T-NeWs service AND MAiNTeNANce, DISCARD CRIteRIA...

The current version of the German DIN ISO 4309-2013 standard accounts for the types of use of steel wire ropes that have been of significance in recent years and thus supersedes DIN 15020-2:1974.This useful document will be provided to manufacturers, experts, crane operators, and other persons, for the provision of support to those in charge of „Maintenance and Care“ as well as to those in charge of „Inspection and Discard“.

� cable cranes and gantry cranes

� cantilever cranes (pil lar, j ib, wall-mounted, or wall-mounted

traveling cranes)

� deck cranes

� derrick cranes, and guy derrick cranes

� derrick cranes with rigid bracing

� f loating cranes

� mobile cranes

� overhead travell ing cranes

� portal or portal-gantry bridge cranes

� portal or semi-portal cranes

� rail-mounted cranes

� tower cranes

� offshore cranes

This international standard applies to ropes used on cranes for

hooks, grabs, magnets, ladles, buckets or stackers, operated

manually, electrically, or hydraulically.

DISCARD CRIteRIA OFSteeL WIRe ROPeS ISO 4309:2010(e)

service AND MAiNTeNANce,iNsPecTiON AND DiscArD

warningThe use of these products may be hazardous. Therefore, never use our products for purposes other than those they were designed for. Customers must ensure that all persons using these products are familiar with their correct use and the related necessary safety precautions. Please bear in mind that any of these products can cause harm, when they are used incorrectly or overstrained. TEUFELBERGER and 拖飞宝 are internationally registered trademarks of TEUFELBERGER Ges.m.b.H. Austria.

SCOPe

DiSCarD CriTEria

� type and number of wire breaks (see wire break table(s))

� rope category number (RCN) or total number of load-bearing

wires in the rope‘s outer strands

� rope design: regular lay / lang lay

� strand construction

� classification group of the mechanism

� singlelayer, multi layer spooling

� wire breaks at a termination

� wire breaks in strand valleys

� local concentration of wire breaks

� rate of increase of wire breaks

DECrEaSE OF rOPE DiaMETEr

� uniform decrease along the rope

� local decrease, e.g., due to failure of rope core

� fracture of strand

� corrosion: external, internal, or fretting corrosion

DEFOrMaTiOnS anD DaMagE

� waviness

� basket deformation

� core or strand protrusion or distorsion

� loop deformation

� local increase in rope diameter

� flattened portion

� kink or tightened loop

� bends in the rope

� damage due to heat or electric arcs

DISCARD CRIteRIA

02/2

014,

V.1

.0.

T-NeWsiNTerNAl / eXTerNAl

Degree of rope damage, expressed in percent of the discard state. The rating may relate to either a single type of damage such as wire

breaks or a decrease in diameter, or to the combined impact of more than one type of damage, e.g., wire breaks and a decrease in dia-

meter.

SeVeRItY RAtING OF tHe VARIOUS DISCARD CRIteRIA

The actual uniform decrease in diameter, expressed in percent of the nominal diameter, is calculated using the following equation:

[(dref–dgem)/dnom] x 100(%)

dref ........reference diameter

dgem ......measured diameter

dnom.......nominal diameter

Example:

For a 6 x 36 IWRC rope having a diameter of 40 mm and a reference diameter of 41.2 mm (which during the inspection is found to have a

measured diameter of 39.5 mm), the decrease in percent is:

[(41.2 - 39.5)/40] x 100 = 4.25 %

note: The severity rating for uniform decrease in diameter is 20% towards discard (i.e., slight).

Table 5 — Uniform decrease in diameter signalling discard of rope — Rope spooling on a single-layer drum and/or running through a steel sheave

DeCReASe OF ROPe DIAMeteR

TEUFELBErgEr Seil ges.m.b.H., Böhmerwaldstraße 20, 4600 Wels, Austria, T +43 7242 615-0, www.teufelberger.com

DISCARD CRIteRIA OF SteeL WIRe ROPeS ISO 4309:2010(e)

rope typeUniform decrease in diameter

(expressed as % of nominal diameter)

Severity rating

Description %

Single-layer rope with fibre core

Less than 6 %

6 % and over but less than 7 %




10 % and over

—

Slight

Medium

High

Very high

Discard

0

20

40

60

80

100

Single-layer rope with steel core

or parallel-closed rope

Less than 3,5 %

3,5 % and over but less than 4,5 %




7,5 % and over

—

Slight

Medium

High

Very high

Discard

0

20

40

60

80

100

rotation-resistant rope

Less than 1 %





5 % and over

—

Slight

Medium

High

Very high

Discard

0

20

40

60

80

100


Rope Category Number

RCN

Number of load-bearing wires in the

outer strandsn

Number of visibly broken outer wires

Sections of rope working in steel sheaves and/or spooling on single layer drum

Multi layer spooling ongrooved drum

Over a length of 6d

Over a length of 30d

Over a length of 6d


23-1 71 ≤ n ≤ 100 2 4 4 8

23-2 101 ≤ n ≤ 120 3 5 5 10

27 201 ≤ n ≤ 220 4 9 9 18

30 261 ≤ n ≤ 280 6 11 11 32rO

TaTi

On

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iSTE

nT

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PES

n ... number of load-bearing wires in the outer strands d ... nominal rope diameter

