CASAR - Special Wire Ropes for Mining Applications

CASAR Drahtseilwerk Saar GmbH is one of the leading manufacturers of special wire ropes for underground and open pit mining applications such as lifting and balance ropes or shovels.

WIRE ROPES FOR DEEP SHAFT MINING

Special wire ropes of the brand CASAR® have been developed based on the specific demands of the mining industry. A combination of several technical features offers an ideal cost benefit relation of the use of the wire rope. CASAR Special Wire Ropes are in use in many deep shaft mining operations especially in Australia, France, Ghana, Germany, Republic of Fiji and Sweden. Depending on the reeving system of the shaft different rope constructions are recommended. The main question to be answered is whether rotation-resistance is required or not. The technicians at CASAR are prepared to study each individual project and to elaborate a solution based on the wide product range. Our main products in the rotation-resistant range are the CASAR DouzeplastV, the CASAR Starlift and the CASAR Powerplast. Our non-rotation resistant wire rope range includes the CASAR Turboplast and the CASAR Duroplast.

WIRE ROPES FOR OPEN PIT MINING

Open pit mining operators are working with wire rope or hydraulic excavators. For the Wire Rope Excavators CASAR developed a specific special wire rope which offers a significantly longer service life. The construction CASAR Shovelplast is in use at several open pit mines in North and South America.

TECHNICAL DESCRIPTION

CASAR Special Wire Ropes are determined through various technical features such as rotation-resistance where it is recommended, a complete plastic covered IWRC, compacted outer strands, a compacted IWRC, multilayer constructions and a parallel way of production.

ROTATION RESISTANCE

In a conventional rope, an external load creates a moment which tries to untwist the rope and rotate the load. A rotation-resistant CASAR special wire rope such as the Starlift does not show any tendency to untwist even when loaded to the safe working load of the application. They have a steel core which is an independent rope, closed in the opposite direction to the outer strands. Under load, the core tries to twist the rope in the one direction, the outer strands try to twist it in the opposite direction. The geometrical design of a rotation-resistant CASAR special wire rope is such that the moments in the core and the outer strands compensate each other. Even with great lifting heights no rope twist occurs.

PLASTIC LAYER

Ropes with a plastic layer between the steel core and the outer strands combine the advantages of a fibre core (the soft bed for outer strands) with the benefits offered by full steel ropes. The plastic layer forms a custom moulded cushion layer for the outer strands. This fixes the elements of the rope in relation to each other, acting rather like a corset which maintains rope stability, even under the highest external forces. The most effective remedy against birdcaging is to use a CASAR Special Wire Rope with an internal plastic layer. By sealing the core, the plastic traps lubricant and ensures a maintenance free core with lifetime lubrication. At the same time it also excludes water and abrasive elements that could penetrate conventional ropes.

The plastic layer absorbs dynamic energy which is an important issue especially at wire rope excavators.

BREAKING LOADS AND SAFETY

CASAR Special Wire Ropes have highest breaking loads, giving the user a high factor of safety. The ropes are designed by a combination of various technologies:

• A large number of strands increasing the metallic area of the rope and offering a smoother contact at both drum and sheaves
• A plastic layer reducing internal stresses, offering a life-time lubrication and avoiding metal-to-metal contacts inside the rope
• Compacted strands increasing the fill factor of the rope elements
• Parallel lay leads to a more compacted rope construction

ADVANTAGES

CASAR Special Wire Ropes offer the user the following advantages:

• Design advantages by reducing the sheave and drum diameters and the size of motor and gearbox; thereby cost-reduction already in the construction process of new units
• Increased safety
• Longer service life due to lower specific stress on the rope;
• Ideal cost efficiency
• Ideal return on investment

CASAR Special Wire Ropes' service life is up to three times longer than that of conventional wire ropes! CASAR is world-wide well represented through a number of partners in various countries.