FEM 5.024 Guideline: Safe Use of High Performance Fibre Ropes in Mobile Crane Applications - english version

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FEM - Product Group Intralogistic Systems / Racking and Shelving 2016 

Leitfaden - Sicherer Einsatz von Hochfesten Faserseilen auf Fahrzeugkranen
Guide – Utilisation en sécurité des câbles synthétiques haute performance pour les applications sur les grues mobiles
1st. edition 2017 only english version available
42 pages,  60,- €

Recent developments of high-performance fibre ropes (HPFR) made from synthetic fibre have led to comparable strength with regard to wire ropes. The main advantages of using HPFR on mobile cranes are:
-    light weight (significant weight reduction)
-    no grease (no re-lubrication, environmentally friendly)
-    easy handling (shorter and easier setup)
-    robust spooling (increased tolerance for spooling failures)

The use of HPFR on mobile cranes has already started, however, there is limited experience in the field with HPFR in comparison to the long-term application of steel wire ropes
For wire ropes, substantial experience over many decades exists, which can be found in international standards (e.g. ISO 4309 etc.). Currently, there is no standard regarding design and discard criteria for the use of HPFR on mobile cranes. Therefore, the Technical Committee of FEM Mobile Cranes decided to develop a FEM guideline about the use of HPFR as ropes (running and stationary) on mobile cranes.
This FEM guideline was developed as a joint project of FEM and members of the fibre rope industry  involving the IFT  of the University of Stuttgart. Experts from FEM product groups for Tower and Harbour Cranes as well as Lifting and Hoisting Equipment (i.e. Serial Hoists) participated to the discussions. FEM recommends to take over parts of this guideline into future European (EN) and/or International Safety Standards (e.g. ISO).
The objective of this guideline is to give guidance for the design and safe use of high performance fibre rope (HPFR) on mobile cranes, especially for running rope on multilayer drums for hoisting purposes. For stationary ropes further criteria regarding design, inspection and discard have to be developed and will be addressed in a later edition.
The guideline covers design measures as well as best practice guidelines on procedures and maintenance to safely operate HPFR on mobile cranes including provisions for assembly.
The design measures are related to tasks performed when using mobile cranes as intended including assembly/disassembly, operation and daily/weekly checks and maintenance; these tasks are to be performed by operators, riggers and other authorised persons.
This guideline applies to mobile cranes as defined in EN 13000 and is considered as complementary to EN 13000 to give further guidance. This guideline is originally developed with mobile cranes in mind, but it is intended to be applicable for other crane types.
This guideline does not deal with so called hybrid ropes which are a combination of steel wire and high performance fibres, where the load bearing capability is shared between steel wires and the high-performance fibre.


1.    Scope
2.    References   
3.    Definitions   
4.    HPFR Design Considerations   
4.1.    General   
4.2.    Rope   
4.2.1.    Types of Ropes   
4.2.2.    Selection of Ropes   
4.3.    Rope Drive Design   
4.3.1.    Experimental Proof of Competence   
4.3.2.    Theoretical Proof of Competence   
4.4.    Rope Design Factor   
5.    Crane Design Considerations   
5.1.    End Termination at Winch Side   
5.2.    End termination at load side   
5.3.    Drum   
5.3.1.    Wrap Limiter   
5.3.2.    Forces on Flange and Mantle   
5.3.3.    Shape of Grooves on Drums   
5.3.4.    Temperature Limits   
5.4.    Sheaves   
5.4.1.    Shape of Grooves   
5.4.2.    Material of Sheave.   
5.4.3.    Minimum D/d Ratio    1
5.5.    Crane   
5.5.1.    Contact Surfaces   
5.5.2.    Substitution on existing Design vs. Optimization on new Designs   
5.5.3.    Clearance between Rope and Drum Flange   
5.5.4.    Fleet Angles   
5.5.5.    Substitution on used Mobile Cranes   
6.    Qualification Testing of HPFR   
6.1.    General   
6.2.    Basic Data of HPFR
6.2.1.    Minimum Breaking Load (MBL)   
6.2.2.    Residual Strength   
6.2.3.    Qualification Testing    Evidence of Bend Fatigue Performance    Multilayer Spooling Performance    Testing Stand and Conditions   
6.2.4.    Interpolation of Test Results   
7.    Care and Maintenance, Inspection and Discard   
7.1.    General   
7.2.    Installation of HPFR   
7.2.1.    Stationary Ropes   
7.2.2.    Running Ropes   
7.3.    Maintenance   
7.3.1.    Maintenance of the Rope   
7.3.2.    Maintenance of Rope-Related Parts of the Crane   
7.4.    Inspection   
7.5.    Discard Criteria   
Appendix A – Selection of Ropes, Explanations (see 4.2.2. A)   
Appendix B – Qualification Tests   
1.    Requirements for testing Party   
2.    Qualification Testing, CBOS   
3.    Multilayer Spooling Test   
4.    Termination Test   
Appendix C – HPFR Test Report – Spreadsheet according to 4.2.2 and 6.   
1.    Covered (jacketed) Fibre Rope   
2.    Rope without Cover (Jacket)   
2.1.    External Abrasion
2.2.    Internal Abrasion   

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