathe mist or
vapour. Do not touch damaged containers or spilled material unless wearing appropriate protective
clothing. Ventilate closed spaces before entering them. Local authorities should be advised if
significant spillages cannot be contained. For personal protection, see section 8.
For emergency Keep unnecessary personnel away. Wear appropriate protective equipment and clothing during
responders clean-up.
6.2. Environmental Prevent further leakage or spillage if safe to do so. Avoid discharge into drains, water courses or
precautions onto the ground.

6.3. Methods and material for Eliminate all ignition sources (no smoking, flares, sparks, or flames in immediate area). Take
containment and cleaning up precautionary measures against static discharge. Use only non-sparking tools. Keep combustibles
(wood, paper, oil etc) away from spilled material. This product is miscible in water.
Large Spills: Stop the flow of material, if this is without risk. Dike the spilled material, where this is
possible. Cover with plastic sheet to prevent spreading. Use a non-combustible material like
vermiculite, sand or earth to soak up the product and place into a container for later disposal.
Prevent entry into waterways, sewer, basements or confined areas. Following product recovery,
flush area with water.
Small Spills: Absorb with earth, sand or other non-combustible material and transfer to containers
for later disposal. Wipe up with absorbent material (e.g. cloth, fleece). Clean surface thoroughly to
remove residual contamination.
Never return spills to original containers for re-use.

6.4. Reference to other For personal protection, see section 8. For waste disposal, see section 13 of the SDS.
sections
SECTION 7: Handling and storage

7.1. Precautions for safe Do not handle, store or open near an open flame, sources of heat or sources of ignition. Protect
handling material from direct sunlight. Explosion-proof general and local exhaust ventilation. Take
precautionary measures against static discharges. All equipment used when handling the product
must be grounded. Use non-sparking tools and explosion-proof equipment. Do not breathe mist or
vapour. Avoid prolonged exposure. When using, do not eat, drink or smoke. Wear appropriate
personal protective equipment. Wash hands thoroughly after handling. Observe good industrial
hygiene practices.
7.2. Conditions for safe Store locked up. Keep away from heat, sparks and open flame. Prevent electrostatic charge
storage, including any build-up by using common bonding and grounding techniques. Store in a cool, dry place out of
incompatibilities direct sunlight. Store in original tightly closed container. Store in a well-ventilated place.
Refrigeration recommended. Keep in an area equipped with sprinklers. Store away from
incompatible materials (see Section 10 of the SDS).
7.3. Specific end use(s) Not available.
SECTION 8: Exposure controls/personal protection

8.1. Control parameters
Occupational exposure limits
Austria. MAK List, OEL Ordinance (GwV), BGBl. II, no. 184/2001
Components Type Value
1,2,4-Trimethyl benzene MAK 100 mg/m3

(CAS 95-63-6)
20 ppm
STEL 150 mg/m3
30 ppm
Belgium. Exposure Limit Values.
Components Type Value Form
1,2,4-Trimethyl benzene TWA 100 mg/m3

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), STEL 10 mg/m3 Mist.
Solvent-refined (CAS
64742-01-4)
TWA 5 mg/m3 Mist.
Stoddard solvent (CAS TWA 533 mg/m3
8052-41-3)
100 ppm
Bulgaria. OELs. Regulation No 13 on protection of workers against risks of exposure to chemical agents at work

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), TWA 5 mg/m3
64742-01-4)

Croatia. Dangerous Substance Exposure Limit Values in the Workplace (ELVs), Annexes 1 and 2, Narodne Novine,
13/09
1,2,4-Trimethyl benzene MAC 100 mg/m3
(CAS 95-63-6)
20 ppm
Czech Republic. OELs. Government Decree 361
1,2,4-Trimethyl benzene Ceiling 250 mg/m3

(CAS 95-63-6)
TWA 100 mg/m3
Residual Oils (petroleum), Ceiling 10 mg/m3 Aerosol
64742-01-4)
TWA 5 mg/m3 Aerosol
Denmark. Exposure Limit Values
1,2,4-Trimethyl benzene TLV 100 mg/m3

