,*,

Indian Standard
TECHNICAL SUPPLY CONDITIONS FOR
STEEL WIRE ROPES AND STRANDS
(Second Revision )
ICS77.140.65
.
.
0 BIS2001
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI I 10002
.&celnlwr 2001
Price Group7
Wire Ropes and Wire Products Sectional Committee, MEl O
FOREWORD
This Indian Standard ( Second Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Wire Ropes and Wire Products Sectional Committee had been approved by the Mechanical Engineering
Division Council.
This standard was first issued in 1972 and revised in 1977. The experience gained in the use of this standard since
its first revision necessitated the present revision. The following are the major changes:
a) Scope has been modified by keeping out the round and flattened strand ropes used for the purpose of
mine hoisting (winding ropes) since IS 13917: 1994/1S0 3154: 1988 Stranded wire ropes for mine
hoisting Technical delivery req.uirements has been published;
b) Definitions for some more terms have been added;
c) Type of rope construction has been clearly explained;
d) Symbolic representation for strand, rope and core has been introduced; and
e) Provision for in house testing of wire rope for breaking force test on completed rope if specified by the
purchaser is added.
Connecting symbols for strand, rope and core are given in Annex D. Details to be furnished with enquiry or
order and information to be given by the manufacturers are given in Annex E and F respectively.
The advantages of parallel or equal lay ropes are that they are more compact compared to cross lay ropes and
have higher breaking force to approximately 10 percent. Since the wires are laid in strands in single lay,
secondary bending/nicking effect of wires in the intermediate layers are practically absent. Also parallel lay ropes
are more resistive to abrasion since outer wire diameter is higher compared to cross lay ropes.
In preparation of this standard assistance has been derived from ISO 2408-1973 Steel wire ropes for general
puWoses Characteristics issued by the International Organization for Standardization (1S0).
The composition of the committee responsible for formulation of this standard is given in Annex G.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2: 1960 Rules for rounding off numerical values (revised). The number of significant places retained in
the rounded off value should be the same as that of the specified value in this standard.
.-
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TECHNICA1
1S 6594:2001
Indian Standard
. SUPPLY CONDITIONS FOR
STEEL WIRE ROPES AND STRANDS
(Second Revision)
1 SCOPE
This standard lays down the technical supply
conditions for steel wire ropes ofround strand, flattened
strand and multi-strand rotation resistant types in
ordinary or Langs lay construction. It also includes
Locked coil wire ropes. Ropes of round strand and
flattened strand types used for hoisting purposes in
mines (winding and man riding haulages) are not
covered by this standard.
2 REFERENCES
The following standards contain provisions, which
through reference in this text constitute provision of
this standard. At the time of publication, the editions
indicated were valid. All standards are subject to
revision, and parties to agreements based on this
standard are encouraged to investigate the possibility
of applying the most recent editions of the standards
indicated below:
IS No.
1608:1995
1716:1985
1717:1985
1804:1996
1835:1976
2363:1981
2633:1986
6745:1972
9182
(Part 1): 1993
(Palt2) :1993
Title
Mechanical testing of metals-tensile
testing (second revision)
Method for reverse bend test for
metallic wire (second revision)
Method for simple torsion testing for
wire (second revision)
Steel wire ropes-fibre main cores
(third revision)
Round steel wire for ropes (third
revision)
Glossary of terms relating to wire
ropes @rst revision)
Methods for testing for the
uniformity of coating on zinc coated
articles (second revision)
Method for determination of mass of
zinc coating on iron and steel articles
Specification for lubricants for wire
ropes and fibre cores:
Lubricants for fibre core of wire ropes
(first revision)
Lubricants for wire strands and ropes
(second revision)
3 TERMINOLOGY
For the purpose of this standard, the definitions given
in IS 2363, in addition to the following shall apply.
3.1 Wire
3.1.1 Tensile Designation
A level of requirement of tensile strength which is
designated by the minimum value of the appropriate
range of tensile strength in N/mmz.
3.1.2 Actual Tensile Strength
The value obtained when dividing the maximum force
achieved during a tensile test by the nominal cross-
sectional metallic area of the wire.
3.2 Rope
3.2.1 Fill Factor
The ratio between the sum of the nominal metallic
cross-sectional areas of all the wires in the rope and
the area of the rope circle (circumscribing the outer
strands of the rope) based on its nominal diameter.
3.2.2 Metallic Cross-Sectional Area Factor
Factor derived by multiplying fill factor with n/4.
3.2.3 Rope Grade
A level of requirement of breaking force which is
designated by a number like 1570,1770, 1960, etc.
NOTE h does not imply that the actual tensile designa-
tion of wires in the rope are necessarily of such grade.
3.2.4 Spinning Loss Factor
The ratio between the minimum breaking force of the
rope to the calculated minimum aggregate breaking
force of the rope.
3.2.5 Breaking Force of Rope
3.2.5.1 Minimum breaking force
The tensile force below, which a sample of the wire
rope shall not fracture when, tested to destruction in
the prescribed manner.
