Wire Rope - Lifting, Rigging, Warehouse & Metal Roofing ... · PDF filelabama Sling Center...

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Mazzella Lifting TechnologiesPhone: 800-362-4601

www.mazzellalifting.com

Progressive CranePhone: 800-83-CRANE

www.progressivecrane.com

Mazzella Crane ServicePhone: 877-96-CRANE

www.mazzellacraneservice.com

Indusco Wire Rope & SuppliesPhone: 410-727-0665

www.induscowire.com

Wire Rope

MazzellaCatalog13_WireRope.indd 644 7/3/13 10:06 AM

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J Henry Holland Phone: 757-460-3300

www.jhenryholland.com

Alabama Sling CenterPhone: 205-744-0230

www.alabamaslingcenter.com

Tennessee Sling CenterPhone: 901-345-8918 (Memphis)

Phone: 423-634-9005 (Chattanooga)

www.tennesseeslingcenter.com

KCI Crane ServicePhone: 205-345-4701

www.kcicraneservice.com

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Large Inventory…maintained forimmediate delivery Stocking well over 2,000,000 feet ofwire rope in our various locations.

■ In sizes from 1/4" to 3" diameter and 9 mm to 52 mm diameter■ Domestic and Non-Domestic■ In stock and ready for same or next day shipment from one of our many service centers


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Product DesignWire Rope is a Machine ................................647Wire Rope Parts List......................................648Strands & Strand Construction ......................649Standard 6 x 19 & 6 x 36 ClassificationRopes ...............................650Seven Primary Features ................................651 - 652Identification&Construction ..........................653Lang Lay Ropes ............................................654How to Unreel, Uncoil & Store .......................655Winding Wire Rope........................................656Using the Right Drum ....................................657Sheave Design ..............................................658 - 659How Sheave Size Affects Wire Rope Strength ................................660How to Determine Overhauling Weights ...............................660Technical Information.....................................661 - 667InspectionWire Rope Inspection ....................................668 - 671Guide to Examination ....................................672 - 673Inspection of Sheaves & Drums ....................674Troubleshooting Guide ..................................675 - 677Products Safety & WarningProduct Safety ...............................................678 - 686Wire Rope Technical Board Warning ........................................686Product DetailGeneral Purpose Wire Ropes 6x7Classification ..................................687Aircraft Cable & Strand ..................................688Standard 6 x 19 & 6 x 36 Classifications .........................................689Standard & High-Performance Wire Ropes for Crane Applications .........690High-Performance Wire Ropes......................691Dyform® 6/6PI ................................................692Constructex® ..................................................693Tiger® Blue .....................................................693Dyform® 18/18PI ............................................694Dyform® 34LR/PI/Max ....................................695Tower Crane Ropes .......................................696Mobile Crane Ropes ......................................697, 710

OilfieldWireRopes ........................................698Rotation-Resistant Ropes..............................699 - 700Specialized Wire Ropes ................................701 - 703BXL—Plastic-Infused Wire Ropes .................704Oilfield&NaturalGasDrillingProducts .........705 - 706Flex-X® 19 & Flex-X® 6 ..................................707PFV® & Tuf-Kote® ..........................................708Starlift Plus, Eurolift & Turboplast ..................709Overhead Crane Ropes.................................711Galvanized Steel Strand ................................712Structural Strand............................................713 - 714Related ProductsWire Rope Lubricant ......................................715Wire Rope Pulling / Splicing Grips.................716 - 720

WarningsProduct Warnings ..........................................721 - 723

For the complete catalog index, refer to the front of the book.

Wire Rope Index


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From childhood, many of us have been conditioned to think of a machine as some device with gears, shafts, belts, cams, and assorted whirring parts. Yet, by the rules of physics, an ordinary pry bar is a simple machine, even though it has only one part.

A wire rope is, in reality, a very complicated machine. A typical 6 x 25 rope has 150 wires in its strands, all of which move independently and together in a very complicated pattern around the core as the rope bends. Clearances between wires and strands are balanced when a rope is designed so that proper bearing clearances will exist to permit internal movement and adjustment of wires and strands when the rope has to bend. These clearances will vary as bending occurs, but are of the same range as the clearances found in automobile engine bearings.

Understanding and accepting the “machine idea” gives a rope user a greater respect for rope, and enables him to obtain better performance and longer useful life from rope applications. Anyone who uses a rope can use it more efficientlyandeffectivelywhenhefullyunderstandsthemachine concept.

How A Wire Rope Machine Works

The extent to which wires move in a rope when it bends is illustrated by the following example—what actually happens when you wrap a 1-inch rope over a 30-inch sheave. Betweenthepointwheretheropefirsttouchesthesheaveon one side, and where it leaves the sheave on the other side, the length of rope in contact with the sheave would be 3-1/8 inches shorter than the length of the side away from the sheave—if the rope did not move and adjust internallyby wires sliding back and forth.

The mathematics is simple: Just subtract half the circumference of a 30" circle from half the circumference of a 32" circle.

Circumference = π x DiameterC= 3.1416 x 32 = 100.5312C = 3.1416 x 30 = 94.24906.2931 / 2 = 3.14

Thus, circumference of a 32-inch circle is slightly more than 6-1/4" longer than that of a 30-inch circle. Since a rope only touches half of a sheave at any time, the length differential which a rope must accommodate is 3-1/8".

By this same reasoning, a 1-inch rope wrapped on a 30-inch hoist, the drum must compensate internally for a 6-1/4" length differential in each wrap.

This change of dimension is achieved by the sliding and adjusting of the strands in relation to one another, and a similar sliding and adjusting of the individual wires within each strand.

By painting stripes around a wire rope as illustrated here, and actually bending the rope, we can see the movement ofstrandsastheropebends.Anytimearopeflexes,thismovement takes place. The sharper the bend, the more the movement.

Quite obviously, the grade of wire will affect such things as strength, resistance to wear, fatigue resistance, corrosion resistance and so on. Today, the greatest portion of all wire rope is made from two grades of wire—Extra Improved, Plow Steel (EIP) and Double Extra Improved Plow Steel (EEIP). Both are tough, strong, wear-resisting carbon steel, with EEIP providing about 10% greater tensile strength. Sometimes wire is plated or galvanized before strands are formed, where special corrosion or wear characteristics are desired. Most wire is “Bright”—that is, without any surface coating or treatment.

A Wire Rope Is A Machine With Many Moving Parts.


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Wire rope consists of three basic components; while few in number,thesevaryinbothcomplexityandconfigurationsoastoproduceropesforspecificpurposesorcharacteristics.The three basic components of a standard wire rope design are: 1) wires that form the strand, 2) multi-wire strands laid helically around a core, and 3) the core.

Wire, for rope, is made in several materials and types: steel, iron, stainless steel, monel and bronze. By far, the most widely used material is high-carbon steel. This is available in a variety of grades each of which has properties related to the basic curve for steel rope wire. Wire rope manufacturers select the wire type that is most appropriateforrequirementsofthefinishedproduct.

Grades of wire rope are referred to as extra improved plow steel (EIP), and double extra improved plow steel (EEIP). (These steel grade names originated at the earliest stages of wire rope development and have been retained as references to the strength of a particular size and grade of rope.) The plow steel strength curve forms the basis for calculating the strength of all steel rope wires; the tensile strength (psi) of any steel wire grade is not constant, it varies with the diameter and is highest in the smallest wires.

Themostcommonfinishforsteelwireis"bright"orun-coated. Steel wires may also be galvanized, i.e., zinc coated. "Drawn galvanized" wire has the same strength as bright wire,butwire"galvanizedatfinishedsize"isusually10%lower in strength. In certain applications, "tinned" wire is used,butitshouldbenotedthattinprovidesnosacrificial,i.e., cathodic, protection for the steel as does zinc.

Strands are made up of two or more wires, laid in any one ofmanyspecificgeometricarrangements,orinacombina-tion of steel wires with some other materials such as natural orsyntheticfibers.Itisconceivablethatastrandcanbemade up of any number of wires, or that a rope can have any number of strands. The following section, IDENTIFICATION and CONSTRUCTION, provides a complete description of wire rope constructions.

The Core is the foundation of a wire rope; it is made of materials that will provide proper support for the strands under normal bending and loading conditions. Core materials includefibers(hardvegetableorsynthetic)orsteel.Asteelcore consists either of a strand or an independent wire rope. Thethreemostcommonlyusedcoredesignationsare:fibercore (FC), independent wire rope core (IWRC), and wire strand core (WSC). Catalog descriptions of the various

available ropes always include these abbreviations to identify the core type.

The Lay

The word “lay” is used to describe three physical characteristics of wire rope. It is both an engineering term and a descriptive term. Lay describes:

1. The DIRECTION strands “lay” in the rope— Right or Left. When you look along a rope, strands of a Right Lay make the rope.2. The RELATIONSHIP between the direction strands lay in the rope and the direction wires lay in the strands. In a Regular Lay rope, wires lay opposite the direction of the strand. In a Lang Lay rope, wires lay in the same direction as strands.3. The LENGTH along the rope which one strand uses to make one complete spiral around the rope core.

A comparison of typical wire rope lays: A. Right Regular Lay D. Left Lang Lay B. Left Regular Lay E. Right Alternate Lay C. Right Lang Lay

A

B

C

D

E

The Parts List of aWire Rope Machine


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Strands are basic building blocks. A strand consists of a “center”whichsupportsaspecifiednumberofwiresaroundit in one or more layers. The strands provide all the tensile strengthofafibercorerope,and92-1/2%ofthestrengthofan IWRC six strand rope.

Such physical characteristics as fatigue resistance and resistance to abrasion are directly affected by the design of strands. In most strands with two or more layers of wires, inner layers support outer layers in such a manner that all wiresmayslideandadjustfreelywhenthestrandflexes.

As a general rule, a strand made up of a small number of large wires will be more abrasion resistant and less fatigue resistant than a strand of the same size made up of many smaller wires.

Illustrated on the right are the basic strand constructions.

Standard Rope Classifications

Most common wire rope constructions are grouped into fourstandardclassifications,basedonthenumberofstrands and wires per strand, as shown in this chart. All ropesofthesamesizeandwiregradeineachclassificationhave the SAME strength and weight ratings, and usually thesamepricing.Ropeswithineachclassificationmaydiffer in working characteristics such as abrasion and fatigue resistance.

The Number of Strands& the Strand ConstructionDetermine the Classification of a Rope.

Classification Wires Per Strand6 X 7 5 through 9

6 X 19 15 through 266 x 36 27 through 498 x 19 15 through 26

Single Layer What is sometimes called the “Single Layer Principle” is the basis for this strand construction. Probably the most common example is a single wire center with six wires of the same diameter around it. It is called simply, a 7-wire (1-6) strand.

Filler WireThis construction has two layers of uniform size wire around a center wire, with the inner layer having half the number of wires as the outer layer. Smallfillerwires,equalinnumbertotheinnerlayer, are laid in the valleys of the inner layer. Example: 25 Filler Wire (1-6-6f-12) strand

Seale The Seale Principle features two layers of wires around a center wire, with the same number of wires in each layer. All wires in each layer are the same diameter, and the strand is designed so that the large outer wires rest in the valleys between the smaller inner wires. Example: 19 Seale (1-9-9) strand.

Warrington The Warrington Principle is a 2-layer construction with uniform-sized wires in the inner layer, and two diameters of wire alternating large and small in the outer layer. The larger outer-layer wires rest in the valleys, and the smaller ones on the crowns, of the inner layer. Example: 19 Warrington [1-6-(6+6)] strand.

Combined PatternsWhen a strand is formed in a SINGLE OPERA-TION using two or more of the above construc-tions, it is referred to as a “Combined Pattern.” ThisexampleisbasicallyaSealestrandinitsfirsttwo layers. The third layer utilizes the Warrington Principle, and the outer layer is a typical Seale pattern of same-size wires. It is described: 49 Seale Warrington Seale [1-8-8-(8+8)-16] strand.

Multiple OperationIn contrast to all the above strand types which are formed in a single operation, a Multiple Operation construction strand is one in which one of the above designs is covered with one or more layers of uniform-sized wires in a different work operation. The second operation is necessary because the outer layers must have a different length of lay or direction of lay. This example is a Warrington strand overlayed with 18 same-size wires. It is described: 37 Warrington 2-Operation [1-6-(6+6)/18] strand.


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The6x19classificationofwireropesincludesstandard6 strand, round strand ropes with 16 through 26 wires per strand.The6x36classificationofwireropesincludesstandard 6 strand, round strand ropes with 27 through 49 wires per strand. Although their operating characteristics vary, all have the same weight per foot and the same minimum breaking force, size for size.

While the 6 x 19 ropes give primary emphasis to abrasion resistance in varying degrees, the 6 x 36 ropes are important for their fatigue resistance.

This fatigue resistance is made possible by the greater number of small wires per strand.

Although there are exceptions for special applications, theconstructionsin6x36classificationareprimarilydesignedtobethemostefficientforeachropediameter.As the rope size increases, for instance, a large number of wires can be used to achieve required fatigue resistance, and still those wires will be large enough to offer adequate resistance to abrasion.

Standard 6 x 19 & 6 x 36 Classification Ropes

6 x 19 Classification Ropes— 6 x 19S (Seale) In this construction, each strand has nine outer wires over nine smaller inner wires over one large center wire. A comparison of cross sections shows that these outside wires are larger than those of 6 x 25FW or 6 x 26WS. Therefore, its resistance to abrasion is increased, but its fatigue resistance is decreased. This is a rope to withstand abrasion or crushing on the drum.

6 x 25FW (Filler Wire) To most wire rope users, 6 x 19 means 6 x 25 fillerwire.Itwasthemostcommonropeinthe6x19classification.Thisropehasagoodbalance between both abrasion resistance and fatigue resistance in relation to other ropes.

6 x 26WS (Warrington Seale) This construction has better resistance to abrasion than a 6 x 25FW. It also features a compact construction with solid support for the wires; hence, it has high resistance to crushing. Its number and relative size of the inner wires add to the stability of the strand and gives a fatigue resistance comparable to a 6 x 25FW.A standard 6 x 26WS construction the best rope for a wide range of applications. In general, we recommend the use of a 6 x 26WS in any application where a 6 x 25FW is used.

6 x 36 Classification RopesInmostropesizes,onlyone6x36classificationrope is made. These constructions were selected to provide fatigue resistance without having wires that are too small. The greater numberofwiresinthe6x36classificationmakes these ropes more susceptible to crushing. This can be minimized, however,by specifying an Independent Wire Rope Core (IWRC) and by using well-designed sheaves, grooved drums and proper operatingtechniques.


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Each Characteristic Affects Other Characteristics

Every wire rope has its own “personality” which is a reflectionofitsengineereddesign.Eachropeconstructionhas been established to produce a desired combination of operating characteristics which will best meet the performance requirements of the work, or application, for which that design is intended…and each rope construction is, therefore, a design compromise.

The best illustration of a design compromise–or best combination of desired characteristics—is the interrelationship between resistance to abrasion and fatigue resistance.

Fatigue resistance (a rope’s capability to bend repeatedly under stress) is accomplished by using many wires in the strands. Resistance to metal loss through abrasion is achieved primarily with a rope design which uses fewer and, therefore, larger wires in the outer layer to reduce the effects of surface wear.

Therefore, from a design standpoint, when anything is done to alter either abrasion resistance or fatigue resistance, both of these features will be affected.

Seven Primary Featuresfor Consideration in Wire Rope Selection

Abrasion Resistance

Fatigue Resistance

1. Strength Wire rope strength is usually measured in tons of 2000 pounds. In published material wire rope strength is shown as minimum breaking force.Minimumbreakingforcereferstocalculatedstrengthfigures that have been accepted by the wire rope industry.

When placed under tension on a test device a new rope should break atafigureequalto,orhigherthan,theminimumbreakingforceshown for that rope.

To account for variables which might exist when such tests are made to determine the breaking strength of a new wire rope an “acceptance” strength may be used. The acceptance strength is 2-1/2% lower than the minimum breaking force and ropes must meet or exceed this strength.

The minimum breaking force applies to new, unused rope. A rope should never operate at, or near, the minimum breaking force. During its useful life, a rope loses strength gradually due to natural causes, such as surface wear and metal fatigue.

2. Reserve Strength The Reserve Strength of a standard rope is a relationship between the strength represented by all the wires in the outer strands and the wires remaining in the outer strands with the outer layer of wires removed. Reserve Strength is calculated using actual metallic areas of the individual wires. Since there is a direct relationship between metallic area and strength, Reserve Strength is usually expressed as a percentage of the rope’s minimum breaking force. Reserve Strength is used as a relative comparison between the internal wire load bearing capabilities of different rope constructions.

Reserve Strength is an important consideration in selection, inspection and evaluation of a rope for applications where the consequences of a rope failure are great. The use of Reserve Strength is premised on thetheorythattheouterwiresofthestrandsarethefirsttobesubjected todamageorwear.Therefore,theReserveStrengthfiguresareless significantwhentheropeissubjectedtointernalwear,damage,abuse, corrosion or distortion.

The more wires there are in the outer layer of a strand construction, the greater will be the rope’s Reserve Strength. Geometrically, as more wires are required in the outer layer of a strand, they must be smaller indiameter.Thisresultsingreatermetallicarearemainingtobefilled by the inner wires. Separate columns are shown for standard Fiber Core and IWRC ropes. For Fiber Core ropes, the Reserve Strength is the approximate percentage of the rope’s metallic area made up by the inner wires of the outer strands.

An IWRC in a rope is considered to contribute 7-1/2% to the rope’s totalstrength.Bydefinition,thecoreisnotincludedintheReserve Strength calculation so a 7-1/2% reduction has been made for ropes with an IWRC.

Rotation Resistant ropes, due to their construction, can experience different modes of wear and failure than standard ropes. Therefore, their Reserve Strength is calculated differently. For Rotation Resistant ropes, the Reserve Strength is based on the percentage of the metallic area represented by the core strand plus the inner wires of the strands of both the outer and inner layers.


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3. Resistance to Metal Loss and Deformation Metal loss refers to the actual wearing away of metal from the outer wires of a rope, and metal deformation is the changing of the shape of outer wires of a rope.

In general, resistance to metal loss by abrasion (usually called “abrasion resistance”) refers to a rope’s ability to withstand metal being worn away along its exterior. This reduces strength of a rope. The most common form of metal deformation is generally called “peening”—since outside wires of a peened rope appear to have been “hammered” along their exposed surface. Peening usually occurs on drums, caused by rope-to-rope contact during take-up of the rope on the drum. It may also occur on sheaves.

Peening causes metal fatigue, which in turn may cause wire failure. The“hammering”,whichcausesmetalofthewiretoflowintoanew shape, realigns the grain structure of the metal, thereby affecting its fatigue resistance. The out-of-round shape also impairs wire movement when the rope bends.

4. Crushing Resistance Crushing is the effect of external pressure on a rope, which damages it by distorting the cross section shape of the rope, its strands or core— or all three.

