ENGLISH SPECIALI
A. - OS'L42 2.3. 11
Track rope calculations for
reversible ropeways
Prof Gabor Oplatka discusses the question of a possible reduction in track rope design
factors for reversible ropeways
I. The problem
'fhe subjecr of fmrher possible rcduc~
cions to ehe track cape design f.1cror is not
new. Thc rhinking behind rhe proposal is
based on thc finding arrribured ro the I'Ope~
way pionc<:r Luis Zucgg co ehe effeet [hat
hi gher te lision i l~ ehe (r<lek tOp<: rechlces
I'CVC I'se bendi ng stress from passage of rhe
ca rriagc whcds of the carriers on ehe linc.
That Gnding is still valid today, ami to that
exrem the pl'Oposal fOl' reduced design fac-
(Q[S is arrracrivc at first sigh r.
Rcduci ng ehe track fOpe design factor,
however, has a !lumbe!' of ol'her, bot'h posi-
tive and negative effccrs, wh ich would cLlr~
rcndy sccm tu be of grcarcr import and
therefore need 1'0 be considered ca reful1y
he fore adecision is taken. A num hel' of rhese
dlccts are listed al1<.! assessed bclow, paying
due ,utention {'o {'he operato(s' und erstand-
able inrel'e,u in I'Opeway insrallarions I'hal' are
simpler, safer a11(! more economica! in terms
orboth initi,ll and follow-up tosts.
2. State of the art
2.1. Design facto r
'The design facrol' (0 1' safe')' r."cor) of ,he
rape is an expression of rhe rario berween
the breaking strcngth or the rope a11(!maxi ~
mum tensi le lorce in {,he rope under operat-
ing condiriol1s. Umi l we are ahle [Q dere i'·
mine the safety h'Ctor for the actllal wires
with rheir reduced levels of tensiO l1 (which is
nor ro be expccted in the fOI'eseeab!e ftHlII'e
in spite of the cfforcs made), we have ro
milke do wirh {'h is design filCtor, although it
is merely arario based on experience :lS a key
1'0 reasonable rope life.
The "ctual figure for the design factor
val'ies from COlllHt'Y ro COllIHl'Y in acco l'-
dance wirh national regulations. Th is is duc
Operali Olia l $Ial e: C,tku lll.led
brea lcillg $Ire'l glll
Without ac[u3[cd track ropc brakc 3. 15 10 3.50
Willl aclua[ed tral:k rope brake 2 .80 [0 3.50
Table I: Standard design factors for track ropes In European countries
in 1993 (source: J. P. Larq uetout)
4 IN i HNAT ION .... l f\OP@ w,\Y "'~VIEW )/2001
1.. , ~.AI\
5.4-. C)\)
tOdifferences nOt only in legal requiremcnts The 101lowi ng co mmenrs I'ebre ro fh e
but also in defin itions of rhe key p:1ramerers, causes of damage listed in Tablc 4:
i,e, breaking strengrh of the rope and l1l axi~ • Roller chains: In the etlrly yetirs the rad ii
mum tensile force under operating condi- selected 101' some I'oll er chains were cxces·
rions. Whar is considered acceprable will sivel y oprimisric and rhe need for additio nal
depend on thc individual case. Fatiguc lub rication to thc ropes On th e chains waS
strength is not always a factor, c,g. in du: nOt recogni:r..ed in lim e. Neverrheless, of rhe