NOTE The value is calculated from the product of the
square of the nominal diameter of the rope, the rope grade
and the breaking force factor appropriate to the construc-
tion of the rope.
1
1S 6594:2001
3.2.5.2 Calculated minimum breaking force
Design value obtained by calculation from the sum of
the product of cross-sectional metallic area of each wire
based on its nominal diameter and its respective tensile
designation and a spinnhg loss factor appropriate to
the rope construction.
3.2.5.3 Actual breaking force
The maximum tensile force obtained by testing a sample
of the rope to destruction in the prescribed manner.
3.2.5.4 Calculated actual breaking force
The value obtained by multiplying the sum of the
breaking force of all the individual wires removed from
the rope with the partial spinning loss factor obtained
from the results of type testing.
NOTE The results of type testing and the derivation of
partial spinning loss factor based on the results obtained
through 3.2.5.3 and 3.2.5.6 shall form part of
manufacturers technical tile.
3.2.5.5 Minimum aggregate breaking force
The value of aggregate breaking force obtained from
the product of the square of the nominal rope diameter,
the metalIic cross-sectional area factor appropriate to
the construction of rope and the rope grade.
3.2.5.6 Calculated minimum aggregate breaking force
The design value obtained fi-omthe sum of the products
of the cross-sectional metallic area (based on the
nominal wire diameter) and the tensile designation of
each wire in the rope.
3.2.5.7 Measured (actua/) aggregate breaking force
The value obtained by adding together the breaking
forces of all the individual wires removed fi-om a rope.
3.2.5.8 Relation between minimum breaking force and
the minimum aggregate breaking force
The minimum aggregate breaking force can be obtained
by multiplying the minimum breaking force of the rope
by the factor shown in the notes of the breaking force
and mass tables in the relevant specification,
NOTE Terminology given in clauses 3.2.1, 3.2.2, 3.2.4
and 3.2.5.4 are for guidance only.
4 MATERIAL
4.1 Wire
The wire ropes shall be manufactured with wires made
from steel having chemical composition to Grades 1,2,
3and40f1S 1835.
4.1.1 Tensile Designation of Wires
The tensile designation of wires shall be selected by
manufacturer as recommended in IS 1835 for round wires
so that the minimum breaking force for the designated
rope grade is achieved.
4.1.1.1 The various wire properties as recommended in
IS 1835 shall be determined for the tensile designation
of wire selected by the manufacturer.
4.1.1.2 All wires of the same nominal diameter in the
same layer of a rope construction shall be of same
tensile designation.
4.1.1.3 The tensile designation of any group of wires
shall not be more than one grade higher or lower than
the designated rope grade.
NOTE For example, if the rope grade is 1770, the tensile
designation of any particular group of wires in the rope
construction may be 1570or 1960.
4.1.1.4 The core wires in the strand, filler wires and wires
forming steel main core shall be of any tensile designation
as specified in IS 1835 provided it shall not exceed the
tensile designation of the main wires in the rope.
4.1.1.5 The triangular core wires used in flattened
strand rope shall have a minimum tensile strength of
785 N/mm2.
5 SIZE
The size of the rope shall be expressed in terms of
nominal diameter and shall be one of those as given
in relevant wire rope specification.
5.1 Permissible Variation
The diameter of the rope as supplied, when measured
before tensioning in the manner described in Annex A
shall be within the limits specified in the relevant wire
rope specification. However in case of a dispute as to
compliance of the rope with maximum permissible
diameter, the wire rope shall be put under tension equal
to not less than 5 percent and not more than 8 percent
of the minimum breaking force of the rope in question.
If the rope diameter under this condition is within the
permissible limit, the rope shall be deemed to have
conformed to the relevant specification.
5.2 Permissible Ovality
The measurements for ovality (out-of-roundness) shall
be taken in accordance with Annex A. The maximum
variation between any of the four measurements shall
not exceed the values given below:
Nominal
Permissible Ovality on Nominal
Rope
Rope Diameter in Percent
Diameter
(mm)
Ropes with Ropes with
Strands Strands :
Exclusively of Having Fibre
Wires Core ~
2 and 3 7

4 and 5 6

6 and 7 5
8 and above 4 6
2
6 GENERAL REQUIREMENTS
6.1 The strand/rope designation is done through
symbols for some of its key features. Those are
described in 6.3.3, Table 1, Table 2, and in Annex D.
NOTE General requirement given in 6.1 is for guidance
only.
6.2 Construction
Rope/strand construction shall be any one of the
following types:
a) Equal lay or parallel lay construction,
b) Cross lay construction, and
c) Contra lay construction.
6.2.1 In equal lay or parallel lay construction all the
wires in the strand are laid in the same direction in one
operation. The lay length at all the layers remains same
and the wires of any two superimposed layers are
parallel to one another resulting line contact.
6.2.2 In cross lay construction wires in the strand are
laid in the same direction in multiple operations. The
wires of the superimposed wire layers cross one another
making point contact.