Crushing resistance therefore is ability to withstand or resist external forces, and is a term generally used to express comparison between ropes.

When a rope is damaged by crushing, the wires, strands and core are prevented from moving and adjusting normally in operation.

In a general sense, IWRC ropes are more crush resistant than fibercoreropes.LangLayropes are less crush resistant than Regular Lay ropes…and 6-strand ropes have greater crush resistance than 8-strand ropes.

5. Fatigue Resistance Fatigue resistance involves metal fatigue of the wires that make up a rope. To have high fatigue resistance, wires must be capable of bending repeatedly under stress— as when a rope passes over a sheave.

Increased fatigue resistance is achieved in a rope design by using a large number of wires. It involves both the basic metallurgy and the diameters of wires.

In general, a rope made of many wires will have greater fatigue resistance than a same-size rope made of fewer larger wires, because smaller wires have greater ability to bend as the rope passes over sheaves or around drums. To overcome the effects of fatigue, ropes must never bend over sheaves or drums with diameter so small as to kink wires or bend them excessively. There are precise recommendations for sheave and drum sizes to properly accommodate all sizes and types of ropes.

Every rope is subject to metal fatigue from bending stress while in operation, and therefore, the rope’s strength gradually diminishes as the rope is used.

6. Bend-ability Bend-ability relates to the ability of a rope to bend easily if an arc. Four primary factors affect this capability: 1. Diameter of wires that make the rope. 2. Rope and Strand Construction. 3. MetalCompositionofwiresandfinish,suchasgalvanizing. 4. Typeofropecore—fiberorIWRC.

Some rope constructions are by nature more bend-able than others. Small ropes are more bend-able than big ones. Fiber core ropes bend more easily than comparable IWRC ropes. As a general rule, ropes made of many wires are more bend-able than same-size ropes made with fewer larger wires.

7. Stability The word “stability” is most often used to describe handling and working characteristics of a rope. It is not a precise term, since the idea expressed is to some degree a matter of opinion, and is more nearly a “personality” trait than any other rope feature.

For example, a rope is called stable when it spools smoothly on and off a drum…or doesn’t tend to tangle when a multi-part reeving system is relaxed.

Strand and rope construction contribute most to stability. Preformed rope is usually more stable than nonpreformed, and Lang Lay rope tends to be less stable than Regular Lay. A rope made of simple 7-wire strands will usually be more stable than a more complicated construction with many wires per strand.

Thereisnospecificmeasurementofropeshavestability.

Reserve Strength of Standard Ropes

Rope Construction

Percent of Minimum Breaking Force Representedby Inner Wires of Outer Strands

Fiber Core IWRC6 x 7 17 —

6 x 19 S 32 306 x 19 OP 40 376 x 19 W 42 39

6 x 21 FW 36 336 x 25 FW 43 406 x 26 WS 36 33

6 x 30 Style G 26 246 x 31 WS 43 406 x 33 OP 44 416 x 36 WS 48 44

6 x 36 2 OP 56 526 x 41 SFW 53 49

Reserve Strength of Rotation Resistant Ropes

Rope Construction

Percent of Minimum Breaking Force Representedby Core Strand and Inner Wires of Strands

of Inner and Outer Layers8 x 25 Resistwist 38

19 x 7 23

Seven Primary Featuresfor Consideration in Wire Rope Selection (Continued)


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Wireropeisidentifiednotonlybyitscomponentparts,butalsobyitsconstruction,i.e.,bythewaythewireshavebeenlaid to form strands, and by the way the strands have been laid around the core.

In Figure 1, "A" and "C" show strands as normally laid into the rope to the right in a fashion similar to the threading in a right-hand bolt. Conversely, the "left lay" rope strands (illustrations "B" and "D") are laid in the opposite direction.

AgaininFigure1,thefirsttwo("A"and"B")showregularlayropes.Followingthesearethetypesknownaslanglayropes("C" and "D"). Note that the wires in regular lay ropes appear to line up with the axis of the rope; in lang lay rope the wires form an angle with the axis of the rope. This difference in appearance is a result of variations in manufacturing techniques: regular lay ropes are made so that the direction of the wire lay in the strand is opposite to the direction of the strand lay in the rope; lang lay ropes are made with both strand lay and rope lay in the same direction. Finally, "E," called alternate lay, consists of alternating regular and lang lay strands.

Figure 1: A comparison of typical wire rope lays

Identification &Construction

A. Right Regular Lay

B. Left Regular Lay

C. Right Lang Lay

D. Left Lang Lay

E. Right Alternate Lay


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Lang Lay Ropes, when properly recommended, installedand used, have several advantages over Regular Lay Ropes, but are more subject to abuse. For the same size and construction, ropes having the same wire sizes and lays, LangLayRopesaresomewhatmoreflexiblethanRegularLay and have several times the wearing surface per wire to resistabrasion,asseeninthephotobelowandinfigureonthe right (top). Both ropes shown in the photos have been ground to the same reduction of rope diameter so as to show this comparison of the abraded areas of the wires. The Lang LayRopesasusuallymadeareabout15%moreflexiblethan the same construction Regular Lay, but this value will vary depending upon the relation of the strand lay to the rope lay.

Partially Worn Regular Lay

Partially Worn Lang Lay

Because of the greater wearing surface per wire in the Lang Lay Ropes, there is less wear on the sheave and drum equipment.

On the other hand, very small tread diametered sheaves or pinching grooves in sheaves are both detrimental to Lang Lay Ropes, the latter frequently causing “bird-caging” of the rope.

Also, Lang Lay Ropes will crush out of shape more readily than Regular ropes when winding onto small drums under heavy winding tension.

The wires of the Regular Lay Ropes are subjected tohigher unit pressure when the rope is passed over sheaves or drum, causing a somewhat heavier transverse pressure within the rope structure. Thus the “bending” stresses are somewhat higher in the Regular Lay Rope and it istermed “stiffer.”

The mobility of, and capacity of shifting among, the wiresis greater in the Lang Lay; it is this very feature, combined with the longer exposed length of wires, that causes a misplacement of the wires in the Lang Lay when bent over

Lang Lay Ropes sheaves at or near the critical tread diameter, not withstanding the somewhat greater inherent flexibilityoftheLangLayfornormal service.

Swivels should not be usedwith Lang Lay Ropes except under certain conditions as individually recommended for any particular equipment.

Failure to comply with these foregoing precautions will lead to very uneconomical rope service.

While the total area of surface wear on the rope as a whole is the same for the two types of same construction ropes for a given depth of wear, the wear on the equipment and largely the rope service rendered would favor the Lang Lay construction.

It is therefore not the total area of worn surface of the rope as a whole, but the nature of such wear that causes longer life to the equipment and to the rope where Lang Lay Ropes can be economically used. To explain this “nature” of wear, we show both on the photo to the left—lines “a-b,” the line of contact of a moving rope with the sheave; “a-b” is parallel to the direction of rope travel, that is, to the longitudinal axis of the rope.

It will be noted that in the Regular Lay, the line of contact is axial with one wire; in the Lang Lay (for the 6 x 19 Seale construction used in this comparison), the line of contact is diagonally across three worn wires.

The shorter exposed length of the worn wires in the Regular Lay Rope causes these wires to spring up, arching radiallyawayfromtheaxisoftheropeasinfigurebelow.That causes heavier individual pressure of the wires on the sheave and an earlier fatigue failure of these wires at the “neck” of wear due to local reverse bending when the contact pressure with the sheave depresses this wire. The stiffer the wire (that is, the higher the strength or grade of wire), the more pronounced this arching of the wires at the thinnest worn section or “neck.”


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A–Correct B–Wrong

ReelDrum

ReelDrum

How to Unreel, Uncoil & Store Wire RopeThe Right Way to Unreel and Uncoil a Wire Rope

There is always a danger of kinking a wire rope if you improperly unreel or uncoil it. You should mount a reel on jacks or aturntablesothatitwillrevolveasyoupulltheropeoff.Applysufficienttensionbymeansofaboardactingasabrakeagainstthereelflangetokeepslackfromaccumulating.Withacoil,standitonedgeandrollitinastraightlineawayfromthe free end. You may also place a coil on a revolving stand and pull the rope as you would from a reel on a turntable.

How to Store Wire Rope Properly

We recommend you store your wire rope under a roof or a weatherproof covering so that moisture cannot reach it. Similarly, you must avoid acid fumes or any other corrosive atmosphere – including ocean spray – in order to protect the rope from rust. If you’re storing a reel for a lengthy period, you may want to order your rope with a protective wrap. If not, at least coat the outer layers of rope with a good rope lubricant.

If you ever take a rope out of service and want to store it for future use, you should place it on a reel after you’ve thoroughly cleaned and relubricated it. Give the same storage considerations to your used rope as you would your new rope.

Be sure to keep your wire rope in storage away from steam or hot water pipes, heated air ducts or any other source of heat that can thin out lubricant and cause it to drain out of your rope.


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Invariably in winding wire rope onto a shipping reel or a coiling drum, the rope is wound over the top of the reel or drum. The fact that the rope comes from under the stock reel to wind reversely on top of the shipping reel has no effect on the physical condition of the rope, provided the stock reel is set at least 20 feet, or preferably more, from the rewinding machine.

The rope should be wound “thread lay,” with close, even winding throughout the length of the rope. If wound unevenly, the turns of rope bunch-up, cross wind and are liable to form doglegs,particularlyonthemoreflexibleropes.

Neverfillthereelfulltotherimoredgeoftheflanges.If possible, leave a clearance equivalent to at least two layers of rope. This will save injury to the rope when the reel is rolled over obstructions on the ground.

The manner in which wire rope is installed or wound on a drum will, to a large measure, determine the service life of that rope. Improperly wound ropes will cause undue crushing of the rope, doglegs, kinks, excessive abrasion and cutting of the individual wires. Bad spooling also causes uneven application of force and motion. This results in fast fatiguing of the line from the end attachment to the drum.

There are five precautionary steps that should be taken before starting the actual winding of the rope off the coil or shipping reel.

1. A check should be made of the drum to determine the condition, size and shape of the grooves. If the drum is a smooth type, then the surface should be checked for straightness and smoothness.2. Flanges should be checked to determine the extent of undercutting at the base.3. Dirt,grit,filledgreaseoranyothertypeofdebrisshould be cleaned off.4. Bearings should be checked.5. Cracks or breaks in segments of the drum should be reported.

Wheneveranyofthesefiveconditionsareobserved,the equipment should be removed from serviceand properly cleaned, repaired or replaced.This recommendation is made not just to improveor maintain good rope life, but to eliminate apotential hazard.

After establishing the satisfactory condition of the drum, the shipping reel is mounted on suitable jacks. The end is

Winding Wire Rope attached to the drum using the attachment provided. A tension should be induced into the line by providing some means of braking the shipping reel. A tight winding is imperative, particularly if multiple layer winding is required.

When winding a rope onto a grooved drum, the groove willproperly guide the rope. If the rope is to be rewound on asmooth drum, then a helper should guide the rope, makingsure each turn is winding tightly against the adjacent turn.

A lead or brass hammer is useful in tapping the line over asit is being wound. Do not use a steel head hammer or pinchbars. These can readily cause damage to the lines.

Calculating Drum Capacity

The length of rope that can be wound on a drum or reel may be calculated as follows. L = the length of the rope in feet. All other dimensions are in inches.

Values of KRope

Diameter K RopeDiameter K

1/4" 3.29 1-1/8" .1915/16" 2.21 1-1/4" .1527/16" 1.19 1-1/2" .1071/2" .925 1-5/8" .0886

9/16" .741 1-3/4" .07705/8" .607 1-7/8" .06753/4" .428 2" .05977/8" .308 2-1/8" .05321" .239 2-1/4" .0476

L = (A + D) x A x B x KK = Constant obtained by dividing .2618 by the square of the actual rope diameter.A = H - D Desired clearance in inches. 2B = Traverse in inches.D = Barrel in inches.H = Flange diameter in inches.L = Rope length in feet.


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Drums should be large enough to properly wind the ropeusing the smallest number of layers. Drums having a diameter 24 times the rope diameter should be considered as a minimum for proper spooling.

Multiple layers on a plain (smooth) faced drum crush thefirstlayerofropemuchmorethanonagrooveddrum.The grooved drum is also recommended to providebetter spooling.

The correct lay for each winding direction. The direction of winding on a drum (overwind or underwind) is determined by standing behind it and looking toward the direction of rope travel.

When winding only one layer on a smooth drum,attaching right and left lay ropes as shown in the drawingsbelow will give the best service.

Multiple Layer Winding

Whenaropewindsinthefirstlayeracrossthefaceofa drum, it usually forms a uniform helix. When spoolingonasmoothdrum,thefirstlayerhelixservesasthedrum lagging for succeeding layers. For continuoussmoothspooling,thefirstlayershouldactasadeadlayer

Using the Right DrumReduces Wear on Ropes.

and not be removed from the drum during normal use. On grooved drums, the grooves control the rope spoolingonthefirstlayer,makingalltheropeusableinthesystem.However, various codes do require a minimum of two to six dead wraps, depending on the application.

Afterspoolingthefirstlayer,theroperidesuponthelast turn and starts winding back across the face of thedrum, but falls into the depression of the successiveturnsofropeonthefirstlayer.

Advancing across the drum on the second layer, the rope, followingthedepressionsofthefirstlayer,actuallywinds back a turn in each revolution of the drum. Itmustthencrossovertwodepressionsofthefirstlayerto have a net advance of one turn per revolution.

This cross over is unavoidable on the second and succeeding layers. Severe punishment of the rope resultsdue to abrasion of the adjacent turns against each otherand the crushing from the next layer above at thesepoints. Parallel and counter-balanced, grooved-controlled,crossover drums minimize this condition.

If scrubbing (adjacent wrap contact) is a major problem, it can be reduced by applying the “winding direction rules” totheheaviestworkedlayerinsteadofthefirstlayerasshown.Toaccomplishthis,thefirstlayermayormaynot be spooled according to the rule as well.


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Bending Wire Rope over Sheavesand Drums

Sheaves, drums and rollers must be of a correct design if optimum service is to be obtained from both the equipment and the wire rope. Because there are many different types of equipment and many different operating conditions, it is difficulttoidentifytheonespecificsizeofsheaveordrummost appropriate for every application. The guideline to follow is this: the most practical design is the one that most closely accommodates the limiting factors imposed by the equipment, the operating conditions and the wire rope.

All wire ropes operating over sheaves and drums are subjected to cyclic bending stresses, thus the rope wires will eventually fatigue. The magnitude of these stresses depends—all other factors being constant—upon the ratio of the diameter of the sheave or drum to the diameter of the rope. Frequently, fatigue from cyclic, high-magnitude bending stress is a principal reason for shortened rope service. In order for a rope to bend around a sheave, the rope's strands and wires must move relative to one another. This movement compensates for the difference in diameter between the underside and the top side of the rope, the distance being greater along the top side than it is on the underside next to the groove. Proper rope movement (and service) is adversely affected if the wires cannot adjust to compensate for this length differential. Also, there can be additional limitations to wire movement because of excessive pressure caused by a sheave groove diameter which is too small, or by lack of rope lubrication. Avoid changing the bending direction from one sheave to another as this reverse bending further accelerates wire fatigue.

The relationship between sheave diameter and rope diameter is a critical factor that is used to estimate the rope's fatigue resistance or relative service life. It is expressed in the D/d ratio mentioned earlier in which D is the pitch diameter of the sheave and d is the diameter of the rope. Table 1 lists suggested minimum D/d values for various rope constructions. Smaller values can affect rope life. Table 2 (on next page) shows the effect of rope construction and D/d on service life.

Sheave Design is Criticalto Wire Rope Service Life.

Construction SuggestedD/d Ratio*

6 x 7 4219 x 7 or 18 x 7 Rotation Resistant 346 x 19 S

6 x 25 B Flattened Strand

30

6 x 27 H Flattened Strand6 x 30 G Flattened Strand6 x 31 V Flattened Strand

6 x 21 FW6 x 26 WS8 x 19 S

267 x 21 FW6 x 25 FW6 x 31 WS

6 x 37 FWS7 x 25 FW

236 x 36 WS6 x 43 FWS7 x 31 WS6 x 41 WS

20

6 x 41 SFW6 x 49 SWS7 x 36 WS8 x 25 FW

19 x 19 Rotation Resistant35 x 7 Rotation Resistant

6 x 46 SFW186 x 46 WS

8 x 36 WS

Table 1: Suggested Sheave and Drum Ratios

These D/d ratios are based on sheave and drum diameters being approximately 400 times the outer wire diameter of the rope. For rope constructions not listed, consult your Lifting Specialist.

*D = Pitch diameter of sheave d = nominal diameter of rope Tofindanypitchdiameterfromthistable,thediameterfortheropeconstruction to be used is multiplied by its nominal diameter (d). For example, the minimum sheave pitch diameter for a 1/2" (nominal diameter) x 30 (minimum ratio) or 15".


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Sheave Design is Criticalto Wire Rope Service Life.(Continued)

Breaking In a New Wire Rope

A new wire rope requires careful installation and following all the appropriate guidelines previously noted. After the rope is installed and the ends secured in the correct manner, the equipment should be started carefully and then permitted to run through a cycle of operation at very slow speed. During this trial operation, closely watch all working parts—sheaves, drums, rollers—to make certain that the rope runs freely, and

Rope Construction Factor6 x 7 or 7 x 7 Aircraft .6019 x 7 or 18 x 7 R.R. .70

6 x 19 S .806 x 19 W

.90

6 x 21 FW6 x 26 WS

6 x 25 B FS6 x 27 H FS6 x 30G FS6 x 31 V FS7 x 21F W

1.006 x 25 FW6 x 31 WS8 x 19 S

8 x 21 FW 1.107 x 25 FW

1.15

6 x 29 FW6 x 36 WS

6 x 36 SFW6 x 43 FWS7 x 31 WS8 x 25 FW

1.256 x 41 WS

6 x 41 SFW6 x 49 SWS7 x 36 FW

6 x 46 SFW

1.356 x 46 WS8 x 36 WS

6 x 61 FWS6 x 57 SFWS

Table 2: Relative Bending Life Factors

Note: This table, with some modifications, is based on outer wire diameter relationships. For rope constructions not listed, consult your Lifting Specialist.

without any possible obstructions as it makes its way through the system. If no problems appear in running the rope, the next step should include several repetitions of the normal operational cycle under increasing loads and speeds. This procedure allows the component parts of the new rope to make a gradual adjustment to the actual operating conditions. Taking the time and effort to perform these breaking-in procedures should result in obtaining the optimum service life from the wire rope.

Bending-Life Factor

Bending-Life Factors (shown in the Relative Service Curve)provide a comparison of the service life of different constructions under repeated bending stresses.

