ROPE MANUAL

DONGYANG MFG
INDEX

A. DONGYANG MFG is

B. Overview of Fiber Rope

C. General Guideline for Management

D. High Performance Ropes

E. Accessories

F. Appendix
A. DONGYANG MFG is
A. DONGYANG MFG is

Since its foundation in 1949

Reserved 19 patents
120 people working

First to develop UHMWPE yarn in KOREA

MEG4 type-approved by LR
(HMPE rope)
B. Overview of Fiber Rope
B.1.Oerview of the Rope
Material properties B. Overview of Fiber Rope

Specific Melting Elongation Tenacity

Material
Gravity Point (°C) (%) (g/den)
Polypropylene 0.91 165 18~22 9
Floating Polyolefin 0.91~0.99 140~196 15~20 9
Type HMPE 0.97~0.98 149 4~5 32~40
PP+Polyester ~0.99 165/260 14~18 -
PP+Polyester 1.01~ 165/260 14~18 -

Non- Nylon 1.14 220~280 22~30 9~10

Floating Polyester 1.38 249~260 12~18 9~10
Type Aramid 1.39~1.47 499 3.5~4.6 18~29
LCP 1.40 329 3.3~3.6 23~29
2. Grasping each material B. Overview of Fiber Rope

Very light and buoyant in water

Polypropylene
Abrasion resistance and temperature resistance are lower than other fibers

Good breaking loads and low stretch

Polyester Good UV resistance and salt water resistance,
Good abrasion strength in both dry and wet condition

High breaking load as well as high elongation

Nylon The abrasion resistance in wet condition is better than in dry (up to 7%)
Lower resistance to UV radiation in sunlight (compared to Polyester)

Extremely high strength fiber

UHMWPE 15 times stronger than steel wire for the same weight
Excellent performance in terms of abrasion and UV resistance.

Extremely high breaking load and no stretch.

Aramid
Mainly used in places where high temperature resistance is essential
3. How to produce a fiber rope? B. Overview of Fiber Rope
4. Various rope constructions B. Overview of Fiber Rope

Twisted rope Braided rope

3-strand 4-strand 6-strand 8-strand 12-strand 32-strand

5. How to measure rope size? B. Overview of Fiber Rope

Diameter
- Unit : mm, inch

Measurement
Twist rope (3, 4 and 6-Strand) - Vernier caliper
Braided rope (8, 12 and 32-Strand) – Measuring tape

Twisted Rope(3,4,6 Strand) Braided Rope (8,12,32 Strand)

 C. General Guideline for
Purchasing, Management and
Retirement
:
How to pick a proper rope and
use it correctly?
B.Flow
THEChart
PROCESS OF ROPE SELECTION C.&General
USING Guideline

Buyer Maker Buyer Maker User User User

SHIP DESIGN MBL PICK A ROPE INSTALLATION RETIREMENT

PRODUCTION
RECOMMEND MAINTENANCE
& TESTING

Step Step Step Step Step Step Step

1 2 3 4 5 6 7
 Step 1. Specifying SDMBL/LDBF C. General Guideline

The minimum breaking load of new, dry mooring lines for which a ship's mooring
Ship Design system is designed, to meet OCIMF standard environmental criteria restraint
Minimum Breaking Load requirements. The SDMBL is the core parameter against which all the other
components of a ship's mooring system are sized and designed with defined
(SDMBL) tolerances.

LDBF is the minimum force that a new, dry, spliced mooring line will break at when
tested according to appendix B. This is for all mooring lines and tail materials except
Line Design Break Force those manufactured from nylon which is tested wet and spliced. This value is declared
(LDBF) by the manufacturer on each line's mooring line certificate and is stated on a
manufacturer's line datasheet. When selecting lines, the LDBF of a line shall be
100%–105% of the SDMBL.

TDBF is the minimum force that a new, dry, spliced mooring tail will break at when
tested. This is for all mooring lines and tail materials except those manufactured from
nylon which is tested wet and spliced. This value is declared by the manufacturer on
Tail Design Break Force each line's mooring line certificate and is stated on a manufacturer's line datasheet.
(TDBF) When selecting lines, the TDBF of a line shall be 125%–130% of the SDMBL.
The TDBF for nylon mooring lines should be specified as break tested wet because
nylon tails change strength characteristics once exposed to water.