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), TLV 1 mg/m3 Mist.
64742-01-4)
Stoddard solvent (CAS TLV 145 mg/m3
8052-41-3)
25 ppm
Estonia. OELs. Occupational Exposure Limits of Hazardous Substances. (Annex of Regulation No. 293 of 18
September 2001)
(CAS 95-63-6)
20 ppm
Stoddard solvent (CAS STEL 600 mg/m3
8052-41-3)
100 ppm
TWA 300 mg/m3
50 ppm
Finland. Workplace Exposure Limits

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), TWA 5 mg/m3 Mist.
64742-01-4)
France. Threshold Limit Values (VLEP) for Occupational Exposure to Chemicals in France, INRS ED 984
1,2,4-Trimethyl benzene VLE 250 mg/m3

(CAS 95-63-6)
50 ppm
VME 100 mg/m3
20 ppm
Germany. DFG MAK List (advisory OELs). Commission for the Investigation of Health Hazards of Chemical
Compounds in the Work Area (DFG)
(CAS 95-63-6)
20 ppm

Germany. TRGS 900, Limit Values in the Ambient Air at the Workplace
1,2,4-Trimethyl benzene AGW 100 mg/m3

(CAS 95-63-6)
20 ppm
Greece. OELs (Decree No. 90/1999, as amended)

(CAS 95-63-6)
25 ppm
64742-01-4)
8052-41-3)
125 ppm
TWA 575 mg/m3
100 ppm
Hungary. OELs. Joint Decree on Chemical Safety of Workplaces

(CAS 95-63-6)
Residual Oils (petroleum), Ceiling 5 mg/m3 Mist.
64742-01-4)
Iceland. OELs. Regulation 154/1999 on occupational exposure limits

(CAS 95-63-6)
20 ppm
64742-01-4)
8052-41-3)
25 ppm
Ireland. Occupational Exposure Limits

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), TWA 5 mg/m3 Inhalable fraction.
64742-01-4)
8052-41-3)
100 ppm
Italy. Occupational Exposure Limits

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), TWA 5 mg/m3 Inhalable fraction.
64742-01-4)
Stoddard solvent (CAS TWA 100 ppm
8052-41-3)
Latvia. OELs. Occupational exposure limit values of chemical substances in work environment

(CAS 95-63-6)
20 ppm
Latvia. OELs. Occupational exposure limit values of chemical substances in work environment
Residual Oils (petroleum), TWA 5 mg/m3

64742-01-4)
Lithuania. OELs. Limit Values for Chemical Substances, General Requirements

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), STEL 3 mg/m3 Fume and mist.
64742-01-4)
TWA 1 mg/m3 Fume and mist.
Luxembourg. Binding Occupational exposure limit values (Annex I), Memorial A

(CAS 95-63-6)
20 ppm
Malta. OELs. Occupational Exposure Limit Values (L.N. 227. of Occupational Health and Safety Authority Act (CAP.
424), Schedules I and V)
(CAS 95-63-6)
20 ppm
Netherlands. OELs (binding)
1,2,4-Trimethyl benzene STEL 200 mg/m3

(CAS 95-63-6)
TWA 100 mg/m3
64742-01-4)
Norway. Administrative Norms for Contaminants in the Workplace
Residual Oils (petroleum), TLV 1 mg/m3 Mist.

64742-01-4)
Poland. MACs. Minister of Labour and Social Policy Regarding Maximum Allowable Concentrations and Intensities
in Working Environment
(CAS 95-63-6)
TWA 100 mg/m3
8052-41-3)
TWA 300 mg/m3
Portugal. OELs. Decree-Law n. 290/2001 (Journal of the Republic - 1 Series A, n.266)

(CAS 95-63-6)
20 ppm
Portugal. VLEs. Norm on occupational exposure to chemical agents (NP 1796)
1,2,4-Trimethyl benzene TWA 25 ppm

(CAS 95-63-6)
Residual Oils (petroleum), STEL 10 mg/m3 Aerosol
64742-01-4)
TWA 5 mg/m3 Aerosol