This service life curve only takes into account bending and tensile stresses. This curve can be utilized to predict comparativeservicelifeofaspecificwireropewithvaryingD/d ratios. That resultant comparison is illustrated by the following example: A rope working with a D/d ratio of 26 has a relative service life of 17. If the same rope works over a sheave that increases its D/d ratio to 35, the relative service life increases to 32. In short, if this rope is used on the larger sheave, one could estimate an increase in its bending service life from 17 to 32 or an 88% increase.


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To determine the weight of the block or overhaul ball that is required to free fall the block, the following informationis needed:

■ Sizeofwirerope■ Numberoflineparts■ Typeofsheavebearing■ Lengthofcraneboom■ DrumFriction (nominally, 100 pounds)

Formula to DetermineBlock Weight:Required Block Weight = Multiply Boom Length byRope Weight Factor “A” and add Drum Friction thenMultiply by Overhaul Factor “B”.

For Example: Using 5 parts of 7/8" Wire Rope, 50 ft. Boom and Roller Bearing Sheaves, Required Weight = [(50 x 1.42) + 100] x 5.38 = 920 lbs.

How to DetermineOverhauling Weights

The radius of bend has an effect on the strength of wirerope. In order to take this fact into account in selecting thesize sheave to be used with a given diameter wire rope, thefollowing table can be used as a guide:

For Example: Using a 1/2" dia. wire rope with a 10" dia. sheave, Ratio“A”=10÷1/2"=20andthestrengthefficiency=91%ascom-pared to the catalog strength of wire rope.

The repeated bending and straightening of the wire ropecauses a cyclic change of stress known as “fatiguing.” Theradius of bend has considerable effect on the fatigue life ofwire rope and the following can be used as comparison ofrelativefatiguelifeasinfluencedbysheavediameter:

For Example: Using a 12" dia. sheave with a 3/4" dia. wire rope, Ratio “B” = 12 ÷ 3/4" = 16 and the units of fatigue life = 2.1. However, a 22.5" dia. sheave using a 3/4” wire rope has a Ratio “B”= 225 ÷ 3/4" = 30 and the units of fatigue life = 10. So, the expected extension of fatigue life when using a 22.5" dia. instead of a 12" diameter sheave would be 10 ÷ 2.1 or 4.7 times greater.

How Sheave Size Affects Wire Rope Strength

Factor “A” Wire Rope WeightRope Diameter Lbs. Per Foot

3/8" .267/16" .351/2" .46

9/16" .595/8" .723/4" 1.047/8" 1.421" 1.85

1-1/8" 2.341-1/4" 2.89

Factor “B” Overhaul Factors

No. RollerBearing

BronzeBushed

1 1.03 1.052 2.07 2.143 3.15 3.284 4.25 4.285 5.38 5.726 6.54 7.037 7.73 8.398 8.94 9.809 10.20 11.3010 11.50 12.80

Ratio “A” =Sheave Dia.Rope Dia.

Strength EfficiencyCompared to Catalog

Strength in %40 9530 9320 9115 8910 868 836 794 752 651 50

Ratio “B” =Sheave Dia.Rope Dia.

Relative FatigueBending Life

30 10.025 6.620 3.818 2.916 2.114 1.512 1.1


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Properties of Extension of SteelWire Ropes

Any assembly of steel wires spun into a helical formation, either as a strand or wire rope (when subjected to a tensile load) can extend in three separate phases, depending on the magnitude of the applied load.

There are also other factors which produce rope extension,which are very small and can normally be ignored.

Phase 1—Initial or PermanentConstructional ExtensionAt the commencement of loading a new rope, extension is createdby the bedding down of the assembled wires with a correspondingreduction in overall diameter. This reduction in diameter isaccommodatedbyalengtheningofthehelicallay.Whensufficientlylarge bearing areas have been generated on adjacent wires towithstand the circumferential compressive loads, this mechanicallycreated extension ceases and the extension in Phase 2 commences. The Initial Extension of any rope cannot be accurately determinedby calculation and has no elastic properties.

The practical value of this characteristic depends upon many factors, the most important being the type and construction of rope, the range of loads and the number and frequency of the cycles of operation. It isnot possible to quote exact values for the various constructions of ropein use, but the following approximate values may be employed to givereasonably accurate results.

Phase 2—Elastic ExtensionFollowing Phase 1, the rope extends in a manner which compliesapproximately with Hookes Law (stress is proportional to strain) until the limit of proportionality or elastic limit is reached.

ItisimportanttonotethatwireropesdonotpossessawelldefinedYoung’s Modulus of Elasticity, but an ‘apparent’ Modulus of Elasticity can bedeterminedbetweentwofixedloads.

The Modulus of Elasticity also varies with different rope constructions, but generally increases as the cross-sectional area of steel increases.

Technical Information

% of Rope LengthFiber Core Steel Core

Lightly LoadedFactor of Safety about 8:1 0.25 0.125

Normally LoadedFactor of Safety about 5:1 0.50 0.25

Heavily LoadedFactor of Safety about 3:1 0.75 0.50

Heavily Loaded with many bendsand/ordeflections Up to 2.00 Up to 1.00

By using the values given, it is possible to make a reasonable estimate of elastic extension, but if greater accuracy is required, it is advisable to carry out a modulus test on an actual sample of the rope. As rope users willfinditdifficulttocalculatetheactualmetallicsteelarea,thevaluescan be found in the Wire Rope Users Manual or obtained from Bridon Engineering.

Elastic Extension = WL ÷ EA (inches) W = load applied (pounds) L = rope length (inches) E = elastic modulus (pounds/in2) A = rope area (in2)

Phase 3—Permanent ExtensionThe permanent, non-elastic extension of the steel caused by tensile loads exceeding the yield point of the material. If the load exceedsthe Limit of Proportionality, the rate of extension will accelerate as theload is increased until a loading is reached at which continuousextension will commence, causing the wire rope to fracture withoutany further increase of load.

Thermal Expansion and ContractionThecoefficientoflinearexpansion(∝) of steel wire rope is (6.94 x 10-6 per °F) and therefore the change in length of 1 foot of rope produced by a temperature change of t (°F) would be: Changeinlength∆L=∆Ltwhere ∝=coefficientoflinearexpansion L = original length of rope (in) t = temperature change (°F)

The change will be an increase in length if the temperature rises and a decrease in length if the temperature falls.

Extension Due to RotationThe elongation caused by a free rope end being allowed to rotate.

Extension Due to WearThe elongation due to inter-wire wear which reduces the cross-sectional area of steel and produces extra constructional extension.

Example: What will be the total elongation of a 200 ft. length of 1-1/8" diameter Blue Strand 6 x 41 IWRC wire rope at a tension of 20,000 Ibs. and with an increase in temperature of 20°F?

Permanent Constructional Extension = 0.25% of rope length = .5 = 6"

Elastic Extension = WL ÷ EA = 20,000 x 200 x 12 ÷ 13,500,000 x .62 = 5.73" Thermal Expansion = ∆L=∝L0 t = 6.94 x 106 x 200 x 20 = .33"

Therefore, Total Extension = 6" + 5.73" + .33" = 12.06"

This page reprinted with permission from Bridon American.


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Pressures between Ropes andSheaves or Drums

In addition to bending stresses experienced by wire ropesoperating over sheaves or pulleys, ropes are also subjected to radial pressure as they make contact with the sheave. This pressure sets up shearing stresses in the wires,distorts the rope’s structure and affects the rate of wear of the sheave grooves. When a rope passes over a sheave, the load on the sheave bearing results from the tension in the rope and the angle of rope contact. It is independent of the diameter of the sheave.

Load on bearing = 2T sin 0 ÷ 2 T = rope tension (pounds) 0 = angle of rope contact

Assumingthattheropeissupportedinawellfittinggroove, then the pressure between the rope and the groove is dependent upon the rope tension and diameter, but isindependent of the arc of contact.

Pressure, P = 2T ÷ Dd P = pressure (psi) T = rope tension (pounds) D = diameter of sheave or drum (in) d = diameter of rope (in)

It must be realized that this method of estimation of pressureassumes that the area of contact of the rope in the groove ison the full rope diameter, whereas in fact only the crowns of the outer wires are actually in contact with the groove. It is estimated that the local pressures at these contact points maybeashighasfivetimesthosecalculated.Ifthepres-sure is high, the compressive strength of the material in the groovemaybeinsufficienttopreventexcessivewearandindentation, and this in turn will damage the outer wires of the rope and effect its working life. As with bending stresses, stresses due to radial pressure increase as the diameter of the sheave decreases. Although high bending stresses generallycallfortheuseofflexibleropeconstructionshavingrelatively small diameter outer wires, these have less ability to withstand heavy pressures than do the larger wires in the lessflexibleconstructions.Ifthecalculatedpressuresaretoo high for the particular material chosen for the sheaves or drums or indentations are being experienced, consideration should be given to an increase in sheave or drum diameter. Suchamodificationwouldnotonlyreducethegroovepressure, but would also improve the fatigue life of the rope.

Technical Information (Continued)

The pressure of the rope against the sheave also causesdistortionandflatteningoftheropestructure.Thiscanbecontrolledbyusingsheaveswiththecorrectgrooveprofile,which, for general purposes, suggests a recommended groovediameterofnominalropediameter+6%.Theprofileat the bottom of the groove should be circular over an angle ofapproximately120°andtheangleofflarebetweenthesides of the sheave should be approximately 52°.

Hardness of Rope Wire

Recommended pulley hardness: 250-300 Brinell for Mn steel or equivalent alloy steel.

Design Factor(Minimum Rope Breaking Strength / Maximum Load on Rope)

Industry standards provide minimum design factors allowed for certain rope applications. Some typical minimum design factors follow:


Rope Grade Approximate HardnessMinimum Tensile

Strength Brinell Rockwell 'C'

EEIP 444/486 46-50

EIP 415/461 44-48

IPS 388/444 42-46

Mobile Crane

Hoist Rope 3.5

Hoist Rope (Rotation Resistant)

5

Boom Hoist Rope 3.5

Wire Rope Slings 5

Tower Cranes 5

Offshore Pedestal Cranes 5

Drill Lines 3

Overhead Cranes 5


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Bend FatigueBend fatigue testing of ropes usually consists of cyclinga length of rope over a sheave while the rope is under aconstant tension. As part of their ongoing developmentprogram, BRIDON has tested literally thousands of ropesin this manner over the years on their own in-house design bend testing equipment.

Through this work, BRIDON has been able to compare theeffects of rope construction, tensile strength, lay direction,sheavesize,grooveprofileandtensileloadingonbendfatigue performance under ideal operating conditions. Atthe same time it has been possible to compare rope life todiscard criteria (e.g. as laid down in ISO 4309) with that tocomplete failure of the rope, i.e. to the point where therope has been unable to sustain the load any longer. Aspart of the exercise, it has also been possible to establishthe residual breaking strength of the rope at discard levelof deterioration.

Effects of D:d Ratio and Loading onFatigue Life—Typical Example Dyform 6

What needs to be recognized, however, is that very fewropes operate under these controlled operating conditions,makingitverydifficulttousethisbaseinformationwhenattempting to predict rope life under other conditions.Otherinfluencingfactors,suchasdynamicloading,differentialloadsinthecycle,fleetangle,reevingarrangement, type of spooling on the drum, change inrope direction, sheave alignment, sheave size and grooveprofile,canhaveanequallydramaticeffectonropeperformance.

However,thebenefitofsuchtestingcanbeparticularlyhelpful to the rope manufacturer when developing new orimproving existing products.

If designers or operators of equipment are seekingoptimum rope performance or regard bending fatigue lifeas a key factor in the operation of equipment, suchinformation can be provided by BRIDON for guidancepurposes.

Service Life Curve for Various D:d Ratios

Oversize ToleranceWire ropes are manufactured slightly larger than thenominal diameter. The maximum allowable oversize tolerances provided by industry standards are shown in the following table:

Bending Ratios D:dTypical minimum bending ratios (sheave or drum dia.: rope dia.) provided by some industry standards are as follows:


Nominal RopeDiameter

ToleranceUnder Over

Up to 1/8" -0 +8%

Over 1/8" to 3/16" -0 +7%

Over 3/16" to 1/4" -0 +6%

Over 1/4" -0 +5%

Drum Sheave

Mobile CraneLoad hoist 18 18

Boom hoist 15 15

Load block – 16

Tower CranesHoist 18 18

Load block – 16

Rotary Drilling Drill line 20 20

Offshore Pedestal Cranes Hoist 18 18

Surface MiningHoist 24 24

Drag 22 22



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The Use of Swivels with Wire RopeUnder certain circumstances it may be necessary to usea swivel in a lifting system to prevent rotation of the load.This is typically done for employee safety considerations. It is possible however, that the use of a swivel will have anadverse affect on rope performance and may, in some cases, damage the wire rope.

There are many types of accessories availablethat incorporate different types and degrees of rotation- preventing swivels. The swivel may be either anindependent accessory or an integral part of a lifting device,such as a crane block with a swivel hook. A typicalindependent accessory is a ball bearing anti-friction swivel.There are also headache balls with swivel hooks.

The type of swivel that causes the most concern from thestandpoint of the wire rope is the independent anti-frictionswivel that attaches directly to the rope. The purpose ofusing a swivel in a lifting system is to prevent rotation of theload. This then allows the wire rope to rotate. Excessiverope rotation can damage a wire rope.

To assist in determining whether or not a swivel should beused in the lifting system, the following recommendationsshould be considered. It must also be recognized that therotation characteristics of different types and constructionsof wire rope vary considerably. The following types andconstructions of wire rope are grouped according to theirrotation characteristics.

Group 1Wire rope constructions having very high rotationcharacteristics should not be used with a swivel underany circumstances.

These rope constructions will rotate excessively with oneend free to rotate, and the rope will unlay and distort andbe easily damaged with a loss of rope breaking force.

■ BlueStrand6x19and6x36ClassLangLay■ AllconstructionsofTriangular(Flattened) Strand Lang Lay■ EnduranceDyform8LangLay■ Constructex

Group 2Wire rope constructions having high rotation characteristicswhen used in single part reeving may require a swivel in the

system to prevent rotation in certain operating conditions.However, this should be done only when employee safety isthe issue.

These rope constructions, when used in a reeving systemwith one end free to rotate, will have a high level of rotation.This will cause the rope to unlay and, to some degree,distortion of the rope will occur.

■ BlueStrand6x19and6x36—ClassRegularLay■ EnduranceDyform6and8RegularLay

Group 3a and 3bThe ropes in this Group are designed with an inner ropethat is laid in the opposite direction to the outer strands toprovide a medium resistance to rotation. Ropes withmedium rotation characteristics are used with a swivel insingle part reeving applications. However, a swivel is notrecommended for multiple part hoisting applications or inany application where the swivel is not necessary for safetyreasons. If it is necessary to use a swivel, the rope must beoperating at a design factor of 5 or greater, must not be shockloadedandmustbeinspecteddailybyaqualifiedperson for distortion.

It should be noted that if a swivel is used on conjunctionwith Group 3a ropes, rope service life might be reduceddue to increased internal wear between the outer strandsand the inner rope.

■ Group3a—Endurance8RRRotationResistant• Group3a—Endurance l9 Rotation Resistant■ Group3b—EnduranceDyform18RotationResistant

Group 4Wire ropes having low rotation characteristics used in eithersingle or multiple part reeving may be used with a swivel.The reason for this is that the ropes will exhibit very little, ifany, rotation when used at the proper design factor.Applicationparameters,suchasafleetangle,mayinduceturn into a wire rope that can be relieved by the use of aswivel. However, if the application does not induce any turnintotherope,orifaswivelisnotbeneficialtotheperformance of the rope, the swivel may not be necessary.

■ Endurance35LS■ EnduranceDyform34LR/PI/MAX

Note: When using a swivel with any wire rope, frequent inspection of the rope is necessary. The rope should not be shock loaded or overloaded.




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Fleet AngleOfallthefactorswhichhavesomeinfluenceonthewindingofaropeonasmoothdrum,thefleetangle,arguably, has the greatest effect.

Fleetangleisusuallydefinedastheincludedanglebetweentwolines:onewhichextendsfromafixedsheavetotheflangeofadrum,andtheotherwhichextendsfromthesamefixedsheavetothedruminalineperpendicularto the axis of the drum (see illustration).

Illustration of Fleet Angle

If the drum incorporates helical grooving, the helix angle of the groove needstobeaddedorsubtractedfromthefleetangleasdescribedabovetodeterminetheactualfleetangleexperiencedbytherope.

At the DrumWhen spooling rope onto a drum, it is generally recommended that the fleetangleislimitedtobetween0.5°and2.5°.Ifthefleetangleistoosmall,i.e.lessthan0.5°,theropewilltendtopileupatthedrumflangeand fail to return across the drum. In this situation, the problem may be alleviatedbyintroducinga‘kicker’deviceorbyincreasingthefleetanglethrough the introduction of a sheave or spooling mechanism.

If the rope is allowed to pile up, it will eventually roll away from the flange,creatingashockloadinboththeropeandthestructureofthemechanism, an undesirable and unsafe operating condition.

Excessivelyhighfleetangleswillreturntheropeacrossthedrumprematurely, creating gaps between wraps of rope close to the flanges,aswellasincreasingthepressureontheropeatthecross-over positions.

Evenwherehelicalgroovingisprovided,largefleetangleswillinevitably result in localized areas of mechanical damage as the wires ‘pluck’ against each other. This is often referred to as ‘interference’, but the amount can be reduced by selecting a Langs lay rope if the reeving allows. The “interference” effect can also be reduced by employing a Dyform rope, which offers a much smoother exterior surface than conventional rope constructions.

Floatingsheavesorspeciallydesignedfleetanglecompensatingdevicesmayalsobeemployedtoreducethefleetangleeffect.

At the SheaveWhereafleetangleexistsastheropeentersasheave,itinitiallymakescontactwiththesheaveflange.Astheropecontinuestopassthroughthesheaveitmovesdowntheflangeuntilitsitsinthebottomofthegroove. In doing so, even when under tension, the rope will actually roll, as well as slide. As a result of the rolling action, the rope is twisted,i.e. turn is induced into or out of the rope, either shortening or length-eningthelaylengthoftheouterlayerofstrands.Asthefleetangleincreases, so does the amount of twist.

Toreducetheamountoftwisttoanacceptablelevel,thefleetangleshould be limited to 2.5° for grooved drums and 1.5° for plain drums and whenusingRotationResistant,ropesthefleetangleshouldbelimitedto 1.5°.

However, for some crane and hoist applications, it is recognized that for practical reasons. It is not always possible to comply with these general recommendations, in which case, the rope life could be affected.

Rope TorqueThe problem of torsional instability in crane hoist ropes would not exist if the ropes could be perfectly torque balanced under load. The torque generated in a wire rope under load is usually directly related to theapplied load by a constant ‘torque factor’. For a given rope construction,the torque factor can be expressed as a proportion of the rope diameter and this has been done below.

