Wire ropes from FATZER: Customized to your needs! Impressive success story Dedicated to tradition Founded in 1836 in Romanshorn, Switzerland, as a hemp rope manufacturer, FATZER has been making ropes of the highest quality . The company originally produced hemp ropes for agriculture, fishing and ship-building needs and began to manufacture steel ropes as well around 1900. Beginning in 1948, the company specialized in technically demanding cableway ropes. Today, FATZER focuses on the development, manufacture and worldwide distribution of high-quality heavy-duty wire ropes for passenger cableways, mines and conveyor-belt systems. With its extensive experience and corresponding reference projects, FATZER plays a leading role among rope manufacturers. As a professional partner for cableway manufacturers and operators, we offer individually customized solutions for every need. The structure, design and production of wire ropes differ depending on the various applications for which they are used and the area of installation. Only solutions precisely customized to individual needs are economical. In this respect, we see our task as delivering exactly what you really need. Customer focus Customer requirements are analyzed critically using highly specialized know-how based on 175 years of rope technology and around 100 years of processing steel wire in order to develop customized, often completely innovative solutions. Most products are produced to meet the customer's needs. High-tensile special wire Whether for use in constructing power plants or extracting raw materials, the ropes are subjected to enormous breaking forces and adverse environmental conditions. The starting point for FATZER products is high-tensile steel wire. Depending on the customer's needs and field of application, this wire is fashioned into haulage, carrying or guide ropes, up to a maximum weight of 200 tons and a diameter of 130 mm. And we continue to be there for you after the project is completed. Our comprehensive range of services also includes inspection, cleaning and maintenance of wire ropes. Our services comprise splice and damage repair for stranded ropes and locked ropes as well as insertion of wires, strands and patches, and shortening. Our machinery: Leading technology Manufacturing special ropes economically requires well thought-out technical equipment. Our plant in Romanshorn is a highly productive facility for the manufacture of stranded ropes and spiral strand ropes. The continuously updated production equipment reflects the state of the art and enables us to manufacture products customized to specific customer needs or standards. The latest technology is used to monitor parameters such as diameter and lay length during the production process. We use machines to test the bending, torsion and haulage properties in the quality control of raw materials as well as the end product. Rope test cableway The cableway market demands increasingly higher performance from systems that must run more quietly. These demands require consistent ongoing and new developments in both the cableway and rope fields. Newly developed and significantly advanced products must first prove themselves in practical trials, and yet direct field tests must be avoided because of potential safety and financial risks. It is therefore just as essential that trials be carried out on our own test systems. In this way the effects of speed, braking force, rope pull, and sheave and rope diameter on the fatigue life and wear of the ropes can be analyzed under realistic conditions. Fatigue strength behavior of spliced stranded ropes as well as of the splice itself is determined under conditions of forced bending and pulsating tension in extended-term tests. With no drive operation mechanism but with their various clamping mechanisms, 6- and 8-strand ropes with a maximum diameter of 60 mm can be accelerated to a speed of up to 18 m/s. Mountain cableways For gondola, chair, 2S and 3S cableways, the low-elongation COMPACTA® and STABILO® haulage ropes and INTEGRA® carrying ropes stand out with their extreme reliability and load capacity. STABILO®: Low-elongation STABILO ropes are the first choice of operators of systems for which downtimes to shorten ropes are only acceptable in specific, planned periods. Its high consistency of diameter is another distinguishing factor of this rope. COMPACTA®: The compacted, smooth surface results in a greater metallic cross-section with the same diameter and also ensures an improved friction connection with drive elements. This reduces wear on rollers, clamps and sheaves, while also increasing fatigue life considerably. INTEGRA®: Fully locked and half-locked ropes have proven themselves as carrying