Portugal. VLEs. Norm on occupational exposure to chemical agents (NP 1796)
Stoddard solvent (CAS TWA 100 ppm

8052-41-3)
Romania. OELs. Protection of workers from exposure to chemical agents at the workplace

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), STEL 10 mg/m3
64742-01-4)
TWA 5 mg/m3
8052-41-3)
TWA 700 mg/m3
Slovakia. OELs. Regulation No. 300/2007 concerning protection of health in work with chemical agents

(CAS 95-63-6)
20 ppm
Residual Oils (petroleum), STEL 3 mg/m3 Fume and mist.
64742-01-4)
15 ppm Fume and mist.
8052-41-3)
100 ppm
TWA 300 mg/m3
50 ppm
Slovenia. OELs. Regulations concerning protection of workers against risks due to exposure to chemicals while
working (Official Gazette of the Republic of Slovenia)
(CAS 95-63-6)
20 ppm
Spain. Occupational Exposure Limits

(CAS 95-63-6)
20 ppm
64742-01-4)
TWA 5 mg/m3 Mist.
Sweden. Occupational Exposure Limit Values

(CAS 95-63-6)
35 ppm
TWA 120 mg/m3
25 ppm
64742-01-4)
TWA 1 mg/m3 Mist.
8052-41-3)
50 ppm
TWA 150 mg/m3
25 ppm

Switzerland. SUVA Grenzwerte am Arbeitsplatz

(CAS 95-63-6)
40 ppm
TWA 100 mg/m3
20 ppm
UK. EH40 Workplace Exposure Limits (WELs)

(CAS 95-63-6)
25 ppm
EU. Indicative Exposure Limit Values in Directives 91/322/EEC, 2000/39/EC, 2006/15/EC, 2009/161/EU

(CAS 95-63-6)
20 ppm
Biological limit values
Germany. TRGS 903, BAT List (Biological Limit Values)
Components Value Determinant Specimen Sampling time
1,2,4-Trimethyl benzene 400 mg/g Dimethylbenzo Creatinine in *

(CAS 95-63-6) esäuren urine
(Summe aller
Isomeren nach
Hydrolyse)
* - For sampling details, please see the source document.
Recommended monitoring Follow standard monitoring procedures.
procedures
Derived no effect levels Not available.
(DNELs)
Predicted no effect Not available.

concentrations (PNECs)
8.2. Exposure controls

Appropriate engineering Explosion-proof general and local exhaust ventilation. Good general ventilation (typically 10 air
controls changes per hour) should be used. Ventilation rates should be matched to conditions. If applicable,
use process enclosures, local exhaust ventilation, or other engineering controls to maintain airborne
levels below recommended exposure limits. If exposure limits have not been established, maintain
airborne levels to an acceptable level.
Individual protection measures, such as personal protective equipment
General information Use personal protective equipment as required. Personal protection equipment should be chosen
according to the CEN standards and in discussion with the supplier of the personal protective
equipment.
Eye/face protection Chemical respirator with organic vapour cartridge and full facepiece.
Skin protection
- Hand protection Wear appropriate chemical resistant gloves.
- Other Wear suitable protective clothing. Use of an impervious apron is recommended.
Respiratory protection Chemical respirator with organic vapour cartridge and full facepiece.
Thermal hazards Wear appropriate thermal protective clothing, when necessary.
Hygiene measures When using do not smoke. Always observe good personal hygiene measures, such as washing after
handling the material and before eating, drinking, and/or smoking. Routinely wash work clothing
and protective equipment to remove contaminants.
Environmental exposure Environmental manager must be informed of all major releases.
controls
SECTION 9: Physical and chemical properties

