High-performance hoist ropes for

Terex Gottwald Harbour Cranes

 Hoist ropes a crucial component

Hoist ropes are safety-critical crane components

Hoist ropes have significant influence on the operating
costs and availability of a crane
Hoist ropes are a focal point in the eyes of
crane owners

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 Hoist ropes straight from the
crane manufacturer

Key criteria for the choice of hoist ropes: Interesting to know:

High degree of safety To maximise safety, Terex
supplies only ropes with new
Long service life rope sockets and rope pendants
Reusing old parts is out of the
question
As a crane manufacturer, Terex is well placed to
assess the special requirements for hoist ropes
and use that knowledge to choose the best ropes.

Special requirements include:

High cargo handling performance of the cranes
Various kinds of handling jobs, such as bulk
materials or container handling
Maritime environments

With its many decades of experience, Terex can

guarantee the highest degree of safety and rope service
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 Special wire ropes for
Terex Gottwald Harbour Cranes

Exclusively high-performance special wire ropes are used as hoist ropes on

Terex Gottwald Harbour Cranes. These are characterised by:
plastic internal layer between the outer strands and the steel core
compacted outer strands
ordinary lay
eight outer strands
non-rotation-resistant design.

Wire

Plastic internal layer

Compacted outer strands

Core Strands in the core

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 Benefits of special wire ropes vs.
standard wire ropes

Increased safety even in critical situations due to

higher breaking forces at identical rope diameter Wire
Plastic
Reduced abrasion of rope due to 8 outer strands internal layer
(instead of 6 strands)
More robust against mechanical loads and reduced
abrasion due to compacted outer strands
Compacted
Increased stability against rope deformation due to outer strands Core Strands in
the core
plastic internal layer
Reduced internal friction due to lubricant fixed in the
core by plastic internal layer
Reduced abrasion of rope and rope pulleys due to
low and constant rope allowance

Conventional Compacted
strands strands
Significantly longer lifetime of special
wire ropes
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 Special wire ropes for
Terex Gottwald Harbour Cranes

Plastic internal layer between the outer strands and

the steel core Plastic
lining
Consisting of special plastic optimised for the
specific application
Protects the rope core against corrosion
Reduces friction between rope core and
outer strands
Fixes lubricant in the rope core
Counteracts internal wire breaks and birdcaging.

Eight compacted outer strands

Offer high breaking forces and greater flexibility
Make ropes more resistant to abrasion. Conventional Compacted
strands strands

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 Special wire ropes for
Terex Gottwald Harbour Cranes

Non-rotation-resistant design
Right and left lay wire ropes
are fitted as pairs
The contra-rotary torques
balance each other out.

Right lay rope

Left lay rope

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 Regular maintenance
ensures a long service life

Terex hoist ropes are preserved with a lubricants which is specially optimised for
the application and ambient conditions.
The lubricant
reduces friction between the rope and rope pulleys
reduces internal friction between the wires and strands
protects the rope surface against corrosion.
The lubricant stored inside the rope will only last a limited time.
To ensure a long service life, the wire rope must be regularly regreased.
Ensure the lubricant used is compatible with that used by the rope manufacturer.
This maintenance must be performed regularly from the start - do not wait for the
first wire breaks to appear.
Interesting to know:
If the lubricant is reddish or blackish red, this does not mean the rope quality is
diminished.
Discolouration is often caused by the corrosion of metal abraded material or,
after longer periods of storage, through superficial extraneous rust film.
Once the lubricant has been removed, the original and undamaged bright metal
surface becomes visible again.

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 Regular inspections
ensure maximum safety

Wire ropes are wear & tear parts and

have a limited service life

The wire ropes and rope end fittings

must be inspected every day to ensure
maximum safety

In addition, qualified personnel must

examine the wire ropes at regular
intervals to determine if they are in a
safe condition.