ropes for passenger cableways and ropeways for material transport Thanks to twisting manufacturing methods, the ropes have extremely low internal stress. INTEGRA-Data®: A bundle of fiber-optic cables or several low-voltage cables can be integrated in the core of the rope. STABILO® COMPACTA® INTEGRA® System CabriO-Bahn Customer Stanserhorn Bahn AG Cableway manufacturer Doppelmayr/Garaventa Project An innovative cableway systems enables guests to soar toward the Stanserhorn under the open skies. The double-decker ropeway with two gondolas has an open upper deck. High-performance urban cableways The 6-strand PERFORMA-DT is characterized by its long service life and minimal elongation and vibration properties. These construction types are thus predestined for use in urban cableways. They guarantee smooth operation without bothersome interruptions. Considering the economic aspects of the long maintenance intervals, low operating costs and ecological advantages (minimal noise emissions), these two products provide maximum benefits for system manufacturers, city planners and civil engineers focused on sustainability. OCTURA®: The 8-strand transport rope provides particularly long-life splices. The plastic core, which heats up during closing, also supports and stabilizes the strands. It is particularly suitable for short systems and systems in which downtimes are acceptable only at the greatest possible intervals. COMPACTA® OCTURA® PERFORMA® System Emirates Air Line London Customer Mace UK Cableway manufacturer Doppelmayr Seilbahnen GmbH Project The Emirates Air Line is a cable car that connects the London neighborhoods Greenwich and Docklands, crossing the Thames between the Greenwich Peninsula and Royal Docks stations. The 8-strand OCTURA® 8x36 Warrington Seale transport rope has a diameter of 50 mm and an overall length of 2,340 m. Thanks to its minimal elongation and the long service life of the special splice used with 8-strand ropes, the downtimes for shortening ropes are minimized; compacting also reduces strand-induced oscillation and noise emissions. Ropeways for material transport Wire ropes that are constantly carrying heavy loads have a tough job. It goes without saying that system-specific solutions are in demand in this area. Whether for use in constructing power plants or extracting raw materials, the ropes are subjected to enormous breaking forces and adverse environmental conditions. In addition to conventional cableway systems, FATZER ropes are also used in innovative RopeCon conveyor systems for transporting loose material. These systems use 6-strand COMPACTA® and PERFORMA® ropes to move the material. PERFORMA®: The plastic profiles between the strands separate the strands from one another and stabilize them in position. The rope runs practically without vibration and soundlessly over rollers and sheaves and is distinguished by minimal elongation and wear of the roller supports and guide wheel linings. COMPACTA® INTEGRA® PERFORMA® System RopeCon® Mount Olyphant, Jamaica Customer Jamalco/Alcoa, Clarendon Cableway manufacturer Doppelmayr Transport Technology GmbH Project In August 2007, around 60 km southwest of Kingston on the Caribbean island of Jamaica, the largest RopeCon® system to date was handed off to Alcoa, the world's largest aluminum producer. Every three seconds the system transports one ton of bauxite from the mining region on Mount Olyphant over a distance of 3.4 km and a vertical drop of 470 m to the valley below for processing. The conveyor runs on four fully locked INTEGRA® haulage ropes with a diameter of 52 mm and a total length of 14.4 km. Winch ropes The wire rope technicians at FATZER work closely with well-known manufacturers of slope-grooming machines and winch systems to develop solutions that meet the special requirements of friction, capstan and drum winches with respect to all aspects of functionality and efficiency. Practical training sessions and seminars, which are continuously modified to meet current needs, support the service technicians and users of low-maintenance winch ropes. PWtrac® Product PW-Trac® winch rope Customers Mountain railway operators on all continents Project With a diameter of 11 mm, the compacted, double-parallel construction is set apart by particularly high breaking forces (up to 119 kN), long fatigue life (up to 10,000 passes), and being absolutely maintenance free. The continuous recording of parameters such as number of winch cycles, tensile force and length of rope used - provide important findings for research and development. The data support FATZER in the optimization of rope handling and performance. Training sessions and personal consultation provide important information and tips for the proper