K-100
™
K-100™ SYNTHETIC CRANE HOIST LINE
Rope Handling, Installation, Inspection,
and Retirement Guidelines
REVISION 11 {04.08.2016}
I M P O R TA N T
BECAUSE OF THE WIDE RANGE OF FACTORS
POTENTIALLY AFFECTING PRODUCT PERFORMANCE,
IT IS STRONGLY RECOMMENDED THAT YOU
READ AND IMPLEMENT THE GUIDELINES AND
INSTRUCTIONS SET FORTH HEREIN AND IN THE
ACCOMPANYING POCKET GUIDE REGARDING
PRODUCT USE, HANDLING, INSTALLATION,
INSPECTION, AND RETIREMENT.
2
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K-100™ SYNTHETIC CRANE HOIST LINE
Rope Handling, Installation, Inspection,
and Retirement Guidelines
CONTENTS
CONSIDERATIONS WHEN WORKING WITH SYNTHETIC K-100TM
Rope Handling...................................................................... 4
Configurations with a Mixed Hoist Rope System.................... 4
Knots.................................................................................... 5
Twist..................................................................................... 5
Diving................................................................................... 5
Temperature......................................................................... 6
Chemical Contact................................................................ 6
Terminations and Connections............................................ 7
Certificate of Compliance (How to Read)............................ 8
RETROFIT AND INSTALLATION PROCEDURES
Pre-Installation Crane Inspection....................................... 10
Retrofitting Procedure........................................................ 10
Attaching Rope to Hoist Drum........................................... 17
Loading Rope onto Hoist Drum......................................... 17
Minimum Wrap Count........................................................ 19
INSPECTION PROCEDURES
Daily Inspections................................................................ 22
Periodic Inspections.......................................................... 24
DATA LOGS
Operator Shift Log............................................................. 27
Shift Inspection Log........................................................... 28
Periodic Inspection Log..................................................... 29
APPENDIX
K-100 Data Sheet............................................................... 33
K-100 Frequently Asked Questions.................................... 34
K-100 Alternate Brummel Termination................................ 36
TECHNICAL BULLETINS:
Effects of Twist on Braided Ropes..................................... 40
How Cold Can You Go....................................................... 42
Inspection and Retirement Guide...................................... 44
Effect of Ultraviolet Light on K-100..................................... 46
Impact of Elevated Temperatures on K-100....................... 47
K-100™ Inspection and Retirement Pocket Guide
Along with the inspection and retirement information provided in
this manual, you will find a copy of Samson’s K-100 Inspection
and Retirement Pocket Guide located in a clear plastic pouch
in the back of this manual.
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3
CONSIDERATIONS WHEN WORKING WITH K-100™
QUALIFIED PERSONS
A qualified person refers to someone who, by extensive
knowledge, training, and experience, has demonstrated the
ability to solve or resolve problems related to the use of K-100
in mobile crane applications. This typically includes a Samson
or Manitowoc employee who has been properly trained, or a
third party who has been trained by Samson or Manitowoc.
ROPE HANDLING
1) Rope should be stored in a snag-free container or on a reel.
2) Always handle and move the rope by lifting the entire rope,
not by grasping a single strand, which can permanently pull
the strand and impact the rope performance.
3) Never move the rope by dragging it on the ground.
Handle the entire rope. Do not pick-up or
pull on single rope strands separately
MIXED ROPE CONFIGURATIONS
If the crane will be configured with a mixed hoist rope system (one wire rope and one
synthetic rope), care must be taken to minimize the interaction of the two ropes.
1) During installation and setup, care must be taken to avoid overlap and crossing
of wire and synthetic ropes.
2) During regular inspections, the operator must ensure that crane surfaces, such
as wear pads, sheaves, etc., have not been damaged by wire in a manner that
can then damage the synthetic rope. If the wire rope has cut grooves or created
sharp edges in a wear pad or other surface, surfaces must be refinished in
accordance with recommendations.
3) During regular inspection, the operator must look for any additional wear from
wire and synthetic interaction.
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CONSIDERATIONS WHEN WORKING WITH K-100™
KNOTS
Tying knots in synthetic ropes used for crane hoist applications is not permissible.
TWIST
Twist has a negative impact on any braided structure. Careful attention must be
paid to prevent twist from being imparted during handling/installation.
Figure 1 (at right) shows an example of a
rope without twist. Notice the alignment
of the braid crossover points in the rope.
The sample below shows a rope with
twist, evidenced by the angling of the
alignment of the braid crossover points
and longitudinal line.
Note: Rope strength can be reduced
by 10% when the rope makes more
than two turns within a 1 meter
span (length). See Technical Bulletin
“Effects of Twist on Braided Rope” on
page 40 in the appendix of this manual.
Straight rope
BLACK LONGITUDINAL LINE
Twisted rope
FIGURE 1: Evidence of twist in a 12-strand rope
DIVING
During spooling at higher layers on the hoist drum, the rope may fall between
wraps on lower layers, resulting in “diving” of the rope. This is more likely to occur
when the lower layers are spooled onto the hoist drum under little or no load,
followed by high tension loading of the top layer. Due to the malleable nature of
the material, the rope can compress and “knife” between lightly packed wraps
below. To mitigate repeated diving events, re-spool the rope according to the
“pre-cycling” process outlined in the installation section. Frequent diving may
increase the rate of wear or abrasion. However, the act of diving does not
compromise the integrity of the rope.
In rare cases, the rope may become stuck between wraps causing backwinding of the line. This will be evident by the load changing its direction of
motion. If this occurs, the operator must reverse the hoisting direction until
the load returns to the point where the change in direction occurred to
allow the rope to pull free.
In the case where the line remains caught between lower wraps, it may be
necessary to pull the line free by hand. Position the hoist such that the rope
path up the boom comes directly back to the location of the dive. DO NOT
pull the line free while the rope remains back-wound (as seen at right) as this
may result in the load dropping and shock loading the rope and boom.
DO NOT pull the line free
while the rope remains backwound as this may result in
the load moving and shock
loading the rope and boom.
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CONSIDERATIONS WHEN WORKING WITH K-100™
TEMPERATURE
a. Do not use in environments over 140°F (60°C).
c. Avoid welding within 5 feet of rope.
b. Do not expose to high heat sources such as open flame, molten metal,
or other high temperature surfaces. For more information on the impact
of elevated temperatures, please see Samson Technical Bulletin “Impact of
Elevated Temperature on K-100” in the Appendix section of this Manual.
d. Rope does not decrease in strength due to cold temperatures. For more information on the impact of cold temperatures, see Samson Technical
Bulletin “How Cold Can You Go” in the Appendix section of this manual.
REMOVING ROPE FROM A REEL OR COIL
FIGURE 2: Removing Rope From Reel
Rope should be removed from the
reel by pulling it off the top while
the reel is free to rotate.
Synthetic-fiber ropes are normally shipped on reels for maximum
protection while in transit. The rope should be removed from the reel by
pulling it off the top while the reel is free to rotate (see Figure 2). This can
be accomplished by passing a pipe through the center of the reel and
jacking it up until the reel is free from the ground. Rope should never be
taken from a reel lying on its side.
To minimize torque and prevent kinking, install the rope correctly —
avoid reverse bends and maintain rope tension at all times.
REEL OR DRUM
REEL
REEL OR DRUM
REEL
CORRECT METHOD: Top to top
CORRECT METHOD: Bottom to bottom
REEL OR DRUM
REEL
INCORRECT METHOD: Top to bottom
6
REEL OR DRUM
REEL
INCORRECT METHOD: Bottom to top
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CONSIDERATIONS WHEN WORKING WITH K-100™
CHEMICAL RESISTANCE
When possible, limit contact with any chemicals as interactions may affect rope
performance. The list below provides a few common chemicals that show little to
no effect on fiber strength. Contact Samson for information on specific
chemical interactions.
Sign
Loss in Tensile Strength
++
0% – 10%
+
11% – 20%
+/-
21% – 40%
-
41% – 80%
--
80% – 100%
Chemical
Chemical Resistance
(EFFECT ON FIBER TENSILE STRENGTH)
Acetic Acid
++
Acetone
++
Calcium Hydroxide
++*
Common Detergent
++
Ethanol
++
Hydrochloric Acid
++
Nitric Acid
++
Oil
++
Sodium Hydroxide
++*
Sulfuric Acid
++
Toluene
++
Water
++
* Tensile strength is significantly reduced (to --) as time
and temperature are increased
TERMINATIONS AND CONNECTIONS
PERMISSIBLE WITH K-100
™
• The use of a swivel or top-swivel headache ball is permitted with K-100.
• Do not to use a wedge socket, becket, or other wire rope termination for the K-100.
• The outboard (dead end) of the rope should be attached to
the headache ball, hook block, or boom nose by attaching thimble eye to a double-sided clevis or H-link. Hardware
should be rated for a WLL to match or exceed the maximum
permissible line-pull of the crane.
• The outboard eye is terminated with a direct-bury splice.
The line pull does not need to be de-rated based on the
splice method.
•
The inboard eye splice is in following with strength
requirement for wire listed in the DIN 15 020 standard,
which specifies the hoist attachment being 2.5x the max
permissible line pull with minimum wrap count and anchoring. Testing of
the inboard eye termination, combined with calculated tension reduction for
minimum friction wraps, has been shown to exceed this required strength.