Variation with rope construction is relatively small and hence the scope for dramatically changing the stability of a hoisting system is limited. Nevertheless,thechoiceofthecorrectropecanhaveadecidinginflu-ence, especially in systems which are operating close to the critical limit. It should be noted that the rope torque referred to here is purely that due to tensile loading. No account is taken of the possible residual torque due, for example, to rope manufacture or installation procedures.

Torsional StabilityTorsional Stability and the Cabling Graph are two methods which can be used to determine torsional stability or the tendency of the rope to cable. The torque factors quoted are approximate maximum values for the particular constructions. To calculate the torque value for a particular rope size, multiply by the nominal rope diameter.

Example: for 20mm dia. Dyform 34LR at 20% of minimum breaking force:

Torque value = torque factor x rope dia. = 0.76% x 20mm = 0.152mm

To calculate the torque generated in a particular rope whensubjected to a tensile load, multiply the load by the torque value and combine the units.

Example: for 20mm dia. Dyform 34LR at 6000 kg f load

Torque generated = torque value x load = 0.152 . 6000 = 912 kgf.mm




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The torsional characteristics of wire rope will have the effect of causing angular displacement of a sheave block when used in multi-fall reeving arrangements. The formula below gives a good approximation under such arrangements.

S2 = 4000L. Tv

sin 0

Where S is the rope spacing in mm L is the length of each part in the reeving Tv is the torque value of the rope 0 is the angular displacement of the sheave block

When the angular displacement of the sheave block exceeds 90°(sin 0 = 1) torsional instability results and ‘cabling’ of the reeving will occur. Therefore, the test for stability of any particular reeving can be expressed as:

S>√4000L.Tv

Where S is the rope spacing in mm L is length of each part in meters Tv is torque value in mm

The preceding equations are all relative to a simple two part reeving. For more complex systems, a similar approach may be used if account is taken of the different spacings of the ropes.

Even Number of Falls

Note: For hoisting arrangements in which the rope falls are not parallel an average rope spacing should be used.

Uneven Number of Falls(Rope Termination at Bottom Block)

EffectiveRopeSpacingandmodifiedformula for stable condition

Effective Rope Spacing S Stable condition if:

S>√6000 . L. Tv

Angular Displacement of BlockTo predict the amount of angular displacement by which asheaveblockmayturnundertheinfluenceofropetorque:

sin 0 = (4 000 L. Tv) (for even number of falls) S2

The equations assume that rope is torque-free in the noloadcondition, therefore, induced torque during or immediately after installationwilladverselyinfluencethecalculatedeffect.

The above data assumes a constant torque value which is avalid assumption for a new rope. Wear and usage can haveasignificanteffectonthetorquevalue,butpracticalworkshows that under such circumstances, the torque value willdiminish, thus improving the stability of the arrangement.Some arrangements may be of such complexity that theevaluation demands a computer study.

Examples:Assuming a pedestal crane working on two falls is ropedwith 20mm diameter DYFORM 34LR and the bottom blockcarries a sheave of 360mm diameter with the falls parallel:

Torque value = 0.76% x 20 = 0.152mm

If the rope is new (worst condition) and no account is taken of block weight and friction then angular displacement for a height of lift of 30 meters is given by:

sin 0 = (4 000 . 30 . 0.152) = 0.141 i.e. 8° 10ꞌ 3602

The reeving would be expected to ‘cable’ at a height of liftcalculated as:

L = S2

4 000 . Tv

= 3602 4 000 . 0.152

= 213 metres

From the crane designer’s viewpoint, a safety factor against ‘cabling’ should be recognized (angular displacement limited at 30°), hence the practical height of lift is approximately 106.5 meters.


Rope Plan

Rope PlanEffective

Rope Spacing



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Cabling Graph

Field research jointly conducted by the Wire Rope Technical Board and the Power Crane and Shovel Association has shown that cabling of the rope parts in a multiple part reeved hoisting arrangement is controlled by several factors. The following calculations and graphs can be used to determine when and if cabling will occur on multiple part reeved hoisting arrangements.

The graph illustrates two dimensional ratios. They are:1. L/S = Length of fall per unit rope spacing2. D/d = Average pitch diameter of traveling and crown block sheave per unit rope diameter.

Various constructions of rope shown on the graph indicatethe limited conditions for torsional stability with the angular displacement of the hoist block to a maximum of 90 degrees. When the operating conditions for a particular installation give a resultant above the appropriate band, then cabling of the falls will most likely occur. If the operating conditions give a resultant below any particular band, the cabling of the falls will most likely not occur. If the operating conditions for any particular installation fall within the band, cabling is unpredictable.

5 Part4/5 of 4 Part

S is determined as followsS = Spacing (Ft)

3 Part2/3 of 2 Part

7 Part6/7 of 6 Part

2 Part

4 Part

6 Part




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The following is a fairly comprehensive listing of criticalinspection factors. It is not, however, presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted standards by which ropes must be judged.

1. AbrasionRope abrades when it moves through an abrasive mediumor over drums and sheaves. Most standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original outer wire diameter. This is not easy to determine, and discovery relies upon the experience gained by the inspector in measuring wire diameters of discarded ropes.

2. Rope StretchAll ropes will stretch when loads are initially applied. As a rope degrades from wear, fatigue, etc. (excluding accidental damage), continued application of a load of constant magnitude will produce incorrect varying amounts of rope stretch.

Phase 1: Initial stretch, during the early (beginning) period of rope service, caused by the rope adjustments to operating conditions (constructional stretch).Phase 2: Following break-in, there is a long period—the greatest part of the rope’s service life—during which a slight increase in stretch takes place over an extended time. This results from normal wear, fatigue, etc.Phase 3: Thereafter, the stretch occurs at a quicker rate. This means that the rope has reached the point of rapid degradation; a result of prolonged subjection to abrasive wear, fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon be removed.

3. Reduction in Rope DiameterAny marked reduction in rope diameter indicates degradation. Such reduction may be attributed to:■ Excessiveexternalabrasion

Wire Rope Inspection

■ Internalorexternalcorrosion■ Looseningortighteningofropelay■ Innerwirebreakage■ Ropestretch■ Ironingormilkingofstrands

In the past, whether or not a rope was allowed to remain in service depended to a great extent on the rope’s diameter at the time of inspection. Currently, this practice hasundergonesignificantmodification.

Previously, a decrease in the rope’s diameter wascompared with published standards of minimum diameters. The amount of change in diameter is, of course, useful inassessingarope’scondition.But,comparingthisfigurewithafixedsetofvaluescanbemisleading.Theselong-accepted minimums are not, in themselves, of any serious significancesincetheydonottakeintoaccountsuchfactorsas: (1) variations in compressibility between IWRC and Fiber Core; (2) differences in the amount of reduction in diameter from abrasive wear, or from core compression, or acombination of both; and (3) the actual original diameterof the rope rather than its nominal value

Asamatteroffact,allropeswillshowasignificantreductionin diameter when a load is applied. Therefore, a ropemanufactured close to its nominal size may, when it is subjected to loading, be reduced to a smaller diameter thanthat stipulated in the minimum diameter table. Yet underthese circumstances, the rope would be declared unsafealthough it may, in actuality, be safe.

As an example of the possible error at the other extreme,we can take the case of a rope manufactured near theupper limits of allowable size. If the diameter has reacheda reduction to nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps,be removed.


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Today,evaluationsoftheropediameterarefirstpredicatedon a comparison of the original diameter—when new andsubjected to a known load—with the current reading underlike circumstances. Periodically, throughout the life of therope, the actual diameter should be recorded when therope is under equivalent loading and in the same operatingsection. This procedure, if followed carefully, reveals acommon rope characteristic: after an initial reduction, the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter throughout its life.

Core deterioration, when it occurs, is revealed by a morerapid reduction in diameter and, when observed, it is time for removal.

Deciding whether or not a rope is safe is not always a simplematter. A number of different but interrelated conditionsmust be evaluated. It would be dangerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimumarbitrarily established in a table if, at the same time, other observations lead to an opposite conclusion.

Because criteria for removal are varied, and because diameter, in itself, is a vague criterion, the table of minimum diameters has been deliberately omitted from this manual.

4. CorrosionCorrosion,whiledifficulttoevaluate,isamoreseriouscauseofdegradationthanabrasion.Usually,itsignifiesalackoflubrication. Corrosion will often occur internally before thereis any visible external evidence on the rope surface. Pittingof wires is a cause for immediate rope removal. Not onlydoes it attack the metal wires, but it also prevents the rope’scomponentpartsfrommovingsmoothlyasitisflexed.Usually, a slight discoloration because of rusting merely indicates a need for lubrication.

Severe rusting, on the other hand, leads to premature fatigue failures in the wires necessitating the rope’s immediate removal from service. When a rope shows more thanonewirefailureadjacenttoaterminalfitting,itshouldbe removed immediately. To retard corrosive deterioration, the rope should be kept well lubricated with a clear wire rope lube that can penetrate between strands. In situations where extreme corrosive action can occur, it may be necessary to use galvanized wire rope.

5. KinksAre tightened loops with permanent strand distortion that result from improper handling when a rope is being installed or while in service. A kink happens when a loop is permitted to form and then is pulled down tight, causing permanent distortion of the strands. The damage is irreparable and the sling must be taken out of service.

6. DoglegsAre permanent bends caused by improper use or handling. If the dogleg is severe, the sling must be removed from service. If the dogleg is minor, exhibiting no strand distortion and cannot be observed when the sling is under tension, the area of the minor dogleg should be marked for observation and the sling can remain in service.

7. “Bird Caging”Bird caging results from torsional imbalance that comesabout because of mistreatments, such as sudden stops, therope being pulled through tight sheaves or wound on toosmall a drum. This is cause for rope replacement unlessthe affected section can be removed.

8. Localized ConditionsParticular attention must be paid to wear at the equalizingsheaves. During normal operations, this wear is not visible.Excessive vibration or whip can cause abrasion and/orfatigue.Drumcross-overandflangepointareasmustbecarefullyevaluated.Allendfittings,includingsplices,shouldbe examined for worn or broken wires, loose or damagedstrands,crackedfittings,wornordistortedthimblesandtucks of strands.

9. Heat DamageAfterafireorthepresenceofelevatedtemperatures,theremay be metal discoloration or an apparent loss of internallubrication;fibercoreropesareparticularlyvulnerable;underthese circumstances the rope should be replaced.

10. Protruding CoreIf, for any cause, the rope core protrudes from an openingbetweenthestrands,theropeisunfitforserviceandshouldbe removed.

11. Damaged End AttachmentsCracked,bentorbrokenendfittingsmustbeeliminated.The cause should be sought out and corrected. In the case of bent hooks, the throat openings—measured at the narrowest point—should not exceed 5%, not to exceed 1/4" opening and any visibly apparent bend or twist from the plane of the unbent hook over normal nor should twisting be greater than 10°.

Wire Rope Inspection (Continued)


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12. PeeningContinuous pounding is one of the causes of peening. Therope strikes against an object, such as some structural partof the machine, or it beats against a roller or it hits itself.Often, this can be avoided by placing protectors betweenthe rope and the object it is striking. Another common causeof peening is continuous working-under high loads—over asheave or drum. Where peening action cannot be controlled,it is necessary to have more frequent inspections and to beready for earlier rope replacement.

13. ScrubbingScrubbing refers to the displacement of wires and strandsas a result of rubbing against itself or another object. This,in turn, causes wear and displacement of wires and strandsalong one side of the rope. Corrective measures should betaken as soon as this condition is observed.

14. Fatigue FractureWires that break with square ends and show little surfacewear have usually failed as a result of fatigue. Such fractures can occur on the crown of the strands or in thevalleys between the strands where adjacent strandcontact exists. In almost all cases, these failures are related to bending stresses or vibration.

If diameter of the sheaves, rollers or drum cannot be increased,amoreflexibleropeshouldbeused.But,iftheropeinuseisalreadyofmaximumflexibility,theonlyremaining course that will help prolong its service life is tomove the rope through the system by cutting off the deadend. By moving the rope through the system, the fatiguedsections are moved to less fatiguing areas of the reeving.

15. Broken WiresThe number of broken wires on the outside of a wire rope are an index of (1) its general condition, and (2) whetheror not it must be considered for replacement. Frequent inspection will help determine the elapsed time between breaks. Ropes should be replaced as soon as the wire breakage reaches the numbers given in the chart on the next page. Such action must be taken without regard to the type of fracture.

16. Electric ArcRope that has either been in contact with a live power lineor been used as “ground” in an electric welding circuit, will have wires that are fused, discolored and/or annealed and must be removed.

On occasion, a single wire will break shortly after installation.However, if no other wires break at that time, there isno need for concern. On the other hand, should more wiresbreak, the cause should be carefully investigated.

On any application, valley breaks—i.e., where the wirefractures between strands—should be given serious attention. When two or more such fractures are found, the rope should be replaced immediately. (Note, however, that no valley breaks are permitted in elevator ropes.)

It is well to remember that once broken wires appear—in arope operating under normal conditions—a good many morewill show up within a relatively short period. Attempting tosqueeze the last measure of service from a rope beyondthe allowable number of broken wires (refer to table on the next page) will create an intolerably hazardous situation.

A diagnostic guide to some of the most prevalent ropeabuses are given on the following pages—these abuses areillustrated and described.

Below are plain views and cross-sections show effects of abrasion and peening on wire rope. Note that a crack has formed as a result of heavy peening.

Abrasion Peening



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When to Replace Wire Rope—Based on Number of Broken Wires

ASMEStandard Equipment

Operating RopesNumber Broken Wires *

Standing RopesNumber Broken Wires

In OneRope Lay

In OneStrand

In OneRope Lay

At EndConnection

ASME B30.2 Overhead & Ganrty Cranes 12 4 NotSpecified NotSpecified

ASME B30.4 Portal, Tower & Pillar Cranes 6 3 3 2

ASME B30.5 Crawler, Locomotive & Truck Cranes 6 3 3 2

ASME B30.6 Derricks 6 3 3 2

ASME B30.7 Base Mounted Drum Hoists 6 3 3 2

ASME B30.8 Floating Cranes & Derricks 6 3 3 2

ASME B30.16 Overhead Hoists 12 4 NotSpecified NotSpecified

ANSI A10.4 Personnel Hoists 6 3 2 2

ANSI A10.5 Materials Hoists 6 NotSpecified NotSpecified NotSpecified

American National Standards Institute (ANSI)American Society of Mechanical Engineers (ASME)

* All ropes in the above applications—one outer wire broken at the point of contact with the core that has worked its way out of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required.

Replacement Criteria forRotation Resistant Ropes

Recommended retirement criteria for all Rotation Resistant Ropes are 2 broken wires in 6 rope diameters or 4 broken wires in 30 rope diameters (i.e. 6 rope diameters for a 1" diameter rope = 6").

Distortion of Rotation Resistant Ropes, as shown to the right, can be caused by shock load / sudden load release and/or induced torque, and is the reason for immediate removal from service.



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Guide to ExaminationTypical Examples of Wire Rope Deterioration

Mechanical damagedue to rope movement over sharp edge projection while under load.

Localized wear due toabrasion on supportingstructure.

Narrow path of wear,resulting in fatigue fractures caused by working in a grossly oversize groove or over small support rollers.

Two parallel paths of broken wires indicative of bending through an undersize groove in the sheave.

Severe wear associated with high tread pressure.

Severe wear in Langs Lay caused by abrasion.

Severe corrosion.

Internal corrosion while external surface shows little evidence of deterioration.

1

2

3

4

5

6

7

8

Typical wire fractures as a result of bend fatigue.

Wire fractures at the strand or core interface as distinct from ‘crown’ fractures.

Break up of IWRC,resulting from highstress application.

Looped wiresas a result of torsionalimbalance and/orshock loading.

Typical example oflocalized wear anddeformation.

Multi strand rope ‘bird caged’ due to torsional imbalance.

Protrusion of ropecenter, resulting frombuild up of turn.

Substantial wearand severe internalcorrosion.

9

10

11

12

13

14

15

16



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The continued safe operation of lifting equipment, lifting accessories (e.g. slings) and other systems employing wire rope depends to a large extent on the operation of well programmed periodic rope examinations, and theassessmentbythecompetentpersonofthefitnessof the rope for further service.

Examination and discard of ropes by the competent personshould be in accordance with the instructions given in theoriginal equipment manufacturer’s handbook. In addition,accountshouldbetakenofanylocalorapplication-specificregulations.

The competent person should also be familiar, asappropriate, with the latest versions of related ASME B30,International, European or National standards.

Particular attention must be paid to those sectionsof rope which experience has shown to be liable todeterioration. Excessive wear, broken wires,distortions and corrosion are the more commonvisible signs of deterioration (see below).

Note: This publication has been prepared as an aid for rope examination and should not be regarded as a substitute for the competent person.

Wear is a normal feature of rope service, and the useof the correct rope construction ensures that it remainsa secondary aspect of deterioration. Lubrication mayhelp to reduce wear.

Broken wires are a normal feature of rope service towardsthe end of the rope’s life, resulting from bending fatigueand wear. The local break up of wires may indicate somemechanical fault in the equipment. Correct lubricationin service will increase fatigue performance.

Distortions are usually a result of mechanical damage,and if severe, can considerably affect rope strength.Visible rusting indicates a lack of suitable lubricationresulting in corrosion. Pitting of external wire surfacesbecomes evident in some circumstances. Broken wiresultimately result.

Internal corrosion occurs in some environments whenlubrication is inadequate or of an unsuitable type.Reduction in rope diameter will frequently guide theobservertothiscondition.Confirmationcanonlybemadeby opening the rope with clamps or the correct use of spikeand needle to facilitate internal inspection.

Note: Non-destructive testing (NDT) using electromagneticmeans may also be used to detect broken wires and/or loss in metallic area. This method complements the visual examination, but does not replace it.

Some of the More Common Types of WireFractures Can Include:

Factors Affecting Rope Performance

Multi-layers of the rope on the drum can result in severedistortion in the underlying layers.

Bad spooling(duetoexcessivefleetanglesorslackwinding) can result in mechanical damage, shown as severecrushing, and may cause shock loading during operation.

Small diameter sheaves can result in permanent set of therope and will certainly lead to early wire breaks.

Oversize groovesofferinsufficientsupporttotheropeleadingtoincreasedlocalizedpressure,flatteningoftherope and premature wire fractures. Grooves are deemed tobe oversize when the groove diameter exceeds the nominalrope diameter by more than 15%.

Undersize grooves in sheaves will crush and deform therope, often leading to two clear patterns of wear andassociated wire breaks.

Excessive angle of fleet can result in severe wear of therope due to scrubbing against adjacent laps on the drum.Rope deterioration at the Termination may be exhibited intheformofbrokenwires.Anexcessiveangleoffleetcanalso induce rotation causing torsional imbalance.