6.2.3 In contra lay construction wires in the strand at
different layers (or at least the outermost layer of wires)
are laid in opposite direction.
6.3 Core
The central or main core of the rope shall be of a size
sufficient to give full support to the strands and shall
be of fibre or wire construction as may be specified by
the purchaser.
6.3.1 Fibre Core
The fibre core shall conform to IS 1804.
6.3.2 Steel Core
The steel core shall normally bean independent wire
rope. For wire ropes of 12 mm diameter or smaller, wire
strand core may be employed. For wire ropes of 13 mm
diameter or more, the core shall be an independent wire
rope, unless otherwise agreed to between the purchaser
and the manufacturer or if the specification to which
the rope conforms demands otherwise. In case of multi-
strand rotation resistant ropes of all sizes, the core shall
be a wire strand.
6.3.2.1 The construction of the wire strand core shall
be the same as that of the outer strands. The direction
of lay of wire strand core shall be the same as that of
the outer strands. The construction of independent
wire rope core shall be generall y 7 x 7. Other construc-
tions for independent wire rope core may also be
permitted if so agreed between the purchaser and the
IS 6594:2001
manufacturer. The independent wire rope core for
ordinary lay wire ropes shall be of Langs lay whereas
for Langs lay wire ropes, the independent wire rope
cores shall be of ordinary lay.
6.3.3 The symbols for the elements of core are shown
below:
Symbols indicating elements of core
Element Symbol
Core c
a) Fibre F
i) Natural fibre FN
ii) Man made (synthetic) Fibre FS
b) Steel core
i) Wire strand Ws
ii) Independent wire rope core WR
CF means core tibre, CFN means core natural tibre, CFS
means core tibre synthetic, CWS means core wire strand,
CWR means core wire roDe.
6.4 Length
A rope with plain ends shall be not less than the
specified length nor shall it exceed the specified length
by more than 5 percent for lengths up to 400 m. For
lengths 400 m and more, the plus tolerance shall be 20
m for each 1000 m of length or part thereof. The length
of the rope with Fitted ends shall comply with
requirements of the order. The rope length shall be
measured without tension unless otherwise specified.
6.5 Mass
The approximate rope mass (expressed in kilogram per
100 m) is calculated as follows:
where
~.
d=
K=
In Table 2
K,. =
K,, =
K, =
3
M=K#
approximate mass per unit length of the
rope in kilogram per 100 m;
nominal diameter of the rope in millimeter;
and
empirical factor for the mass per unit
length for a given rope construction in
kg/(100 m.mm).
(The values for Kshown in Tables 1 and 2
are for fully lubricated ropes. Ropes which
are not lubricated may be lighter.)
factor for ropes with natural fibre core,
factor for ropes with man made (synthetic)
fibre core, and
factor for ropes with steel core (wire strand
core and independent wire rope core).
&
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IS 6594:2001
Table 1 Numerical Values of Factors Kand Kfor Strand
(Clauses 6.1,6.5 and6.6)
Construction Arrangement of Mass Factor Minimum Breaking Force
of Strand Wires for Strand Factor for Strand
(K)
(k-)
I
(1)
I
(2)
I
(3)
I
(4)
1X3
(3-o) 0.4010 0.4919
1X4 (4-o) 0.4273 0.5127
t
]X7
(6-1 ) 0.5019 0.5443
Ix19M
(12/6-1) 0.4954 0.5253
1x19J (12:6-1)
Ix37M (18/12/6-1) 0.4889 0.5184
1X37J
(18:12:6-I)
IX61M
(24/1 8/12/6-1) 0.4830 0.512 I
1X61J
(24:18:12:6-I)
Ix91M (30/24/1 8/12/6-1) 0.4817 0.5108
1x91J
(30:24: 18:12:6-I)
IX127M
(36/30/24/l 8/12/6-1) 0.4817 0.5108
IX127J
(36:30:24:18:12:6-1)
lxlfj9f$4
(4213613012411 8/12/6-1) 0.4817 0.5108
1xl(j9J
(42:36:30:24:18:12:6-1)
Multiple operation constructions
Cross lay = M
Contra lay = J
6.6 Minimum Breaking Force
The minimum breaking force (expressed in kilo Newton)
is the force, which shall be reached at least, in the tensile
test to destruction. It is calculated as follows:
~ . Kd2&
o
1000
where
FO = minimum breaking force in kilo Newton,
d = nominal diameter of the rope in millimetre,
R, = rope grade (in Newton per square millimetre),
and
K = empirical factor for the minimum breaking
force for a given rope construction.
The values of K are given in Tables land 2.

*->
In Table 2
K, = factor for rope with fibre core (natural fibre
core and man made fibre core), and
K; = factor for rope with steel core (wire strand
core and independent wire rope core).
6.7 Lay
6.7.1 Direction of Lay
The direction of lay shall be right hand (Z) unless
otherwise specified in the order. It shall be ordinary lay
or Langs lay as specified in the respective specifica-
tion, or the order as applicable.