9.1. Information on basic physical and chemical properties
Appearance
Physical state Liquid.

Form Liquid.
Colour Not available.
Odour Not available.
Odour threshold Not available.
pH Not available.
Melting point/freezing point -70 °C (-94 °F) estimated
Initial boiling point and 159 °C (318,2 °F) estimated
boiling range
Flash point 47,0 °C (116,6 °F) Pensky-Martens Closed Cup
Evaporation rate Not available.
Flammability (solid, gas) Not available.
Upper/lower flammability or explosive limits
Flammability limit - lower 0,9 % estimated
(%)
Flammability limit - 6 % estimated
upper (%)
Vapour pressure Not available.
Density 849,00 kg/m3
Vapour density Not available.
Relative density Not available.
Solubility(ies)
Solubility (water) Negligible
Solubility (other) Oil
Partition coefficient Not available.
(n-octanol/water)
Auto-ignition temperature 260 °C (500 °F) estimated
Decomposition temperature Not available.
Viscosity 14,2 cSt
Viscosity temperature 40 °C (104 °F)
Explosive properties Not available.
Oxidising properties Not available.
9.2. Other information
Flash point class Combustible II
Kinematic viscosity 14,2 mm²/s (40 °C (104 °F))
Percent volatile 40 %
Specific gravity 0,85
VOC 40 %
SECTION 10: Stability and reactivity

10.1. Reactivity Strong oxidising agents. The product is stable and non-reactive under normal conditions of use,
storage and transport.
10.2. Chemical stability Risk of ignition.
10.3. Possibility of hazardous No dangerous reaction known under conditions of normal use.
reactions
10.4. Conditions to avoid Avoid heat, sparks, open flames and other ignition sources. Avoid temperatures exceeding the flash
point. Contact with incompatible materials.
10.5. Incompatible materials Strong oxidising agents.
10.6. Hazardous At thermal decomposition temperatures, carbon monoxide and carbon dioxide.
decomposition products
SECTION 11: Toxicological information

General information Occupational exposure to the substance or mixture may cause adverse effects.
Information on likely routes of exposure
Inhalation May cause damage to organs through prolonged or repeated exposure by inhalation. Prolonged
inhalation may be harmful.
Skin contact No adverse effects due to skin contact are expected.

Eye contact Direct contact with eyes may cause temporary irritation.
Ingestion Droplets of the product aspirated into the lungs through ingestion or vomiting may cause a serious
chemical pneumonia.
Symptoms Dizziness. Aspiration may cause pulmonary oedema and pneumonitis. Irritation of eyes and
mucous membranes. Irritation of nose and throat. Skin irritation.
11.1. Information on toxicological effects
Acute toxicity May be fatal if swallowed and enters airways.

Components Species Test results
1,2,4-Trimethyl benzene (CAS 95-63-6)
Acute
Dermal
LD50 Rabbit > 3160 mg/kg
Inhalation
LC50 Rat > 2000 ppm, 48 Hours
Oral
LD50 Rat 6 g/kg
* Estimates for product may be based on additional component data not shown.
Skin corrosion/irritation Based on available data, the classification criteria are not met.
Serious eye damage/eye Based on available data, the classification criteria are not met.
irritation
Respiratory sensitisation Based on available data, the classification criteria are not met.
Skin sensitisation Based on available data, the classification criteria are not met.
Germ cell mutagenicity Based on available data, the classification criteria are not met.
Carcinogenicity Based on available data, the classification criteria are not met.
IARC Monographs. Overall Evaluation of Carcinogenicity
PETROLEUM SOLVENTS (CAS 8052-41-3) 3 Not classifiable as to carcinogenicity to humans.
Reproductive toxicity Based on available data, the classification criteria are not met.
Specific target organ Based on available data, the classification criteria are not met.
toxicity - single exposure
Specific target organ Causes damage to organs through prolonged or repeated exposure.
toxicity - repeated
exposure
Aspiration hazard May be fatal if swallowed and enters airways.
Mixture versus substance No information available.
information
Other information Not available.
SECTION 12: Ecological information

12.1. Toxicity The product is not classified as environmentally hazardous. However, this does not exclude the
possibility that large or frequent spills can have a harmful or damaging effect on the environment.
Components Species Test results
Aquatic
Fish LC50 Fathead minnow (Pimephales promelas) 7,19 - 8,28 mg/l, 96 hours
* Estimates for product may be based on additional component data not shown.
12.2. Persistence and No data is available on the degradability of this product.
degradability
12.3. Bioaccumulative No data available.
potential
Partition coefficient
n-octanol/water (log Kow)
Stoddard solvent 3,16 - 7,15
Bioconcentration factor (BCF) Not available.
12.4. Mobility in soil No data available.