Step
1
Step 2. Taking a recommendation C. General Guideline

LDBF is the minimum force that a new, dry, spliced mooring line will
break at when tested. This is for all mooring line and tail materials
except those manufactured from nylon which is tested wet and spliced.
This value is declared by the manufacturer on each line’s mooring line
certificate and is stated on a manufacturer’s line data sheet. As
outlined in appendix B, when selecting lines, the LDBF of a line shall
be 100%–105% of the ship design MBL.

(Ex)
Ship Design MBL : 50 ton
LDBF : 50ton x (100~105%) = 50~52.5ton

The LDBF for nylon (polyamide) mooring lines should be specified as

break tested wet because nylon lines change strength characteristics
once exposed to water and generally do not fully dry to their original
construction state.

Step
2
Step 3. Understanding properties C. General Guideline

Before using a rope, you should consider the following properties of the rope.
Most rope manufacturers recommend ropes to you if you present the following conditions.

The strength should always be some factor greater than the intended working load
for a given application. While there is a tendency to select products with the highest
Strength
tensile strength possible, care should be taken to assure other performance
properties are not sacrificed.

Working loads, often called working load limits (WLL), are calculated by dividing the
Working loads &
rope minimum breaking strength (MBS) by the required safety factor (sf).
Safety factor
WLL = MBS / SF

Ropes with higher elastic elongation are typically used to provide a form of energy
Elongation absorption in a system, while ropes with relatively low elongation fiber provide
increased position control and less stored energy at a given load.

Diameter & Linear Density Linear density means the mass per unit length of fiber rope under pre-load, in ktex.

A material's slow deformation that occurs while under load over a long period of time.
Creep is mostly nonreversible. For some synthetic ropes, permanent elongation and
Creep
creep are mistaken for the same property and used interchangeably when in fact
creep is only one of the mechanisms that can cause permanent elongation.

Specific gravity (buoyancy of a rope / material) is a measure of the density of a

Flotation material; a Specific Gravity of 1.0 is equivalent to a density of 1g per cm3 (i.e. a
Specific Gravity <1 means the material floats).

Step
3
Step 4. Manufacturing a rope C. General Guideline

Raw Material Inspection

ROPE Extrusion

MANUFACTURING
PROCESS
Forming

Laying

Inspection

Packaging

Storage or Sale

Step
4
Step 4. Testing a rope C. General Guideline

Testing Method

Standard
: ISO 2307

Sample Length
: 6~11m

Test Speed
: 250mm/min

Pre-Stretched
: 10 cycles
(MBL spec 50%)

Step
4
Step 4. Class societies available C. General Guideline

Approved Class

Note
A manufactured rope is tested to suit the user's application and supplied to the
buyer. The Class Societies listed above are the most commonly required.

Step
4
Step 5. Rope installation C. General Guideline

● Uncoiling
The best way to uncoil is to use a turn-table.
A rope should be uncoiled from the end outside.

Turn-table

☞ Never pull it from the center of the coil

Step
5
Step 5. Rope installation C. General Guideline

● Using chafe guard ( rope protector )

Cover a part of rope contacting bollards/fairleads with chafe guard.

● Number of wraps on tension drum

Maintain the number of following wraps
on the tension side of split drum winches
at full extension.

Synthetic fiber ropes: 5~6 times

HMPE lines: more than 10 times

Step
5
Step 5. Rope installation C. General Guideline

● Twist/Torsion
Detect as many twist as possible and remove/correct all.
Excessive twisting ☞ Strength degradation & cover failure

● Using tails
For HMPE lines, use mooring tails
at the shore end all the time.