case of I'opeways builr for re mpO I'ary use 172 [!'ack I'Opes located on roller chains,
and /o r a limited numbe r of rides, and ca n ~ only rhose listed in the mble h;\d tO be dis-
not always be a fana r, c.g, in the case of carded due to permanenr damage.
rellirbishmenc pl'ojects wh el'e I'igluer radii • Corrosion: Ga lva nizcd wire is rarcly t1Sed
luve [0 be se!ected because of lim ired space for rrack rapes because of rhe tight tole r-
in the terminals, T hanks to the improvc- anccs involved . Loca l cO I'I'osion occurs
ments mad e 111 cenns oF rope consrwction bene:l l'il rhe ou rel' wires as rhe resulr ofinrcr·
and lubl'ical'ion, and I'Opeway design raking rupred lubricant flow during the stranding
mo re account of the limits of rope perfo r~ process,
mance. tatiglle st rength req ll lremellts Ctin be • Farigue brea ks fl'om repeated stress
mer even where rhe ropes :l1'e subjecl'ed [0 I'eversals wirh transverse forccs tend to be
considerable loads, thc exception,
lt can be seen by comparing Tables 1 and
2 I'ha r I'he GEN standard is based on I'he 3. Scope for design factor reductions
lower of rhe nat ional design facro rs. To rhar Track rope design 0 1' safety factors Can be
extent rhc call for rcduced design factors h"s reduced in tlHee ways:
already bee n met in palt. a. by reducing rhe breaking strength of the
wirrs for the same rope geol11ctry am! at
2.2. Service life for track ropes constant puH a10ng the I'ope,
']"rack wpe pertormance in terms or se r- b. by in c,'easin g pulling force along the
vice life in $wirzedand is summal'ized in I'Ope using rhe same rope,
Tablcs 3 and 4. Ir should be noted that not c, by reducing rope diameter ar cOlismnr
On\; of the ropes had to bc replaced due to
yeafs of number of %
pCl'manenr damage dlHing rhe fit's r re n yeal's service copcs di.scarded
of service, and rhat track rapes that have 1 to 10 94 0
completed fo rty yta rs of service are consid- J t 10 20 102 11.8
el'ed Guigue- l'esiSl'ing. ( Ti'ack I'OpeS I'el'il'ed 211030 146 8.9
duc (Q manufacrUl'ing faults, accidcnr· 3 11040 133 9.8
4 1 [0 50 41 0
im!uced damagc or dcmolition/refurbish- SI [0 GO 0 0
menc of rhe insml bl'ion :ll'e nor dassifled as
discards. Thc multilayel' srl'anded ropes of Toble 3: Number arid age of track ropes In
eqllal round strands thaI' were discarded Swltzerlarld and percentage discarded due
decades ago Me riOt rel evant to rhi s disCliS- to permanent da mage up to 1999 (source:
sion and have rhe refOl'e been exd uded) (00.) A. Ha ller)
MIll1mU11l Opcrational s[at e
breakiu g stre ngeh Without al:tu alcd tral:k ro pe brakc 3.1 5
3.05 IQ 3.25 With at.tuatt d track rOp C bn.lte 2.70
2.70 to 3. 15 E):ceptiOI' (lIla:ll: im IllU wjnd aud/Qr ki ng I ropcway closcd) 2.25
Tab le 2: Design factors fa r minimum brt!oklng strcngth pursuant to the
CEN sta ndard ....
 • ROPES ENGLISH SPECIAL I
•