12.5. Results of PBT Not available.
and vPvB
assessment
12.6. Other adverse effects No other adverse environmental effects (e.g. ozone depletion, photochemical ozone creation
potential, endocrine disruption, global warming potential) are expected from this component.
SECTION 13: Disposal considerations

13.1. Waste treatment methods
Residual waste Dispose of in accordance with local regulations. Empty containers or liners may retain some product
residues. This material and its container must be disposed of in a safe manner (see: Disposal
instructions).
Contaminated packaging Empty containers should be taken to an approved waste handling site for recycling or disposal.
Since emptied containers may retain product residue, follow label warnings even after container is
emptied.
EU waste code The Waste code should be assigned in discussion between the user, the producer and the waste
disposal company.
Disposal Collect and reclaim or dispose in sealed containers at licensed waste disposal site. This material and
methods/information its container must be disposed of as hazardous waste. Do not allow this material to drain into
sewers/water supplies. Do not contaminate ponds, waterways or ditches with chemical or used
container. Dispose of contents/container in accordance with local/regional/national/international
regulations.
Special precautions Dispose in accordance with all applicable regulations.
SECTION 14: Transport information

ADR
14.1. UN number UN1268
14.2. UN proper shipping PETROLEUM DISTILLATES, N.O.S. or PETROLEUM PRODUCTS, N.O.S.
name
14.3. Transport hazard class(es)
Class 3
Subsidiary risk -
Label(s) 3
Hazard No. (ADR) 30
Tunnel restriction Not available.
code
14.4. Packing group III
14.5. Environmental No.
hazards
14.6. Special precautions Read safety instructions, SDS and emergency procedures before handling.
for user
RID
name
Class 3
Subsidiary risk -
Label(s) 3
hazards
for user
ADN
14.2. UN proper shipping Petroleum distillates
name
Class 3
Subsidiary risk -
Label(s) 3
hazards

for user
IATA
14.2. UN proper shipping Petroleum products, n.o.s.
name
Class 3
Subsidiary risk -
hazards
ERG Code 3L
for user
Other information
Passenger and cargo Allowed with restrictions.
aircraft
Cargo aircraft only Allowed with restrictions.
IMDG
name
Class 3
Subsidiary risk -
14.5. Environmental hazards
Marine pollutant No.
EmS F-E, S-E
for user
14.7. Transport in bulk Not established.
according to Annex II of
Marpol and the IBC Code
ADN; ADR; IATA; IMDG; RID
SECTION 15: Regulatory information

15.1. Safety, health and environmental regulations/legislation specific for the substance or mixture
EU regulations
Authorisations
Restrictions on use
Regulation (EC) No. 1907/2006, REACH Annex XVII Substances subject to restriction on marketing and use as
amended
Stoddard solvent (CAS 8052-41-3)
Directive 2004/37/EC: on the protection of workers from the risks related to exposure to carcinogens and
mutagens at work
Directive 92/85/EEC: on the safety and health of pregnant workers and workers who have recently given birth or
are breastfeeding

Other EU regulations
Directive 2012/18/EU on major accident hazards involving dangerous substances
Directive 98/24/EC on the protection of the health and safety of workers from the risks related to chemical
agents at work
Directive 94/33/EC on the protection of young people at work
Other regulations The product is classified and labelled in accordance with EC directives or respective national laws
This Safety Data Sheet complies with the requirements of Regulation (EC) No 1907/2006.
National regulations Follow national regulation for work with chemical agents.
15.2. Chemical safety No Chemical Safety Assessment has been carried out.
assessment
International Inventories
Country(s) or region Inventory name On inventory (yes/no)*
Australia Australian Inventory of Chemical Substances (AICS) No
Canada Domestic Substances List (DSL) No
Canada Non-Domestic Substances List (NDSL) No
China Inventory of Existing Chemical Substances in China (IECSC) Yes
Europe European Inventory of Existing Commercial Chemical Substances Yes
(EINECS)
Europe European List of Notified Chemical Substances (ELINCS) No
Japan Inventory of Existing and New Chemical Substances (ENCS) No
Korea Existing Chemicals List (ECL) Yes
New Zealand New Zealand Inventory No
Philippines Philippine Inventory of Chemicals and Chemical Substances Yes
(PICCS)
United States & Puerto Rico Toxic Substances Control Act (TSCA) Inventory Yes
*A "Yes" indicates that all components of this product comply with the inventory requirements administered by the governing country(s)
A "No" indicates that one or more components of the product are not listed or exempt from listing on the inventory administered by the governing
country(s).
SECTION 16: Other information