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7
CONSIDERATIONS WHEN WORKING WITH K-100™
HOW TO READ A CERTIFICATE OF COMPLIANCE
BREAKING STRENGTH
DETERMINATION
Understanding your Certificate
of Compliance with regard
to breaking strength and test
methods can be somewhat
confusing. Breaking strength,
like many other properties, is
a function of both the testing
method and data interpretation.
The same rope can have different
breaking strengths depending
on the test method used. Most
test methods are created by
standards organizations, and
since most of these committees
are regionalized, these standards
are normally designed to meet
regional needs. Recognized
international committees such
as International Standards
Organization (ISO), British
Standards Institute (BSI),
and European Committee for
Standardization (EN) have
developed the widely used test
methods ISO-2307, BS-5053,
and EN-919, respectively. In the
U.S., the Cordage Institute (CI)
and the American Society for
Testing and Materials (ASTM)
have also developed the
common test methods CI-1500
and ASTM D-4268, respectively.
Most test methods are quite
similar; however, different
interpretations of results can and
do lead to different presentations
of specifications.
Certificates of Compliance for
K-100 will list “ISO-2307”.
CERTIFICATE OF SYNTHETIC ROPE TEST
It is hereby certified that the product described herein has been produced in accordance with the design, performance and
quality standards stated in the Samson Quality Assurance Manual.
Synthetic Rope Product Description:
Length (m): 205
Terminations:
Approx. Weight (Kg/100m): 32
Direct bury splice with BL thimble (part# 9300480) one end / constant diameter splice other end
OEM required termination strengths per Manitowoc Engineering Specification #80072248_revB
Dyneema® HMPE / Vectran® LCP
Load Bearing Fiber Type(s):
Customer:
SAMSON ROPE
2090 THORNTON STREET
FERNDALE
WA 98248 USA
Test Method: ISO 2307:2010
Mill Order No.:
Certificate No.:
PO #:
Production Job #:
D00000
D00000-0-0
000000
00000000
Test Date: 00/00/0000
Unspliced Rope Minimum Break Strength Specification* (kN):
373
Actual Break Strength (kN):
(rope sample spliced with direct bury eye-each-end)
398.5kN
Sample Break Location (per ISO 2307):
Outside R marks
Measured Actual Diameter (mm):
(measured under 0.55kN load)
25.1
(*) If the “Actual Break Strength” is at least 336kN (90% Unspliced Rope Minimum Break Strength), but below 373kN, and
“Sample Break Location” is “outside R marks” the test sample is found to meet specified strength per ISO 2307:2010
I certify that the above information is correct and that the examination and test were carried out by a competent person.
Signature:
Randy Stevens / Director of Quality and Services
Date of Issue:
00/00/0000
WARNING: This document certifies only that the product has been manufactured, inspected, and tested as described
herein. Any implication, certification, or warranty concerning the use of this product only applies to the nominal strength of
new, unused synthetic rope. Any equipment this product is used with must be properly maintained and operated by
qualified personnel. Synthetic rope must be properly stored, handled, used, and maintained to prevent damage, abuse, or
improper maintenance, which can cause rope failure. Synthetic rope must be regularly inspected utilizing examination and
discard code of practice in following with Samson’s inspection and retirement guidelines. The product certified is approved
for use only on certain specified crane models. The list of approved crane models for this product is available at the
following url: http://www.samsonrope.com/Documents/Manitowoc/Manitowoc%20SKUs%20approved%20cranes.pdf
THE STRONGEST NAME IN ROPE
2090 Thornton Street
Ferndale, WA USA 98248
ISO-2307
ISO-2307 test standards are widely accepted internationally,
and have some similarities with U.S. standards. What separates
these standards from U.S. standards is the interpretation of
breaking strength. ISO-2307 standards allow a deduction in
breaking strength due to the effects of splicing (or other means
of termination). Terminating any rope will distort the construction,
thereby reducing its breaking strength. A rope tested using these
methods has to achieve 90% of the rated strength and is still
deemed to be compliant with the manufacturer’s specifications,
provided the rupture occurs within the splice or termination.
Listed strengths using the ISO-2307 testing methods are
unterminated strengths.
8
22mm
12-Strand Braid
Braid
22mm KZ-100
K-100 12-Strand
Samson Part #: 89505660673900
(T) 360.384.4669
www.samsonrope.com
(F) 360.384.0572
NEW ROPE TENSILE STRENGTHS
New rope tensile strengths are based on tests
of new and unused spliced rope in accordance
with the applicable test method. It can be
expected that strengths will decrease as soon
as a rope is put to use. Because of the wide
range of rope use, changes in rope conditions,
and exposure to many other factors affecting
rope strength, it is recommended that all care,
handling, and inspection guidelines are followed
in accordance with this manual, and that the
estimation of residual rope strength be made by
a qualified person.
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RETROFIT & INSTALLATION PROCEDURES
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RETROFITTING PROCEDURE
ITEMS NEEDED TO PROPERLY PERFORM A RETROFIT:
• Small side grinder with:
Sanding discs (flap wheel/pads)
Wire brush wheel or cup
• Die grinder with:
De-burring stones or bits
Small sanding discs and flap wheels
• Dual-action sander with sanding pads (will leave a smooth surface
on the hoist flanges)
• Cleaning solutions
• Primer and touch-up paint
• Extra spool to store removed cable on
• Jack stands with pipe to hold spool of rope
• Soft dead-blow/rubber hammer (rope installation requirement)
PRE-INSTALLATION INSPECTION:
1) Disconnect the cable from the hook block and carefully
unspool all of the wire rope from the hoist. Dispose of the
wire cable or salvage properly.
2) After the wire cable is removed, the hoist must be
conditioned to receive a new coating of paint. Proper
surface preparation of the hoist is essential.
3) Any surface which may contact the rope during operation
must be inspected prior to installation. Inspect for rough
surfaces, loose paint, pocking, gouges, or sharp edges.
Special attention should be given to the following areas
(with particular focus on the flange surfaces, as these
contact areas will be more frequent and severe):
HOIST AREAS
OF FOCUS: Top
edges of the
wedge pocket
10
a. Hoist (drum, flanges, drum pockets, under the lip of
the drum .pocket, wedge, cable packer)
HOIST AREAS OF
FOCUS: Flange
surface and
roughness in the
grooves
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RETROFITTING PROCEDURE
PRE-INSTALLATION INSPECTION: (CONTINUED)
b. Sheaves (boom nose, hook block) – groove condition, sharp edges,
freely rotating
c. Boom contact points (wear pads, sharp edges)
d. Boom nose and hook block pins, anti-two-block weight(s)
BOOM NOSE, HOOK BLOCK PINS, AND WEAR PADS: Rough corners damaged by the
steel-wire rope (rope should not yet be in operation on this machine)
SHEAVES: Potential sharp
edges on the corner and wire
damage marks in the grooving
ANTI-TWO-BLOCK WEIGHTS: Potential rough edges at the entry and exit points, as well as
where the rope runs through the block
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11
RETROFITTING PROCEDURE
The allowable
surface roughness
for maximum life is
300 micro inches.
SURFACE ROUGHNESS
4) Surface roughness must be equivalent
to a finish of 300 micro inches RMS
or smoother. Surfaces rougher than
300 micro inches RMS should be
ground down and repainted to reduce
rusting. Achieving lower roughness
will further reduce wear rate of the
synthetic rope due to contact with
these surfaces. If the sheave wheels
are made of steel and rusty, they will
also need to be cleaned, deburred,
and prepped.
Contact Samson/Manitowoc for a microfinish comparator.
SHARP EDGES
5) Sharp edges that may come into
contact with the rope are not
permissible. Any sharp areas
which may cause cutting should
be rounded off. Geometries with
a radius lower than 2 mm are
considered as sharp edges.
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RETROFITTING PROCEDURE
BLAST CLEANING STANDARDS
6) The minimum surface requirement is a commercial finish of 300 micro
inch (7.6µm) RMS value. There are several standards for surface preparation.
Proper surface preparation is essential for good performance and longevity of
K-100.
a.SSPC-SP7 / NACE 4 Brush-Off Blast Cleaning. When viewed without magnification, the surface shall be free of all visible oil, grease, dirt, dust,
loose mill scale, loose rust, and loose coating. Tightly adherent mill scale,
rust, and coating may remain on the surface. Mill scale, rust, and coating are
considered tightly adherent if they cannot be removed by lifting with a dull
putty knife.
b.SSPC-SP6 / NACE 3 Commercial Blast Cleaning. When viewed without
magnification, the surface shall be free of all visible oil, grease, dust, dirt, mill
scale, rust, coating, oxides, corrosion products and other foreign matter of at
least 66-2/3% of unit area, which shall be a square 3 in. x 3 in. (9 sq. in.).
Light shadows, slight streaks, or minor discolorations caused by stains of rust,
stains of mill scale, or stains of previously applied coating in less than 33-1/3%
of the unit area is acceptable.
c.SSPC-SP10 / NACE 2 Near-White Blast Cleaning. When viewed without
magnification, the surface shall be free of all visible oil, grease, dust, dirt, mill
scale, rust, coating, oxides, corrosion products and other foreign matter of
at least 95% of each unit area. Staining shall be limited to no more than
5 percent of each unit area, and may consist of light shadows, slight streaks,
or minor discolorations caused by stains of rust, stains of mill scale, or stains
of previously applied coatings. Unit area shall be approximately 3 in. x 3 in.