handling and maintenance of winch ropes. Service and installation Thanks to our years of experience in the manufacture and maintenance of wire ropes, we are able to optimally support cableway manufacturers and operators. We perform services in the areas of rope installation and service quickly and with no hassles. Our offerings include splice work as well as rope inspection, rope cleaning, relubrication and repairs. We also pass our expertise on to customers other interested parties in regularly scheduled training sessions and seminars. Our comprehensive range of services also includes maintenance of wire ropes. Our services comprise splice and damage repair for stranded ropes and locked ropes as well as insertion of wires, strands and patches, and shortening. Splicing - Splice work using pressure-resistant splice tape - Rope shortening & splice inspection Rope inspection and cleaning - Cleaning of carrying, haulage and guide ropes - Visual rope inspections - Relubrication to increase fatigue life Quality assurance - Performance of all QA measures such as tearing tests, measurement of e-modules, etc. - Testing of system breaking load, documented a test certificate - Continual quality control by external institutions - All FATZER materials can be traced with certificates Installation - Worldwide installation with in-house installation team Project consultation - Technical consultation during the project planning stage - Calculation of fatigue life for various rope types - Calculation of overall operating costs, total cost of ownership STABILO® When the strands of a wire rope settle and work their way into the core, there are consequences. The diameter decreases, the rope elongates and the fatigue life decrease because notches develop on strands that come in contact with one another, which eventually leads to wire breaks. With STABILO® the interior, which the strands surround, is completely filled. The polyethylene core rod is heated up during closing and the plastic between the strands is compressed. This creates a load-bearing body that supports and stabilizes the strands. At the same time it prevents the strands from touching and, thanks to restraint-guided closing, holds them at uniform distances. The classic areas of use for STABILO® ropes are continuously circling cableways, in which downtimes for rope shortening are acceptable only at specified, predictable periods or at the possible intervals. 6 x 25 Filler Wire 6 x 36 Warrington-Seale STABILO® 6 x 47 Filler Wire 1 2 Customer benefits - progression of elongation can be calculated within precise tolerances - embedding of strands to the level of strand shoulders - lubricated strands - high consistency and stability of diameter - infrequent shortening required - rope elongation can be calculated and predicted Design properties: Core: solid polymer rod Strands: 6x, not compacted 3 References 1 Ba Na Big Resort, Vietnam Diameter: 56 mm Rope length: 11,840 m 2 Melchsee-Frutt, Switzerland Diameter: 56 mm Rope length: 6,300 m 3 Roza Khutor, Sochi, Russia Diameter: 56 mm Rope length: 7,768 m COMPACTA® The compacted strands of the COMPACTA® rope increase the filling factor of the strands and thereby increase their load-bearing metallic cross-section. This has consistently positive effects: First, the diameter decreases; secondly, the breaking force increases by around 10 percent; and thirdly, the fatigue life of the rope increases. Thanks to the smoothed contours of the outer wires, bearing pressures around the clamps and rollers are reduced. And in the event that strands come into contact with one another, the greater contact surface reduces tension peaks. Compared to conventional ropes, they therefore have more stable diameters and are more resistant to torsion and twisting forces. Their nearly flat surface also ensures an improved friction connection to drive elements and thus reduces wear on roller, clamps and sheaves. 6 x 19 Seale Compacted rope Conventional rope 6 x 25 Filler Wire 6 x 36 Warrington-Seale COMPACTA® 1 2 3 Customer benefits - increased rope breaking force for a given diameter and reduced diameter for the same rope breaking force - less wear on roller, clamps, drive and return sheaves - more stable torsion factor and compressive strength - improved damping of rope oscillation and vibration - increased fatigue strength thanks to reduced internal strand tension and distributed load-bearing characteristics of the individual wires Design properties Core: solid plastic Strands: 6x, compacted References 1 Peak to Peak, Whistler Mountain, Canada Diameter: 46 mm Rope length: 9,490 m 2 Roza Khutor/Sochi, Russia Diameter: 56 mm Rope length: 7,768 m 3 Anglo American mine, Australia Diameter: 34 mm Rope length: 