Pic

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6

A. Severed by Wear

B. Tension

C. Fatigue

D. Corrosion Fatigue

E. Plastic Wear

F. Martensite

G. Sheared End

Guide to Examination (Continued)


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Inspection ofSheaves & DrumsUnder normal conditions, machines receive periodic inspections and their overall condition is recorded. Such inspections usually include the drum, sheaves and any other parts that may come into contact with the wire rope and subject it to wear. As an additional precaution, rope-related working parts, particularly in the areas described below, should be re-inspected prior to the installation of a new wire rope.

Theveryfirstitemtobecheckedwhenexaminingsheavesand drums is the condition of the grooves (Figs. 1, 2 and 3). To check the size, contour and amount of wear, a groove gauge is used. As shown in Figure 1, the gauge should contact the groove for about 150° of arc.

Two types of groove gauges are in general use and it is important to note which of these is being used. The two differ by their respective percentage over nominal rope diameter.

For new or re-machined grooves, the groove gauge is nominal plus the full oversize percentage. The gauge carried by most wire rope representatives today is used for worn grooves and is made nominal plus 1/2 the oversize percentage.

This latter gauge is intended to act as a sort of “no-go” gauge. Any sheave with a groove smaller than this mustbe re-grooved or, in all likelihood, the existing rope willbe damaged.

When the sheave is re-grooved, it should be machined to the dimensions for “recommended minimum new groove” given. Please refer to the Wire Rope Users Manual or contact your local Lifting Specialist for the table that lists requirements for new or re-machined grooves. The chart gives the groove gauge diameter in terms of the nominal wire rope diameter plus a percentage thereof. Similarly, the size of the “no-go” gauge is given, against which worn grooves are judged. Experience has clearly demonstrated that the service life of the wire rope will be materially increased by strict adherence to these standards.

Figure 1: Cross-sections illustrating three sheave groove conditions: A is correct, B is too tight and C is too loose.

Figure 2: These sheave groove cross-sections represent three wire rope seating conditions: A is a new rope in a new groove, B is a new rope in a worn groove and C is a worn rope in a worn groove. (See also Figs. 1 and 3)

Figure 3: Illustrating the various dimensions of a sheave and the use of a sheave gauge.

A

B C

A

B C


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Troubleshooting GuideThefollowingisasimplifiedguidetocommonwireropeproblems.Intheeventofnootherstandardbeingapplicable,Bridon recommends that ropes are inspected / examined in accordance with ASME B30.5.

Problem Cause / ActionMechanical damage caused by the ropecontacting the structure of the crane on which it is operating or an external structure—usually of a localized nature.

■ Generally results from operational conditions.■ Check sheave guards and support / guide sheaves to ensure that the rope has not “jumped out” of the intended reeving system.■ Review operating conditions.

Opening of strands in Rotation Resistant ropes—in extreme circumstances the rope may develop a “birdcage distortion” or protrusion of inner strands.

Note—Rotation Resistant ropes are designedwith a specific strand gap which may be apparenton delivery in an off tension condition. These gaps will close under load and will have no effect on the operational performance of the rope.

■ Check sheave and drum groove radii using sheave gauge to ensure that they are no smaller than nominal rope radius +2.5%—Bridon recommends that the sheave and drum groove radii are checked prior to any rope installation.■ Repair or replace drum / sheaves if necessary.■ Checkfleetanglesinthereevingsystem—afleetanglein excess of 1.5 degrees may cause distortion.■ Check installation method—turn induced during installation can cause excessive rope rotation resulting in distortion.■ Check if the rope has been cut “on site “ prior to installation or cut to remove a damaged portion from the end of the rope. If so, was the correct cutting procedure used? Incorrect cutting of Rotation Resistant, low rotation and parallel closed ropes can cause distortion in operation.■ Rope may have experienced a shock load.

Brokenwiresorcrushedorflattenedropeonlower layers at crossover points in multi-layer coiling situations.

Wire breaks usually resulting from crushing or abrasion.

■ Check tension on underlying layers. Bridon recommends an installation tension of between 2% and 10% of the minimum breaking force of the wire rope. Care should be taken to ensurethattensionisretainedinservice.Insufficienttension will result in these lower layers being more prone to crushing damage.■ Review wire rope construction. Dyform wire ropes are more resistant to crushing on underlying layers than conventional rope constructions.■ Do not use more rope than necessary.■ Checkdrumdiameter.Insufficientbendingratioincreases tread pressure.

Wires looping from strands. ■ Insufficientservicedressing.■ Consider alternative rope construction.■ If wires are looping out of the rope underneath a crossover point,theremaybeinsufficienttensiononthelowerwrapson the drum.■ Check for areas of rope crushing or distortion.■ Possiblefleetangleproblemscausingroperotation.

“Pigtail” or severe spiralling in rope. ■ Check that the sheave and drum diameter is large enough— Bridon recommends a minimum ratio of the drum / sheave to nominal rope diameter of 18:1.■ Indicates that the rope has run over a small radius or sharp edge.■ Check to see if the rope has “jumped off” a sheave and has run over a shaft.



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Troubleshooting Guide (Continued)

Problem Cause / ActionTwo single axial lines of broken wires running along the length of the rope approximately 120 degrees apart indicating that the rope is being “nipped” in a tight sheave.

■ Check sheave and drum groove radii using sheave gauge to ensure that they are no smaller than nominal rope radius + 2.5%—Bridon would recommend that the sheave / drum groove radii are checked prior to any rope installation.■ Repairorreplacedrum/sheavesifnecessary.

One line of broken wires running along the lengthoftheropeindicatinginsufficientsupportfortherope,generally caused by oversize sheave or drumgrooving.

■ Check to see if the groove diameter is no greater than 15% greater than the nominal rope diameter.■ Repairorreplacedrum/sheavesifnecessary.■ Checkforcontactdamage.

Short rope life resulting from evenly / randomlydistributed bend fatigue wire breaks caused bybending through the reeving system.

Fatigue induced wire breaks are characterized ends byflatonthebrokenwires.

■ Bending fatigue is accelerated as the load increases and as the bending radius decreases. Consider whether either factor can be improved.■ Checkwireropeconstruction—Dyformropesarecapable of doubling the bending fatigue life of a conventional steel wire rope.

Short rope life resulting from localized bend fatigue wire breaks.

Fatigue induced wire breaks are characterized ends byflatonthebrokenwires.

■ Bending fatigue is accelerated as the load increases and as the bending radius decreases. Consider whether either factor can be improved.■ Checkwireropeconstruction—Dyformropesarecapable of doubling the bending fatigue life of a conventional steel wire rope.■ Localizedfatiguebreaksindicatecontinuousrepetitivebends over a short length. Consider whether it is economic to periodically shorten the rope in order to move the rope through the system and progressively expose fresh rope to the severe bending zone. In order to facilitate this procedure it may be necessary to begin operating with a slightly longer length of rope.

Broken rope—ropes are likely to break whensubjected to substantial overload or misuseparticularly when a rope has already been subjected to mechanical damage.

Corrosion of the rope both internally and/or externally canalsoresultinasignificantlossinmetallicarea.The rope strength is reduced to a level where it isunable to sustain the normal working load.

■ Review operating conditions.

Wave or corkscrew deformations normally associated with multi-strand ropes.

■ Check sheave and drum groove radii using sheave gauge to ensure that they are no smaller than nominal rope radius +2.5%—Bridon recommends that the sheave / drum groove radii are checked prior to any rope installation.■ Repairorreplacedrum/sheavesifnecessary.■ Checkfleetanglesinthereevingsystem—afleetanglein excess of 1.5 degrees may cause distortion.■ Checkthatropeendhasbeensecuredinaccordancewith manufacturers instructions.■ Checkoperatingconditionsforinducedturn.



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Troubleshooting Guide (Continued)

Problem Cause / ActionRotation of the load in a single fall system. ■ Review rope selection.

■ ConsideruseofRotationResistantrope.Rotation of the load in a multi-fall system resulting in “cabling” of the rope falls.

Possibly due to induced turn during installation or operation.

■ Review rope selection.■ ConsideruseofRotationResistantrope.■ Reviewinstallationprocedureoroperatingprocedures.

Core protrusion or broken core in single layer six or eight strand rope.

■ Caused by repetitive shock loading— review operating conditions.

Ropeaccumulatingor“stacking”atdrumflange—duetoinsufficientfleetangle.

■ Review drum design with original equipment manufacturer—consider adding rope kicker, fleetingsheave,etc.

Sunken wraps of rope on the drum normally associatedwithinsufficientsupportfromlowerlayers of rope or grooving.

■ Check correct rope diameter.■ Ifgrooveddrumcheckgroovepitch.■ Checktensiononunderlyinglayers—Bridonrecommends an installation tension of between 2% and 10% of the minimum breaking force of the wire rope—Care should be taken to ensure that tension is retained in service. Insufficienttensionwillresultintheselowerlayersbeing more prone to crushing damage.■ Makesurethatthecorrectropelengthisbeingused. Too much rope (which may not be necessary) may aggravate the problem.

Short rope life induced by excessive wear and abrasion.

■ Checkfleetangletodrum.■ Checkgeneralalignmentofsheavesinthereevingsystem.■ Checkthatallsheavesarefreetorotate.■ Reviewropeselection.ThesmoothsurfaceofDyform wire ropes gives better contact with drum and sheaves and offers improved resistance to “interference” between adjacent laps of rope.

External corrosion. ■ Considerselectionofgalvanizedrope.■ Reviewlevelandtypeofservicedressing.

Internal corrosion. ■ Considerselectionofgalvanizedrope.■ Reviewfrequencyamountandtypeofservicedressing.■ Considerselectionofplasticimpregnated(PI)wirerope.



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Product Safety:Instructions & Warnings on the Use of Steel Wire RopeThe following Instructions and Warnings combine toprovide guidance on Product Safety and are intended foruse by those already having a working knowledge ofwire ropes, as well as the new user. They should be read, followed and passed on to others.

Failure to read, understand and follow these instructionscould result in harmful and damaging consequences.

1. Rope Selection Criteria Ensure that the correct type of wire rope is selected for the equipment by referring to the OEM’s instruction manual or other relevant documents. If in doubt, contact Bridon for guidance.

1.1 Rope Strength If necessary, refer to the appropriate Regulations and/or application standards and calculate the maximum force to which the rope will be subjected.

The calculation may take into account the mass to be lifted or moved, any shock loading, effects of high speed, acceleration, any sudden starts or stops, frequency of operation and sheave bearing friction.

By applying the relevant design factor and, where applicable,theefficiencyoftheropetermination,the required minimum breaking load or force of the rope will be determined, the values of which are available from the relevant National or International standards orfromspecificProductDataliterature.Ifindoubt, ask for advice from Bridon.

1.2 Bending Fatigue The size and number of sheaves in the system will influencetheperformanceoftherope.

Wire rope which bends around sheaves, rollers or drums will deteriorate through ‘bending fatigue’. Reverse bending and high speed will accelerate the process. Therefore, under such conditions select a rope with high bending fatigue resistance. Refer to Product Data Information, and if in doubt, ask for advice.

1.3 Abrasion Wire rope which is subject to abrasion will become progressively weaker as a result of:

Externally—dragging it through overburden, sand or other abrasive materials and passing around a sheave, roller or drum.

Internally—being loaded or bent.

Abrasion weakens the rope by removing metal from both the inner and outer wires. Therefore, a rope with large outer wires should normally be selected.

1.4 Vibration Vibration in wire rope will cause deterioration. This may become apparent in the form of wire fractures where the vibration is absorbed.

These fractures may be internal only and will not be visually identified.

1.5 Distortion Wire rope can be distorted due to high pressure against a sheave, improperly sized grooves or as a result of multi-layer spooling on a drum.

Rope with a steel core is more resistant to crushing and distortion.

1.6 Corrosion Rope with a large number of small wires is more susceptible to corrosion than rope with a small number of large wires. Therefore, if corrosion is expected to haveasignificanteffectonropeperformance.Therope may have to be lubricated frequently in service or a galvanized rope may be selected.

1.7 Cabling ‘Cabling’ of rope reeving due to block rotation can occur if the rope is incorrectly selected. Applications involving high lifts are particularly vulnerable to this condition,therefore,ropesspecificallydesignedto resist rotation need to be selected.

1.8 Fixing of Rope Ends Ropes which have high rotation characteristics must notbeselectedunlessbothendsoftheropearefixed or the load is guided and unable to rotate.

1.9 Connecting Ropes In the event that it is necessary to connect one rope to another (in series), it is essential that they have the required strength, are of the same type and both have the same lay direction (i.e. connect ‘right’ lay to ‘right’ lay).

Failure to heed this warning could result in catastrophic failure particularly at a termination, which is capable of being pulled apart (i.e. splice) due to unlaying.

1.10 Rope Length Rope length and/or difference in length between two or more ropes used in a set may be a critical factor and must be considered along with rope selection.



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Wire rope will elongate under load. Other factors, such as temperature, rope rotation and internal wear, will also have an effect. These factors should also be considered during rope selection.

1.11 Preformed and Non-preformed Ropes Single layer round strand rope is normally supplied preformed. However, if a non-preformed rope is selected then personnel responsible for its installation and/or maintenance need to take particular care when handling such rope, especially when cutting.

For the purposes of this instruction, Rotation Resistant ropes should be regarded as non-preformed ropes.

1.12 Operating Temperatures Wire rope with a steel core should be selected if there isanyevidencetosuggestthatafibercorewillnot provide adequate support to the outer strands and/or if the temperature of the working environment may be expected to exceed 180°F.

For operating temperatures above 200°F, de-rating of the minimum breaking force of the rope is necessary (e.g. between 200°F and 400°F reduce by 10%; between 400°F and 600°F reduce by 25%; between 600°F and 800°F reduce by 35%).

Do not use ropes with high carbon wires above 800°F.

Failure to observe this general guidance could result in failure of the ropes to support the load.

For temperatures over 800°F, other materials, such as stainless steel or other special alloys, should be considered.

Rope lubricants and any synthetic filling and/or covering materials may become ineffective at certain low or high operating temperature levels.

Certain types of rope end terminations also have limiting operating temperatures and the manufacturer or Bridon should be consulted where there is any doubt. Ropes with aluminium ferrules must not be used at temperatures in excess of 300°F.

2. Storage 2.1 Unwrap the rope and examine the rope immediatelyafterdeliverytocheckitsidentification and condition and verify that it is in accordance

withthedetailsontheCertificatesand/orother relevant documents.

Check the rope diameter and examine any rope terminations to ensure that they are compatible with the equipment or machinery to which they are to befitted.

2.2 Select a clean, well ventilated, dry, undercover location. Cover with waterproof material if the delivery site conditions preclude inside storage.

Rotate the reel periodically during long periods of storage, particularly in warm environments, to prevent migration of the lubricant from the rope.

Never store wire rope in areas subject to elevated temperatures as this may seriously affect its future performance. In extreme cases, its original as-manufactured strength may be severely reduced rendering it unfit for safe use.

Ensure that the rope does not make any direct contactwiththefloorandthatthereisaflowofair under the reel.

Failure to do so may result in the rope becoming contaminated with foreign matter and start the onset of corrosion before the rope is even put to work.

Support the reel on a simple A-frame or cradle located on ground, which is capable of supporting the total mass of rope and reel. Ensure that the rope is stored where it is not likely to be affected by chemical fumes, steam or other corrosive agents.

Failure to do so may seriously affect its condition rendering it unfit for safe use.

2.3 Examine ropes in storage periodically and, when necessary, apply a suitable dressing which is compatible with the manufacturing lubricant. Contact the rope supplier, Bridon or original equipment manufacturer’s (OEM) manual for guidance on types of dressings available, methods of application and equipment for the various types of ropes and applications.

Re-wrap the rope unless it is obvious that this will be detrimental to rope preservation.

Failure to apply the correct dressing may render the original manufacturing lubricant ineffective and rope performance may be significantly affected.


Product Safety:Instructions & Warnings on the Use of Steel Wire Rope(Continued)


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Ensure that the rope is stored and protected in such a manner that it will not be exposed to any accidental damage either during the storage period or when placing the rope in or taking it out of storage.

Failure to carry out or pay attention to any of the above could result in a loss of strength and/or a reduction in performance. In extreme cases, the rope may be unfit for safe use.

3. Certification and Marking MakesurethattherelevantCertificatehasbeen obtained before taking the rope into use for a lifting operation.

Check to verify that the marking on the rope or its packagematchestherelevantCertificate.

Note: The rating of a component part of a machine or lifting accessory is the responsibility of the designer of the machine or accessory. Any re-rating of a lifting accessory must be approved by a competent person.

RetaintheCertificateinasafeplaceforidentification of the rope when carrying out subsequent periodic statutory examinations in service.

4. Handling and Installation 4.1 Handling and installation of the rope should be carried out in accordance with a detailed plan and should be supervised by a competent person.

Incorrectly supervised handling and installation procedures may result in serious injury to persons in the vicinity of the operation, as well as those persons directly involved in the handling and installation.

4.2 Wear suitable protective clothing, such as overalls, industrial gloves, helmet, eye protectors and safety footwear (and respirator, particularly where the emission of fumes due to heat is likely).

Failure to wear suitable protective clothing and equipment may result in skin problems from over exposure to certain types of rope lubricants and dressings; burns from sparks, rope ends, molten lubricants and metals when cutting ropes or preparing sockets for re-use; respiratory or other internal problems from the inhalation of fumes when cutting ropes or preparing sockets for re-use; eye injuries from sparks when cutting ropes; lacerations This page reprinted with permission from Bridon American.

to the body from wire and rope ends; bruising of the body and damage to limbs due to rope recoil, backlash and any sudden deviation from the line of path of rope.

4.3 Ensure that the correct rope has been supplied by checking to see that the description on the Certificateisinaccordancewiththatspecifiedinthe purchaser’s order.

4.4 Check by measurement that the nominal diameter of the new rope conforms to the nominal size stated on theCertificate.

Forverificationpurposes,measurethediameterby usingasuitableropevernierfittedwithjawsbroad enough to cover not less than two adjacent strands. Take two sets of measurements spaced at least 3′apart,ensuringthattheyaretakenatthelargest cross-sectional dimension of the rope. At each point, take measurements at right angles to each other.

The average of these four measurements should be withinthetolerancesspecifiedintheappropriate StandardorSpecification.

For a more general assessment of rope diameter, use a rope calliper.

4.5 Examine the rope visually to ensure that no damage or obvious signs of deterioration have taken place during storage or transportation to the installation site.

4.6 Check the working area around the equipment for any potential hazards which may affect the safe installation of the rope.

4.7 Check the condition of the rope-related equipment in accordance with the OEM’s instructions. Include the following—

Drum Check the general condition of the drum.

If the drum is grooved, check the radius and pitch and ensure that the grooves will satisfactorily accommodate the size of the new rope. Check the condition and position of the kicker plates orwearplates,iffitted,toensurethatthenewrope will spool correctly on the drum.

Sheaves Ensure that the grooving is of the correct shape and size for the new rope

Check that all sheaves are free to rotate and in good condition.