RCN OF SPeCIAL teUFeLBeRGeR ROPeS

Design type Diameter range rCn

PERFECTION TK15 7 - 24 23-2

EVOLUTION TK16 9 - 30 23-1

EVOLUTION TK16 32-42 23-2

EVOLUTION TK17 10 - 42 23-2

EVOLUTION TK18 44 - 80 27rO

TaT

iOn

-rE

SiS

Tan

T r

OP

ES


WIRe BReAK tABLeS: eXCeRPt FROM DIN ISO 4309:2013-06

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Rope Category Number

RCN

Total number of load-bearing

wiresin the

outer strands

n

Number of visibly broken outer wires

Sections of rope working in steel sheaves and/or spooling on single layer drum (wire breaks randomly distributed)

Multi layer spooling ongrooved drum

Drive mechanism group classes M1 to M4 or of unknown class All classes

Ordinary lay Langs lay Ordinary lay and Langs lay

Over a length of 6d


Over a length of 6d


Over a length of 6d


02 51 ≤ n ≤ 75 3 6 2 3 6 12

03 76 ≤ n ≤ 100 4 8 2 4 8 16

04 101 ≤ n ≤ 120 5 10 2 5 10 20

05 121 ≤ n ≤ 140 6 11 3 6 12 22

06 141 ≤ n ≤ 160 6 13 3 6 12 26

08 181 ≤ n ≤ 200 8 16 4 8 16 32

09 201 ≤ n ≤ 220 9 18 4 9 18 36

10 221 ≤ n ≤ 240 10 19 5 10 20 38

11 241 ≤ n ≤ 260 10 21 5 10 20 42

13 281 ≤ n ≤ 300 12 24 6 12 24 48

>13 n > 300 0,04 x n 0,08 x n 0,02 x n 0,04 x n 0,08 x n 0,16 x n

n ... number of load-bearing wires in the outer strands d ... nominal rope diameter

iMPOrTanT! When using the wire brake values l isted in the tables, be sure to distinguish between singlelayer or multi layer spooling on

the drum. If a rope section is used in a multi layer spooling configuration, external wear wil l usually be predominant, which is why wire

breaks occur at the rope‘s surface. In this case, the standard allows higher numbers of wire breaks than in cases where the rope is used

in a singlelayer spooling configuration or runs only over pulleys, in which case material fatigue wil l be the predominant type of loading.

ISO 4309 provides a method for the assessment of the cumulated overall state. Whereas use of this method is not mandatory, it is highly

recommendable for safety reasons. With respect to their discard state, wire ropes must always be subjected to a comprehensive evalua-

tion. Since all types of damage in a certain area wil l cause a loss in load-bearing capacity, it wil l make sense to assess the overall state.

Even though individual discard criteria may sti l l be within their acceptable range, the cumulated overall state may already have exceeded

its discard limits.

The frequency of periodical inspections must be defined by a person skil led in the art. In this connection, the following must be taken

into consideration:

� legislation concerning cranes or hoisting equipment in the country of use;

� crane type and ambient conditions in which it is operated;

� classification group of the mechanism;

� result of previous inspection(s);

� empirical values from the inspection of ropes on comparable cranes;

� time period during which the rope was in use;

� frequency of use.

note: person skilled in the art

A person having such knowledge and experience regarding wire ropes on cranes and hoists as is necessary for this person to assess the

condition of the rope, make a judgment as to whether it may remain in service, and stipulate the maximum time interval between inspec-

tions.

This is only a brief summary of what is new in ISO 4309. For more detailed information, we recommend that you read the standard itself.

If necessary, we offer special rope inspection workshops held by our experienced application engineers. For those, please contact your

TEUFELBERGER sales consultant.




PS 610 F 26 - 40 4

PERFECTION F30 10 - 26 4

FSS 2 - 625 F 10 - 22 4

FSS 2 - 619 S 7 - 14 2

EXECUTION K3 20 - 30 8

EXECUTION D6s 30 - 52 6

EXECUTION D6 30 - 52 6

EXECUTION M6 44 - 70 13

EVOLUTION Q8 12 - 50 6

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EVOLUTION Q8 52 - 54 10

Q 810 V 13 - 32 9

PERFECTION M8 38 - 70 13

QS 816 V(G) 10 - 42 9

QS 816 V(G) 44 - 50 11

QS 816 V(G) 52 - 70 >13

QS 808 S 10 3

BS 909 S 11 5

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T-NeWs service AND MAiNTeNANce, DISCARD CRIteRIA...

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