Langs lay ropes shall be used only when the ends of
the rope and the load are secured against rotation. The
requirement does not, however, apply to multi strand
rotation-resistant ropes, in which the outer layer of the
strands may present the Langs lay appearance.

4
IS 6594:2001
Table 2 Numerical Values of Factors Kand K for Rope
(Clauses 6.1, 6.5 and6.6)
Rope Construction Arrangement
of Wires
in the Strand
I
x? ](6-1)
x19M ](12/6-1)
x37M (18/12/6-1)
x17 S,6X19S (8-8-1),(9-9-1)
x25 S (9-9/6-1)
X19W (6+6-6-1)
x21 F,6x25F (10-5F-5-1)
(12-6F-6-1)
x 26 SW ~ (lo-5+5-5-1)
X31 SW) ( 12-6+6-6-1)
x 36 SW ) (14-7+7-7-1)
X41 Sw ) (16-8+8-8-1)
x 49 Sws (16-8+8-8-8-1)
x 55 Sws) (16-8+8-8-8/6-1)
x 12 (12-Fibre)
x24M (15/9-Fibre)
x24 S (12-12-Fibre)
X19S (9-9-1)
x25F (12-6F-6-1)
X36 SW (14-7+7-7-1)
x 37 SF (12-12-6F-6-1)
7x7(11x7:6x7),
(6-1 )
8x7(12 x 7:6 x 7)
4x7(17 x 7:1] x 716 x 7),
(6-1 )
6x7(18x7:12x7/6x7)
2x6:3x24
(6-O)&(l 5/9-Fibre)
)xV8
7A
)XV22
(12/12-A)
)xV25 (12/9-A)
ixV31
(1 8/12-A)
NOTES
i)
ii)
iii)
1)
Mass Factor for Rope
(m
With With
Natural Synthetic
Fibre Fibre Core
Core
(K,.) (K,,)
(3)
(4)
0.3212 -
0.3453 -
0.3574 0.3485
0.3460 0.3374
0.3460 0.3374
0.3726 0.3633
F
0.3726 0.3633
0.3802 0.3707
0.3802 0.3707
T
0.2506 0.2306
0.3184 0,3041
T
0.3485 0.3362
0.3565 0.3440
0.3565 0,3440
T
0.3620 -
0.4100 0.40Qo
0.4100 0.4000
0.4100 0,4000
0.4100 0.4000
With
Steel
Core
(KJ
(5)
).393
).380 I
).380 I
).409 !
).409 (
).418:
).418:
).425
).434
),434
).402 I
).402 I
).447 I
).447 I
).447 I
),447 I
(6)
1.10
1.10
1.10
1.10
1.10
1.10
1.10
1.22
I .22
1.22
1.05
1.03
1.16
1.16
1.16
1.16
m
l===
Core
$
(K,)
(7) (8)
0.3184
0.3469
1.13 0.3322
1.13 0.3073
1.13 0.2948
1.13 0.3310
F
1.13 0.3310
1.13 0,3377
I
1.13 0.3299
T
T
1.26 0.2870
1.26 0.2936
1.26 0.2866
+
T
0.3000
1,09 0.3620
1.09 0.3510
1.09 0.3510
1.09 0.3510
Nith Steel
Core
(Kz)
(9)
0.3588
0.3319
0.3184
0.3574
0.3574
0.3647
0,3563
0.3386
0.3464
0.3382
0.3281
0.3184
0,3840
0.3720
0.3720
0.3720
Multiple operation construction
Cross lay = M
Contra lay = J
One operationequal lay construction
F = Filler, S = Scale, W = Warringto~ SW = Scale Barrington, SWS = Scale WarrinEton Scale.
Flattened Strand Construction = V
It is not intended to restrict this group of constructions only to the varieties specified here. Other varieties in Scale Barrington
(Sw),
Scale Warrington Scale (SWS), Scale Filler (SF) types can be developed and are permitted to be manufactured under this group
with the consent of the users. Some of the examples are given below :
6 x 46 SW ( 18-9+9-9-l),
6 x 37 SF (12.12-6F-6.1), 6 x 49 SF (16-16.8F&])
Whenthe core wire in the strand becomes too large, it may be replacedby a small strandof 7wires (laid 6 wires over I wire).
Example :
6 X 61 SF (18-18-9F-9 /6-1)
5
IS 6594:2001
Stranded rope in which the direction of lay of wires in the strands is in opposite direction to the lay of the strands
in the rope is called ordinary lay.
Sz
Zs
SZ Right hand ordinary lay
ZS Left hand ordinary lay
Stranded rope in which the direction of lay of wires in the strands is in the same direction to the lay of strands
in the rope is called Langs lay.
Zz
Ss
Right hand Langs lay
Left hand Langs lay
NOTE The first letter denotes the direction of wires in the strand while the second letter denotes the direction
in the rope,
of strands
.
