INSTALLATION INSTRUCTIONS FOR ROPE ASSEMBLIES WITH HYEND SOCKETS FROM FATZER AG Created Kai-J. Thiem (THK) Checked Martin Bechtold (BEM) Released Kai-J. Thiem (THK) Version 2.0 Date 30.08.2016
Proof of Change Version Reason for change Author Date 1.0 Release THK 18.07.2016 2.0 Various adaptions THK 30.08.2016 Table of Contents 1 Introduction... 2 2 Transport, Unloading and Storage... 3 2.1 General... 3 2.2 Transport... 3 2.3 Unloading... 8 2.4 Storage... 8 3 Unpacking and Handling... 9 3.1 General... 9 3.2 List of equipment... 9 3.3 Uncoiling... 11 4 Installation... 13 4.1 General... 13 4.2 HYEND Open Spelter Socket... 14 4.3 HYEND Adjustable Open Spelter Socket... 15 4.4 HYEND Conical Spelter Socket with Threaded Bar... 16 4.5 HYEND Cylindrical Spelter Socket with Internal and External Thread... 17 4.6 HYEND Take-Up Spelter Socket... 18 4.7 HYEND Cylindrical Spelter Socket... 19 4.8 HYEND Conical Coupler Spelter Socket... 20 4.9 HYEND Open Swaged Socket... 21 4.10 HYEND Open Swaged Socket with Turnbuckle... 22 4.11 HYEND Closed Swaged Socket... 23 4.12 HYEND Closed Swaged Socket with Turnbuckle... 23 4.13 HYEND Threaded Swaged Stud... 24 Version: 2.0 Page : 1 / 24
1 Introduction This document contains information and guidelines about the handling and the installation of rope assemblies with HYEND Sockets produced by FATZER AG. Rope assemblies are made from steel and in principle are robust. However, improper unloading, storage, unpacking, handling and installation may cause permanent damage. Therefore, the rules and guidelines presented in this document shall be observed. Additional rules and guidelines are documented in the general terms and conditions of FATZER AG. Violation of these rules and guidelines may extinguish or reduce the product warranty. Each installation of rope assemblies must be planned by the company responsible for the installation in accordance with the project specifications and local laws and regulations. The information and instructions provided in this document shall be used in the planning. They provide a general guideline for the installation planning. Any project specific requirements and boundary conditions will not be covered and need to be taken into account by the company responsible for the installation. Version: 2.0 Page : 2 / 24
2 Transport, Unloading and Storage 2.1 General The type of packaging of rope assemblies depends on their dimensions and weight as well as on the method of transport. Usual methods of transport and corresponding packaging are described in the following paragraphs. Rope assemblies with a rope diameter smaller than approximately 60 mm can usually be transported on normal size trucks and in standard containers. Rope assemblies with a rope diameter greater than approximately 60 mm require transport with oversize trucks. Upon arrival at the construction site, the rope assemblies shall be unloaded and stored. General instructions for these procedures are given at the end of this chapter. 2.2 Transport 2.2.1 Straight configuration Rope assemblies may be in straight configuration for transport. Depending on the length and the amount of assemblies, they are placed on wooden pallets on a truck (Picture 1), on wooden pallets in a container (Picture 2) or on a single wooden beam (Picture 3). Picture 1: Straight rope assemblies on wooden pallets on a truck Picture 2: Straight rope assemblies on wooden pallets in an container Version: 2.0 Page : 3 / 24
Picture 3: Straight rope assembly on a single wooden beam 2.2.2 Coiled in a wooden box Rope assemblies may be coiled and placed in wooden boxes for transport. These boxes vary with size and weight of the coils (Picture 4 and Picture 5). Picture 4: Coiled rope assemblies (small and light) in a wooden box Picture 5: Coiled rope assemblies (large and heavy) in a wooden box In the case of airfreight these wooden boxes are built to be as light as possible. Special care during handling has to be taken to prevent damage to the box and the rope assemblies. Picture 6 shows coiled rope assemblies in a wooden box for airfreight. Picture 6: Coiled rope assemblies in a wooden box for airfreight Version: 2.0 Page : 4 / 24
2.2.3 Coiled on wooden beams or pallets Rope assemblies may be coiled and placed on wooden beams or pallets for transport (Picture 7). Picture 7: Coiled rope assemblies on wooden beams and on a wooden pallet In the case that the dimensions of these entities fit standard size transport, they can be placed into covered trucks (Picture 8) or into containers (Picture 9). Since the truck or the container protects the ropes during transport, no separate cover is placed over the rope assemblies. Picture 8: Coiled rope assemblies on wooden pallets in a covered truck Picture 9: Coiled rope assemblies on wooden pallets in a container Version: 2.0 Page : 5 / 24