Step
5
 Step 5. Rope installation C. General Guideline

A 1. Drum Capacity
A : Traverse
B : Flange Diameter
C B C : Core Diameter

A(B² - C²)
15.3(Rope Dia.)²

C L = Length of Rope.
A = Length of Winding.
B = Diameter of Barrel.
C = Width between Flanges.
B K = A Constant developed according to
the diameter of the rope.
A Dia
K
L = {(A+B) x A x C} / K (mm)
16 81490
18 103100
(EX)
A : 350mm , B : 350mm, C : 485mm 19 114900
Rope diameter : 26mm 20 127400
22 154100
= (700 x 350 x 485) / 215200 24 183300
= 552 meter 26 215200
28 249600

Step
5
 Step 6. Maintenance : Storage C. General Guideline

■ Rope Storage and Care

Recommended conditions for proper storage

No UV No Chemical

Max. 65% of
relative
Ventilation
humidity

Long

Approx. 20°C Life Time

of Storage Store loosely
Temperature

Step
6
 Step 6. Watching out a rope twist C. General Guideline

■Elimination of Twist

Twist may reduce a rope’s life

time. Also, it has a negative
impact on any braided structure.

Twist increases the likelihood

Straight
that a rope will kink and get
caught in pieces of equipment.
Strong twist can cause a rope's
cross-section to become non-
round, which accelerates wear
and reduces its strength.
Eliminating twist from a rope
improves its handling comfort Twisted
and prolongs its life span.

Step
6
Step 6. Facing torsion risks C. General Guideline

TERAMAX
12S/T
22mm

Twist Per Meter

0 0.5 0.8 1 3
(TPM)

MBL (ton) 49.9 47.9 46.9 44.4 37.3

Residual strength
100.0 96.0 94.0 89.0 74.7
ratio (%)

Variation of tensile strength due to twist

※ When a rope makes more than two turns within a 1 meter span,
its strength can be reduced by 10%.

Step
6
Step 6. Protecting a rope surface C. General Guideline

■ Protection for ropes

There are a variety of factors that could damage fiber ropes in use. Abrasion is a very important factor that
determines the performance when using a rope. Our high performance rope protectors prevent ropes from
directly contacting sharp edges or rough surfaces, thereby minimizing wear and tear and preventing
performance degradation.

Step
6
 Step 6. Degradation by mooring angle C. General Guideline

■ Strength degradation by angles during mooring

In general, a mooring rope’s breaking

strength indicates the data
tested/measured in a lab with a specimen
placed in vertically direct line. But a
mooring rope usually is set by passing
through many bollards and fairleads with
many angles. These angles make a rope
take more loads than one generated in
horizontally direct line. The following
picture describes how much loads a rope
takes depending on mooring angles. It is
known that the bigger cosθ angle from the
vessel is, the more loads on a fiber rope is
geometrically increased.

Step
6
 Step 6. Precaution agt snapback C. General Guideline

■ Warning: Snap back zone

1) Snap Back Zone

The highest number of injuries and deaths during a mooring

operation on a ship is due to the parting of the rope or wire
hitting back to a crew member standing in the area of the
rope recoiling. The area traveled by the parted rope having a
force enough to kill a person on its way is known as the snap
back zone.

2) The best ways to avoid accidents by rope bight are:

• The crew members must be aware of where they are

standing while handling the ropes or when near them. It must
be repeatedly made known to them so that they should never
stand on the snapback zone.

• Inexperienced crew such as cadets and fresh ratings should

bellow to handle a rope only under supervision.

Step
6
 Step 6. Type of Inspection C. General Guideline

Deployment Inspection Routine Inspection Detailed Inspection

The full length of line on the in-service Either the full length of line, or the full
section of the line (typically on the length of the in-service section of the line
The working length of line (outboard of tension side of the mooring winch) is (typically on the tension side of the
the tension side of the winch) is inspected. This is a visual inspection, mooring winch) is inspected externally and
Description
inspected for defects which may impair externally and internally where possible internally where possible (i.e. unjacketed
of line
the performance of the line. This is (i.e. unjacketed lines). lines).
inspection
typically completed during mooring
operation. Jacketed lines will require a routine Jacketed ines will require a detailed
inspection as recommended by line inspection as recommended by line
manufacturer and operator experience. manufacturer and operator experience.

Example 250 mooring hours or six months, 1,000 mooring hours or ship special survey
Every mooring operation
Frequency whichever occurs first (e.g. five years), whichever occurs first

Manufacturer's representative, third party

Mooring party Ship personnel
Who does expert or ship personnel
(Training requirement stated in LMP) (Training requirement stated in LMP)
(Training requirement stated in LMP)
Inspection reports may be issued against standardised criteria.