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Rope Guards Checkthatanyropeguardsarecorrectlyfittedand are in good condition.

Check the condition of any wear plates or rollers which are protecting structural members.

Failure to carry out any of the above could result in unsatisfactory and unsafe rope performance.

Note: Grooves must have clearance for the rope and provide adequate circumferential support to allow for free movement of the strands and facilitate bending. When grooves become worn and the rope is pinched at the sides, strand and wire movement is restricted and the ability of the rope to bend is reduced.

4.8Whenanewropeisfitted,avariationinsize compared with the old worn rope will be apparent. The newropemaynotfitcorrectlyintothepreviouslyworn grooveprofileandunnecessarywearandropedistortion is likely to occur. This may be remedied by machining out the grooves before the new rope is installed. Before carrying out such action, the sheaves or drum should beexaminedtoensurethattherewillbesufficient strength remaining in the underlying material to safely support the rope.

The competent person should be familiar with the requirements of the appropriate application / machinery standard.

Note: General guidance to users is given in the Wire Rope Users Manual.

Transfer the wire rope carefully from the storage area to the installation site.

Coils Place the coil on the ground and roll it out straight ensuring that it does not become contaminated with dust, grit, moisture or any other harmful material.

If the coil is too large to physically handle it may be placed on a ‘swift’ turntable and the outside end of the rope pulled out allowing the coil to rotate.

Never pull a rope away from a stationary coil as this will induce turn into the rope and kinks will form. These will adversely affect rope performance.

Reels Pass a shaft through the reel and place the reel in a suitable stand, which allows it to rotate and be braked to avoid overrun during installation. Where multi-layer coiling is involved, it may be necessary for the reel to be placed in equipment which has the capability of providing a back tension in the rope as it is being transferred from reel to drum. This is to ensure that the underlying (and subsequent) laps are wound tightly on the drum.

Positionthereelandstandsuchthatthefleetangle during installation is limited to 1.5 degrees.

If a loop forms in the rope, ensure that it does not tighten to form a kink.

A kink can severely affect the strength of a six strand rope and can result in distortion of a Rotation Resistant rope leading to its immediate discard.

Ensure that the reel stand is mounted so as not to create a reverse bend during reeving (i.e. for a winch drum with an overlap rope, take the rope off the top of the reel).

4.9 Ensure that any equipment or machinery to be roped is correctly and safely positioned and isolated from normal usage before installation commences. Refer to the OEM’s instruction manual and the relevant ‘Code of Practice’.

4.10 When releasing the outboard end of the rope from a reel or coil, ensure that this is done in a controlled manner. On release of the bindings and servings used for packaging, the rope will want to straighten itself from its previously bent position. Unless controlled, this could be a violent action. Stand clear.

Failure to control could result in injury.

Ensure that the as-manufactured condition of the rope is maintained during installation.

If installing the new rope with the aid of an old one, onemethodistofitawireropesock(orstocking)to each of the rope ends. Always ensure that the open end of the sock (or stocking) is securely attached to the rope by a serving or alternatively by a clip. Connect thetwoendsviaalengthoffiberropeofadequate strength in order to avoid turn being transmitted from the old rope into the new rope. Alternatively, a length of fiberorsteelropeofadequatestrengthmaybereeved into the system for use as a pilot / messenger line. Do not use a swivel during the installation of the rope.




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4.11 Monitor the rope carefully as it is being pulled into the system and make sure that it is not obstructed by any part of the structure or mechanism which may cause the rope to come free.

Failure to monitor during this operation could result in injury.

This entire operation should be carried out carefully and slowly under the supervision of a competent person.

4.12 Take particular care and note the manufacturer’s instructions when the rope is required to be cut. Apply secure servings on both sides of the cut mark.

Ensure that the length of serving is at least equal to two rope diameters. (Note: Special servings are required for spiral ropes, i.e. spiral strand and locked coil.)

Oneservingeithersideofthecutisnormallysufficient for preformed ropes. For non-preformed ropes, (i.e. Rotation Resistant ropes) a minimum of two servings each side of the cut will be necessary.

Arrange and position the rope in such a manner that at the completion of the cutting operation the rope ends will remain in position, thus avoiding any backlash or any other undesirable movement.

Cut the rope with a high speed abrasive disc cutter. Other suitable mechanical or hydraulic shearing equipment may be used although not recommended when a rope end is required to be welded or brazed.

When using a disc cutter be aware of the danger from sparks, disc fragmentation and fumes.

Ensure adequate ventilation to avoid any build-up of fumes from the rope and its constituent parts including anyfibercore(naturalorsynthetic)anyropelubricant(s) andanysyntheticfillingand/orcoveringmaterial.

Rope produced from carbon steel wires in the form shipped is not considered a health hazard. During subsequent processing (e.g. cutting, welding, grinding, cleaning), dust and fumes may be produced which contain elements which may affect exposed workers.

The products used in the manufacture of steel wire ropes for lubrication and protection present minimal hazard to the user in the form shipped. The user must however, take reasonable care to minimize skin and eye contact and also avoid breathing their vapor and mist.

4.13Ensurethatanyfittings,such asclampsorfixtures,arecleanand undamaged before securing rope ends.

Makesurethatallfittingsaresecurein accordance with the OEM’s instruction manual or manufacturer’s instructions andtakeparticularnoteofanyspecific safety requirements e.g. torque values (and frequency of any re-application of torque).

When terminating a rope end with a wedge socket, ensure that the rope tail cannot withdraw through the socket by securing a clamp to the tail or by following the manufacturer’s instructions. The tail length should be a minimum of 20 rope diameters for all Rotation Resistant wire rope and a minimum of 6 rope diameters for 6 and 8 strand ropes.

(See Fig. 1 for two recommended methods of securing the rope tail of a wedge socket termination).

The loop back method uses a rope grip and the loop should be lashed to the live part of rope by a soft wire servingortapetopreventflexingoftheropeinservice.

The method of looping back should not be used if there is a possibility of interference of the loop with the mechanism or structure.

Failure to secure in accordance with instructions could lead to loss of the rope and/or injury.

4.14 When coiling a rope on a plain (or smooth) barrel drum, ensure that each lap lies tightly against the preceding lap. The application of tension in the rope greatly assists in the coiling of the rope.

Any looseness or uneven winding will result in excessive wear, crushing and distortion of the rope.

Withplainbarreldrums,itisdifficulttoachieve satisfactory multi-layer coiling beyond three layers.


Figure 1Product Safety:Instructions & Warnings on the Use of Steel Wire Rope(Continued)


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Figure 2:Proper method of locating rope

anchorage point on a plain drum.

Note: Thumb indicates side ofrope anchorage


The direction of coiling of the rope on the drum is important, particularly when using plain barrel drums, and should be related to the direction of lay of the rope in order to induce close coiling.

(See Fig. 2 for proper method of locating rope anchorage point on a plain drum.)

When multi-layer spooling has to be used it should be realized that after thefirstlayeris wound on a drum, the rope has to cross the underlying rope in order to advance across the drum in the second layer. The points at which the turns in the upper layer cross those of the lower layer are known as the cross-over points and the rope in these areas is susceptible to increased abrasion and crushing. Care should be taken when installing a rope on a drum and when operating a machine to ensure that the rope is spooled and layered correctly.

4.15 Check the state of re-usable rope end terminations for size, strength, defects and cleanliness before use. Nondestructive testing may be required depending on the material and circumstances of use. Ensurethattheterminationisfittedinaccordancewith the OEM’s instruction manual or manufacturer’s instructions. When re-using a socket and depending on its type and dimensions, the existing cone should be pressed out. Otherwise, heat may be necessary.

When melting out sockets which have previously been filled with hot metal, the emission of toxic fumes is likely. Note that white metal contains a high proportion of lead.

Correctly locate and secure any connection pins and


fittingswhenassemblingendterminationstofixtures. Refer to manufacturer’s instructions.

Failure to pay attention to any of the above could result in unsafe operation and potential injury.

4.16Limitswitches,iffitted,mustbecheckedand readjusted, if necessary, after the rope has been installed.

4.17RecordthefollowingdetailsontheCertificate after installation has been completed: type of equipment, location, plant reference number, duty and date of installation and any re-rating information / signatureofcompetentperson.Thensafelyfilethe Certificate.

4.18 ‘Run in’ the new rope by operating the equipment slowly, preferably with a low load, for several cycles. This permits the new rope to adjust itself gradually to working conditions.

Note: Unless otherwise required by a certifying authority, the rope should be in this condition before any proof test of the equipment or machinery is carried out.

Check that the new rope is spooling correctly on the drum and that no slack or cross laps develop.

Apply as much tension as possible (2%-5% of the MBF of the rope) to ensure tight and even spooling, especiallyonthefirstlayer.

Where multi-layer spooling is unavoidable, succeeding layers should spool evenly on the preceding layers of rope.

Irregular spooling usually results in severe surface wear and rope malformation, which in turn is likely to cause premature rope failure.

4.19 Ensure that the as-manufactured condition of the rope is maintained throughout the whole of the handling and installation operation.

4.20 If samples are required to be taken from the rope for subsequent testing and/or evaluation, it is essential that the condition of the rope is not disturbed. Refer to the instructions given in 4.12 and, depending on the rope type and construction, any other special manufacturer’s instructions.

5. Inspection 5.1 Inspect the rope and related equipment at the beginning of every work period at least daily in most instances and particularly following any incident which could have damaged the rope or installation.


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The entire length of rope should be inspected and particular attention paid to those sections that experience has proven to be the main areas of deterioration. Excessive wear, broken wires, distortion and corrosion are the usual signs of deterioration. For a more detailed examination, special tools are necessary, which will also facilitate internal inspection.

In the case of ropes working over drums or sheaves, it is particularly necessary to examine those areas entering or leaving the grooves when maximum loads (i.e. shock loads) are experienced, or those areas which remain for long periods in exposed places, such as over a jib head sheave.

On some running ropes, but particularly relevant to standing ropes (e.g. pendant ropes), the areas adjacent to terminations should be given special attention by rope diameter measurements and visual examination for broken wires and corrosion.

Note: Shortening the rope repositions the areas of maximum deterioration in the system. Where conditions permit, begin operating with a rope which has a slightly longer length than necessary in order to allow for periodic shortening.

When a non-preformed rope or multi-layer rope is used with a wedge socket and is required to be shortened, it is essential that the end of the rope is secured by welding or brazing before the rope is pulled through the main body of the socket to its new position.

Slacken the wedge in the socket. Pass the rope through the socket by an amount equivalent to the crop length or sample required. Note that the original bent portion of the rope must not be retained within the wedge socket. Replace the wedge and pull up the socket. Prepare and cut in accordance with section 4.12. Ensure that the rope tail cannot withdraw through the socket, see section 4.13.

Failure to observe this instruction will result in a significant deterioration in the performance of the rope and could render the rope completely unfit for further service.

In cases where severe rope wear takes place at one end of a wire rope, the life of the rope may be extended by changing round the drum end with the load end, i.e. turning the rope ‘end for end’ before


deterioration becomes excessive.

5.2 Remove broken wires as they occur by bending backwards and forwards using a pair of pliers until they break deep in the valley between two outer strands. Wear protective clothing, such as overalls, industrial gloves, helmet, eye protectors and safety footwear during this operation.

Do not shear off the ends of broken wires with pliers as this will leave an exposed jagged edge, which is likely to damage other wires in the rope and lead to premature removal of the rope from service. Failure to wear adequate protective clothing could result in injury.

Note: Broken wires are a normal feature of service, more so towards the end of the rope’s life, resulting from bending fatigue and wear. The local break up of wires may indicate some mechanical fault in the equipment.

Record the number and position in the rope of any removed broken wires.

5.3 Do not operate an appliance if for any reason (e.g.ropediameter,certifiedbreakingforce,rope construction, length or strength and type of rope termination) the wire rope and its termination is considered unsuitable for the required duty.

5.4 Do not operate an appliance if the wire rope fittedhasbecomedistorted,beendamagedorhas deteriorated to a level such that discard criteria has been reached or is likely to be reached prior to normal expected life based on historical performance data.

Rope distortion is usually a result of mechanical damageandcansignificantlyreduceropestrength.

5.5 An authorized competent person must examine the rope in accordance with the appropriate Regulations.

5.6 Do not carry out any inspection, examination, dressing / lubrication, adjustment or any other maintenance of the rope while it is suspending a load, unless otherwise stated in the OEM’s instruction manual or other relevant documents.

Do not carry out any inspection or maintenance of the rope if the appliance controls are unattended unless the surroundingareahasbeenisolatedorsufficientwarning signs have been posted within the immediate vicinity. If the appliance controls are attended, the authorized person must be able to communicate effectively with the driver or controller of the appliance during the inspection process.


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5.7 Never clean the wire rope without recognizing the potential hazards associated with working on a moving rope.

Failure to pay attention or take adequate precaution could result in injury.

If cleaning by cloth / waste, the material can be snagged on damaged surfaces and/or broken wires.

If cleaning by brush, eye protectors must be worn. If usingfluids,itshouldberecognizedthatsomeproducts arehighlyinflammable.Arespiratorshouldbewornif cleaning by a pressurized spray system.

Failure to take adequate precaution could result in injury or damage to health.

Onlyusecompatiblecleaningfluidswhichwillnot impair the original rope lubricant nor affect the rope associated equipment.

Theuseofcleaningfluids(particularlysolventbased) is likely to ‘cut back’ the existing rope lubricant leading to a greater quantity of lubricant accumulating on the surface of the rope. This may create a hazard in appliances and machinery which rely on friction between the rope and the drive sheave (e.g. elevators, friction winders and ski lifts).

5.8 Lubricants selected for in-service dressing must be compatible with the rope manufacturing lubricant and should be referenced in the OEM’s instruction manual or other documents approved by the owner of the appliance. If in doubt, contact Bridon.

5.9 Take particular care when applying any in-service lubricant / dressing. Application systems which involve pressure should only be operated by trained and authorized persons and the operation carried out strictly in accordance with the manufacturer’s instructions.

Most wire ropes should be lubricated at regular intervals (including cleaning) in order to extend safe performance.

Ensure that any in-service lubricant dressing penetrates into the core of the rope.

Ensure that the in-service lubricant dressing is not applied excessively so that the amount of lubricant on the rope will hinder rope examination.


A ‘dry’ rope unaffected by corrosion, but subject to bend fatigue, is likely to achieve only 30% of that normally attained by a ‘lubricated’ rope.

Note: The authorized person carrying out a rope inspection must be capable of recognizing the potential loss of safe performance of such a rope in comparison with lubricated rope.

Clean the rope before applying a fresh dressing / lubricant if it is heavily loaded with foreign matter e.g. sand, dust.

5.10 The authorized person responsible for carrying out wire rope maintenance must ensure that the ends of the rope are secure. At the drum end, this will involve checking the integrity of the anchorage and ensuring that there are at least three dead wraps tightly spooled. At the outboard end, the integrity of the termination must be checked to ensure that it is in accordance with the OEM’s manual or other documents approved by the owner of the appliance.

Adjust the lengths of ropes in multi-rope systems in order that equal forces (within approved limits) are evident.

5.11 Damage to, or removal of, component parts (mechanical or structural) caused by abnormal contact with wire rope can be hazardous to the safety of the appliance and/or the performance of the rope (e.g. damage to the drum grooving such that spooling is erratic and/or the rope is ‘pulled down’ into underlying layers, which might cause a dangerous condition or, alternatively, cause localized rope damage at ‘cross-over’ positions, which might then radically affect performance; loss / removal of wear plates protecting the structure leading to major structural damage by cutting and/or failure of the wire rope due to mechanical severance).

5.12 Following any periodic examination or routine or special inspection where any corrective actionistakentheCertificateshouldbeupdated and a record made of the defects found, the extent of the changes and the condition of the rope.

5.13 Apply the following procedures for the selection and preparation of samples, from new and used lengths of rope, for the purpose of examination and testing to destruction.

Check that the rope end, from which the sample will be taken, is secured by welding or brazing. If not, select the sample length further away from the rope end and prepare new servings.


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Wire Rope TechnicalBoard Warning

Handle the rope in accordance with the instructions given in Section 4. Serve the rope using the buried wire technique and apply a rope clamp or grip as close to the cut mark as practically possible. Do not use solder to secure the servings.

Ensure that the sample is kept straight throughout the whole procedure and ensure that the minimum sample lengthis10′unlessotherwisespecified.

The rope should be cut with a high speed abrasive disc cutter or an oxyacetylene torch. Weld the rope ends of the sample as described in section 4.12, after which the clamp or grip can be removed.

Theidentificationoftheropemustbeestablishedand the sample suitably marked and packed. It is recommendedthatthe10′sampleisretainedstraight and secured to a wood pallet for transportation.

Failure to comply with these procedures will result in measured breaking force values which are not truly representative of the actual strength of the rope.

6. Wire Rope Discard 6.1 Discard the wire rope in accordance with current Regulations and in accordance with the OEM’s instruction manual.

Note: The authorized competent person should also be familiar with the latest versions of ANSI, ASME or ISO Standards. Other standards and instructions


covering rope discard may also be applicable. In the case of synthetic sheaves (or synthetic linings), refer to the OEM’s instruction manual or contact the sheave (or lining) manufacturer for specific discard criteria.

6.2 If a wire rope is removed from service at a level of performance substantially different to historically established performance data and without any obvious reason(s), contact Bridon for further guidance.

6.3Onlyqualifiedandexperiencedpersonnel,taking the appropriate safety precautions and wearing the appropriate protective clothing, should be responsible for removing the wire rope.

Take particular care when removing ropes with mechanical damage as they may fail abruptly during the change-out procedure.

Take the utmost care when removing ‘exhausted / failed’ ropes from drums and sheaves as they may be grossly distorted, lively and tightly coiled.

Failure to take adequate precautions could result in injury.

6.4 Store discarded rope in a safe and secure location or compound and ensure that it is suitably marked to identify it as rope which has been removed from service and not to be used again.

Discarded rope can be a danger (e.g. protruding broken wires, excessive grease / lubricant and rope mass) to personnel and equipment if not handled correctly and safely during disposal.

6.5 Record the date and reason for discard on the Certificatebeforefilingforfuturereference.

6.6 Pay attention to any Regulations affecting the safe disposal of steel wire rope.

Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused.Wire Rope failure may cause serious injury or death!Protect yourself and others:■ ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.■ NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED.■ NEVER OVERLOAD a wire rope.■ INFORM YOURSELF: Read and understand manufacturer's literature or "Wire Rope and Wire Rope Sling Safety Bulletin".*■ REFER TO APPLICABLE CODES, STANDARDS and REGULATIONS for INSPECTION REQUIREMENTS and REMOVAL CRITERIA.** For additional information or the BULLETIN, ask your employer or wire rope supplier.