44,000 m OCTURA® Systems that cover short distances or have long operating hours and little downtime put above-average strain on the ropes. In these cases it definitely makes sens to use a compacted 8-strand rope with a Fullplast insert in order to increase the fatigue life of the rope considerably. The 8-strand compacted OCTURA® is the basis of a long fatigue life. Frequently, however, the problems related to product lifespan are not found in the open stretches of the rope; instead, it is the spices that limit the lifespan of the rope. Comprehensive tests and valuable feedback from our customers have shown that the fatigue life of the rope is approximately doubled with the 8-strand FATZER splice. OCTURA® compacted strands polyethylene core to stabilize strands 8 x 25 Filler Wire 8 x 36 Warrington Seale 8 x 47 Warrington Seale 1 2 Customer benefits - minimal strand-related vibration - low running noise emissions - minimal elongation characteristics and increased consistency of diameter - infrequent shortening required - rope elongation can be calculated and predicted - no strand contact and therefore considerably longer fatigue life Design properties - Core: solid polymer core - Strands: 8x, compacted 3 References 1 Marquam Hill Aerial Tram, USA Diameter: 34.5 mm Rope length: 2,300 m 2 Providência/Rio de Janeiro, Brazil Diameter: 47 mm Rope length: 1,180 m 3 VW plant cableway, Slovakia Diameter: 45 mm Rope length: 2,100 m PERFORMA® PERFORMA technology, which used plastic profiles between the strands, was developed with the goal of eliminating strandrelated vibration in haulage and hoisting operations. These profiles fill the surrounding circular area nearly completely, separating the strands from one another and stabilizing them in position. As a result of its smooth surface structure, the rope runs practically without vibration and noiselessly across roller and sheaves. And just as compelling is the rope's greatly reduced settlement. Using PERFORMA ropes is especially recommended for systems that operate for extended periods every day, as well as in situation in which vibration and noise would compromise the comfort and well-being of passengers, residents and passers-by. The innovative PERFORMA-DT® was conceived especially for heavy, detachable systems. How PERFORMA® ropes are constructed: extruded round polyethylene rod as core six strands of compacted construction six extruded, fabric-reinforced profile rods made of plastic with high resilience and elongation at break PERFORMA® 1 2 3 Customer benefits - no strand-related vibration while passing over rollers - previously unattainably low running noise emissions - maintenance free - advantageous elongation characteristics and increased consistency of diameter - no strand contact and therefore considerably longer fatigue life - longer fatigue life for roller fillings, so that maintenance costs are reduced Design properties - core: polyethylene rod - high-tensile I-profiles - Strands: 6x, compacted References 1 Montjuïc, Barcelona, Spain Diameter: 44 mm Rope length: 1,650 m 2 MGM Las Vegas Center, USA Diameter: 36 mm Rope length: 3,350 m 3 Lagoas Park/SATU Oeiras, Portugal Diameter: 30 mm Rope length: 2,650 m Special ropes In addition to ropes for transporting passengers and materials, Fatzer also develops and produces wire ropes for special applications with static or dynamic demands, and has developed this area into another of its competencies in the field of wire rope technology. These special ropes are used primarily in the areas of rope-manufacturing plants, winch systems, rope traction devices, and mining equipment and hoists. As a qualified and innovative partner, Fatzer provides customized system solutions for demanding fields. Shaped and round wires with large diameters and low carbon content are used in the outer layers in half-locked guide ropes. This keeps wear and the formation of martensite to a minimum. Shaped wires in the outer layers also prevent the penetration of dirt and dust particles, thus minimizing susceptibility to wire breaks. Structure of the COMPACTA® special rope with electrical conductors compacted strands 6 copper wires for electrical supply stranded around a PE core Half-locked guide rope Spiral rope 1 2 Customer benefits - special construction individually customized to customer needs - depending on use with power supply lines, fiber-optic cables and ready-made terminations - comprehensive consulting services beginning the the project planning stage with our experienced engineers and developers References 1 FAM Magdeburg, Germany Diameter: 75 mm Rope length: 4x150 m Construction type: 3-layer, fully locked carrying rope for gib 3 2 Saucito mine, Mexico Diameter: 60 mm Rope length: 16x620 