* Incident report (e.g. line failure, or

* Inspection report * Inspection report
other significant damage), liaise with
Output * Repair requirements
manufacturer
* Repair requirements * Recommendations
* Go/no go decision to use lines in next
(end-for-end/retire/repair)
mooring operation
* Recommendations * Details of repairs undertaken
* Document repairs

Step
6
Step 7. Retirement : checking factors C. General Guideline

Visual Inspection Risk Factors

Any cut strands should be reported to a qualified person. It cause degradation of rope
Cut strand
residual strength quickly.

Broken filaments and yarns. Open the strand and look for powdered fiber, which is one
Abrasion
sign of internal wear.

Fused fibers, Brittle fibers, Stiffness. This means that the rope is damaged by chemical
Discoloration
contamination.

Inspect for Flat areas, lumps or bumps. This can indicate core or internal damage from
Inconsistent Diameter
overloading or shock loads.

It can indicate excessive dirt or grit embedded in the rope or shock load damage and is
Inconsistent Texture
usually reason to replace the rope.

It is the signs of heat damaged with more strength than the amount of melted fiber
Glossy or Glazed Areas
indicates.

Step
7
Step 7. Retirement : residual strength C. General Guideline

Residual Test of Nylon 8S/T 64mm

- This test was conducted on the
condition mentioned below. The
diameter was 62mm under initial loads
after measurement and then the
specimen was broken during testing
without any cycles of load considering it
is already being used. Given strength
degradation of both moisture (-15%)
and eye spliced testing (-10%), Nylon
rope has 76.5% breaking strength which
is commonly acceptable. The breaking
Sample length : 6m with eyes spliced strength was recorded at 50.2 ton after
Test speed : 250mm/min testing, which means the rope has 60.8%
Temperature : 22.6.℃ of residual strength in conclusion. With
Humidity : 64.9% this result, it is known that there’s some
Cycle : No Cycles loss in strength due to a lot of use and
MBL spec. : 82.5ton (new rope) it is recommended that this rope should
Breaking load : 50.2 ton be replaced to a new one.

Step
7
 Step 7. Retirement : Tracing factors C. General Guideline

At least the following records shall be kept for each life safety rope and equipment item:

* Key Factors (User)

(1) Equipment identification

(2) Date of purchase

(3) Date placed in service

(4) Manufacturer and model number

(5) Month and year of manufacture

(6) Dates of use, including how used, weather conditions, potential damage,
and other circumstances relating to use

(7) Dates of cleaning and inspection

Step
7
D. High Performance Rope
(UHMWPE Rope)
1. High Performance Fiber D. High performance Rope

Specific Melting Elongation

Material Tenacity (g/den)
Gravity Point (°C) (%)

Floating
HMPE 0.97~0.98 149 3.6 32~40
Type

Non- Aramid 1.39~1.47 499 3.5~4.6 18~29

Floating
Type LCP 1.40 329 3.3~3.6 23~29

Extremely high strength fiber.

UHMWPE For the same weight it has 15 times the tensile strength of steel.
Excellent performance in terms of abrasion resistance and good UV-
resistance.
Extremely high breaking load, no stretch.
Aramid Mainly used in places where high temperature resistance and abrasion is
essential.
Ropes with a Liquid Crystal Polymer (LCP) core, made using Vectran®
LCP fibers, covered by your choice of jacket for extra UV and abrasion
resistance.
2. UHMWPE Fiber D. High performance Rope

■ What is UHMWPE Rope?

UHMWPE (Ultra High Molecular Weight PolyEthylene) rope is an extremely tough plastic
with high abrasion and friction resistance. It's a superior alternative to steel wire rope and
used in maritime, lifting and high friction industries.