List of abbreviations Not available.
References Not available.
Information on evaluation The classification for health and environmental hazards is derived by a combination of calculation
method leading to the methods and test data, if available.
classification of mixture
Full text of any H-statements
not written out in full under
Sections 2 to 15 H226 Flammable liquid and vapour.
H304 May be fatal if swallowed and enters airways.
H315 Causes skin irritation.
H319 Causes serious eye irritation.
H332 Harmful if inhaled.
H335 May cause respiratory irritation.
H372 Causes damage to organs through prolonged or repeated exposure.
H411 Toxic to aquatic life with long lasting effects.
Revision information None.
Training information Follow training instructions when handling this material.
Disclaimer Bel-Ray Company, LLC cannot anticipate all conditions under which this information and its product,
or the products of other manufacturers in combination with its product, may be used. It is the
user’s responsibility to ensure safe conditions for handling, storage and disposal of the product, and
to assume liability for loss, injury, damage or expense due to improper use. The information
provided in this Safety Data Sheet is correct to the best of our knowledge, information and belief at
the date of its publication. The information given is designed only as a guidance for safe handling,
use, processing, storage, transportation, disposal and release and is not to be considered a
warranty or quality specification. The information relates only to the specific material designated
and may not be valid for such material used in combination with any other materials or in any
process, unless specified in the text.

10 - Presentation – Vermeulen Europoort & Wire rope basics
111
4/11/2018
Wire Ropes – Lomé container terminal
by:
Who are we?

• Vermeulen Europoort BV, established in 1989 in
the Port of Rotterdam, the Netherlands
• What do we do?
– Steel wire rope supply (whole sale)
– Supply of steel wire rope configurations (client specific)
– Crane inspections
– Reeving / unreeving of cranes
– Inspection and maintenance of Dutch waterworks
– Special projects
1
4/11/2018
• Experience with inspections and problem

assessment in Europe
• Experience with reeving of STS cranes within

Europe
• Support and advice on cable selection
What did we do?
2
4/11/2018
Who do we work with?
Why are we here?

Improvement of the value of the operational assets by:
• Increasing the lifetime of cable configurations (STS/RTG)

– Cable inspection
– Cable selection
– Cable handling
– Cable use
• Decreasing the downtime of STS/RTG cranes that is caused

by replacing steel wire ropes
– Installation- plan, equipment, setup and tools
– Cable handling
– Cable installation
3
4/11/2018
What is the plan?

• Inspect a STS crane in operation
• Inspect a STS crane in idle mode
• Witness the reeving of a STS crane
• Problem assessment on RTG’s
• Deliver a problem analysis, advise on cable

selection and reeving plan
Wire ropes – the basics
4
4/11/2018
Wire rope
Wire
Strand
Rope
Left hand lay
Right hand lay
Langs lay
1) Wire rope core

2) Wire
3) Strand core
4) Strand
5
4/11/2018
Rotation resistant rope
• Rope made of multiple layers

of strands
• Each layer closed in opposite
direction
+ No un-twisting of the rope

+ No rope twist even with great
lifting heights
Compacted wire rope
+ Higher breaking load - More expensive

+ Greater flexibility - Useless for “simple” applications
+ Better rope to sheave contact
+ More abrasion and corrosion resistant
6
4/11/2018
Wire ropes & plastic
• Keeps water/dust out

