Maintenance work on ski lift ropes
Maintenance work on the “Zeller 1” ski lift in the Feldberg ski area highlights how early repairs can extend the service life of a haul rope and avoid costly rope replacement. Specialists at Jakob Rope Systems check ski lift haul ropes for damage and repair them.
Proper and timely maintenance extends the service life of haul ropes. Therefore, Jakob Rope Systems’ rope specialists step in to assist ropeway operators with damage inspections and repairs to ski lift haul ropes. Jakob Rope Systems also documents all work performed for the relevant authorities as part of its service.
Damage to the rope surface usually affects the visible outer wires of the strands. Detecting and repairing this damage early can prevent costly consequential damage. Timely repairs also help keep the lift available for operation.
Haul rope repair at Feldberg ski resort
At the Feldberg ski resort in Germany’s Black Forest, the “Zeller 1” ski lift serves as a feeder lift for the red, intermediate-level Zellerabfahrt 1 run. The two-person T-bar drag lift can easily transport up to 1,000 people per hour over 550 meters. The ski lift haul rope was struck during work with a construction machine. This resulted in signs of embrittlement due to friction martensite on the rope surface. Jakob Rope Systems was called in to assist the ropeway operator with repairs.
A Jakob Rope Systems rope specialist inspected the haul rope on site. His inspection revealed that the damage was limited to the rope surface and could be properly repaired. A proven method for repairing damage to the rope surface is to grind away the friction martensite and any visible notches. Martensite forms when localized friction generates heat, hardening the surface of the wire material.
As the rope wires are repeatedly bent during operation, the hardened layers may crack prematurely, accelerating wire breakage. Because these breaks tend to accumulate over a short section of the damaged rope, untreated damage can quickly cause the rope to reach its discard criteria.
As a connecting lift in the ski area, the reliable operation of “Zeller 1” is important for the winter sports region. Early repair of the damaged section of the rope, before the start of the winter season, helped ensure long-term operating safety and extend the service life of the haul rope.
Safe operation through early inspections
Rolf Wiedmer has worked as a field technician at Jakob Rope Systems for more than 30 years. The rope specialist explains: “Ski lift haul ropes are subjected to a variety of stresses. They have to withstand tensile forces and constant bending while also being exposed to wind, weather, and temperature fluctuations.
Surface damage can result from collisions, rope derailments, or T-bars getting caught. The sooner minor damage is detected, the better the chances of an economical repair.”
Experience shows that, under normal operating conditions, ski lift haul ropes can remain safely in service for several decades. This requires regular inspections, proper maintenance, and consistent protection against mechanical damage.
During visual inspections by the ropeway operator and qualified specialists, the rope is inspected for wire breaks, corrosion, surface damage, and changes in geometry. Early repairs can often prevent costly consequential damage and downtime during the ski season.