6
&<
6.7.2 Length of Lay
The length of lay shall not exceed 8 times the nominal
diameter of the rope.
6.8 Joints
6.8.1 Joints in wires shall be avoided as far as possible,
but where necessary, those shall be as widely apart as
far as possible, and in no case more than one wire
shall be joined in any length of 10 m of strand.
6.8.2 The joints shall be as far as possible brazed or
electrically welded. If the joint is brazed, it shall be
properly scarfed; if welded it shall be properly annealed.
6.8.3 Tucked joints may be allowed except for ropes for
winding or hoisting purposes in mines. The permissible
wire sizes for such joints are specified in the respective
rope specification.
7 FREEDOM FROM DEFECTS
The completed rope shall be free fkom defects, loose
wires and strands or other irregularities. It shalI be
evenly laid and shall remain in the condition when
properly unwound from a reel or coil.
8 PREFORMING
Round and flattened strand wire rope shall be
preformed unless otherwise agreed upon. A multi
strand rotation-resistant rope may not require
preforming by its inherent design.
8.1 Test for Preforming
A test of the preforming of the rope shall be carried out
by unlaying at one end of the rope, two strands oppo-
site to each other for approximately two rope lay
lengths.
When these two strands are re-laid into the rope the
wires shall maintain their position in the strand and
the strands shall resume their position in the rope.
NOTE This operation may result in a very small increase in
the diameter of that portion of the rope so tested.
9 LUBRICATION
9.1 The cover wires, the core of the strand, the wires
of the main steel core and the rope while being laid up,
shall be thorough Iy treated with lubricant complying
with IS 9182 (Part 2).
NOTE The lubricant used shall be mutually compatible,
it more than one lubricant is used.
9.2 The fibre main core shall be well impregnated with a
suitable lubricant conforming to IS 9182 (Part I). The
impregnation of lubricant in the fibre core maybe done
by vacuum, dip or any other suitable process. In dip
1S 6594:2001
impregnation the core shall be immersed in the lubricant
maintained at a temperature of 90C+ 5C for a minimum
period of 4 h to ensure complete saturation of core.
The retention of lubricant in the core taken fi-om a new
rope shall be a minimum of 10 percent by mass of tibre
core.
10 TESTS
10.1 Tests on Wires Prior to Rope Manufacture
The rope manufacturer shall ensure that the wires
comply with IS 1835 and in particular meet the require-
..-.4
1
ments of this standard with regard to tensile, torsion,
reverse bend and when appropriate, galvanizing tests.
The test results shall be recorded and shall be available
for inspection by the purchaser or his representative
at the manufacturers works. The copy of the test results
shall be supplied to the purchaser if so desired in the
original enquiry or order for the rope.
10.2 Tests on Completed Ropes ( for Routine Test)
10.2.1 Breaking Force
The minimum breaking force of the rope shall be as
specified in the relevant rope specification. The testing
shall be done as per Annex B. [n case of ropes having
a minimum breaking force of 900 kN or more, the
breaking force may at the option of the manufacturer,
be tested in accordance with the procedure given
in 10.2.1.1.
If, in addition to the manufacturers test conducted as
per 10.2.1.1, the purchaser specifies in the order a
sample of the rope to be tested to destruction, the test
shall be carried out in the manner described in Annex
B. This test maybe undertaken in-house if facilities are
available or at an independent test house.
10.2.1.1 One metre long sample shall be cut-off from
the end of the rope length and unstranded. The wires
belonging to different layers of strands as well as the
wires of the steel core in case the main rope core is of
steel core shall be kept separately.
The total number of wires to be tested shall be
equivalent to the number of wires in arty one strand
representing same number of wires from each layer and
location. The average breaking force shall be worked
out against each set of wires and shall be multiplied by
the total number of wires present under each set in the
rope construction to obtain the actual aggregate
breaking force of the rope afier summing up all these
values.
The actual aggregate breaking force value so obtained
on multiplication by the partial spinning loss factor
obtained through type testing as described in 3.2.5.4
for the related rope construction gives the actual
breaking force of the rope.
7
IS 6594:2001
,+,
....-
When actual breaking force is determined through
destruction test, the value achieved shall be considered
as the breaking force of the rope. The rope shall be
deemed to comply with breaking force requirements
provided the value so arrived is more than the minimum
breaking force required.
10.3 Tests on Individual Wires
When specified in the order the following procedure
for testing of wires from the completed rope shall be
adopted.
10.3.1 Sampling Procedure
Approximately one metre length of rope sample shall
be cut-off from the parent reel/coil and unstranded the
wires, excluding all core wires, filler wires and the main
core wires, The wires belonging to each layer and
location in the strand shall then be segregated and
mixed in separate groups (layer and location wise).
10.3.1.1 Six sets of nine wires each (total 54 wires)
shall then be chosen out of these segregated groups
representing proportionately wire samples from each
group (with a minimum of one number for each set) by
the purchaser or his representative and shall be tested
in the following manne~
a) Nine for the tensile test,
b) Nine for the torsion test,
c) Nine for the reverse bend test,
d) Nine for a repeat tensile test in case of failure,
e) Nine for a repeat torsion test in case of failure,
and
t) Nine for a repeat reverse bend test in case of
failure.