il.L e e e e
,."
no· YCIl U R IWU IWO IWB IWB EWB EWß EWß EWß note
Re
2 12 ,., Re
I
term
0
tower
2
line
'.7 0
term.
0
towe r
0
li n e
0
ftC term . lower line
yd
3. 4 17 y" 81 0 0 0 0
•0 0 0
<6 2 17 17 3.
• 0 0 0 0 y" y"

.,
Y'"
2.
3.
4
4
2.
2.
.0
n•
'0
I
0
•
0
•0 •I yu
y"
0
y"
y"
y" 2
2 2. no 0 0 0 0 yd
"
H.S 2
"2. 2
,.,
yt.s 20 A 23 I y" y"

,.,...
42
37 " 30
15 0
0
2
0
2.
10
0
0
I
0
15
I
y"
y"
60 2 33 3 0 30 0 0 0 0 4
3. I 35 2 .0 Y'"
4I 2 35 n. 12 y" y"
26 2 37 .0 0
• 5 YC} 2

'"3. , 2 3.
3.
n.
no
0
0
0
0
0
0
0
0
0
•
0
0
y"
,.. 3

Toble 4: Data (or track ropot dltcarded due to permanent damage in Switzerland (source:A, Haller), Legend: d ~ rope diameter, no, ~ number of
= =
ropes, years =years of service, RL relocatlon, RC roller choln, IWB = internal wire breaks. EWB = external wire breaks. C = corrosion, term. ~
terminal area, tower ~ tower sectlon,lIne = on the IIne, I ;;;; diagram no longer m@onlng(ul after 9th year of service, 2 ;;;; pronounced corrosion da-
mage to who/e rop e. 3 .= pronounced local corroslon on all ropes

puH along the rope (for practical purposes
presllmably rhe most impo rranr case).
A combina tio n of rhc t1ucc is also feasi-
ble. Ir goes without saying dmt nOne of rhese
meas ures m:l.Y be applied ro excess.
.,
01002 BOURG EN BRESSE Codox FrMC~
Phone +33 4 74 32 82 82 - Telefa x +33 4 74 32 81 05
4. Impacts of lower design factor.
4.1. Eff«1S on ,he li ne
A. A I'educt" ion in I'he breaking stre ngth of
the wircs has no direct effecr on fhe li ne as
rope lTI<lSS and thus linc geo l1lcrry rel11ain
unchan ged .
France Plant · 25, avenue de Lyon · BP. 38
~~ 'Y"~I, ~r!;IIII!el/~fjfturqPf,(\>In
ß, The I'csu lrs of an increase in pull along
t hc track ropc:
• H,educed sag in l'he indi vidU:l1 rope spn l\s
• Flarrer fOI'ce disp lace mcnr cUI'ves on rhe
downh ilI sieles of du: towers and thcrcforc
reduced forces iti the haul ropes (wh ich
mea ns sma ll el'~djamerel' haut I'Opes, Sill aller
shcavcs and Icss powcrful prima ry l11overs)
• Shorter hu ngers thnnks to thc reduced
risk of caniage lir[~off I'csulring f,'om rhe
flatter fo rce d isplaccm cnr curvcs and
incrcascd de<irance for carrier swing (which
rneans lower rel'lninal sr['ucrtll'es and rowel's)
• Bigher surface pressures on the mwer
saddles and roller chains (requ iring biggcr
f{ldii, wh ic h me:l.ns f.,1Ste l' passage over the
towers but reduced transverse srabilicy in the
track ropcs on thc towers)
• Reduced lo,ernl deAeccion of the trock
ropes in strong winds
• Highcr forces in thc anchors ami more
powerful rensiOliing ge{l r
• Increased towel' forces ar positive chord
displacement and reduccd tower forces at
neg{l tive chord displ{lcement (wlth rhe pos-
sibili ry of om itting such towers)
C, T he results of rcd ucing rape diameter ar
COnsrallr pull along the rope:
• Lighrer Hack ropes
• Cost savings in terms of track rope pu r-
chtlse, shippillg and install atiol)
• Reduced sag {wirh ["h e sa me effeclS :1S in
secrion ß excepr for the last (Wo)
• Highcr surface press ures On the carriage
wheels
• Reduced impact of wavincss in the rapes
on the smoorhness of the ride
• R.ed uced !ateral deFl ecdon of ['he track
rapes in strang winds

4.2. Effects On the tr:\ck rope

A. Wi l'es wirh a lower brea ki ng strength

6 !NTERNAT!ONAL ROPEWAY REV!EW 312002

 ROPES .

have superior deformacioll properti es ;l.nd therr.:forc grcatcr capaciry co

absorb loeal peak stresses (whieh Illeans rh:u wil'c brea ks should take
longe r tO develop ur such points).
ß. 'I'he resu!rs of an increase in pull along ehe track rape:
• Incrcascd [cmilc stresses in {he fOp eS
• Ir'lcreased alternat'illg tensilc stresses in rapes pcrm anel1l'ly anchored
at hoch cnds
• Nominally unchangcd forced bending (o n rhe tOwer saddles and
roller chains) hut reduced fatiguc strcngth duc [0 higher rensile srress-
es and sUI'face pl'CSSUI'CS (wh ich mCanS bending radii muse be increased
{Q achicvc ehe same rope life)