• Cushion between layers
(reduces internal friction)
• Prevents internal wire break
• Reduces internal stresses
• Shock absorbing
• Seals lubricant
Wire Rope handling
7
4/11/2018
Moving a coil or a reel
Unwinding a coil / reel
8
4/11/2018
Unwinding a coil / reel
Wire rope installation
9
4/11/2018
The correct lay direction for your drum
Installing a rope onto the drum

• A rope has a “preferred
direction”, always check
this!
• Bottom to bottom
• Top to top
10
4/11/2018
Checking the sheaves
D:d ratio
To small ratio causes:
• Loss of strength
• Heavy wear and tear
• Wire rope deformation
* Curve for 6x37
11
4/11/2018
Measuring a cable diameter
Some questions for you
12
4/11/2018
Storage
• Is there any storage of wire ropes?
– Where are wire ropes stored?
– How are wire ropes stored?
– What is currently on stock?
Maintenance
• Maintenance schedule?
• Maintenance instructions?
• Maintenance plan?
• Are the ropes re-lubricated?
– With what lubricant?
13
4/11/2018
Inspection
• Inspection schedule?
• Inspection instructions?
• Inspection frequency?
• Inspection criteria?
• Inspection log?
When is a rope replaced?
• After damage?
• Is there a common place for damages?
• After a certain amount of running hours?
• After a inspection (normal wear and tear)?
• According to a schedule?
• Randomly?
• When is a rope rejected (criteria)?
14
4/11/2018
Reeving / un-reeving
• Is there a reeving plan?
• What equipment is used?
• Own reeving crew or third party?
How long does it take to

replace?
…… Persons …… Persons …… Persons

…… Hours …… Hours …… Hours
15
4/11/2018
What do you recognize?
Thank you for your attention!
16
4/11/2018
• To be completed
17

On-Site Assessment Report: Lomé Container Terminal S.A. Route A3 D'akodessewa (Zone Portuaire) 09 BP 9103 Lomé, Togo

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On-site assessment report

Lomé Container Terminal S.A.

- Reeving of cranes, bridges and locks

Day 1 - Introduction of Vermeulen Europoort

Day 2 - Discussion with LCT maintenance planner

Day 3 - Inspection of RTG 6

1.1 – Current situation

- Increased expected life time of wire ropes

Detailed purchase orders

Reliable/expert wire rope supplier:

2.1 – Current situation

2.2 – Quality control incoming wire ropes – Points of improvement

3.1 – Current situation

3.1.1 – Inside storage location

Furthermore Vermeulen advises to:

- Keep the storage facility structured and clean

Consequences ISO 4309 and Vermeulen advice for storage at LCT:

Quality of the wire ropes stored inside:

4.1 – Current situation

Tools for inspection

4.2.1 – Additional points of inspection

Sheaves and drums

4.2.2 – Additional tools for inspection

Calibrated digital caliper

Within chapter 8 of this documents Vermeulen

The proposed wire rope lubricant is commonly

- Daily inspection crane operator/maintenance engineer:

- Inspection one week after installation:

- First full crane inspection (after 2 Months)

Remark: Boom hoist wires only have to be inspected every 6 months.

4.2.5 – Updated inspection forms

- Wire rope inspection form - STS Main hoist Attachment 2

- Wire rope inspection form - RTG Hoisting wires Attachment 6

5.1 – Current situation

Time required for installation of a wire rope:

Main hoist wire rope Trolley wire rope

For reference purposes:

Total STS downtime: 24 hours

5.2.1 – Installation drum preparation

Amount of Diameter Length

Old STS crane

Wire rope installation:

Total STS downtime: 12 hours

6.1 – Condition of the wire ropes

Wire breaks and damages

Furthermore there were wire rope clamps mounted onto

Catenary wire ropes:

Boom hoist wire rope:

6.2 - Condition of the drums

- Minimum/maximum groove radium

- Steel protection frame with protection material (photo below, middle):

- Support beam on trolley (photo below, right):

7.1 – Condition of the wire ropes

Wire breaks and damages

During the inspection no wire breaks were detected.

7.2 – Condition of the drums

- Minimum/maximum groove radium

Working with the original ropes

RTG wire rope problems