10.3.1.2 For ropes of 6 x 7, 6 x 8 and 6 x 9 construc-
tions where the total number of main wires are less
than 54, the number of wires for each set shall be
chosen as 6 instead of nine (total 36 wires) and shall
be tested similarly as indicated in 10.3.1.1.
10.3.1.3 The wires meant for tensile test may also be
utilized for measuring the diameter of wires.
10.3.1.4 If the purchaser also requires galvanizing test,
this shall be carried out on six wires from the set of
wires reserved for repeat test.
10.3.2 Tensile Test
Test samples taken in the manner described in 10.3.1.1
and 10.3.1.2 and tested in the manner described in IS
1608 shall show a tensile strength in accordance with
1S 1835 subject to a reduction of not more than 50 N/mmz
from the minimum value for the particular size and tensile
designation of the wire.
10.3.3 Torsion Test
The test shall be carried out in the manner described in
IS 1717 and shall comply with the appropriate
requirements of IS 1835 except that the minimum
number of torsion may be 75 percent (to the nearest
whole number of torsion) of those specified therein.
10.3.4 Reverse Bend Test
The wires shall be tested in accordance with IS 1716
and shall comply with the appropriate requirements of
IS 1835 except that the minimum number of reverse bend
may be 80 percent (to the nearest whole number of
bend) of those specified therein.
10.3.5 Galvanizing Test
The tests for zinc coating shall be carried out in
accordance with IS 6745 and IS 2633, and shall comply
with the requirements of 1S 1835 allowing a reduction
up to 5 percent of the minimum mass of the zinc coating
values specified and a reduction of one dip of half
minute duration than the specified number in the
respective specifications mentioned above.
10.3.6 Diameter of Wire
The wire shall comply with IS 1835 with respect to the
tolerance of diameter.
11 RETEST
If two or more wires fail to comply with any one of the
tests specified in 10.3.1.1 and 10.3.1.2 to 10.3.6 retest
shall be made but limited to the test under which the
failure occurred. If in the retest even two wires fail in
any one test the rope represented by the sample shall
be deemed not to comply with the specification.
12 INDEPENDENT TESTONCOMPLETED ROPE
12.1 If the purchaser is not satisfied with the tests, the
manufacturer shall be at liberty to have tests carried
out by an independent testing authority agreed to
between the purchaser and the manufacturer, and if the
results of such tests are satisfactory the rope shall be
deemed to comply with the standard.
12.2 Such independent tests shall be carried out in
accordance with the provisions of this standard.
13CERTIFICATE OF TEST
With each coil or reel of completed rope the manu-
facturer shall supply a certificate of test. The form of
the certificate shall be as indicated in Annex C.
8
14 MARKING
,4,
.-
..-4
1S 6594:2001
15 PACKING
The size, construction, rope grade, lay, core, coating
and length of wire rope, reel/coil number along with
the order number of purchaser and any other marking
which may be specified by the purchaser shall be
legibly mentioned on a suitable tag securely attached,
when wire ropes are supplied in coils. [n case wire ropes
are supplied in reels, the information maybe stenciled
on both sides of the reels or stenciled on one side of
the reel and a suitable tag giving the same information
may be attached on the other side of the reel.
The rope shall be suitably protected to avoid damage
in transit and corrosion. Ropes of ordinary lay may be
supplied in coils or reels as required by the purchaser.
hrOTE Langs lay ropes and multi strand rotation-
resistant ropes should preferably be supplied on reels unless
specified otherwise,
ANNEX A
(Clauses 5.1 and 5.2)
METHOD FOR MEASURING THE DIAMETER OF WIRE ROPE
A-1 The actual diameter of wire ropes shall be measured
with a suitable caliper fitted with jaws broad enough to
cover two or more adjacent strands as shown in Fig. 1.
The measurements shall be taken on a straight portion
of the rope without tension at two points spaced at
least one meter apart and at each point two readings of
diameter at approximately right angles to each other.
The average of these four measurements shall be
within the tolerances specified with reference to the
nominal diameter.
A-2 Alternatively, the measurement shall be taken on
a straight portion of the rope without tension at three
points spaced at least one meter apart and at each point
two readings of diameter at approximately at right
angles to each other by a normal vernier calipers. The
average of these six measurements shall be within the
tolerances specified with reference to the nominal
diameter.
I I 1
t 1
u
FIG. I METHOD OF MEASURI NG ROPE DI AMETER
9
IS 6594:2001
ANNEX B
(Ckwse 10,2.1)
METHOD OFDETERMINATIONOF BREAKING STRENGTH
B1 TESTING MACHINE
A testing machine of suitable capacity and certified
accuracy shall be used. The machine shall be subjected
to the approval of the purchaser and the manufacturer
or their representatives.