(9 sq. in.).
d.SSPC-SP5 / NACE 1 White Metal Blast Cleaning. When viewed without
magnification, the surface shall be free of all visible oil, grease, dust, dirt,
mill scale, rust, coating, oxides, corrosion products and other foreign matter.
Initial Steel Surface
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Brush Off
SSPC-SP7/NACE 4
Commercial
SSPC-SP6/NACE 3
Near White
SSPC-SP10/NACE 2
White Metal
SSPC-SP5/NACE 1
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RETROFITTING PROCEDURE
ACCEPTABLE COATINGS / PAINTS
7) The hoist areas must be prepared to receive a new finish coating. One or two
coats of oil-based enamel paints, high-solids urethanes, epoxies coating, or
powder coating may be used. Other paint alternatives are acceptable as well,
as long as they are not thick and brittle, as they are capable of causing
damage to the rope.
a. There are many potential paint options. The following are acceptable paints available from Grove Crane Care to serve as an example:
• A033671 Black Enamel
• 8878707432 Gray Enamel
•8878707437 Yellow Enamel
• 8878700085 Gray Enamel, National
• 8878707395 Black Enamel, National
b. Coatings may peel off due to the high force exerted by the rope on the hoist
drum. Thick coatings that may result in sharp debris when delaminated are
not acceptable, as these may damage the rope.
c. No loose or peeling paint is permissible. Any mill scale should be removed. The smoothness and roundness of the hoist drum pocket are critical.
d. All previous paint coatings should be removed. A good, clean surface with
no .sharp edges or gouges is required for painting.
e. A good solvent such as acetone or alcohol should be used to thoroughly
clean the hoist for good paint adhesion.
LOOSE OR PEELING PAINT
8) Carefully remove any dust, grindings, or
debris from the drum and flange areas
in preparation for the new paint coating.
Examine the entire hoist drum and flanges
to ensure that all paint and debris have
been removed.
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RETROFITTING PROCEDURE
PROPER PREPARATION
9) The cleaned surfaces should closely
resemble this example.
10) Thoroughly clean the prepared hoist first
with acetone, then isopropyl alcohol (or
other paint manufacturer-recommended
degrease method).
SURFACE AS RECEIVED
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SURFACE AFTER CLEANING
15
RETROFITTING PROCEDURE
PAINT APPLICATION
11) Apply all coatings according the
manufacturer’s recommendation.
Carefully apply the paint evenly.
Ensure no brush bristles are left in the
new paint coating if using a brush.
12) All areas of the coated surfaces should
be completely coated. Two coatings
are recommended.
a.Check the surfaces to ensure there
are no pitted or open areas where the
coating or paint is broken or chipped
and the edges are all rounded
b.The second coat of paint must be
allowed to cure completely. Careful
inspection of the coated surfaces
must be done at this time. Any open
pockets or pitted areas must be
touched up. Failure to do this will
cause the coating to peel in these areas and come off. Good adhesion
of the new finish is critical.
FINAL INSPECTION
ACCEPTABLE PAINT FINISH EXAMPLES
16
12) Adhere to the proper drying time for the
product, as K-100 should not be installed
until the finish is completely dry.
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INSTALLATION
ATTACHING ROPE TO HOIST DRUM
1) The rope soft eye is to be attached at the hoist termination point.
a. Insert rope eye through the slot in the hoist drum.
b. Position of the eye/wedge is critical to ensure that the wedge
does not cut the rope and to prevent diving on the first layer
of wraps on the drum.
• Insert the wedge into the eye.
• Pull the eye/wedge into position such that the rope body
lays in contact with the flange.
c. Pull rope eye and wedge into the hoist drum slot. Use a rubber mallet to secure wedge completely within the drum.
NOTE: For approved crane models with
hoist terminations located external to
the drum flange, no pre-spliced eye will
be provided. Instead, Samson’s K-100
Alternate Brummel Termination method
(instructions included in the Appendix)
must be used.
Correct placement —
eye/wedge should be
aligned with the flange
LOADING ROPE ONTO HOIST DRUM
1) Spooling under load should be performed during initial
installation and following all periodic inspections.
a. Some level of back tension should be applied to
assist packing of lower layers in place prior to rope training procedure. A rope tensioning device
providing 2 – 5% rope break strength should be used
if available. However, hand tension is allowable if there
is no tensioning device on site.
b. To minimize rope diving on the drum, it is highly recommended to train the rope by loading to 5 –10% of the rope break strength (25 – 50% max permissible line pull). By applying this load to the entire rope
length, void space between fibers / strands will be
reduced to achieve target operating diameter.
Any rope tensioning devices used with this product
should be suitable for synthetic rope. Contact a qualified
person for specific details.
Example of a properly packed first layer
c. Care must be taken to ensure tight packing of the first layer.
d. Remove all twist from the rope during installation (refer to Figure 1 on page 5).
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INSTALLATION
LOADING ROPE ONTO HOIST DRUM
2) Before operation of the machine under normal service, the
entire rope should be cycled under increasing load conditions
to promote proper spooling.
a. Reeving, loading, and boom angle must be chosen
according to Table 1 (shown below) to allow removal
of entire rope from the hoist drum at full boom extension
without exceeding crane load chart.
i. Angle and radius are guidelines to allow for maximum
rope removal under loaded condition.
ii. Actual boom orientation may vary to achieve specific
rope removal targets for each training pick.
b. Each training pick is to be performed with load suspended
during both lift and lowering to maintain tension on rope
over entire operation.
c. Three picks to be performed under each of the
following conditions:
i. Load not to exceed Training Load 1 as referenced in
Table 1, rope removed to 3rd wrap on drum.
ii.Load not to exceed Training Load 2 as referenced in
Table 1, rope removed to 8th wrap on drum.
d. Following final pick, boom is to be retracted while load is
suspended to store rope on hoist under tension.
TABLE 1: SYNTHETIC ROPE TRAINING CONDITIONS TO IMPROVE SPOOLING PERFORMANCE
Reeving, loading, and boom
angle must be chosen according
to Table 1 to allow removal of
entire rope from the hoist drum
at full boom extension without
exceeding crane load chart.
Crane Model
Reeving
(parts of line)
Boom Angle/Radius
Training Load 1*
Training Load 2**
YB7725
4
78˚ / 12 ft
12,500 lb
25,000 lb
NBT40
4
81˚ / 15 ft
11,000 lb
22,500 lb
NBT50
4
74˚ / 25 ft
11,000 lb
22,500 lb
NBT55
4
74˚ / 25 ft
11,000 lb
22,500 lb
NBT60
4
78˚ / 15 ft
11,000 lb
22,500 lb
RT530E-2
4
76˚ / 15 ft
11,500 lb
23,000 lb
RT540E
4
75˚ / 20 ft
11,500 lb
23,000 lb
RT600E
4
75˚ / 20 ft
16,800 lb
33,600 lb
RT765E-2
4
78˚ / 20 ft
16,800 lb
33,600 lb
RT770E
6
78˚ / 20 ft
25,000 lb
49,000 lb
RT880E
5
78˚ / 15 ft
21,000 lb
44,000 lb
RT890E
5
78˚ / 15 ft
21,000 lb
44,000 lb
RT9130E-2
8
78˚ / 20 ft
33,500 lb
65,000 lb
TMS700E
6
78˚ / 12 ft
25,000 lb
49,000 lb
TMS800E
8
77˚ / 25 ft
33,500 lb
65,000 lb
* Training Load 1: < = 25% of maximum line pull x number of parts of line
** Training Load 2: < = 50% max permissible line pull x number of parts of line
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MINIMUM WRAP COUNT
A minimum number of 8 wraps must
be maintained on the drum at all
times during operation to ensure load
is not applied to drum termination.
Maintain a minimum of 8 wraps on the drum at all times during operation.
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19
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INSPECTION PROCEDURES
21
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K-100™ INSPECTION PROCEDURES
Refer to Samson’s K-100 Inspection and Retirement Pocket Guide or mobile
app (available on the Apple Store) during each inspection.
GENERAL
The Pocket Guide includes
information on proper rope
inspection techniques and a
visual guide to internal and
external abrasion
1. All inspections should be performed by a designated person. A qualified person must examine any deficiencies identified to determine whether
they constitute a hazard.
DAILY INSPECTION
1. All running ropes in service must be visually inspected once each working
day. The visual inspection should consist of observation of all rope that can
reasonably be expected to be in use during the day’s operations. These
visual observations should be concerned with discovering gross damage that
may be an immediate hazard. The inspector’s focus should be on sections
susceptible to rapid deterioration, or ropes used in applications requiring
special attention. When damage is discovered, a qualified person must
inspect the affected section(s) prior to operation as detailed in the
“Periodic Inspection” (see page 24) to determine if the rope needs
to be retired from service.
2. Care shall be taken when inspecting sections of potential rapid deterioration
such as flange contact points, crossover points, and repetitive pickup
points on drums.
3. The inspector should also document findings on a daily inspection log.
4. Specific types of damage requiring removal from service for inspection
by a qualified person include the following:
• External abrasion level of 5 or higher or internal abrasion level of 3 (refer to
abrasion comparator on Samson’s K-100 Inspection and Retirement Pocket
Guide or mobile app).
• Twist in braided ropes. See Figure 1 on page 5.
• Gross damage or deterioration of the end connection(s).
• Observation of 1 or more strands with localized cutting damage.
• Indication of melted fibers from contact with high temperature surfaces and/
or environments.
• Inconsistent diameter, which may indicate damage to rope strands or core.
