A wire rope doesn’t break out of nowhere!

Cable car accidents appear in the media from time to time, and not just during the ski season, as was recently the case in Italy, near Naples. These headlines raise many questions among the general public: How can something like this happen? Despite strict regulations and modern technology? How safe are cable car systems really? – We clarify!

What is the function of a wire rope in a cable car?

Wire ropes used in ropeway systems are high-performance components. They generally perform two tasks: they bear the weight of the gondola and passengers and also transmit kinetic energy and braking forces via pulleys, drive sheaves and tensioning devices, whereby they are constantly exposed to the weather.

What stresses must a wire rope withstand?

Many different forces act on a wire rope during operation: The mechanical load caused by the movements and weight of the gondola and its contents, starting and braking. Added to this are weather-related influences such as wind, temperature fluctuations and moisture, which promote corrosion and wear of the system.

However, there are signs that indicate the need to replace the rope before it reaches a critical condition. Visible wire breaks, wear and tear or changes in the rope structure can be easily detected during the regular inspections required by law.

The maintenance of wire ropes

The inspection of wire ropes includes both visual inspections by trained specialists and magneto-inductive testing methods. The rope is magnetized so that hidden defects can be measured due to disturbances in the magnetic field.

These inspections must be carried out and documented at least once a year for cable cars and are regulated by the EU Cableway Installations Regulations and various national regulations. In addition, visual inspections are carried out by operating staff on a weekly basis during operation.

How can cable car accidents still happen?

By regularly inspecting ropeway installations, cracks and similar problems can be ruled out with a very high degree of certainty. There can be many reasons for this: Improper operation or a sudden overload can be the cause. However, external influences such as heavy icing or falling trees can also pose a risk.

Should a dangerous situation arise, there are safety precautions in every modern ropeway. For example, emergency braking systems, restraining devices and redundant rope systems that can intercept failures. Subsequent investigations into the cause of the accident ensure that a malfunction does not occur a second time.

You would like to know what condition your systems are in from a rope technology perspective? Within the scope of an expert opinion, we determine whether maintenance measures need to be carried out. Learn more!