WARNING

© 1993, Wire Rope Technical Board Form No. 193


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6 x 7 Classification

6x7ClassificationWireRopesgivelongserviceinoperating conditions where ropes are dragged along theground or over rollers. Larger sheaves and drums (than thoseusedformoreflexibleconstructions)arerequiredtoavoidbreakagefromfatigue.6x7ClassificationRopescontain 6 strands with 3 through 14 wires, no more than 9 of which are outside wires.

In a 6 x 7 rope, the wires are larger than those of otherconstructions of the same diameter. Wires of a 6 x 7 areapproximately twice the diameter of outer wires of a 6 x 25 FW rope. The large size of the outer wire gives theclassexcellentabrasionresistance—atgreatsacrificeof bendability and resistance to fatigue. The standard 6x7ropeconstructionismadewithfibercoreandrightregular lay.

General PurposeWire Ropes

Characteristics 6 x 7 RopeExcellent abrasion resistance;

less bending fatigue resistance.

Typical ApplicationsDragging and haulage in mines, inclined planes and tramways,

sand lines.

Diameter(in.)

Bright / Fiber Core Galvanized / Fiber Core

Diameter (in.)

Approx. Wt. / Ft.

(lbs.)

MinimumBreaking Force

(Tons of 2,000 lbs.)

Approx. Wt. / Ft.

(lbs.)


(Tons of 2,000 lbs.)

3/16 0.056 1.5 – – 3/161/4 0.094 2.64 0.094 2.38 1/4

5/16 0.15 4.1 0.15 3.69 5/163/8 0.21 5.86 0.21 5.27 3/8

7/16 0.29 7.93 0.29 7.14 7/161/2 0.38 10.3 0.38 9.27 1/2

9/16 0.48 13 0.48 11.7 9/165/8 0.59 15.9 0.59 14.3 5/83/4 0.84 22.7 0.84 20.4 3/4

WarrantyAnywarranty,astoqualityorperformanceoffitnessforuseofwireropeproducts,isalwayspremisedontheconditionthatthe published strengths apply only to new, unused rope, that the mechanical equipment on which such products are used is properly designed and maintained, that such products are properly stored, handled, used and maintained, and properly inspected on a regular basis during the period of use.

Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including butnotlimitedtopersonalinjury,laborcosts,alossofprofitsresultingfromtheuseofsaidproductsorfromsaidproductsbeing incorporated in or becoming a component of any other product.

WARNING SEE WARNING INFORMATION ON PAGES 721 - 723.


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Aircraft Cable & Strand7 x 7 7 x 7 Galvanized

Min. BreakingForce (lbs.)

Stainless SteelMin. Breaking

Force (lbs.)Diameter

(in.)Approx. Weight

1000 ft. / lbs.1/16 7.5 480 4803/32 16 920 9201/8 28.5 1700 1700

5/32 43 2600 24003/16 62 3700 37001/4 106 6100 6100

5/16 167 9200 90003/8 236 13,000 12,000

7 x 19 7 x 19 GalvanizedMin. Breaking

Force (lbs.)



(in.)Approx. Weight

1000 ft. / lbs.3/32 17 1000 9201/8 29 2000 1760

5/32 45 2800 24003/16 65 4200 37007/32 86 5600 50001/4 110 7000 6400

9/32 139 8000 78005/16 173 9800 90003/8 243 14,400 12,000

1 x 19 1 x 19 GalvanizedMin. Breaking

Force (lbs.)



(in.)Approx. Weight

1000 ft. / lbs.1/16 8.5 500 5003/32 20 1200 12001/8 35 2100 2100

5/32 55 3300 33003/16 77 4700 47001/4 135 8200 8200

5/16 210 12,500 12,5003/8 300 17,500 17,500

7 x 7

7 x 19

Vinyl Coated Galvanized Aircraft CableDiameter

(in.)Coated to

inches ConstructionApprox. Weight

1000 ft. / lbs.

Min. Breaking

Force (lbs.)3/32 3/16 7 x 7 28 9201/8 3/16 7 x 7 39 17001/8 3/16 7 x 19 39 2000

3/16 1/4 7 x 19 78 42001/4 5/16 7 x 19 125 70003/8 7/16 7 x 19 272 14,400

Galvanized Extra High Strength StrandNominalDiameter

Strand (in.)

Number of Wires in Strand

Approx. Weight

1000 ft. / lbs.Minimum Breaking

Force of Strand (lbs.)1/8 1 x 7 32 1830

5/32 1 x 7 51 29403/16 1 x 7 73 39907/32 1 x 7 98 54001/4 1 x 7 121 6650

9/32 1 x 7 164 89505/16 1 x 7 205 11,2003/8 1 x 7 273 15,4007/16 1 x 7 399 20,8001/2 1 x 7 517 26,9001/2 1 x 19 504 26,7009/16 1 x 7 671 35,0009/16 1 x 19 637 33,7005/8 1 x 7 813 42,4005/8 1 x 19 796 40,2003/4 1 x 19 1155 58,300

Preformed,madeinaccordancewithcommercialspecifications.MilitaryandFederalSpecificationropeavailable.

Most Common Construction



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Minimum Breaking Forces and Weights for Standard 6 x 19 and 6 x 36 Classification Ropes

Standard 6 x 19 & 6 x 36 Classification Ropes

DiameterFiber Core IWRC

Approx.Wt. / Ft.

(lbs.)


(Tons of2,000 lbs.)

Approx.Wt. / Ft.

(lbs.)


(Tons of2,000 lbs.)in. mm

EIP EIP EEIP1/4 – .11 3.02 .12 3.40 –5/16 – .16 4.69 .18 5.27 –3/8 10 .24 6.72 .26 7.55 –7/16 11 .32 9.09 .35 10.2 11.21/2 13 .42 11.8 .46 13.3 14.6

9/16 14 .53 14.9 .58 16.8 18.55/8 16 .66 18.3 .72 20.6 22.73/4 19 .95 26.2 1.04 29.4 32.47/8 22 1.29 35.4 1.41 39.8 43.81 25 1.68 46 1.85 51.7 56.9

1-1/8 29 2.13 57.9 2.34 65 71.51-1/4 32 2.63 71 2.89 79.9 87.91-3/8 35 3.18 85.4 3.49 96 1061-1/2 38 3.78 101 4.16 114 1251-5/8 – 4.44 118 4.88 132 1461-3/4 – 5.15 136 5.66 153 1691-7/8 – 5.91 155 6.49 174 192

2 – 6.73 176 7.39 198 2172-1/8 – 7.60 197 8.34 221 2432-1/4 – 8.52 220 9.35 247 2722-3/8 – – – 10.42 274 301

6 x 19 Class6 x 19 Seale, 6 x 25 Filler Wire and

6 x 26 Warrington Seale

6 x 36 Class6 x 36 Warrington Seale, 6 x 36 Warrington Seale,

6 x 41 Warrington Seale and 6 x 49 Warrington Seale


Ask your Lifting Specialist about stainless steel wire rope.


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Standard Wire Rope

6 x 19 Classification■ Highqualitysixstrandrope■ Highstrength—confirmedbyBridon’s“Powercheck” testing of a sample■ Excellentresistancetowear■ Fullylubricated■ SteelCore,FiberCore

Standard & High- Performance Wire Ropesfor Crane Applications

6 x 36 Classification■ Highqualitysixstrandrope■ Highstrength—confirmedbyBridon’s“Powercheck” testing of a sample■ Consistentbendingfatigueperformance■ Fullylubricated■ SteelCore,FiberCore

6 x 26 Alternate Lay Rope■ Highqualitysixstrandrope■ Highstrength—confirmedbyBridon’s“Powercheck” testing of a sample■ Fullylubricated■ Goodresistancetodrumcrushing

Standard Wire Ropes High-Performance Wire Ropes

6 x 19Class

6 x 26Alternate

Lay6 x 36Class

EnduranceDyform 34LR

Endurance35LS

EnduranceDyform 18

EnduranceDyform 6

EnduranceDyform 6PI

EnduranceDyform 8

EnduranceDyform 8PI Constructex

Telescopic Mobile CraneMain Hoist Rope ■ ■ ■ ■ ■Auxiliary Rope ■ ■ ■ ■ ■Tower CraneMain Hoist Rope ■ ■ ■ ■ ■Derricking Rope ■ ■ ■Trolley Rope ■ ■ ■Container CraneMain Hoist Rope ■ ■ ■ ■ ■Boom Hoist Rope ■ ■ ■ ■Trolley Rope ■ ■Mobile Lattice Boom CraneMain Hoist Rope ■ ■ ■ ■ ■ ■Boom Hoist Rope ■ ■ ■Auxiliary Rope ■ ■ ■ ■ ■Dockside CraneMain Hoist Rope ■ ■Boom Hoist Rope ■ ■ ■ ■Overhead CraneMain Hoist Rope ■ ■ ■ ■ ■Steel Mill Ladle CraneMain Hoist Rope ■ ■ ■ ■ ■Offshore Pedestal CraneMain Hoist Rope ■ ■ ■Whipline Rope ■ ■ ■Boom Hoist Rope ■ ■ ■Unloader RopesMain Hoist Rope ■ ■ ■ ■ ■Boom Hoist Rope ■ ■ ■ ■ ■Closing Rope ■ ■ ■ ■ ■Racking Rope ■ ■ ■Pilling RopesMain Hoist Rope ■Pipe Handling Rope ■



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Endurance Dyform 34LR/PI■ Strongestofallropesintherotationresistantproduct— confirmedbyBridon’s“Powerchecked”testingofa sample from each production length.■ Greatestresistancetorotationofallropesintherotation resistantproductrange—confirmedbyBridon’sunique “Twistcheck” type testing program.■ Superiorbendingfatiguelifewhencomparedwith conventionalrotationalresistantropes—confirmedby laboratorytestingandextensivefieldexperience.■ Excellentresistancetocrushingandabrasionresulting from the overall compactness and robustness of the rope and the Dyform strands—recommended multi-layer spooling is involved.■ Reducedelongationresultsfromincreasedsteelcontent and the Dyform process.■ Optionalplasticcoating(PI)ofIWRCtofurtherextend fatigue life, improve structural stability and resistance to corrosion.

Endurance 35LS■ Greatestresistancetorotationofallropesintherotation resistantproductrange—confirmedbyBridon’sunique “Twistcheck” type testing program.■ Mostflexibleconstructionintherotationresistant product range.

Endurance Dyform 18/18PI■ Highstrengthrotationresistantropeincorporating Dyformstrands—confirmedbyBridon’s“Powercheck” testing of a sample from each production length.■ Goodresistanttorotation—confirmedbyBridon's unique “twistchecked” type testing program.■ Superiorbendingfatiguelifewhencomparedwith conventionalmultistrandropes—confirmedby laboratorytestingandextensivefieldexperience.■ Excellentresistancetocrushingandabrasionresulting from the overall compactness and robustness of the rope and the Dyform strands recommended when multi-layer spooling is involved.■ Optionalplasticcoating(PI)ofIWRCtofurtherextend fatigue life, improved structural stability and resistance to corrosion.

High-PerformanceWire Ropes

Endurance Dyform 6/6PI

■ Strongestofallropesinthesixstrandproductrange— confirmedbyBridon’s“Powerchecked”testingofa sample from each production length.■ Superiorbendingfatiguelifewhencomparedwith conventionalsixstrandropes—confirmedby laboratorytestingandextensivefieldexperience.■ Excellentresistancetocrushingandabrasionresulting from the overall compactness and robustness of the rope and the Dyform strands—recommended when multi-layer spooling is involved.■ Reducedelongationresultsfromincreasedsteelcontent and the Dyform process.■ Optionalplasticcoating(PI)ofIWRCtofurtherextend fatigue life, improved structural stability and resistance to corrosion.

Endurance Dyform 8/8PI■ Highbreakingforce—confirmedbyBridon’s “Powerchecked” testing of a sample from each production length.■ Superiorbendingfatiguelifewhencomparedwith conventionaleightstrandropes—confirmedby laboratorytestingandextensivefieldexperience.■ Excellentresistancetocrushingandabrasionresulting from the overall compactness and robustness of the rope and the Dyform strands—recommended when multi-layer spooling is involved.■ Reducedelongationresultsfromincreasedsteelcontent and the Dyform process.■ Optionalplasticcoating(PI)ofIWRCtofurtherextend fatigue life, improved structural stability and resistance to corrosion.

Constructex■ Ninestrandropemadeupofthreedifferentstrand construction. Each outside strand manufactured with a soft plastic center.■ Highstrength—confirmedbyBridon’s“Powerchecked” testing of a sample.■ Excellentresistancetocrushingandwearresulting from the overall compactness and robustness of the rope.■ Flexibleconstructionwithgoodfatiguelifein most applications.



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Strongest of all ropes in the six strand productrange—confirmedbyBridon’s“Powercheck”testingof a sample from each production length.

Superior bending fatigue life when compared withconventionalsixstrandropes—confirmedbylaboratorytestingandextensivefieldexperience.

Excellent resistance to crushing and abrasionresulting from the overall compactness and robustnessof the rope and the Dyform strands—recommendedwhen multi-layer spooling is involved.

Reduced elongation results from increased steelcontent and the Dyform process.

Optional plastic coating of IWRC to furtherextend fatigue life, improve structural stability and resistance to corrosion.

Endurance Dyform® 6/6PI

Diameter(in.)

Weight(lbs. / ft.)


(tons)

3/8 .28 8.87/16 .38 11.91/2 .50 15.3

9/16 .63 19.35/8 .78 22.73/4 1.13 32.47/8 1.53 43.81 2.00 57.5

1-1/8 2.54 71.51-1/4 3.13 87.91-3/8 3.79 1061-1/2 4.50 125

Dyform is a registered trademark of Bridon American.



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Nine Strand rope made up of three different strandconstructions. Each outside strand manufacturedwith a soft plastic center.

High strength—confirmedbyBridon’s“Powercheck”testing of a sample.

Excellent resistance to crushing and wear resulting from the overall compactness and robustness of the rope.

Flexible construction with good fatigue life in most applications.

Ask aboutBridon’s Tiger Blue—Plastic Filled RopeTiger® Blue Hoist Ropes■ 6x36and6x41■ Fullyplasticfilledrope for demanding applications requiring excellent resistance to wear and bending

Constructex®

Diameter(in.)

Weight(lbs. / ft.)


(tons)5/8 0.9 25.53/4 1.1 36.57/8 1.5 48.51 2 62.5

1-1/8 2.6 79.51-1/4 3.2 97.61-3/8 3.8 1191-1/2 4.6 1391-5/8 5.3 1621-3/4 6.2 185

Constructex is a registered trademark of Bridon American.



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High strength Rotation Resistant rope incorporatingDyformstrands—confirmedbyBridon’s“Powercheck”testing of a sample from each production length.

Good resistance to rotation—confirmedbyBridon’s unique “Twistcheck” type testing program.

Superior bending fatigue life when comparedwithconventionalmulti-strandropes—confirmedbylaboratorytestingandextensivefieldexperience.



Optional plastic coating of IWRC to further extend fatigue life, improve structural stability and resistance to corrosion.

Endurance Dyform® 18/18PI

Diameter(in.)

Weight(lbs. / ft.)


(tons)3/8 .031 8.37/16 .420 11.21/2 .550 14.6

9/16 .700 19.25/8 .860 22.73/4 1.24 34.27/8 1.69 43.81 2.21 57.5

1-1/8 2.79 71.51-1/4 3.45 87.91-3/8 4.17 1061-1/2 4.97 125




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Strongest of all ropes in the Rotation Resistant productrange—confirmedbyBridon’s“Powercheck”testingofasample from each production length.

Greatest resistance to rotation of all ropes in the RotationResistantproductrange—confirmedbyBridon’sunique “Twistcheck” type testing program.

Superior bending fatigue life when compared with conventionalRotationResistantropes—confirmedbylaboratorytestingandextensivefieldexperience.



Optional plastic coating of IWRC to further extendfatigue life, improve structural stability and resistanceto corrosion.

Endurance Dyform® 34LR/PI/Max

Endurance Dyform® 34LR

Diameter Weight(lbs. / ft.)


(tons)in. mm 1960 2160– 14 .65 20.1 21.5

9/16 – .68 20.8 22.75/8 16 .84 26.1 28.2– 18 1.07 33.5 35.9

3/4 19 1.21 37 40– 20 1.32 41.6 44.6– 21 1.51 45 48.6– 22 1.61 49.7 54.2

7/8 – 1.65 50.4 54.8– 23 1.75 54 56.9– 24 1.92 59.3 641 – 2.15 62.4 70– 26 2.28 69.5 74– 28 2.63 76 82.6

1-1/8 – 2.73 79.5 83.6– 30 3.07 92.5 94

1-1/4 32 3.37 98.2 110.2


Endurance Dyform® 34 XL

Diameter Weight(lbs. / ft.)