22
SamsonRope.com
K-100™ INSPECTION PROCEDURES
DAILY INSPECTIONS (continued)
CUT STRANDS Any cut strands should be
reported to a qualified person
COMPRESSION Visible sheen, stiffness reduced by
flexing the rope (not to be confused with melting),
often seen on winch drums
PULLED STRAND Strand pulled away from the rest
of the rope, is not cut or otherwise damaged
MELTED OR GLAZED FIBER Fused fibers, visibly
charred or melted fibers, yarns, and/or strands,
extreme stiffness—unchanged by flexing
DISCOLORATION/DEGRADATION Fused fibers,
brittle fibers, stiffness
INCONSISTENT DIAMETER Flat areas, lumps
or bumps
ABRASION Broken filaments and yarns
InternAl AbrASIon
Abrasion
repair or retire
1
2
CONTINUE USE
3
CONSULT A QUALIFIED P ER SON*
R ET I R E R O P E
What
> Brokenfilamentsandyarns
Cause
> Abrasion
> Sharp edges and surfaces
> Cyclic tension wear
CORReCtIVe aCtION
Consult abrasion images and rate internal/
external abrasion level of rope. Evaluate rope
based on its most damaged section.
n Minimal strength loss (continue use)
n Strength loss (consult Samson)
n Severe strength loss (retire rope)
*AqualifiedpersonissomeonewhohasdemonstratedtheabilitytosolveorresolveproblemsrelatedtotheuseofK-100
in mobile crane applications. This typically includes a Samson or third party employee who has been properly trained.
eXternAl AbrASIon
1
C O N TI N UE US E
2
3
CONSULT A QUALIFIED P ER SON*
4
R ETIR E R OP E
5
6
R ETIR E R O P E
7
The Pocket Guide includes information on proper rope inspection techniques and a visual guide to internal and external abrasion
SamsonRope.com
23
K-100™ INSPECTION PROCEDURES
PERIODIC INSPECTIONS
1.
Periodic Inspection should be conducted every 500 hours of operation or
once every three months, whichever comes first, or as recommended by
a qualified person. Periodic inspections must be performed by a
qualified person.
2. The entire length of rope will be removed from the hoist drum during this inspection by the following procedure:
a. Remove all load from the hoist line.
b. Crane boom will be retracted and angle dropped to zero.
c. Hoist rope will be removed by hand at boom tip and stored in an
open container or on a suitable reel.
d. During removal, hand-over-hand inspection will be conducted
by a qualified person.
e. Check for abrasion at termination and layer transitions per
Periodic Inspection Log.
f. Termination at the hoist will be inspected without removing the eye
and wedge from the hoist drum. Care shall be taken when observing
the following:
(i) Base of eye where rope exits hoist drum.
(ii) Back of eye within hoist drum.
(iii) Other damage should be noted and referenced by distance
from outboard termination.
g. Following inspection, the rope will be re-installed following
Rope Installation guidelines defined in this manual.
3.
Prior to re-installation of the rope on the hoist, the crane must be visually
inspected for potential wear concerns at all points where rope comes
in contact with the crane. Special attention should be paid to the
following areas:
a.
b.
c.
d.
Hoist — flanges, drum, wedge, cable packer
Sheaves (boom nose and hook block)— groove condition, sharp edges,
freely rotating
Boom contact points—wear pads, sharp edges
Boom nose and hook block pins
4. Any addressable damage must be repaired prior to returning the
rope to service.
Refer to Samson’s Inspection
and Retirement Pocket Guide
or download Samson’s mobile
app for inspection guidelines.
24
SamsonRope.com
K-100™ INSPECTION PROCEDURES
PERIODIC INSPECTIONS (continued)
5.
No precise rules can be given for determining the exact time for rope
replacement since many variables are involved. Once a rope reaches
any of the specified removal criteria, it may be allowed to operate to the
end of the work shift based on the judgment of a qualified person. The rope
must be removed after that work shift, at the end of the day, or prior to the
equipment being used by the next work shift. Refer to Samson’s K-100 Inspection and Retirement Pocket Guide or Samson’s mobile app for the
following inspection guidelines.
Specific inspection attributes and removal criteria:
a. Any of the points listed in the daily inspection
b. External abrasion level of 5 or higher, internal abrasion level of 3
c. Broken core within the braid
d. Hardness or glazing due to melted and fused fibers
e. Inconsistent diameter, which may indicate damaged rope strands,
damaged rope core, or compression
f. Discoloration of the base fiber, indicating chemical contact
g. Localized cutting damage that affects more than half of the yarns
in a single strand.
The Pocket Guide
includes information on proper
rope inspection techniques and
a visual guide to internal and
external abrasion
6. Care should be taken when inspecting sections of rapid deterioration,
such as:
a. Sections exposed to frequent bending around boom or block sheaves
b. Sections of the rope exposed to repetitive contact with abrasive surfaces
while under load (flange wall, boom contact points, etc.)
SamsonRope.com
25
NOTES
26
SamsonRope.com
K-100™
OPERATOR
SHIFT LOG
MAIN HOIST ROPE CERT. NUMBER: ___________________
AUXILIARY HOIST ROPE CERT. NUMBER: ___________________
DATE
LINE USED
PARTS OF APPROX. #
OPERATOR (MAIN
OR AUX) LINE USED OF PICKS
ESTIMATED LOADS
MIN.
MAX.
OPERATING TIME
HOURS
NOTABLE OBSERVATIONS
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
SamsonRope.com
27
K-100™
SHIFT
INSPECTION LOG
HOIST ATTACHMENT
EYE SPLICE
OUTBOARD (WORKING) END EYE
SPLICE WITH THIMBLE
High Bend Zone
ROPE IDENTIFICATION:
INSPECTION DATE:
INSPECTOR:
INSPECTION TIME:
EXTERNAL ABRASION (circle one)
LOCATION
Outboard Termination
High Bend Zone
Flange Contact Top Layer
OTHER DAMAGE LOCATIONS
Note distance from outboard eye
Continue Use CONSULT*
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
7
7
7
EXTERNAL ABRASION (circle one)
Continue Use CONSULT*
1
1
1
2
2
2
3
3
3
4
4
4
COMMENTS (other wear)
RETIRE
SNAG/CUT
HARDNESS
GLAZING
RETIRE
5
5
5
6
6
6
7
7
7
OTHER COMMENTS:
ROPE IDENTIFICATION:
INSPECTION DATE:
INSPECTOR:
INSPECTION TIME:
EXTERNAL ABRASION (circle one)
LOCATION
Outboard Termination
High Bend Zone
Flange Contact Top Layer
OTHER DAMAGE LOCATIONS
Note distance from outboard eye
Continue Use CONSULT*
1
1
1
28
3
3
3
4
4
4
RETIRE
5
5
5
6
6
6
7
7
7
EXTERNAL ABRASION (circle one)
Continue Use CONSULT*
1
1
1
OTHER COMMENTS:
2
2
2
2
2
2
3
3
3
4
4
4
COMMENTS (other wear)
RETIRE
5
5
5
6
6
6
7
7
7
SNAG/CUT
HARDNESS
GLAZING
*Consult a qualified
person for inspection
if abrasion is
3 or greater.
Reference Samson’s
K-100 Inspection and
Retirement Pocket
Guide or mobile app
for a visual guide to
internal and external
abrasion.
*Consult a qualified
person for inspection
if abrasion is
3 or greater.
Reference Samson’s
K-100 Inspection and
Retirement Pocket
Guide or mobile app
for a visual guide to
internal and external
abrasion.
SamsonRope.com
K-100™
PERIODIC
INSPECTION LOG
HOIST ATTACHMENT
EYE SPLICE
OUTBOARD (WORKING) END EYE
SPLICE WITH THIMBLE
High Bend Zone
ROPE IDENTIFICATION:
INSPECTION DATE:
INSPECTOR:
INSPECTION TIME:
LOCATION
EXTERNAL ABRASION (circle one)
Continue Use CONSULT*
Outboard Termination
Transition – Layer 4–5
Transition – Layer 3–4
Transition – Layer 2–3
Transition – Layer 1–2
Inboard Eye
Other Location_______________
OTHER DAMAGE LOCATIONS
(Note distance from outboard eye)
1
1
1
1
1
1
1
2
2
2
2
2
2
2
3
3
3
3
3
3
3
4
4
4
4
4
4
4
RETIRE
5
5
5
5
5
5
5
6
6
6
6
6
6
6
INTERNAL ABRASION (circle one)
Continue Use
CONSULT*
RETIRE
1
1
1
1
1
1
1
2
2
2
2
2
2
2
3
3
3
3
3
3
3
7
7
7
7
7
7
7
EXTERNAL ABRASION (circle one)
Continue Use CONSULT*
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
RETIRE
5
5
5
5
5
5
6
6
6
6
6
6
INTERNAL ABRASION (circle one)
Continue Use
CONSULT*
RETIRE
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
7
7
7
7
7
7
COMMENTS (other wear)
SNAG/CUT
HARDNESS
GLAZING
BOOM CONTACT POINTS: Good/Fair/Poor/Other (note) Wear Pads: ____________ Nose: ____________ Hook Block Pins: ____________
BOOM CONDITION AND FREE ROTATION:
n Good
SHEAVE CONTACT/CONDITION AND FREE ROTATION:
n Fair
n Good
n Poor
n Fair
n Other: ____________________________________________
n Poor
n Other: ___________________________________
OTHER COMMENTS:
Consult a qualified person for inspection if external abrasion is 3 or greater, or if internal abrasion is 2 or greater.