m Construction type: half-locked guide rope for mine shaft 3 Supply winch, Linthal power plant, Switzerland Diameter: 28 mm Rope length: 2,470 m Construction type: 6x19 Seale with 7 copper lines INTEGRA® and INTEGRA-Data® Our fully and half-locked ropes are available in both conventional and "twisted" designs. The profile wires are preformed in their later spiral position, which creates an absolutely tension-free rope that can be easily manipulated during rope placement. Only shaped wires with the smallest shape tolerances and high accuracy of fit are used. Fully and half-locked ropes can be used in a wide range of applications: Their proven versatility as carrying ropes extends from cableways for transporting passengers and materials to conveyor and guide ropes in mine hoists. The INTEGRA-DATA® rope also allows electric supply lines or fiber-optic cables to be integrated in the rope core. INTEGRA® Shaped wire layer(s) Core rope Fiber-optic cable integrated in the core rope INTEGRA-DATA® INTEGRA-DATA One or more bundles of leads with integrated optical fibers are cabled into INTEGRA-DATA® ropes. Analog low-voltage cable 1-layer Nominal ø 16 - 45 mm 2-layer 3-layer and multiple-layer Nominal ø 28 - 90 mm Nominal ø 50 - 120 mm Bollard anchoring End socket anchoring Track rope 3 1 2 Cable end closure End socket 3 Reserve reel Track rope 1 2 Cable end closure Fiber-optic cable is exposed (1) and spliced to the non-metallic optical-fiber connection cable (3) in the socket (2). 1 2 Customer benefits - universal data connection between upper station and base station - replaces additional, risk-plagued signal and control ropes - twisted version tension-free and twist free - fast, safe retraction - reliable signal and data transmission Construction types - core: round wire - outer layer: up to 6 shaped wire layers 3 References 1 Piz Val Gronda, Austria Diameter: 72 mm Rope length: 4x2,900 m Construction type: 3-layer, fully locked, 3 carrying ropes with 6 electric supply cables, 1 rope with LWL 2 BUGA Koblenz, Germany Diameter: 54 mm Rope length: 4x1,135 m Construction type: 2-layer, fully locked, 1 carrying rope with 18 multi-mode and 6 single-mode fibers 3 Mt. Olyphant RopeCon, Jamaica Diameter: 52 and 42 mm Rope length: 4x3,600 m Construction type: 3-layer, fully locked PWtrac®/PWtrac winch rope PLUS Around the world, drivers of slope-grooming machines count on PWtrac® winch ropes from original equipment manufacturer FATZER. And with good reason: They are the safest, most reliable ropes used for the difficult work on steep slopes and are distinguished not only by their reliability and long service life, but also by particularly high breaking forces. PWtrac® winch ropes have been securing slope-grooming machines around the world since 1983. The 9-strand winch ropes are a special product that was developed in collaboration with the engineers at the winch manufacturer Plumettaz and are optimized for used with capstan winches. Training sessions provide information on the correct handling of the ropes, visual inspections and the optimization of fatigue life. But the ability to analyze rope damage in practical situations and derive protection measures from these situations is also integral to these seminars. PWtrac® 1 2 Customer benefits - high breaking forces (up to 119 kN) - long fatigue life (up to ±10,000 passes) - run times of up to 1,320 hours - excellent winding characteristics - compacted surfaces, which increase both the friction and the breaking force of the rope Construction types - 9-strand steel rope with diameters of 9 to 11 mm. Produced with suitable hook upon request. References 1 Kässbohrer, Germany 3 2 Sochi, Russia Numerous PistenBullys prepared the pistes for the Olympic Winter Games in Sochi. PWtrac® ropes were used exclusively to ensure safety on the steep slopes. 3 Saas Fee, Switzerland This PistenBully was caught in an avalanche. Its PWtrac® winch rope prevented it from being swept further down the slope. TRUsplice® and splice kit FATZER rope transport passengers and materials safely and reliably when they are properly transported, installed and spliced. Once it arrives at its destination, the rope is first pulled into place, which involves feeding it into the rope-guiding elements and raising it to its final position. The tension on the rope must be slackened for the final splicing. The splice interlocks the two rope ends, forming an endless loop, which is required for continuously circling cableways (e.g. cable car systems, chairlifts). FATZER has developed a proprietary splicing process in which the original core remains in the center of the splice and the insertion ends are wrapped with FATZER's pressure-resistant splice tape. TRUsplice® is a tailor-made