In the case that the dimensions of these entities do not fit standard size transport in covered trucks or in containers they require oversize transport. If no sea transport is planned and therefore no contact with salt water is to be expected, the rope assemblies remain uncovered (Picture 10). If sea transport is required or by agreement the rope assemblies may be individually wrapped in foil (Picture 11) or collectively covered with a membrane (Picture 12). Picture 10: Coiled rope assemblies on wooden beams without cover in an oversize transport Picture 11: Coiled rope assemblies on wooden beams individually wrapped in foil in an oversize transport Picture 12: Coiled rope assemblies on wooden beams before and after covering with a membrane in an oversize transport Version: 2.0 Page : 6 / 24
2.2.4 Spooled on a reel Very long rope assemblies may be spooled on steel reels or wooden reels (Picture 13). Picture 13: Rope assemblies spooled on reels Version: 2.0 Page : 7 / 24
2.3 Unloading 2.3.1 General The following instructions shall be observed. Unloading shall be done by qualified and experienced personnel. The equipment for unloading shall be suitable for the task. The rope assemblies and the packaging shall not be damaged during unloading. Rope assemblies shall be lifted and put down slowly and carefully. If present, special handling instructions attached to the rope assemblies or to the packaging shall also be observed. Unloading shall be done by the following means: Rope assemblies in straight configuration shall be unloaded by crane. Coiled rope assemblies in wooden boxes and on wooden pallets shall be unloaded by forklift. Coiled rope assemblies on wooden beams shall be unloaded by crane. Rope assemblies on reels shall be unloaded by crane or by forklift. 2.3.2 Unloading with forklifts The following instructions shall be observed. The lengths of the forks shall be long enough to support the whole box, pallet or reel. The forks shall not touch the rope assemblies directly. Suitable protection shall be placed between fork and rope assembly at any time. 2.3.3 Unloading with cranes The following instructions shall be observed. 2.4 Storage Suitable slings shall be used to attach the crane hook to the rope assembly or to the packaging. A cross beam shall be used to lift big rope assemblies. Sockets shall be supported during lifting. The following rules and instructions shall be observed. The storage area shall be equipped with hard soil. The storage area shall be a dry, clean, dust-free and well-ventilated place, preferably indoors. Foil wrappings and membrane covers shall be opened immediately upon arrival to allow free air circulation. Rope assemblies shall be stored in a way that allows free air circulation. Rope assemblies shall not get into direct contact with the ground. Rope assemblies shall be protected from overheating as this might affect the blocking compound and cause leaking. Rope assemblies shall be protected from corrosive media, chemicals, dirt, dust and humidity. Stainless steel rope assemblies shall be protected from being contaminated by steel particles and steel dust as these may cause corrosion. Version: 2.0 Page : 8 / 24
3 Unpacking and Handling 3.1 General Rope assemblies are made from steel and in principle are robust. However, improper unpacking and handling may cause permanent damage. Therefore, the rules and guidelines presented in this chapter shall be observed. Unpacking and handling of rope assemblies shall be done by qualified and experienced personnel or under the supervision of an expert. Special equipment not commonly present on construction sides is required for unpacking and handling rope assemblies (see 3.2). Unpacking and handling has to be planned in advance to ensure that all required equipment is available. Ropes shall not be twisted. Ropes shall not be pulled over edges or rough surfaces. If possible rope assemblies shall be gripped and lifted by the sockets or next to the sockets. If this is not possible the socket shall be supported to prevent excessive bending of the rope. The bending radius shall always be a minimum of 15 times the rope diameter (15xd). The rope assembly shall be protected from any contact with objects that might cause scratches, dents or similar defects to its surface. Rope assemblies shall not be put on the ground but placed on wooden beams, matting or other suitable supports. The securing straps that hold the coiled rope assembly together shall not be removed before start of uncoiling. Coiled rope assemblies are under tension. Uncontrolled removal of the securing straps might result in sudden and dangerous uncoiling. 3.2 List of equipment The following equipment might be required for unpacking and handling. This list is not exhaustive and not all listed items might be needed in all situations. The actually required equipment has to be determined by the responsible staff. A turntable for coiled rope assemblies (Picture 14). The Turntable shall be equipped with breaks. A Take-Off stand for rope assemblies on reels (Picture 15). The Take-Off stand shall be equipped with breaks. Trolleys or rollers to support the ropes (Picture 16) Swivel for the crane (Picture 17) Version: 2.0 Page : 9 / 24
