INSTRUCTIONS FOR HANDLING & USE OF SYNTHETIC ROPES
FOR THE TROUBLEFREE & LONGER SERVICE LIFE OF THE SYNTHETIC ROPES THE BELOW MENTIONED CONDITIONS / INSTRUCTIONS MUST BE FOLLOWED:
Maximum working load (WLL): the maximum load that the rope must operate, depending on the conditions of use, must not exceed the 20% of the minimum breaking load of the rope for a design factor of 1:5. For critical applications, the design factor can reach 1:12 and
The WLL will be reduced accordingly.
Avoid overloading over the above maximum working load
Inspect full length regularly and operating length before and after each use
Do not suspend loads or subject the rope to pressure (crushing forces) for a long period of time, it will cause permanent deformation (creep)
Care must be taken so that twist is not induced in the rope during its service life as there is a reduction in the strength of 5-10% (depending on construction & material) per turn per meter
Keep rope clean-imbedded dirt is abrasive on fibers ("sandpaper" effect) and will speed up the wear
Distribute the wear - reverse occasionally from time to time so that the outer spliced part comes in and vice versa
If a rope part gets damaged, cut out this section and splice the rest good (uninjured) part
Avoid kinks - sharp angles, shock and dynamic loads and the combination of friction and high loads
Avoid unnecessary wear - winch drums, pulley sheaves etc. Should be smooth; don't drag rope over rough surfaces
Know the working limit (WLL) of your rope
Use only rope in good condition, without cuts, kinks, knots, or pulled out strands
Knots reduce ropes' strength by up to 50%. Make a splice instead of a knot
The maximum working load of the rope is voided if shock and dynamic loads are applied on the rope
Do not bend over angled parts, corners and sharp edges or use over rough surfaces without sheaves or chafe protection
Do not stand within recoil (snapback) area should rope or attachment break - death or limb can occur
Do not use over sheaves or around surfaces with less than a 5:1 d/d (bend) ratio
For hoisting operations, where protection of life is paramount, a factor of safety of at least 1:12 for a new rope must be used
Never use a swivel in a synthetic line under heavy load, loss of turn will cause permanent damage/deformation to the rope
Train the personnel that works with the ropes
Normal working conditions are the use under the conditions of moderate dynamic loading, not over the maximum working load. That means that the load has to be handled slowly and steadily for the minimization of the dynamic effects. The loads over the WLL
Will have to be considered as shock loads, which can overstress and destroy the yarns, and contribute in the early damage of the rope even when handling loads under the WLL.
The loads applied to the rope must never be over the working load limit (WLL or SWL).
For applications where the WLL has not been determined or a successful experience record is not available for the type and size of rope used, the following variables should be considered in determining the design factor (1:5 up to 1:12)
Loading conditions and/or exposure to Dynamic Loading:
Downsizing of larger diameter ropes to a smaller rope
Loads are not accurately known
High-level shock loads, extreme dynamic or high cyclic loads are likely to occur
Tension is on the rope for long periods
Knots are used, reducing strength up to 50%
Experience of or guidance available to users:
Operators are poorly trained
Operation/use procedures are not well defined and/or controlled
Conditions of use:
Inspection of rope/attachments is infrequent
Abrasion, cutting surfaces and dirt is present
Ropes kept in service for long periods may develop fatigue
Ropes will be subject to sharp bends, or used over pulleys or surfaces with too small a radius
Environmental considerations:
Temperatures higher than fiber limits are present
Hazardous chemicals are present - Fiber resistance to chemicals must be considered
Death, injury or loss of valuable property may result if rope fails
Below you will find some of the reasons for which the condition of the rope will have to be re-evaluated before using it again and you must either cut & splice the part that shows the large localised wear (internally or externally) or the pulled-out strand or the melting due to increased temperature caused from friction against a metal surface under load or the rope to be degraded and used afterwards in a less demanding application or to be retired and withdrawn from further use and be destroyed/recycled according tothe local legislation or the corporate or other regulations on handling end of life products.
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