• Reduced pulsating bending lInder rhe caniage wheels ;\1 co" St::lIl t
wheelloads (whieh means wheelloads can bc increased in [he frame·
work of whecllincr perfol'lnance)
or
C. The results redudng rope diameter ar co nsr:m r pu1l alollg the (Üpe:
• Increased tcnsile suesses in rh e ropes
• Jncreased alrcrnating rensile snesses in ropes permancndy anchorcd
ar both ends
• Highct· surrace pressures in addition ro higher tensi le s{l"esses whet·e
forccd bending occurs, i.e. on rower sadd les and roller chains (which
meallS the radii should not bc reduccd in li ne wi!"h the red ucti on in
rope diamel'er)
• No change in fhe [ensio n ~t'o-she;lr ratio at constant wheclloads bm
or
an incrcasc in pu Isaring bcnding loads by t·he squ,lre rOO t tensile strcss
• Higher su rr;l ce pressures for rrack rape brak ing (which can be co m-
pensarcd by incrcasing the length of the brake shoes)
• I-ligher surfacc pressurcs on rhe cat·ringe wheels (Wllich means sofr lin-
erSshould be used so that only rhe service life of (he lilters is ;lfTected)

5. Open questions
• Are there orher aspccts to be considered?
The above list' cann ot claim to be cam piere, and I'isk analysis is
No matter which machine type or make

-
ealled for to check out orhe r f."ICto rs.
• How wi ll thc ropcs react?
Any red llclion in track rope design facrors bclow rhei r presen~ lev-
• you use. HALL Tracks are 100 percent compatible
and impress with innovative technology,
els will rake us inro unch:lrted te rri to ry, which makes ir impossible to prime quality and a convincing cost-benefit ratio.
cxtra polarc for a11 the consequenccs wi rh I'he necessa ry degree of rclia~ All component s and spare parts earn an "excellent"
bility. Invesrigatiol1s are needcd [0 srlldy Ihe effecrs on rope perro r- rating and have proved th ei r worth under tough
mance of any changes t'o {"he indiv idual componelHs of rope loading, everyday slope conditions at many
namdy tens ion, bcnding and st.ll'face pl'essure, and also rhe behavior of ski resorts around the world.
ropes subj ected to such loads in cases of mechanical damage, lightllillg
discha"ge, erc.
• Rope inspccrion inrervals?
At hi gher operating loads, any rope danuge ca n be ex pected to
develop mO I'e quiekly. This wi ll reduce (he ea rly waming I1lal'gin ;lnd
ca n lead [0 apremature discard cOI,dition. For that reason it will be
necessary to shonen the inspccrion and rest iIHerv:l Is.
• Ti me and reSO\l rces needcd to clarify these ope n quesrions?
Thc rime reqll ired fOI' :l positive result from tests on sc!ccred insra l·
lations (i n situ) will bc not less chan lWenty yeacs. (So why did we not
swrr twenty yeafs :.lgo~ Prcs umably rhe same question will be asked in
[wenry years' rime). 1_1boratO ry tests, roo, rake time and mOlley. They
also requirc conrinui ry and cal'e, Aparr from th;lt, thc res ulrs of labo- HALL tracks
raco ry rest'Sdo not always fully match (he situation in th e (leid.
full power!
6. Acknowledgements HANS HALL Inc. HANS HALL Gm~H
I wis h to thallk Mr. August HalIei' fol' I'he track rope sratistics for 71 17 S. 400 West, Suite 5 Pistenfahrzeugketten & Teile
revers ible ropeways in Switzerland and Mr. Gody H ofm ~lIl1\ for sug- Midvale. UT 84047 Krügerstraße 11
ges ring rhe subject cf this paper and reading thc manuscripr wirh such USA 0.88250 Weingarten
a cri tical eye, GABOR OPLATKA Office: (801) 561-9990 Tel. +49(0)751 / 561430
Fax: (801) 561·9992 Fax +49(0)751 / 52736
bil' ,moss@hans·hall.com info@hans-hall.com