Reference Samson’s K-100 Inspection and Retirement Pocket Guide or mobile app for a visual guide to internal
and external abrasion.
SamsonRope.com
29
30
SamsonRope.com
APPENDIX
SamsonRope.com
31
32
SamsonRope.com
K-100
™
SamsonRope.com
The first synthetic line designed specifically for mobile cranes:
A lightweight, safe, and reliable alternative to steel-wire rope.
The combination of high-performance synthetic fibers
provides strength similar to wire rope with over 80% in weight
reduction. The high strength of these high-performance fibers
allows the rope to meet the maximum line pull requirements
with a 5:1 safety factor. A proprietary coating has been added
to K-100 to improve rope performance in cyclic bend over
sheave applications inherent on mobile cranes.
The physical structure of K-100 also contributes to its
performance characteristics. The rope construction provides
a firm cross section that enables efficient multi-layer spooling,
prevents load spin, birdcaging, and limits permanent damage
due to improper spooling.
The result is a crane hoist line that is easy and safe to handle/
reeve, more durable for spooling, and can reduce weight in the
overall system.
Dyneema® is a registered trademark of Royal DSM N.V.
Dyneema is DSM’s high-performance polyethylene product.
Samson has leveraged fiber, coating, and rope construction
technology from multiple industries it serves to create
K-100. Designed specifically for use on mobile cranes, K-100
hoist rope features high strength-to-weight ratio, bend fatigue
durability, and robust spooling capabilities.
Nominal Diameter
Approximate Weight
ISO 2307 Strength*
MILLIMETER
INCHES
KG/METER
POUNDS/FOOT
METRIC TONS
POUNDS
16 mm
5/8"
0.17 kg
0.11 lb
21.4 t
47,200 lb
18 mm
3/4"
0.24 kg
0.16 lb
28.9 t
63,700 lb
20 mm
13/16"
0.27 kg
0.18 lb
32.6 t
71,900 lb
22 mm
7/8"
0.32 kg
0.22 lb
38.1 t
84,000 lb
25 mm
1"
0.42 kg
0.29 lb
49.3 t
109,000 lb
28 mm
1-1/8"
0.54 kg
0.36 lb
60.2 t
133,000 lb
30 mm
1-1/4"
0.64 kg
0.43 lb
69.9 t
154,000 lb
*Unspliced strength Max permissible line pull is calculated with a 5:1 safety factor.
FEATURES & BENEFITS
n 80% lighter than wire
n Easy handling/reeving and installation
n Reduces number of change outs due to mitigation of
kinking, birdcaging, or damage from diving
n Torque-neutral construction mitigates load spin and cabling
n Corrosion resistant — no rusting, no lubing
n Reduces risk of hand injury from broken wires
n Reduced wear on drums, sheaves
n Standardizes main and auxiliary hoist to one rope
n Same load pull and load chart but with 5:1 safety factor
The product name K-100 was chosen to honor Karim Ziyad.
He was the pioneering Manitowoc engineer that collaborated with
Samson to develop the use of synthetic hoist ropes. Karim passed
away in a bicycling accident in 2013. His keen intellect and honest
friendship will be fondly remembered and greatly missed.
CraneLines@SamsonRope.com
|
Tel +1 360.384.4669
|
SPECIFICATIONS
FIBER (CORE/COVER) Polyester (Control Core) / High-modulus Blend
SPECIFIC GRAVITY 1.05
COLOR Orange with a black longitudinal line
ELASTIC ELONGATION % (At % of break strength)
10%................... 0.9%
20% .................. 1.3%
30% .................. 1.8%
SPLICE/CLASS Product Specific Class II
For questions regarding
Manitowoc cranes, please visit
www.ManitowocCranes.com/K100
2090 Thornton Street, Ferndale, WA 98248 USA
© 2015 Samson Rope Technologies, Inc. All rights reserved.
SamsonRope.com
33
K-100 Frequently Asked Questions
SamsonRope.com
™
What is K-100?
K-100 is a synthetic rope for mobile cranes made from a combination
of high-performance fibers. It offers a number of benefits over the wire
rope it replaces. It is 80% lighter at similar strengths and its braided,
torque-neutral construction significantly reduces load spin. K-100 is
durable in bend fatigue and has robust spooling capabilities. Because
K-100 is made of non-metallic fibers, it will not rust.
What is K-100 made of?
The product is made of proprietary high modulus fibers, including
Dyneema®, that produce a rope with strength comparable to wire at
similar diameters. These materials are much stronger and lighter than
more familiar components, like polyester and nylon.
How long does K-100 last?
This is dependent on the operating conditions and care of the rope.
Because K-100 has a low susceptibility to birdcaging or cabling and
kinking, replacement due to these causes will be reduced.
The life of a synthetic rope is dependent on the duty cycle, applied
loads, and the application of abrasion protection measures. Fatigue
testing has been completed on K-100 to simulate up to seven years
of life. Testing has shown that fatigue life is three to six times greater
than standard wire rope and comparable to rotation-resistant wire.
How does temperature impact the strength of K-100?
The impact of temperature on a synthetic rope is dependent on
the rope’s fiber. K-100 is a blend of high-performance fibers that
perform quite well in a range of temperatures. Cold temperature
will not reduce its strength. At temperatures below 32°F (0°C), the
strength can increase up to 10%.
Elevated temperatures over 140°F (60°C) ambient will reduce the
strength of K-100 to the point that it that may not meet requirements
for a given application.
How much testing has been completed with K-100?
Evaluations for reliability testing have been conducted in laboratory
settings and on cranes used on active job sites.
Why would I want to use K-100?
The product reduces the rope weight by 80%, providing safe handling,
faster and easier change-outs, and reduced risk of back injuries.
It mitigates birdcaging, kinking, or cabling from load spin.
When hoisting low load to high load, diving can occur similar to wire
rope. However, this diving is reversible and typically does not damage
the integrity of the rope.
How does the strength of K-100 compare to wire rope for
mobile crane applications?
K-100 is specified for the crane model to allow for the same maximum
permissible line pull with a 5:1 safety factor. To reach that 5:1 safety
factor, the new rope is slightly larger in size but is still compatible with
the existing sheave profiles.
For example, a 22 mm line of K-100 replaces a 19 mm wire rope.
It works in the same sheaves and provides the same total length on
the hoist drum.
How much does K-100 stretch?
Unlike ropes made with traditional fibers like nylon and polyester,
K-100 is made of high-performance fibers which have very
low stretch. At the max permissible line pull, the rope has an elastic
elongation of 1.3%.
Reliability testing: 36,500+ lift cycles
Tension fatigue testing: 50,000 cycles
Spooling, duty cycle, and calibration testing: 275+ hours
Laboratory machine time at four different locations: 5,100 hours
Total number of tensile break tests: 400+
Total number of bend fatigue test samples used: 60+
Total length of ropes used for all testing: 6+ miles
Total lifts at customer job site: 3,000+
Which cranes can use K-100?
K-100 is only qualified on Grove/Manitowoc mobile cranes.
Models include:
YB7725
NBT60
RT765E-2
RT9130E-2
NBT40
RT530E-2
RT770E
TMS700E
NBT45
RT540E
RT880E
TMS800E
NBT50
RT650E
RT890E
How are the ends of K-100 terminated?
K-100 is spliced with a soft eye on the inboard end (hoist drum side)
and a thimble on the outboard end (headache ball or hook block or
boom nose). The thimble allows for connection to the headache ball
with a double-sided clevis adapter.
What are the spooling characteristics of K-100?
When installed properly, K-100 will level wind on the hoist in a method
similar to wire. While the rope will naturally form to fill the void spaces
on the drum, this will typically not damage the integrity of the rope and
is not a permanent effect.
Diving can occur with K-100. It is most likely to occur when lower
layers are spooled with minimal load, followed by high tension loading
of the upper layer. It may increase the rate of wear, but diving does
not compromise the strength of the rope. The frequency of this
occurring can be reduced by re-spooling the rope under tension per
the installation procedure.
CraneLines@SamsonRope.com
34
|
Tel +1 360.384.4669
SamsonRope.com
K-100 Frequently Asked Questions
™
SamsonRope.com
How is K-100 inspected and when should it be retired?
It is inspected and retired per Samson’s inspection and retirement
guidelines. See SamsonRope.com or a K-100 owner’s manual for
more details.
Can existing cranes be retrofit for K-100?
Yes, they can be retrofitted. Inspection and preparation of surfaces
are required to be compatible with K-100. Contact Manitowoc Crane
Care or Samson for more details.
How often is K-100 inspected?
Samson recommends a minimum of one visual inspection of the
working section of the line per operating shift.
Is K-100 “non-conductive” for use around electrical power lines?
The base fibers of K-100 are made from non-conductive materials.
However, after K-100 is coated and exposed to dirt or moisture, it can
conduct electricity. That conductivity will be significantly lower than
steel, but proper industry procedures must be followed when working
around energized power sources.
Like any other rope, inspection frequency and criteria are based
on application-specific considerations (i.e. duty cycle, environmental
conditions, etc.) and should be determined by a qualified
person on-site.
Is K-100 resistant to chemicals?
The chemical resistance of a synthetic rope is dependent on the rope’s
fiber. K-100 is highly resistant to acids, bases, and lubricating products
typically found in the crane environment.
What happens if K-100 is twisted during reeving or installation?