Picture 14: Example of a turntable Picture 15: Example of a Take-Off Stand Picture 16: Example of a trolley and a roller Picture 17: Example of a swivel for a crane Version: 2.0 Page : 10 / 24
3.3 Uncoiling The following rules and instructions shall be observed (Picture 18 and Picture 19). The sequence is not exhaustive and not all steps may be required in all situations. The actual uncoiling process has to be determined by the responsible staff. The coiled rope assembly shall be placed on a turntable or in a Take-Off stand. The rope assembly shall be slowly uncoiled by pulling the outer socket. Twisting of the rope shall be avoided. The securing straps that hold the coiled rope assembly together shall be removed step by step in a controlled manner. The turntable or the Take-Off stand shall be prevented from uncontrolled and fast turning by using the breaks. The uncoiled rope assembly shall be placed on trolleys or rollers to avoid contact with the ground (Picture 16) The process shall be continued until the whole rope assembly is fully uncoiled. The uncoiled rope assembly shall be placed on dry and clean supports e.g. wooden beams (Picture 20) Picture 18: Uncoiling with a turntable Picture 19: Uncoiling with a Take-Off stand Picture 20: Rope assemblies after uncoiling placed on beams Version: 2.0 Page : 11 / 24
Improper handling may lead to mechanical damage of the rope and the sockets. The following list shows possible damages. The list is not exhaustive. Out of lock z-shaped wires (Picture 21) Contamination with dirt etc. Damaged corrosion protection Damaged threads Broken wires in exceptional cases FATZER AG shall be informed about all damages immediately. Picture 21: Out of lock z-shaped wires caused by improper uncoiling Version: 2.0 Page : 12 / 24
4 Installation 4.1 General If not otherwise agreed upon, pins, threaded bars, washers, nuts etc. are fully assembled in order to keep the parts that belong to one socket together. The following chapters provide brief instructions on how to connect different types of sockets to the structure and how to do the length adjustment on adjustable sockets. The following instructions regarding threads shall be observed: All internal threads of galvanized sockets are bright. The temporary corrosion protection applied in the workshop (usually a light grease) does not provide long-term protection. The temporary corrosion protection shall be removed and replaced by a permanent protection (e.g. a suitable zinc dust paint) immediately after installation. All external threads of galvanized sockets are galvanized. A suitable lubricant (preferably with MoS2) may be used to improve the movement of threaded connections during installation. Tightening grub screws onto threads may damage the threads and prevent further adjustments by threading. Threads must not be used for tensioning the rope assemblies. Threaded coupler bars, turnbuckles and nuts shall only be turned when free of load. The rope assemblies shall be protected from effects of other activities on the construction site. Those include but are not limited to sparks from welding sparks and dust from steel-cutting operations dirt In particular, stainless steel rope assemblies shall be protected from being contaminated by steel particles and steel dust as these may cause corrosion. In no case, it is allowed to modify the rope assemblies. It is also not allowed to weld onto the rope or the sockets. Version: 2.0 Page : 13 / 24
4.2 HYEND Open Spelter Socket All components of the socket and the connection plate of the structure are shown in Picture 22. The following steps are required for installation: 1. Position the socket over the connection plate (Picture 23). 2. Install the pin into the socket and the connection plate (Picture 24). 3. Secure the bolts of the pin caps with a metal glue (e.g. Loctite) to prevent loosening (Picture 25). Any grease in the threaded connection shall be removed beforehand. The instructions from section 4.1 apply. Picture 22: Components of the HYEND Open Spelter Socket Picture 23: Positioning of the spelter socket over the connection plate Picture 24: Installation of the pin into the spelter socket and the connection plate Picture 25: Secured pin caps Version: 2.0 Page : 14 / 24