■We currently have three UHMWPE product lines:

- Teramax
- Teramax Plus
- Miramax

We produce our own UHMWPE yarn named MirAcle®. Also, we make our Teramax lines
made of various brands of UHMWPE yarns such as Miracle, Spectra and Dyneema etc.
C. High Performance Ropes
3. DONGYANG UHMWPE Line up D. High performance Rope
2-1. Teramax Rope
■ Teramax

Structure 12-strand
Material UHMWPE
Specific Gravity 0.97 (Floating)
Melting Point 150˚C
Elongation at Break 4%
Workable Below -20˚C

Characteristics
- 1/7 of wire rope weight
- Excellent resistance to UV / chemicals
- No difference in tensile strength wet
- Kink / Torque Free
C. High Performance Ropes
3. DONGYANG UHMWPE Line up D. High performance Rope
2-1. Teramax Rope
■Teramax Plus
Structure 12-strand Core
&
32-strand jacket
Material (Core) UHMWPE
Material(Jacket) UHMWPE or
Polyester
Specific Gravity 0.97 ~ 1.09
Melting Point 265˚C / 150˚C
Elongation at Break 4~5%
Characteristics
- Extremely high strength / low stretch
- Excellent resistance to UV / chemicals
- No difference in tensile strength wet
- Kink / Torque Free
C. High Performance Ropes
3. DONGYANG UHMWPE Line up D. High performance Rope
2-1. Teramax Rope
■MiraMax

Characteristics
- UHMWPE + Polyester Mixed with
special coating
- Maximizing abrasion resistance
- Superior anti-fatigue performance
- Easy to handle
- High flexibility
C. High Performance Ropes
4. Manufacturing process D. High performance Rope
2-1. Teramax Rope

SPECIAL TERAMAX
FIBER
YARN SETTING STRAND (CORE
(UHMWPE)
YARN ROPE)

EYE SAND
COVERING
SPLICING BARRIER

TERAMAX Sand COVER/JACKET

(CORE ROPE) barrier

PROTECTOR
(option)
C. High Performance Ropes
4. Manufacturing process D. High performance Rope
2-1. Teramax Rope

CORE(12S/T) OUTER (32S/T) NEW PROTECTOR

E. Accessories
1. Mooring Tail E. Accessories

According to the book, the figure is

Need For Tail Ropes double, but we recommend 1.7 times.

- HMPE lines should be used with a tail rope to reduce dynamic loads induced
during mooring operation and distribute the loads more evenly among mooring
lines in service.

- A mooring tail takes a role to absorbing shock/energy within the mooring system.

■Single Leg Tail: Standard 11m tails with 1m one

end and 2m other end, adequate for sheltered pier
side moorings where little or no wave induced by
vessel motions occur.

■Grommet Type Tail: The strength of a Grommet

mooring tail is 1.7 times stronger than a single leg
(of the same material, construction and size) and its
length depends on the customer’s requirements.
☞ MEG4 mentions 2 times, but we recommend 1.7 times for more safety.
2. How to use mooring tail? E. Accessories

- Tails are generally connected to mooring lines either through

the use of mechanical connecting devices or directly with
HMPE ropes in a way called cow hitch.

- A cow hitch is the most commonly used method to connect Cow hitch
two ropes. It can be used if both ropes have eyes and are
protected with a strong protective cloth to prevent damage to
the eyes.

-A soft shackle is a newer alternative to the cow hitch. The

advantage of this solution is that part of the mooring
Soft shackle
configuration can be replaced without having to re-install the
ropes. The soft shackle floats and is light in weight, easy to
open and close, self locking under load and abrasion resistant.

※ According to OCIMF MEG4, it is recommended that a mooring tail made of

PP/Polyester mixture has 25% higher MBL than a mooring line’s MBL and
nylon tail has 37% higher.
Heavy shackle
3. DONGYANG Rope protector E. Accessories

We have our proprietary HMPE(MirAcle® ) manufacturing technology and the NEW PROTECTOR based on it boasts a even
higher performance than other conventional rope protectors.
4. Comparison of each protector E. Accessories

Polytector Netech New Protector

Eye Protector ○ ○ ○

Rope Body
○ ○ ○
Protector
After Eye Before or After Before eye
Install
splicing Eye splicing splicing
Yellow, Blue,
Color White White
Grey
Applicable General Teramax & Teramax &
Product Purpose Item Teramax Plus Termax Plus

Life Time Short Long Very long

F. Appendix
DONGYANG Service for C/S F. Appendix

■ BEFORE and ON DELIVERY

Meeting with field sources and engineers before/on product delivery -

product promotion, training crew members for use.
DONGYANG Service for C/S F. Appendix

■ AFTER DELIVERY

DONGYANG can get onboard for rope check-ups on a regular basis if required. After
checking all of the mooring lines in service, a check-up report will be provided to you
as a part of our service that leads you to use our ropes more safely and even longer.