Similar to wire rope, induced twist is not desirable and care should be
taken when reeving the hook block to keep from adding twist to the
line. If the twist level in the line exceeds 2 turns per meter, action must
be taken to remove the twist prior to maximum load lifting operations.
Solvents should be reviewed carefully.
Inquiries for specific chemicals should be addressed on a case-bycase basis and directed to Samson.
What must be done if the rope is damaged?
Contact Manitowoc Crane Care or Samson for assistance with
guidelines and evaluation.
The outboard termination can be re-spliced by a qualified technician.
How much does K-100 cost?
Based on current economies of volume and the materials market,
the product cost is 3 times the cost of high-end, rotation-resistant wire.
This cost is offset with decreased maintenance costs and improved
operational efficiency, among other benefits.
Is K-100 covered by any current standards?
K-100 strength specifications are verified in accordance
with ISO 2307.
The new ASME B30.30 standard is in draft form at this time. Samson
and Manitowoc are participating in developing a subsection of the
standard to specifically address synthetic rope for crane applications.
K-100 is manufactured under Samson’s ISO 9001: 2010
quality program.
How is K-100 installed?
K-100 is installed similar to wire rope. It should be installed on the
hoist drum under load to get optimal packing on the bottom layers of
the hoist.
K-100 is to be trained with increasing loads before heavy lifts per
the process available from Samson/ Manitowoc User’s Manual.
What other industries and applications are using synthetic
rope technology?
High-performance synthetic slings are commonly used under the
hook in many industries.
Offshore Oil and Gas
n Heavylift slings (over 300 metric tons)
n Deepwater winch lines (180 metric tons x 5,000 meters)
Mining
What is the influence of UV exposure on K-100?
To quantify the efficiency of Samson’s proprietary coating on K-100,
accelerated UV testing was conducted, per ASTM G154: Standard
Practice for Operating Fluorescent Ultraviolet (UV) Lamp Apparatus
for Exposure of Nonmetallic Materials. Samples were tested in various
intervals of simulated Miami, Florida sun; the worst case scenario being
one year of constant exposure. Tensile break tests were conducted
prior to and after the simulation. Test results confirmed the rope
maintained 90% of new rope strength following exposure simulating
one year in Miami sunlight.
n Winching and recovery operations
n Dump rope in dragline operations
Are there any surface finish requirements for the cranes?
All contact surfaces should be free of sharp edges and have a smooth
finish with surface roughness less than 300 micro inches RMS value.
Reference Samson’s retrofit procedure for additional requirements and
information regarding surface finishes.
n Trawl and seine lines on vessels
CraneLines@SamsonRope.com
|
Tel +1 360.384.4669
|
Mooring
n Primary mooring lines for liquid natural gas tankers
Tug
n Mainlines and pendants for harbor escort and offshore tug boats
Utility
n Stringing lines and winch lines
Commercial Fishing
For questions regarding
Manitowoc cranes, please visit
www.ManitowocCranes.com/K100
2090 Thornton Street, Ferndale, WA 98248 USA
© 2015 Samson Rope Technologies, Inc. All rights reserved.
SamsonRope.com
35
SAMSON SPLICING INSTRUCTIONS
K-100™ Alternate Brummel Termination
This termination is only to be used on specific hoists with a wedge and pocket attachment point located
on the hoist flange external to the drum. Prior to installation, consult Samson or your K-100 distributor to
verify whether your crane requires this alternate termination. The goal of this instruction is to guide the
user through the procedure necessary to splice open-ended K-100 rope on the outside flange pocket.
Actual flange pocket application
step
1
Mock up of outside flange pocket for instruction
1 Pick
M arking t h e bitt e r e n d
From the bitter end, count 10 picks and make Mark 1.
10 Picks
1 2 3 4 5 6 7 8 9 10
2
step
Mark 1
inserting the rope and seating the wedge
2A
Holding both parts of the rope, pull the rope
tightly into the pocket, seating the wedge as
deeply as the rope and wedge will allow. Position
amount of rope wrapped around wedge such that
Mark 1 is located 2 picks outside of the pocket.
Seat the wedge
Mark 1
2B
From the base of the pocket, along the standing
part of the rope, count 2 picks and make Mark 2.
From Mark 2, count 10 picks and make Mark 3.
Tape the rope tightly just beyond Mark 3.
2 picks
Mark 2
Tape
10 picks
Mark 3
Mark 1
PAGE 1 OF 4
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36
SamsonRope.com
SAMSON SPLICING INSTRUCTIONS
K-100™ Alternate Brummel Termination
3
step
e x tracting t h e cor e
3A
Relieve the compression on the rope by
pulling the wedge out of the pocket.
Mark 2
Mark 2
Mark 3 Tape
Mark 3
Relieve
compression
Mark 1
3B
Mark 1
Remove and discard core material from
Mark 3 to the bitter end of rope.
Extract
core
Mark 2
Cut core
Mark 3
Mark 1
3C
Re-insert the rope into the pocket and
around the wedge. Marks 1 and 2 should
line up directly opposite each other. Holding
both parts of the rope, pull it tightly into the
pocket, seating the wedge as deeply as the
rope and wedge will allow.
Re-seat
the wedge
Mark 2
Mark 1
PAGE 2 OF 4
SamsonRope.com | Email CustServ@SamsonRope.com | Tel +1.360.384.4669
SamsonRope.com
37
SAMSON SPLICING INSTRUCTIONS
K-100™ Alternate Brummel Termination
st
ep
4
F or M t h e b ru M M e l
4A
At Mark 2, using a fid, open a path through the center of
the rope. Insert the bitter end of the rope and pull tight.
Mark 2
Mark 1
Mark 2
Mark 1
4B
From the exit point, count 2 picks towards Mark 3 and
pass the bitter end through the rope again.
Mark 2
Pass bitter end
through rope
Pick 1 Pick 2
Mark 2
Mark 1
PAGE 3 OF 4
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SAMSON SPLICING INSTRUCTIONS
K-100™ Alternate Brummel Termination
4C
Count 2 more picks and pass the bitter end through
the rope once more. This completes 3 passes of the
bitter end through the rope. Pull the bitter end
to tighten the Brummel.
Pull bitter
end tight
Pick 1
step
5
Pick 2
F inis h ing t h e splic e
Count 4 picks from the last exit point, apply
tape and cut off the excess rope. Tape the
cut end of the rope to the standing part.
Cut off
rope end
Finished splice
.
DOCUMENT K100_Brummel_Splice_TMS9000_Mar2016.pdf
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PAGE 4 OF 4
39
SamSon TEchnical BullETin
Published Date: March 2012
The Effect of Twist on Braided Ropes
Overview
Twist reduces the strength of a braided rope and can lead to unexpected
failures. In order to avoid this, it is important to be able to identify twist in
a rope, take appropriate actions to remove it from the line, and prevent
further twisting.
Braided vs Laid Ropes
Braided Rope Construction All braided ropes, including 8-strand,
12-strand single braids, double braids, and core-dependant double braids,
are constructed from an equal number of “S-strands,” or strands that twist
to the left, and “Z-strands,” or strands that twist to the right. This creates a
balanced, or torque-neutral construction that will not naturally twist while
under load. In order for a rope to maximize its full-strength potential, all
strands of the rope must share the load equally. This load sharing (and thus
the strength of the rope) is reduced when a rope is twisted.
Mooring lines with twist induced.
Laid Rope Constructions Laid ropes, such as 3-strand, 6-strand, and wire
rope constructions, are not torque neutral at all loads. Laid ropes can be
“torque balanced” at a specific load range, however this will not eliminate all
untwisting while the rope is loaded. As a load is applied to a laid rope, the
rope will naturally untwist until it reaches a torque-balanced state.
Why does twist reduce the strength
of a braided rope?
As a braided rope, that has been twisted, is loaded,
the strands become loaded unequally. Depending on
the direction of twist either the S- or Z-strands will take
more of the load.
Effect of Twist on Rope Strength
Rope strength is decreased with the amount of twist
induced into the rope. The effect of twist varies with
the fiber type, diameter, and construction of the rope.
Figure 2 shows 24 mm (1" diameter) AmSteel®-Blue,
a 12-strand single braid construction, to illustrate how
little twist it takes to affect the strength of the rope.
FiguRE 1 The loose strands at the top of the rope do not
contribute to the strength of the rope. The tight strands at the
bottom of the picture bear most of the load.
% of new Rope Strength
Figure 1 illustrates this phenomenon, where all of the
Z-strands are tight and all of the S-strands are loose.
The loose S-strands will not bear the same load as the
tight Z-strands. The tight strands will carry more load than
the loose strands leading to a loss in rope efficiency.
100%
®
24 mm AmSteel-Blue
80%
60%
40%
0 1 2 3 4 5 6 7 8 9 10
TWIST LEVEL (turns per meter)
FiguRE 2 Rope strength vs twist.
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SamSon TEchnical BullETin
Published Date: March 2012
continued
The Effect of Twist on Braided Ropes
Identifying Twist
Identifying twist in a braided rope is
relatively easy. Simply follow a single line
of picks (or crowns) down the length of the
rope (see Fig. 3). If the picks form a straight
line parallel to the length of the rope, there
is no twist. If the line of picks spirals around
the circumference of the rope, that section
of rope is twisted.
NO TWIST
Picks in a straight
line
MODERATE TWIST
Picks not in a
straight line
HEAVY TWIST
Picks spiral around
the rope tightly
FiguRE 3 Twist in a rope is identified by the alignment of the picks.