4.3 HYEND Adjustable Open Spelter Socket All components of the socket are shown in Picture 26. The following steps are required for installation: 1. If the threaded bar is not installed the following steps shall be observed: Align the spelter sockets and the threaded coupler bar. Engage the threaded coupler bar in the spelter socket and in the open socket at the same time 2. Screw the threaded coupler bar into the right position. The zero position of the threaded coupler bar is shown in the assembly drawing provided by FATZER AG. In the zero position, the rope assembly has the length under load as defined by the client. The minimum thread engagement is shown in the assembly drawing provided by FATZER AG. It is one times the thread diameter. Adjustment of the length of the rope assembly is possible by turning the threaded coupler bar. A hook wrench to DIN 1810B may be required for turning the threaded coupler bar (Picture 27). 3. Follow the steps in section 4.2 for installing the pin. 4. Secure the threaded coupler bar in the spelter socket and in the open socket with the grub screws. The instructions from section 4.1 apply. Picture 26: Components of the HYEND Adjustable Open Spelter Socket Picture 27: Hook wrench to DIN 1810B Version: 2.0 Page : 15 / 24
4.4 HYEND Conical Spelter Socket with Threaded Bar All components of the socket are shown in Picture 28. The following steps are required for installation: 1. Screw the threaded bar fully into the spelter socket (Picture 29). The minimum thread engagement is one times the thread diameter (Picture 30). 2. Secure the threaded bar in the spelter socket with the grub screw (Picture 30). 3. Insert the threaded bar into the bearing plate (Picture 31). 4. Place the washer over the threaded bar and screw the nut onto the threaded bar (Picture 32). The nut shall be fully screwed onto the threaded bar with a minimum of two visible thread pitches at the end of the threaded bar. A hook wrench to DIN 1810B may be required for turning the threaded coupler bar (Picture 27). The instructions from section 4.1 apply. Picture 28: Components of the HYEND Conical Spelter Socket with Threaded Bar Picture 29: Threaded bar installed and secured with grub screw Picture 30: Minimum thread engagement of the threaded bar Picture 31: Threaded bar inserted into the bearing plate Version: 2.0 Page : 16 / 24
Picture 32: Threaded bar with washer and nut installed 4.5 HYEND Cylindrical Spelter Socket with Internal and External Thread All components of the socket and the bearing plate of the structure are shown in Picture 33. The following steps are required for installation: 1. Insert the spelter socket into the bearing plate (Picture 34). 2. Screw the nut onto the threaded bar (Picture 35). The nut shall be fully screwed onto the threaded bar with a minimum of two visible thread pitches at the end of the threaded bar. A hook wrench to DIN 1810B may be required for turning the threaded coupler bar (Picture 27). The instructions from section 4.1 apply. Picture 33: Components of the HYEND Cylindrical Spelter Socket with Internal and External Thread Picture 34: Spelter socket inserted into the bearing plate Picture 35: Installed bearing nut Version: 2.0 Page : 17 / 24
4.6 HYEND Take-Up Spelter Socket All components of the socket are shown in Picture 36. The following steps are required for installation: 1. Fully screw the lugs onto the threaded bars until no visible thread is left (Picture 37). Use a metal glue (e.g. Loctite) to secure the connection. 2. Insert the threaded bars into the bores of the spelter socket and secure them with a washer and two nuts each. The nuts shall be fully screwed onto the threaded bar with a minimum of two visible thread pitches at the end of the threaded bar (Picture 38). A hook wrench to DIN 1810B may be required for turning the threaded coupler bar (Picture 27). 3. Follow the steps in section 4.2 for installing the pin. 4. Adjust the length of the rope assembly via the nuts if required. The instructions from section 4.1 apply. Picture 36: Components of the HYEND Take-Up Spelter Socket Picture 37: Transition zone between threaded bar and lug Picture 38: Installed nuts Version: 2.0 Page : 18 / 24
4.7 HYEND Cylindrical Spelter Socket All components of the socket are shown in Picture 39. The following steps are required for installation: 1. Insert the spelter socket into the bearing plate (Picture 40). 2. Place an open washer (usually not part of the supply) between the spelter socket and the bearing plate (Picture 41). 3. Position the socket against the bearing plate. Alternatives to the open washer are possible and can be planned in by the responsible person. The instructions from section 4.1 apply. Picture 39: Components of the HYEND Cylindrical Spelter Socket Picture 40: Spelter Socket inserted into the bearing plate Picture 41: Spelter Socket with open washer Picture 42: Positioned Spelter Socket Version: 2.0 Page : 19 / 24