All applicable national and local testing

regulations must be observed

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 Possible damage to hoist ropes (I)
Wire breaks
Number of wire breaks
The number of visible wire breaks on the outside along the
most worn section of the rope is a good guide as to when to
discard the rope. Discard the rope if the number of damaged
strands discovered in a length of 6 x the rope diameter or
30 x the rope diameter is equivalent to the discard number
(refer to DIN 15020).
Position of wire breaks
If concentrations of wire breakages are found, or if a Wire
breaks
complete strand is broken, the rope must be replaced
immediately.
Chronological sequence of wire breaks
Wire breaks do not occur proportionately to the time in use. Time in service
They only occur after a certain amount of time in operation
and then occur with increasing frequency.
Decrease in rope diameter
The rope must be discarded if its diameter has decreased by
15% or more due to core wear.
Corrosion and abrasion
The rope must be discarded if its diameter has decreased
10% or more due to corrosion or abrasion.
Abrasion to outer strands
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 Possible damage to hoist ropes (II)

Rope deformation
The rope will have to be discarded if deformation is severe or of a particular type.

Frequent forms of deformation:

Corkscrew deformation Kinking in a wire rope

Unlaying in a wire rope Pinching in a wire rope

Knotting in a wire rope Bending in a wire rope

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 Damage to wire ropes during
transport and in storage

Transport
Avoid physical damage,
e.g. from the forks of a fork-lift truck

Storage
Optimum conditions:
Enclosed storage
Dry, dust-free and cool
Protected against physical damage
Remove any packaging that has become
damp
Under good conditions, hoist ropes can be
stored for up to 4 years.
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 Tailored spare-parts solutions

Wire ropes from Terex are available at short

notice due to careful scheduling.

Terex hoist ropes are configured specially for

each crane individually.

Depending on customers wishes, we supply:

By favourably priced container transport or
Express courier or air freight.

Terex's scope of supply includes:

Special wire ropes from audited rope
manufacturers
New rope sockets and rope pendants
Threading eye already fitted
3.1 rope certificate to EN 12385-1
(Disposable) rope winder.
High-performance hoist ropes
Service options:
Apart from supply, Gottwald is also
pleased to fit the ropes for you
We do this in conjunction with our
worldwide network of service
stations
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 Qualifying process for wire rope
manufacturers

Terex supplies hoist ropes made only by experienced

manufacturers of special wire ropes:
Diepa Drahtseilwerk Dietz, Germany
Verope AG, Switzerland

All suppliers have to be assessed through a qualifying process

This includes:
Evidence of a quality management system to EN ISO 9001

Approval by Terex experts in a supplier audit

Detailed inspections of sample products

Comprehensive practical tests on

Terex Gottwald Habour Cranes.

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 Diepa Drahtseilwerk Dietz

Manufacturer of special wire ropes

Based in Neustadt, near Coburg, Germany

Family firm since 1873

Approx. 390 employees

Certified to ISO 9001:2008

Many years' experience in the development and

manufacture of special wire ropes

OEM supplier to Terex Gottwald Harbour Cranes

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 Verope AG

Manufacturer of special wire ropes

Based in Zug, Switzerland

Founded by Mr. Pierre Verreet

Certified to ISO 9001:2008

Many years' experience in the

development of special wire ropes

Excellent manufacturing capability due to

cooperation with worldwide leading wire
rope manufacturer

OEM supplier to Terex Gottwald Harbour

Cranes

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 Comparison of Diepa and Verope

Rope type: PZ 371 Rope type: Veropro 8

Quality Special wire rope Special wire rope
Terex qualifying process Terex qualifying process passed
passed Quality proven in practical use
Tried-and-tested in Terex
Gottwald Harbour Cranes
over many years

Production In Germany In South Korea

Delivery time Ex works within four working Ex works within four working days
days

Pricing Well balanced value-for- Pricing advantage due to

money manufacturing location and
purchase agreement

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 Summary

High-performance hoist ropes are crucial for high levels of safety and long rope
lifetimes

Terex uses only high quality special wire ropes by Diepa und Verope for both new
cranes and as replacements

Terex hoist ropes are configured specially for each crane individually, including:
Special wire ropes from audited rope manufacturers
New rope sockets and rope pendants
Threading eye already fitted
3.1 rope certificate to EN 12385-1
(Disposable) rope winder.

Terex provides tailored transport solutions

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