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The maintenance and timely replacement of critical crane components are essential for the safety and reliability of lifting operations. One of the most important components of the Liebherr LR1600 in SL configuration is the crane rope, which contributes significantly to the stability and control of the boom. Recently, the rope winch rental company Tension Winding Solutions (TWS) used an innovative replacement method to replace a worn rope without fully erecting the crane. This resulted in minimal downtime, increased safety, and a more efficient work process.

Need for exchange.
The original derrick boom rope was corroded, deformed, and had reached the end of its service life. To ensure operational safety, it was replaced with an 8-strand rope from DIEPA. The rope has a diameter of 28 mm, a breaking strength of 822 kN, and an impressive length of 1.2 km.

Under normal circumstances, such a replacement is performed on a fully assembled crane. However, due to time constraints and limited working space, this was not an option for the customer. TWS therefore developed an innovative solution that not only accelerated the replacement but also significantly reduced costs and operational complexity.

An innovative method: replacement without complete crane assembly.
Instead of disassembling the entire crane, only the derrick boom and winch were transported to the TWS test rig for boom adjustment. There, the cable drum could be precisely operated using a specially developed control unit, without requiring the crane itself.
Thanks to this control system, the old rope was safely unwound and the new rope was wound up with a precisely defined pre-tension. A rope winding machine with a constant pre-tension function ensured this uniform tension in the rope, ensuring precise winding. This prevents pressure points or deformation and significantly extends the service life of the rope.

Implementation and technical advantages.
The actual rope installation, including reeving into the boom’s rope guide, was completed in just two days. Thanks to this innovative method, the work could be completed with just two TWS skilled workers. In comparison, a conventional installation requires at least five technicians plus an additional support crane.

A critical phase in the process was the release of the rope while the luffing bridle was in the rest position. This required the utmost precision to maintain control of the rope and prevent it from suddenly slipping out. In addition, a real-time strength measurement of the rope was performed during the winding process, the values ​​of which were documented in a “Cable Service Statement.” This data provides a valuable reference for future maintenance work and inspections.

Advantages of this alternative exchange method. In summary, this modern approach brought the following significant advantages over the conventional method:
✔ Minimal downtime – The crane did not have to be fully assembled and was ready for use again more quickly.
✔ Increased safety – The precisely controlled procedure minimized the risk of sudden rope movements or uncontrolled slipping.
✔ Cost and time savings – Fewer personnel and no additional crane support required, increasing efficiency and reducing costs.

Preventive maintenance for maximum service life.
To maximize the longevity of the new rope, we recommend fully uncoiling it after 1.5 to 2 years and shortening it by 50 cm on the winch side. This shifts the transition and pressure points, allowing wear to be distributed more evenly and extending the rope’s service life.
With this innovative replacement method, TWS proves that technological innovation not only increases operational efficiency but also contributes to safety and sustainability in the field of heavy lifting technology.