4.8 HYEND Conical Coupler Spelter Socket All components of the socket are shown in Picture 43. The following steps are required for installation: 1. Align the spelter sockets and the threaded coupler bar (Picture 43). 2. Engage the threaded coupler bar in both spelter sockets at the same time (Picture 44). 3. The threaded coupler bar shall be screwed in until no visible thread is left (Picture 45) and the distance between the sockets complies with the assembly drawing provided by FATZER AG). 4. Secure the threaded coupler bar with the grub screws (Picture 46). The instructions from section 4.1 apply. Picture 43: Components of the HYEND Conical Coupler Spelter Socket Picture 44: Engaged Spelter Sockets Picture 45: Fully coupled Spelter Sockets Picture 46: Spelter Sockets secured with grub screws Version: 2.0 Page : 20 / 24
4.9 HYEND Open Swaged Socket All components of the socket are shown in Picture 47. The following steps are required for installation: 1. Screw the open socket onto the threaded stud. The socket is in the zero position when the open socket is in line with the groove in between the threaded part and the swaged part of the threaded stud (Picture 48). In the zero position, the rope assembly has the length under load as defined by the client. Adjustment of the length of the rope assembly is possible by turning the open socket. The minimum engagement length of the threaded stud into the socket is given as long as the thread of the stud is not visible (Picture 49). 2. Follow the steps in section 4.2 for installing the pin. The instructions from section 4.1 apply. Picture 47: Components of the HYEND Open Swaged Socket Picture 48: Zero position Engagement length OK Engagement lenght not OK Picture 49: Minimum thread engagement Version: 2.0 Page : 21 / 24
4.10 HYEND Open Swaged Socket with Turnbuckle All components of the socket are shown in Picture 50. The following steps are required for installation: 1. Screw all the parts together. The concept for the zero position and minimum length of thread engagement for the turnbuckle and the adapter follows the description in chapter 4.9. Adjustment of the length of the rope assembly is possible in two ways. a) Adjustment via the socket This is done by turning the open socket only. It can only be done before the open socket is connected to the connection plate. b) Adjustment with the turnbuckle This can also be done when the open socket is connected to the connection plate. 2. Follow the steps in section 4.2 for installing the pin. 3. Secure the turnbuckle with the grub screws. The instructions from section 4.1 apply. Picture 50: Components of the HYEND Open Swaged Socket with Turnbuckle Version: 2.0 Page : 22 / 24
4.11 HYEND Closed Swaged Socket All components of the socket are shown in Picture 51. The following steps are required for installation: 1. Follow the steps in section 4.9. The connecting plate of the structure will be made of two parts. The pin is usually not part of the delivery. The instructions from section 4.1 apply. Picture 51: Components of the HYEND Closed Swaged Socket 4.12 HYEND Closed Swaged Socket with Turnbuckle All components of the socket are shown in Picture 52. The following steps are required for installation: 1. Follow the steps in section 4.10. The connecting plate of the structure will be made of two parts. The pin is usually not part of the delivery. The instructions from section 4.1 apply. Picture 52: Components of the HYEND Closed Swaged Socket with Turnbuckle Version: 2.0 Page : 23 / 24
4.13 HYEND Threaded Swaged Stud All components of the socket and the bearing plate of the structure are shown in Picture 53. The following steps are required for installation: 1. Insert the threaded stud into the bearing plate (Picture 54). 2. Place the washer over the threaded stud and screw the nuts onto the threaded stud (Picture 55). The nuts shall be fully screwed onto the threaded stud with a minimum of two visible thread pitches at the end of the threaded stud. The installation of the threaded stud must always be done with two nuts and both nuts need to be tightened against each other to block them from turning. The instructions from section 4.1 apply. Picture 53: Components of the HYEND Threaded Swaged Stud Picture 54: Threaded Stud inserted into the bearing plate Picture 55: Threaded Stud with washer and nuts installed Version: 2.0 Page : 24 / 24