insert that is specially customized to cradle the strands of the rope. This reduces strand contact to a minimum and increases the fatigue life of the rope. TRUsplice® FATZER splice tape 1 2 3 Customer benefits - reduces operating costs over the fatigue life of the rope - increases the fatigue life of the splice - increased system availability - reduced running noise emissions - gentler coupling processes around the splice - possible to eliminate a casing patch References 1 Melchsee-Frutt, Switzerland The insertion ends of the previously straightened strands are wrapped with FATZER's special splice tape, which prevents wire breaks and the diameter of the strands to the size of the removed core. 2 Grimentz-Zinal, Switzerland A splicing bridge, which hangs from the carrying ropes, had to be installed here to complete the splicing work 3 Montjuïc, Barcelona, Spain When splicing PERFORMA® ropes, the plastic profiles cabled between the strands are fused. Transport logistics FATZER provides consulting and services in the areas of rope installation and servicing. These include splicing work, rope cleaning and inspection, and rope repairs. FATZER is happy to provide expert help in the selection of the ideal rope for your needs and are available to provide you with consultation around rope transport. Professional support during the RFP and project phases is assured. 1 2 Customer benefits - overall planning, handling and monitoring of transport processes - special logistics solutions - handling of all international customs formalities References 1 Grimentz-Zinal, Switzerland Logistics solutions specially developed for FATZER with two coupled flatbed trucks and a bobbin configuration that enables the ropes to be spooled from one bobbin to the other at bridges and embankments that are structurally incapable of bearing the full load. 3 2 Merida Pico Espejo, Venezuela The transport of the total of around 600 tons of steel rope began with the bobbins being transported by land to the Rhine Harbor in Basel, and then to Rotterdam for the Atlantic crossing to Venezuela. 3 Wengenalp, Switzerland The last few meters to the base station had to be covered by rail for this customer. Product Consulting and project support Product consulting and project support FATZER is your go-to reference for all questions related to ropes. Our years of experience and specialization in the manufacture of cableway ropes make for a compelling, industry-specific knowledge base to optimize our support for cableway system manufacturers and rope users alike. We are happy to provide expert help, from the selection of the ideal rope, to a suitable rope transport, to service and maintenance once operation has begun. Choosing the right rope: Even in the systemplanning phase before a project begins, parameters that influence the choice of rope are being decided. Whether it is a winter mountain cableway intended for operation during a three-month season or an urban system that will operate 24/7 will have a decisive impact on the selection of rope. In the past, the minimum breaking force was the main factor in the selection of the rope construction; today, other characteristics such as • • • • • • • fatigue life of the rope predictability of rope maintenance and replacement 100% availability costs beyond the planned rope and system lifespan financial planning noise emission after-sales service play a more important role as the basis for product decisions. In addition to various long-lived products, FATZER possesses pivotal tools for calculating the system-specific TCO (total cost of ownership) over the planned fatigue life. Required work on the splice and the rope can be accounted for in the planning phase so that costs and maintenance work can be predicted. Extended guarantee and maintenance packages can be customized to the customer‘s needs. Use after type of ropeway Haulage- and hoisting ropes: STABILO® COMPACTA® OCTURA® PERFORMA® SPECIAL1 Cable Car Chair lift Funitel 2S / 3S3 3 3 3 3 Ropeway with endsocket3 Ropeway with haulage rope as sling3 Funicular railway APM Urban- and shuttle ropeways, in particular short ropeways, with stop-off points and noise-sensitive environments PP-core, copperweighted, with electrical conductor, with steel-core Not available for Stabilo, OCTURA (from 2015), beyond a ø from 34mm 3 With PP-core 1 2 Seasonal ropeways (short operating times) TRUSplice2 Worldwide presence 05.2014.250 FATZER is one of the four successful divisions of the BRUGG Group, which provides around 2,000 secure jobs in 54 companies in 16 countries. Several installation and splicing teams on all continents allow us to be on site at our customers' locations quickly.
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