※ Please refer to Checkup Report on the next Page.

CHECKUP
REPORT
VESSEL NAME:
INSPECTION DATE :
1. Vessel Outline

Basic material information

Used Product name

Date on manufacture & Installation of Manufacture date:

Used product Supply date:
Kind of the used vessel

Vessel shipbuilding or final

maintenance date
Possibility on chemical exposure

Possibility on physical damage

Knowledge on rope’s user

Layout on Mooring line
2. Checkup for Applicable Item and Method
A) Outline on Maintenance service of special products

 TERAMAX, TERAMAX PLUS, (UHMWPE) products are performed for checkup

 This is the second inspection. Including the beginning of last year.
 As requested by user, only one time per vessel is performed for checkup service
Report will be submitted about checkup contents and relevant issues after inspection.
 Inspection will be performed free of charge when vessel calls at domestic port,
all concerned cost will be at user expense if vessel stay at overseas port.
 Maintenance is as follows if any problem on product occurs after inspection
A. In case of part maintenance resulting from outer jacket of product,
work method is informed, all concerned cost is up to user when our own technician works.
B. In case of entire maintenance resulting from outer jacket of product,
after transporting it to our factory, outer jacket should be re-worked at all part,
all its cost is up to user.

 When occurs other unavoidable cost, it can be settled after mutual agreement.
For their opinion on our inspection method, as subjective judgement,
we can’t take any responsibility if any problem occurs in future.
2. Checkup for Applicable Item and Method

B) Inspected item

C) Method on checkup
C) Inspector

 Visual inspection

 Attendee :
 Interviewer :
2. Checkup for Applicable Item and Method

D) Judgement standards

Level Status Sustainability Rope visual condition

A Very good
Available
B Good

C Normal Cautious

D Bad

Required to be replaced

F Very bad
3. Rope check Content

A) Rope Categorization

 1. Check-up Method: Visual Check for EYE, MAIN LINE, WINCH

 2. Valuation:
Level Status Sustainability
A Very good
Available
B Good
C Normal Cautious
D Bad
Required to be replaced
F Very bad
B) Checkup Result

MESSENGER LINE (TERAMAX PLUS 200M)

Size supply Overall
No. Coating Damage the evaluation Remarks
(mm) date Abrasion SPLICE part
status form
1 40 2019.02
2 40 2019.02
3 40 2019.02
4 40 2019.02
B) Checkup Result

Checkup for Eye part (TERAMAX PLUS 250M)

Size supply Overall
No. Coating Damage the evaluation Remarks
(mm) date Abrasion SPLICE part
status form
1 38 2019.02
2 38 2019.02
3 38 2019.02
4 38 2019.02
5 38 2019.02
6 38 2019.02
7 38 2019.02
8 38 2019.02
9 38 2019.02
10 38 2019.02
11 38 2019.02
12 38 2019.02
13 38 2019.02
14 38 2019.02
15 38 2019.02
16 38 2019.02
17 38 2019.02
18 38 2019.02
References

■ Mooring Equipment Guidelines (MEG4) - OCIMF

- A note on new terminology
- Section 1. introduction to mooring.
- 1.4. Mooring system design principles
- 1.6. General Mooring guide lines
- Section 5, Mooring lines.
- 5.1. introduction
- 5.1. mooring system design and line selection
- 5.4. maintenance, inspection and retirement
- 5.6. High Modulus Synthetic Fibre lines
- 5.7. Conventional Fibre lines
- 5.8. Synthetic mooring tails

■ Cordage Institute 2001-04

- Fibers for cable, cordage, Rope and twine.
 Contact Information
• Address: 147, Dasan-ro, Saha-gu, Busan, Korea
• Telephone: (82) 51 260 2703~7 (Direct)
• Fax: (82) 51 260 2777
• Email: [email protected] Web site: www.ropes.co.kr