Causes of Twist in a Braided Rope
Although a braided rope will not twist on its own under load
like a laid rope, there are various ways a braided rope can
become twisted; for example when it is attached to a laid
synthetic or wire rope. As a laid rope is loaded, it unwinds,
transferring twist to the braided rope component.
Using a braided pendant with a braided mainline will reduce
the likelihood of twisting the mainline.
Using a swivel to connect the messenger line to the mainline
or pendant can reduce twist in the pendant and mainline.
> To prevent twist, do not connect a braided rope to
a laid rope or wire rope
It is also important to handle the rope correctly and not
introduce twist into the line.
Improper reeling or
unreeling of a rope
can cause twist.
Rope should never
be taken from a reel
lying on its end. It is
best to support the reel
horizontally so it may
spin freely and then
pull the rope off the top.
IMPROPER
PROPER
Removing Twist
If a twisted line has been identified, take the following steps to remove the twist:
1. Payoutasmuchofthetwistedsectionofropeaspossibleontoaflatsurface.
2. Manuallyuntwistthelinebyflippingtheeyerepeatedlyintheoppositedirection
of the twist until the twist is removed.
3. It may be necessary to milk the twist to the end of the line for the best results.
4. Wind the line back onto the winch or spool under reasonable tension taking
care to prevent re-twisting of the line.
5. If the strands appear damaged or the twist is impossible to remove, contact
a Samson representative for advice.
DOCUMENT TB_Effect_of_Twist_on_Braided_Ropes_Mar2012.pdf
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41
SamSon TeCHniCal BulleTin
How Cold Can You go?
Published Date: November 2005
Revised: June 2009
Samson recently modeled and analyzed the application of our high-performance mooring lines under hot climate
conditions [1]. In this technical bulletin, we look at how our mooring lines perform in an extremely cold environment.
Samson mooring lines are routinely exposed to different
climatic conditions. Some concerns were raised regarding
the performance of ropes that are directly exposed to the
extreme cold. The pictures in Fig. 1 depict AmSteel®-Blue on
a winch buried under heavy ice on board a ship sailing in a
cold environment. In order to understand how our mooring
lines perform in an extremely cold environment, we studied
the flexibility and strength of ropes being directly exposed to
a broad range of temperatures.
FLEXIBILITY
Fig. 2 shows that rope made from Dyneema® fiber, such as
AmSteel®-Blue, remains quite flexible even at an extremely
cold temperature
of -125°C
(-193°F).
Modulus
vs. Temperature
Modulus, GPa
1.00E+12
1.00E+11
1.00E+10
-150
-100
-50
0
50
100
150
Temperature, C
Figure 2 Stiffness of Dyneema® fiber vs. Temperature
Figure 1 AmSteel®-Blue mooring line on Shuttle Tanker KOMETIC
buried in ice and snow
STRENGTH
Tensile Strength, % of Room
Temperature Strength
Fig. 3 shows that Dyneema® fiber rope actually becomes
stronger at lower temperatures. The rope may gain
5–10% of breaking strength if the environment becomes
as cold as -50°C (-58°F). Projections show that the rope
gains even more strength at -150°C (-193°F). [2]
120.0%
100.0%
80.0%
60.0%
40.0%
20.0%
0.0%
-100
-50
0
50
100
150
Temperature, C
Figure 3 Strength of Dyneema® fiber vs. Temperature
DOCUMENT TB_How_Cold_Can_You_Go_Jun2009.pdf
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42
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S a m S o n T e C H n i C a l B u l l e T i n continued
How Cold Can You go?
Published Date: November 2005
Revised: June 2009
ICE
In cold environments, there is a concern that ice
may damage the rope through abrasion or cutting
due to the ice’s rigidity and sharp edges. To test
this theory, we froze wet AmSteel®-Blue rope
to -5°C (23°F) in two different configurations,
as shown in Fig. 4.
CONCLUSION
The safe operation temperature for ropes constructed
from Dyneema® fiber, such as AmSteel®-Blue, Force-8,
Neutron-8, DPX™-75, Turbo-75, etc., is at least as low
as -125°C (-193°F).
For additional information, please contact our
Engineering Department at 360-384-4669.
REFERENCES:
[1]. Technical Bulletin, AmSteel®-Blue Mooring Under
Hot Climates, Samson, 2004.
[2]. DSM Dyneema® fiber technical data sheet, 2002.
Figure 4 Frozen rope bent at 45° on the left and 180° on the right
We then measured the strength of the frozen rope
samples. The results in Table 1 show that there
was no loss of strength regardless of the frozen
configuration.
TaBle 1. Strengths of frozen 7/16" AmSteel®-Blue
Configuration
45° Bend
180° Bend
% of Minimum
Break Strength
100%
102%
DOCUMENT TB_How_Cold_Can_You_Go_June2009.pdf
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43
SamSon TechnIcal BulleTIn
Inspection & Retirement Pocket Guide
Published Date: August 2013
A new wAy to tAlk About synthetic ropes
NA L
nd
Inspection aocket
P
t
en
em
ir
et
R
Guide
7
SINGLE
BRAIDS
The visual inspection of synthetic ropes before use is critical in most industrial applications.
The residual strength of a rope, the prime indicator of its useful and safe remaining working
life, must be assessed before committing the rope to continued use. With high-performance
synthetics like HMPE replacing steel-wire ropes in many applications, the need for a method
to determine the state of a rope is more critical than ever before. The problem is that there
is no common, standardized language or reference scale to describe the state of a rope.
To date, judgment on the state of the rope has required a synthetic rope expert to complete
an inspection on-site. The alternative is removing the rope from service and testing the rope
to destruction in order to evaluate residual strength.
TE RN AL
This information is provided as a guideline.
If you are unsure of the condition of your
rope/sling, please contact your sales or
technical support representative.
ecklist*
for any period of time will
ome characteristics of
rength while others will.
al conditions that should be
Email: CustServ@SamsonRope.com
Cut Strands
anyoftheseconditions,
owingbeforedecidingto
pe,
in service,
oes,
s, and
mage.
dedto:
e observed damage
.
e damage is over
ational, International Guideline
Retirement Criteria: Guidelines
e of Rope, 2004.
RepaIR oR ReTIRe
What
> Two or more cut strands in
proximity
Cause
> Abrasion
Compression
NoT peRMaNeNT— RepaIR
What
> Sharpedgesandsurfaces
> Cyclic tension wear
CorreCtive aCtion
If possible, remove affected section and
resplice with a standard end-for-end splice.
If resplicing is not possible, retire the rope.
Cause
Pulled Strand
NoT peRMaNeNT— RepaIR
> Visible sheen
> Stiffnessreducedbyflexing
the rope
> Nottobeconfusedwithmelting
> Often seen on winch drums
What
> Fibermoldingitselftothe
contact surface under a radial load
CorreCtive aCtion
Work back into the rope.
CorreCtive aCtion
Flex the rope to remove compression.
Melted or Glazed Fiber
Cause
> Strand pulled away from the rest
of the rope
> Isnotcutorotherwisedamaged
> Snaggingonequipmentor
surfaces
Discoloration/Degradation
RepaIR oR ReTIRe
What
Cause
Inconsistent Diameter
RepaIR oR ReTIRe
> Fusedfibers
> Visiblycharredandmeltedfibers,
yarns, and/or strands
> Extreme stiffness
> Unchangedbyflexing
> Exposure to excessive heat, shock
load,orasustainedhighload
CorreCtive aCtion
If possible, remove affected section and
resplice with a standard end-for-end splice.
If resplicing is not possible, retire the rope.
What
Cause
> Fusedfibers
> Brittlefibers
> Stiffness
> Chemical contamination
CorreCtive aCtion
If possible, remove affected section and
resplice with a standard end-for-end splice.
If resplicing is not possible, retire the rope.
SamsonRope.com
Abrasion
RepaIR oR ReTIRe
RepaIR oR ReTIRe
What
Cause
> Flat areas
> Lumps and bumps
> Shockloading
> Broken internal strands
CorreCtive aCtion
If possible, remove affected section and
resplice with a standard end-for-end splice.
If resplicing is not possible, retire the rope.
What
Cause
> Brokenfilamentsandyarns
> Abrasion
> Sharpedgesandsurfaces
> Cyclic tension wear
CorreCtive aCtion
Consult abrasion images* and rate internal/
external abrasion level of rope. Evaluate rope
based on its most damaged section.
n Minimal strength loss (continue use)
n Significant strength loss (consult Samson)
n Severe strength loss (retire rope)
*Refer to images on opposite side.
The Pocket Guide includes information on proper rope inspection techniques and corrective action steps.
The Samson Inspection and Retirement Pocket
Guide is designed to alleviate this problem by
establishing a common language and a reference
scale to describe the current state of a rope. The
Pocket Guide is based on a statistical analysis of
several years of lab testing reports of ropes used
in a variety of different applications and tested to
destruction in the Samson R&D labs. All testing in
the Samson labs is well documented with photos
of the samples tested and pre-test assessments of
the general state of the rope. The type of damage,
its extent, and any mitigating conditions (like chafe
gear) are all properly noted. The rope is then tested
to destruction to determine the actual residual
strength of the sample.