B-2 TEST LENGTHS
The test length (distance between the grips ) shall be
as given in Fig. 2.
B-3 TEST PIECE
B-3.1 The minimum length of the test piece is made
up of the test length plus an allowance for gripping.
B-3.2 The test piece shall be representative of the
rope as a whole and free from defects. Prior to
selection, the ends of the test piece shall be secured to
prevent turn being put into or taken out of the test
piece. In the same way, the rope from which the test
piece is taken shall be secured. When cutting the test
piece from the rope, neither the test piece nor the rope
shall be damaged.
During testing the test piece shall be gripped in such
a way that all wires in the rope take part in the
acceptance of the applied force. It may be useful to
provide the test piece with conical sockets. If such
sockets are used, care has to be taken so that the casting
material penetrates well to ensure intimate cohesion
with the untwisted wires.
B-4 TESTING
B-4.1 Not more than 80 percent of the minimum
breaking force given in relevant rope specification may
be applied quickly; the remaining force shall be applied
slowly, at a rate of application of force of approximately
10 MPa per second.
B-4.2 The actual breaking force is reached when no
further increase of force is possible.
B-4.3 Tests in which breakage occurs inside or
adjacent to the grips failing to achieve the required
minimum breaking force, may be discarded at the
option of the manufacturer and a retest may be
conducted.
B-4.4 The elongation of the rope under test shall be
measured and a graph indicating the load extension
shall be supplied if agreed in the order.
B-5 The test report may also include the following
particulars if required by the purchaser:
a)
b)
c)
d)
e)
The reference to the method used, that is, this
Indian Standard;
The results (in terms of magnitude and unit);
Any unusual features noted during the test;
Any operation not included in this Indian
Standard or regarded as optional; and
The elongation of test piece in percentage at
80 percent of minimum breaking force.
L
Rope Diameter Minimum Test Length
(dj mm (L) mm
d<6 300
6sds20 600
d>20 30xd
FIG. 2 TESTLENGTHS
10
IS 6594:2001
ANNEX C
(C2ause13)
CERTIFICATE OFTEST
Certificate No .................................
Reel/Coil No ...............................
1) Name and address ofmaker orsupplierof rope ..............................................................
2) Particulars of rope
a) Diameter of rope
b) Number of strand
c) Number of wires per strand
d) Lay
e) Coating . ...........................................
3) Rope grade : .................................................................
a) Date of test of sample of rope :................. ......................
b) Breaking force of rope (Aggregate/Actual): ...................
4) Name and address oftesthouse making test and examination: .........................................
5) Name and designation of signatory of test house conducting the test and examination: .. ..... .... ..............
.................................................................................................................................................. .......................... .....
6) Anyother details :.................................................................
I certify that the above particulars are correct andthatthe wire rope conforms to IS................................................
. . .. . . . . .. . . . . .. . . . . . . . . . . . . . .
Signatureof competent person
Date., . . . . ..................................
ANNEX D
(Clause 6.1; and Foreword)
CONNECTING SYMBOLS FOR STRAND, ROPE AND CORE
D-1 ARRANGEMENT OF WIRES IN STRAND
Type of Strand
Single operation (equal lay or
parallel lay)
Multiple operation in same
direction (cross lay)
Multiple operation in same
direction (contra lay)
Warrington layer
Strand centre
Connecting Symbol Illustration
Dash(-) 9-9-1
12-6F-6-1
Oblique stroke (O 12/6-1
18/12/6-1
Colon (:) 12:6-1
18:12:6-1
Plus sign ( + ) 6+6-6- 1
14-7+7-7- 1
Dash() 6-1
12-F (Fibre)
11
IS 6594:2001
D-2 ARRANGEMENT OF STRANDS IN ROPE
Type of Strand
General rope with one layer of strands
Core Fibre (CF)
Rotation-resistant: Multi-operation
(2 layer) contra lay between outer layer
and first layer of strands
Core Fibre (CF)
Rotation-resistant: Multi-operation (3
Iayers) contra lay between outer layer
and second layer and cross lay
between second and first lay
Core wire strand (CWS)
Connecting Symbol
Cross sign (x) between number of
strands and number of wires per
strand
Dash ()
Colon ( : )
Dash()
Colon ( : )
Oblique stroke (/)
Dash ()
=
Illustration
6x 19S-CF
11x7:6x 7-CF
18x 7: 12x 7/6x 7-CWS
ANNEX E
(Foreword)
INFORMATION TO BE GIVEN WITH THE ENQUIRY OR ORDER
E-1 The following particulars should be given with
the enquiry or order :
a)
b)
c)
d)
e)
f)
@
h)
j)
Length and points between which measure-
ments are to be taken;
Nominal diameter;
Material of the core, fibre or steel;
Construction of rope;
The type of galvanizing, if required:
Type .........................