The resulting guide provides a means of estimating
the state of the rope and whether it should be
repaired or retired from use. The Inspection and
Retirement Checklist section of the Guide describes
the seven common forms of damage: cut strands,
compression, pulled strands, melted or glazed fiber,
discoloration/degradation, inconsistent diameter,
and abrasion. It provides a visual reference for
each and a determination of the cause and possible
corrective action that can be taken.
AbrAsion
Cutting is characterized as a highly concentrated density of
broken filaments localized in one or several strands at one
particular position on the rope. Cutting is generally easier
to assess than abrasion in terms of the volume of broken
filaments in relation to the size of the rope.
Abrasion is characterized as a low density of broken
filaments distributed across a larger volume of rope, both
along the length of the rope as well as among the various
strands at any position along the rope. Abrasion can be
both external—along the surface of the rope, and internal,
within the structure of the rope itself.
It is easy to visualize how external abrasion occurs—ropes
dragged across rough surfaces can easily break surface
fiber filaments. Internal abrasion is caused by fiber filaments
rubbing against one another, or by the ingress of grit or
gravel into the braid of the rope. In ropes that are dragged
against rough surfaces without proper chafe protection,
or experience repeated bending over sheaves and across
fairleads, the surface fibers are slowed in relation to the
internal fibers, causing fiber-on-fiber abrasion.
The effect of abrasion on the residual strength of the rope
is more difficult to assess than cutting or other forms of
physical damage. To help assessment in the field, the
second side of the Pocket Guide is devoted to a visual
comparator of the various states of both internal and
external abrasion.
Of all the forms of damage that a rope is subjected
to, the most commonly observed are abrasion
and cutting. Both result in broken filaments in
the rope and in a potential reduction in strength.
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SamSon TechnIcal BulleTIn
Inspection & Retirement Pocket Guide
Published Date: August 2013
Understanding Abrasion
continued
E X TE RNAL
EX TER N A L
EX TER N AL
1
2
3
INTE RNAL
I N TER N A L
I N TER N AL
E XTE RNAL
E XTE RNAL
E XTE RNAL
EXTERNA L
There are two types of abrasion: internal abrasion caused
by the relative movement of internal and external yarns, and
external abrasion caused by contact with external surfaces. An
unprotected rope moving over a rough surface, such as a poorly
maintained chock can be subjected to both. Upon inspection,
it’s easy to see that the external strands are abraded by a rough
surface: often, fibers can be left behind on the surface that
caused the abrasion, and the surface of the rope readily shows
abraded yarns.
Compare surface yarns with internal yarns.
Inspect for internal abrasion.
The same rough surfaces
can also cause internal
abrasion due to the
movement of the internal
strands relative to each
other. When the rope’s
surface strands pass over
rough surfaces, they are
slowed relative to the
strands next to them,
causing friction. Heat is
created from friction—
and heat is among the
biggest enemies of
synthetic ropes.
This information is based on testing performed by Samson and
is provided as a guideline. If you are unsure of the condition of
your rope, please contact your Samson representative.
4
INTE RNAL
5
INTE RNAL
6
INTE RNAL
Inspection a
Retirement Po
Guide
7
INTERNA L
SINGLE BRA
Samson’s R&D department conducted extensive testing and years of field service visit data to develop these inspection guidelines.
the AbrAsion compArAtor
The Abrasion Comparator shows a 12-strand HMPE rope —
AmSteel®-Blue—in a range of abrasion states from new rope to
rope ready for retirement. The images represent a scale numbered
from 1 through 7 that ranges from minimal strength loss (steps
1 and 2), significant strength loss (steps 3 through 5), to severe
strength loss (steps 6 and 7). Each is further tagged with an
action—for ropes with significant strength loss, consult Samson;
for severe strength loss, retire the rope. Images are provided for
both external abrasion and internal abrasion. When consulting your
Samson dealer or representative you now have a ready reference
to accurately describe the state of the rope in question.
L
L
E XT E RNAL
The comparator is an easy reference that can be used in the field to
help assess the state of a rope. Small and easily held in the hand
while performing an inspection, it helps establish a guideline and a
EX TER NA L
EXTERNAL
common language when discussing the state of a rope. It is printed
on extremely durable synthetic paper that is resistant to tearing and
comes packaged in a vinyl sleeve to make it ‘pocket friendly.’
For a complete description of the methodology used in preparing
Samson’s “Inspection and Retirement Pocket Guide,” see the
technical paper “Inspection Criteria for HMPE Rope” available in
the Resources and Literature section of SamsonRope.com
5
INT E RNAL
6
INTERNA L
7
INTERNAL
SHOWN AT ACTUAL SIZE: The detailed photos make
comparison quick and accurate.
DOCUMENT TB_Inspection&Retirement_Pocket_Guide_Aug2013.pdf
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45
SAMSON TECHNICAL BULLETIN
Published Date March 2016
Effect of Ultraviolet Light on K-100
™
For cranes frequently operating in outdoor environments, synthetic rope
degradation due to ultraviolet (UV) light can be a point of concern. The design
of K-100™ incorporates a proprietary coating to mitigate UV degradation
and extensive testing was conducted to confirm its effectiveness.
Samson’s research and development team collaborated
with a worldwide leader in polymer coating additives to
enhance UV protection of K-100. The objective was
to provide UV protection without adversely impacting
other performance characteristics of the rope.
To quantify the efficacy of Samson’s proprietary coating
on K-100, accelerated UV testing was conducted
per ASTM G154: Standard Practice for Operating
Fluorescent Ultraviolet (UV) Lamp Apparatus for Exposure
of Nonmetallic Materials. Samples were tested in various
intervals of simulated Miami, Florida sun; the worst case
scenario being one year of constant exposure. Tensile
break tests were conducted prior to and after the
simulation. Test results confirmed the rope maintained
90% of new rope strength following exposure simulating
one year in Miami sunlight.
UV Testing / Simulated Miami Florida Sun
100%
–
–
–
–
50%
–
–
–
–
Maintained 90% of New Rope Strength
months
SamsonRope.com
4
8
|
Email CustServ@SamsonRope.com
–
–
–
–
–
–
–
–
–
–
Proprietary UV
Protective Coating
12
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SAMSON TECHNICAL BULLETIN
Published Date March 2016
Impact of Elevated Temperatures on K-100 Synthetic Crane Hoist Line
™
The impact of elevated temperature on synthetic rope is commonly misunderstood.
There are two common questions raised on this topic; the impact of environmental
ambient temperature and the effect of synthetic ropes interacting with contact
surfaces inherent to their application (like a crane hoist line that comes in contact
with the boom and other surfaces on the crane).
Immediately following this period of heat soak, load was
applied to the test samples until failure occurred. The same
elevated environment temperature was maintained up to the
failure point. The resulting peak loads provide an estimated
instantaneous strength loss within the given temperature
ranges, shown in Figure 1. Continuous exposure to constant
ambient temperature allows the entire rope structure to come
to equilibrium with the elevated temperature environment.
In addition, other Samson test results indicate that ropes
made with Dyneema® fiber stored in ambient temperatures
up to 75°C for extended periods have been shown to have
no significant reduction in strength when then tested at
room temperature.
FIGURE 1
% SPEC STRENGTH
INSTANTANEOUS STRENGTH VS. SPEC STRENGTH
100
–
–
–
–
50
–
–
–
–
–
100%
100%
98%
96%
94%
92%
25
30
40
50
60
70
ROPE ON 70°C HOT PLATE
45
40
35
30
25
25°C AMBIENT TEMP.
20
Quantum-12
15
AmSteel -Blue
30-40°C ROPE TEMP.
TM
DPX-75
TIME (MIN)
50
70°C HOT PLATE
100
150
200
FIGURE 2
Ambient Temperature
Samson performed break testing on K-100 samples after
exposure to elevated environmental temperatures. This
testing explored the instantaneous strength-reducing effects
of environmental temperature conditions ranging from
ambient air temperatures of ~25°C to 70°C, which exceeds
the recommended maximum operating temperature (60°C)
for K-100 by 10°. Samples were exposed to the target
elevated temperature for 30 minutes utilizing an apparatus
in line with the break test machine.
Effects of Conductive Heat
When a rope comes in contact with a hot surface, the heat
is conducted into the rope. However, unlike the effects of
ambient heat, the conducted heat may not increase the entire
rope’s temperature to the same temperature as the contact
surface. The data in Figure 2 demonstrates test results for
three of Samson’s ropes made with 100% Dyneema® high
modulus polyethylene (HMPE) or a Dyneema®/polyester
blend. It is important to note that Samson’s K-100 is made
of a blend of high performance fibers, the majority being
Dyneema®. The non-Dyneema® fibers are more resistant to
high temperatures than Dyneema® or traditional fibers like
polyester. Therefore, the data below should be considered
the worst case scenario and it stands to reason that K-100
tested would outperform these three ropes in the same test.
TEMP (°C)
Samson conducted a number of tests on K-100™
to investigate the effect of elevated temperature on
breaking strength.
250
Lab tests placing the ropes on a 70°C constant heat
source show the temperature increases with time, as shown
in Figure 2. Unsurprisingly, the rope’s opposite surface
never reaches the heat source temperature, instead reaching
a steady-state equilibrium between the heat source
temperature and the environment.
TEMP (°C)
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47
2090 Thornton Street
Ferndale, WA 98248 USA
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www.SamsonRope.com
For questions regarding Manitowoc cranes, please visit
www.ManitowocCranes.com/K100
K-100™ is a trademark of Samson Rope Technologies, Inc.
© 2015/2016 Samson Rope Technologies, Inc. All rights reserved.
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