Preformed or non-preformed;
Rope grade;
Breaking force of rope;
Whether ordinary lay or Langs lay, right
hand or left hand:
k) Particulars of ends and fittings, whether
spliced, socketed or plain, with sketches indi-
cating dimensions if limiting conditions apply;
m) Particulars of inspection and tests required;
n) Whether to be delivered on reels or in coils;
P)
AS per IS . ... under which the rope to be
supplied; and
q) Additional particulars relevant to standard, if
required.
E-2 If the purchaser is uncertain about any of these
particulars reference shall be made to the rope maker,
giving details of rope application.
12
IS 6594:2001
,+~
..
. .--a
i
ANNEX F
(Foreword)
INFORMATIONTO BE GIVENBYTHE MANUFACIWRE~ IFREQUIRED
F-1 The following information should be given by the
manufacturer, if required :
a) Length of the rope and points between which
d)
measurements are to be taken;
b) Nominal diameter of rope;
e)
c) Details of construction :
9
i) Langs number of strands,
g)
ii) Langs construction of strands, and
h)
iii) Langs whether ordinary lay or Langs lay,
J)
right hand or Ietl hand; preformed or non-
preformed;
Quality of material and designation and tensile
range of wire;
Material of use;
The type of galvanizing: Type .......................
Lubricant used;
Minimum breaking force of completed rope;
and
Particulars of end fittings, when specified.
ANNEX G
(Foreword)
COMM1lTEE~MFOSITION
Wire Ropes and Wire Products Sectional Committee, ME1O
Organization
Directorate General of Mines Safety, Dhanbad
Aerial Ropeway & Mechanical Handling Co. Pvt. Ltd, Kolkata
Amar PromotersPvt Ltd, SoIan
BharatCoking Coal Ltd, Dhanbad
Bharat Wire Ropes Ltd, Mumbai
Central Mining ResearchInstitute, Dhanbad
Directorate General of Aeronautical Quality Assurance, New Delhi
DkectorateGeneral ofCivil Aviation,New Delhi
Directorate General of Supplies & Disposals, New Delhi
EasternCoaltields Ltd, Kolkata
Fort WilliamIndustriesLtd, Hooghly
JCT Ltd (Steel Division), Hoshiarpur
Ministry Of Defence (Naval), New Delhi
Ministry of Surface Transport, New Delhi
Representative(s)
Srnu D. SAHA(Chairman)
SmuDrrw-wPArm!w(Alternate)
Sim A. K. ffiNRA
SruuRANJANMrxmm (Alternate)
SW VmmomA-win
SmoR.K.P%mAO
SmuD. M. !+mH
.%0 S. p. CmUDHARY
Sm R. P. CWsmoRm (A1/emate)
Smt S. B. PRASAD
SsnuSANJAY Cwi w (Alternate)
Wu R. C. SmWA
SHRIN. M. WALECHA(Affernate)
%u M. GANOARAJU
SHRIS. M. MUNJAL(Afrerna(e)
N-noH.K. CHAKRABORIY
SHRI L N. BAWOEE
SHruJ. L. IUnsr (Alternafe)
StnuMANMOHAN SINGH
Smu S. K. .%m (Alternate)
CM. Brwmwwwtow
WrruB. L. KHDWAL(Alternate)
Smu G. D. ROY
Sm T. K. DLrrrA (Alternate)
(Corr[inued on page I 4)
13
IS 6594:2001
-A-
{
(Continuedfl~m page 13)
organization
National Test House, Ghaziabad
North Eastern Coaltields Ltd, Kolkata
Oil and Natural Gas Commission, Dehra Dun
Research Designs &Standards Organization, Lucknow
South Eastern Coalfrelds Ltd, Kolkata
Usha Breco Ltd, Kolkata
Usha Martin Industries Ltd, Ranchi
Vldarbha Hardware Industries, Akola
BIS Directorate General
Representative(s)
Sr-rsuD. S. M~M
SmoB.N. SARKAR (Alternate)
War A. T-Y
Srrru R. K. GARG
StcaP.K. SooD(Alternate)
DsvuryDRECTOR (STAmARDS)
Smr S. K. MISHRA
SmrrG. RmaswAhn(Alternate)
Smu & KM BASU
SInu C. K. KARMAKAR(Alternate)
%U RANAPRATAP
Smu K. K. SENGUPTA (Alternate)
SmuO. P.DALMIA
StrrrrSANJAY K. DALMIA(Alternate)
Sftru M. L.CHOPRA, Director& Head (MED)
[Representing Director General (Ex-oflicio)]
Member-Secretary
SHR1p. V~TEXWARAtiO
Joint Director (MED), BIS
14
Bureau of Indian Standards
Bl S is a statutory institution established under the Bureau of Zndian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.
Copyright
BIS has the copyright of all its publications. No part of these publications may be reproduced in any form
without the prior permission in writing of BIS. This does not preclude the free use, in the course of
implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.
Enquiries relating to copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
BIS Catalogue and Standards: Monthly Additions.
This Indian Standard has been developed from Doc : No. ME 10 (473).
Amendments Issued Since Publication
Amend No. Date of Issue Text Affected
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