(tons)in. mm5/8 16 .84 30.63/4 19 1.21 42.91 – 2.15 71.7– 26 2.28 74– 28 2.63 84.4

1-1/8 – 2.73 86.9– 29 2.94 86.9

1-1/4 32 3.37 110.2Endurance Dyform® 34 MAX

1 – 2.26 76.9– 26 2.39 79.3– 28 2.76 91.6

1-1/4 32 3.74 122



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Endurance® 35LS (Main Hoist Rope)

■ RotationResistant■ Flexibleconstruction■ Excellentspooling

Endurance Dyform® 34LR(Main Hoist Rope)

■ RotationResistant■ Reduceddowntime■ Longerlife■ Recommendedformulti-layerapplications■ Reducedsheavewear

Endurance Dyform® 6(Derricking Rope & Trolley Rope)

■ Longservicelife■ Crushresistant■ Lowerdowntime■ Lowerlifetimecost■ Robustconstruction

6 x 19 Class and 6 x 36 Class(Derricking Rope & Trolley Rope)

■ SingleLayerRopes■ Consistentperformancewithlowerinitialcost

Tower Crane Ropes


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Endurance 8RR (Main Hoist Rope)

■ RotationResistant■ Consistentperformancewithlowerinitialcost■ Suitableforsingle-partandmulti-partreeving

Constructex®

(Boom Hoist Rope)

■ Exceptionalservicelifeinthemost demanding applications■ Highbreakingforce■ ExcellentCrushResistance

Endurance Dyform® 18(Main Hoist Rope & Whipline Hoist Rope)

■ RotationResistantDyformHoistRope■ Longservicelife■ CrushResistant■ Recommendedformulti-layerspooling■ Suitableforsingle-partandmulti-partreeving

Endurance 19(Main Hoist Rope & Whipline Hoist Rope)

■ RotationResistant■ Consistentperformancewithlowerinitialcost■ Suitableforsingle-partreeving

Endurance Dyform® 6(Boom Hoist Rope & Main Hoist Rope)

■ Toughsixstrandwirerope■ Highbreakingforce■ Longservicelife■ Crushresistant■ Recommendedformulti-layerspooling■ Suitableasahoistropewhereheightofliftis low and rotation is not critical

Endurance Dyform® 34LR(Main Hoist Rope & Whipline Rope)

■ RotationResistantDyformHoistRope■ Longservicelife■ Crushresistant■ Recommendedformulti-layercoiling■ Recommendedforhighlifts■ Suitableforsingle-partandmulti-partreeving

Mobile Lattice BoomCrane Ropes

6 x 19 Class & 6 x 36 Class(Main Hoist Rope & Boom Hoist Rope)

■ SingleLayerRopes■ Consistentperformancewithlowerinitialcost■ Recommendedformainhoistropewhere height of lift is not critical


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Oilfield Wire RopesSand Line■ Largeouterwiresfor resistance to wear■ Exceptionalspooling characteristics■ Resistancetokinking■ Easytosplice

Diameter Approx.Weight

Min. BreakingForce

in. lb. / ft. tons3/8 .21 5.97/16 .29 7.91/2 .38 10.3

9/16 .48 135/8 .59 15.93/4 .84 22.7

Swaged Tubing Line■ Excellentresistance to crushing■ Highbreakingforce■ Goodresistance to abrasion

Tubing Line■ Combinationofflexibility and resistance to crushing■ Outstandingresistance to wear and fatigue

Constructex■ Swagedtoincrease wearing surface and density■ Longservicelifedue to resistance to scrubbing and crushing■ Highbreakingforce■ Flexibleconstruction

Rotary Drill Line■ Combinationofstrength, flexibilityandresistance to peening ■ Goodresistancetowear and fatigue■ Longservicelifewhen sheaves and drums are of moderate size


Min. BreakingForce

in. lb. / ft. tons7/8 1.7 47.41 2.22 62

1-1/8 2.8 73.5

Note: Typical Construction 6 x 7 Fiber Core

Note: Typical Construction 6 x 31 Swaged


Min. BreakingForce

in. lb. / ft. tons3/4 1.04 29.47/8 1.41 39.81 1.85 51.7

1-1/8 2.34 65

Note: Typical Construction 6 x 26 IWRC


Min. BreakingForce—EIP

Min. BreakingForce—EEIP

in. lb. / ft. tons tons1 1.85 51.7 56.9

1-1/8 2.34 65 71.51-1/4 2.89 79.9 87.91-3/8 3.49 96 1061-1/2 4.16 114 1251-5/8 4.88 132 1461-3/4 5.66 153 169

Note: Typical Construction 6x19 (S) & 6x26 (WS)


Min. BreakingForce

in. lb. / ft. tons5/8 .90 25.53/4 1.1 36.57/8 1.5 4.851 2 62.5

1-1/8 2.6 79.51-1/4 3.2 97.61-3/8 3.8 1191-1/2 4.6 1391-5/8 5.3 162



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■ Strands:8■ Wiresperstrand:19to25■ Core:IWRC■ Standardgrade(s):PurplePlus■ Lay:RightRegular■ Finish:Bright

The 8 x 19 Classification rotation-resistant ropes are recommended for hoisting unguided loads with a single-part or multipart line.

The eight outer strands are manufactured in right lay, with the inner strands being left lay.

Theseropesareslightlystrongerandsignificantlymore rugged than the 19 x 7 construction. However, the rotation-resistant properties of the 8 x 19 rotation-resistant ropes are much less than those of the 19 x 7 construction.These ropes are manufactured in right regular lay in the 8 x 19 Seale and 8 x 25 Filler Wire constructions.

Rotation-Resistant Ropes:8 x 19 Classification


RopeDiameter

Approx.Weight(lb./ft.)

NominalStrength

(tons)in. mm Purple Plus7/16 11 .36 91/2 13 0.47 11.6

9/16 14.5 0.6 14.75/8 16 .73 18.13/4 19 1.06 25.97/8 22 1.44 351 26 1.88 45.5

1-1/8 29 2.39 57.31-1/4 32 2.94 70.51-1/2 38 4.24 100

■ Strands:19■ Wiresperstrand:7■ Core:WSC■ Standardgrade(s):PurplePlus■ Lay:Regular■ Finish:Bright

19 x 7 is recommended for hoisting unguided loads with a single-part line.

The rotation-resistant properties of this rope are secured by two layers of strands. The inner strands are left lay, while the 12 outer strands are right lay, which enables one layer to counteract the other layer’s rotation.

The rotation-resistant characteristics of the 19 x 7 wire ropes are superior to those of the 8 x 19 Class wire ropes.

Rotation-Resistant Ropes:19 x 7 Classification

RopeDiameter


NominalStrength

(tons)in. mm Purple Plus7/16 11 .35 8.331/2 13 .45 10.8

9/16 14.5 .58 13.65/8 16 .71 16.83/4 19 1.02 247/8 22 1.39 32.51 26 1.82 42.2

1-1/8 29 2.3 53.11-1/4 32 2.84 65.11-3/8 35 3.43 78.41-1/2 38 4.08 92.8


700








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■ Strands:19■ Wiresperstrand:7/19■ Core:WSC■ Standardgrade(s):RoyalPurple■ Lay:RightRegular■ Finish:Bright

SFP 19 is recommended for both multi-part load and single-part fast line applications where rotational stability of the lifted load is needed, such as for use as a long fall on offshore pedestal cranes, rough and all terrain cranes, and crawler cranes.

SFP 19 provides:

Fatigue Resistance. Improved fatigue properties are derived throughthecombinationoftheflexible19x19constructionand die drawn strands. The drawn strand surfaces minimize the interstrand and interlayer nicking that take place in round rotation-resistant ropes.

Abrasion Resistance. Die drawn ropes provide improved abrasion resistance as compared with round wire ropes because of the greater wire and strand bearing surfaces contacting sheaves and drums.

Resistance to Drum Crushing. SFP 19 wire ropes are resistant to the effects of drum crushing due to the compacted strands and smoothness of the rope surface.

Rotation-Resistant Ropes: Super Flex PAC 19

■ Strands:35■ Wiresperstrand:7■ Core:WSC■ Standardgrade(s):2160N/mm2

■ Lay:RightRegular■ Finish:Bright

SFP 35 is a rotation-resistant rope of high strength that can resist block twist in long falls.

SFP 35 provides:

Superior Rotation Resistance—the SFP 35 rope is the most rotation-resistant rope manufactured by WW. Due to its rotation-resistant properties, SFP 35 may be used with a swivel in both single-part and multipart reeving.

High Strength. WW’s compaction process provides a high-strength rope which exceeds EEIP nominal breaking strength.

Application. SFP 35 excels in crawler and truck-type crane load lines, and tower crane hoist ropes.

Flexibility. SFP 35’s multiple strand construction provides increased flexibilitywhichimprovesservicelifeandhighspeedspooling.Thecompacted multiple strand construction also reduces sheave and drum abrasion and provides excellent resistance to drum crushing.

Rotation-Resistant Ropes: Super Flex PAC 35

RopeDiameter


NominalStrength

(tons)in. mm Purple Plus1/2 13 .54 14.6

9/16 14.5 .69 18.55/8 16 .83 22.73/4 19 1.19 32.47/8 22 1.62 43.81 26 2.12 56.9

1-1/8 29 2.68 71.51-1/4 32 3.31 87.91-3/8 35 4.01 1061-1/2 38 4.77 125

Note: 5/8 and below 19 x 7 construction; 3/4 and larger 19 x 19 construction

Rope Diameter

Approx. Weight

Nominal Strength

in. mm (kg/m) (lb/ft) (kN) * (tons) *– 19 1.79 – 344 –

3/4 – – 1.21 – 38.7– 22 2.40 – 466 –

7/8 – – 1.65 – 531 – – 2.15 – 70– 26 3.36 – 660 –– 28 3.90 – 758 –

1-1/8 – – 2.73 – 86.9

* Acceptance strength is not less than 2-1/2% below the nominal strengths listed. Tons of 2,000 lbs.


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■ Strands:6■ Wiresperstrand:19to36■ Core:IWRC■ Standardgrade(s):RoyalPurple■ Lay:RightRegular■ Finish:Bright

6-PAC is recommended for use where the rope is subjected to heavy use or where conditions are extremely abusive, such as offshore pedestal, crawler and lattice boom equipped truck crane boom hoist applications. 6-PAC is also recommended for winch lines, overhead cranes, multipart hoist lines where rotation-resistant ropes are not required, and other applications where flexibility, high strength and resistance to crushing are important, and a cost-effective 6-strand rope is desired.

6-PAC provides:

Fatigue Resistance. Improved fatigue properties are derived from thecombinationof6-PAC’sflexibleconstructionsandthecompactedstrands. The compacted strand surface minimizes the interstrand and interlayer nicking that take place in standard 6-strand ropes.

Abrasion Resistance. 6-PAC’s compacted strand design provides improved abrasion resistance as compared to standard 6-strand ropes because of the increased wire and strand surfaces contacting sheaves and drums.

Flexibility. 6-PAC’sdesignprovidesincreasedflexibility,making it easy to install, and 6-PAC also offers better spooling at high line speeds.

Resistance To Multilayer Drum Crushing. 6-PAC dramatically increases the amount of wire contact with the drums and sheaves, reducing the wire rope, sheave and drum wear normally associated with standard wire rope. Damage at the crossover points is also reduced.

Specialized Wire Ropes: 6-PAC

RopeDiameter Standard

ConstructionsApprox.Weight(lb./ft.)

NominalStrength

(tons)

in. mm Purple Plus

3/8 9.5 6 x 19 Seale .285 8.37/16 11 6 x 19 Seale .388 11.21/2 13 6 x 26 .503 14.69/16 14.5 6 x 26 .642 18.55/8 16 6 x 26 .795 22.73/4 19 6 x 31 1.143 32.47/8 22 6 x 31 1.547 43.81 26 6 x 31 2.075 56.9

1-1/8 29 6 x 31 2.575 71.51-1/4 32 6 x 31 3.169 87.91-3/8 35 6 x 36 3.758 1061-1/2 38 6 x 36 4.564 1251-5/8 41.3 6 x 36 5.356 1461-3/4 45.5 6 x 36 6.212 169

For Bethpac, or 6-PAC over 1-3/4" diameter, please refer to WW’s Bethlehem Mining Products catalog or contact our Customer Service Department.


702








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■ Strands:8■ Wiresperstrand:19to36■ Core:Plasticfilled(BXL)■ Standardgrade(s):RoyalPurple■ Lay:Right■ Finish:Bright

8-PAC is recommended for hoist ropes for steel mill ladle cranes and hoist and trolley ropes for container cranes, or other hoisting applications with heavy-duty cycles or where severe bending occurs.

Other features of 8-PAC include:

Superior Performance. 8-PAC has higher breaking strength and gives superiorperformanceindifficulthoistingapplicationscomparedtostandard 6-strand and 6-strand compacted ropes.

Abrasion Resistance. 8-PAC compacted strand design provides improved abrasion resistance as compared to standard 6 and 8 strand ropes because of the increased wire and strand surfaces contacting the sheaves and drums.

Superior Flexibility. 8-PACissignificantlymoreflexiblethanstandard 6 and compacted 6 strand ropes with better spooling and longer service life.

Resistance To Multi-layer Drum Crushing. 8-PAC’splastic-filled(BXL)core offers increased resistance to crushing through better support of the outer strands.

Specialized Wire Ropes: 8-PAC

Note: Other sizes available

RopeDiameter Standard

ConstructionsApprox.Weight(lb./ft.)

NominalStrength

(tons)in. Purple Plus5/8 8 x 26 WS .8 253/4 8 x 26 WS 1.17 367/8 8 x 26 WS 1.6 48.31 8 x 26 WS 2.1 62.8

1-1/8 8 x 26 WS 2.63 791-1/4 8 x 31 WS 3.26 98

■ Strands:6■ Wiresperstrand:26/31■ Core:IWRC■ Standardgrade(s): Royal Purple Plus■ Lay:RightRegular■ Finish:Bright

SUPER-PAC is a double compacted product ideal for applications where abrasion and drum crushing are an issue. When compared with standard ropes,

SUPER-PAC provides:

Better Resistance to Multi-layer Drum Crushing. SUPER-PAC dramatically reduces the damage at cross over points on smooth face drums, such as those found on many boom hoist systems on mobile cranes. This is achieved by compaction of the strands and the rope, makingatoughbutflexibleproduct.

Abrasion Resistance. The compaction process also increases the contact between the rope and the drum and sheaves, reducing sheave and drum wear.

Super Strength. The double compaction process also increases the minimum breaking strength of standard EIP rope more than 20%.

Superior Fatigue Resistance. SUPER-PAC is engineered for overall performance, its wire tensile strength being the key to its superior fatigue resistant properties. In addition to contribution to SUPER-PAC’s EEEIP breaking strength, the wire used in the manufacture of SUPER-PAC remains ductile, minimizing the occurrences of external and internal wire breaks caused by operating stresses.

Application. SUPER-PAC is ideal for all types of boom hoist and lowering ropes.

Specialized Wire Ropes: Super-PAC

RopeDiameter


NominalStrength

(tons)in. mm Purple Plus5/8 16 .995 293/4 19 1.43 407/8 22 1.92 521 26 2.42 68

1-1/8 29 2.96 851-1/4 32 3.51 102


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■ Strands:6■ Wiresperstrand:26/31or36■ Core:IWRC■ Standardgrade(s): Royal Purple Plus■ Lay:RightRegular

TRIPLE-PAC was developed for the most demanding hoist applications. TRIPLE-PAC offers the extra high strength and crushing resistance needed for applications such as boom hoist ropes, boom pendants and multipart load lines.

TRIPLE-PAC provides superior abrasion and fatigue resistance as compared with most compacted ropes due to WW’s unique design of compacting the IWRC, individual strands and the rope itself.

Other benefits include:

High Strength. TRIPLE-PAC is designed to provide a nominal strength of 35% above EIP. WW achieves this strength through selected grades of steel and TRIPLE-PAC’s unique design and manufacturing processes.

Superior Resistance to Multi-layer Drum Crushing. TRIPLE-PAC provides superior resistance to crushing through its design. Its triple compaction provides a denser cross section, enabling the rope to withstand the rigors of multilayer spooling. Damageatthecrossoverpointsisalsosignificantlyreduced.In addition, TRIPLE-PAC’s design increases the amount of wire contact with sheaves and drums, reducing wire rope, drum and sheave wear.

Specialized Wire Ropes: Triple-PAC

RopeDiameter

StandardConstruc-

tions


NominalStrength

(tons)in. mm Purple Plus7/16 11 6 x 26 .412 13.81/2 13 6 x 26 .543 189/16 14.5 6 x 26 .681 22.75/8 16 6 x 26 .858 27.83/4 19 6 x 31 or 36 1.3 39.77/8 22 6 x 31 or 36 1.72 53.71 26 6 x 31 or 36 2.3 69.8

1-1/8 29 6 x 31 or 36 2.89 87.81-1/4 32 6 x 31 or 36 3.54 107.91-3/8 35 6 x 31 or 36 4.04 129.61-1/2 38 6 x 31 or 36 4.99 153.6

■ Strand:6■ Wiresperstrand:27■ Core:IWRCorfibercore■ StandardGrade(s):PurplePlus■ Lay:Lang■ Finish:Bright

This rope is particularly suitable where severe conditions of crushing and abrasion are encountered on the drum or where a higher strength design factor is required than can be obtained with a similar round rope.

The triangular strand shape not only provides better resistance to crushing, but also offers a greater exposed surface area for contact with sheaves, drums or underlying layers of spooled rope. This feature, in connection with the use of Lang lay construction, distributes the abrasive wear over a greater number and length of wires.

The smooth surface of the rope also helps minimize wear on drums and sheaves.

Specialized Wire Ropes: Flattened Strand

RopeDiameter

Approx.Weight

Nominal Strength

(tons)Purple Plus

in. mm Fiber Core IWRC Fiber

Core IWRC1-1/8 29 2.28 2.39 63.7 68.51-1/4 32 2.81 2.95 78.1 841-3/8 35 3.4 3.57 64.1 1011-1/2 38 4.05 4.25 111 1191-5/8 42 4.75 4.99 130 1401-3/4 45 5.51 5.79 152 1611-7/8 48 6.33 6.65 171 184

2 52 7.2 7.56 194 2072-1/8 54 8.13 8.54 215 2332-1/4 58 9.1 9.56 240 260


704








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■ Strands:6■ Wiresperstrand:19to36■ Core:IWRC■ Standardgrade(s): Purple Plus■ Lay:RegularorLang■ Finish:Plastic-infused

BXL is infused with a specially-engineered polymer, creating a well-balanced matrix. BXL is recommended for numerous hoist, marine and logging rope applications.

BXL provides:

Fatigue Resistance. Improved fatigue resistance is derived from the cushioning and dampening effect of the polymer on the wires and strands. BXL also evenly distributes stresses, which may lead to fatigue breaks.

Abrasion Resistance. The polymer acts as a barrier between the individual strands, preventing penetration of any adverse material. BXL distributes and reduces contact stresses between the rope and sheave, reducing wire rope wear.

Resistance to Multi-layer Drum Crushing. BXL’ssmoothprofileevenly distributes crushing pressures from the overlying layers of rope in multilayer drum winding applications.

Extended Sheave and Drum Service Life. BXL minimizes corrugation and wear normally associated with standard rope usage by restricting water and dirt penetration and eliminating pickup of abrasive materials.

Clean Handling. The exterior rope surface is free from the grease normally applied to standard ropes.

BXL—Plastic-Infused Wire Ropes

RopeDiameter


Nominal Strength(tons) *

in. mm BXL 6-Pac BXL BXL 6-Pac

BXL3/8 9.5 0.27 – 7.5 –7/16 11 0.37 – 10.2 –1/2 13 0.49 0.513 13.3 15.59/16 14.5 0.61 – 16.8 –5/8 16 0.76 0.826 20.6 22.73/4 19 1.09 1.224 29.4 32.37/8 22 1.49 1.608 39.8 43.81 26 1.94 2.154 51.7 56.9

1-1/8 29 2.46 2.672 65 71.51-1/4 32 3.03 3.214 79.9 87.91-3/8 35 3.67 3.905 96 1061-1/2 38 4.37 4.529 114 1251-5/8 41.3 5.12 – 132 –1-3/4 45.5 5.94 – 153 –1-7/8 48 6.82 – 174 –

2 52 7.76 – 198 –2-1/8 54 8.77 – 221 –2-1/4 58 9.83 – 247 –2-3/8 60 10.9 – 274 –2-1/2 64 12.2 – 302 –

* Acceptance strength is not less than 2-1/2% below the nominal strengths listed. Tons of 2,000 lbs.


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6 x 19 Rotary Drill Line

Features: Excellent balance between fatigue and wear resistance

Oilfield & Natural Gas Drilling Products

6 x 7 Sand Lines & Swabbing Lines

Features: High abrasion resistance

6 x 21 Cable Tool Line

Features: Increased resistance to bending fatigue on Cable Tool Rigs

Diameter(in.)

StandardConstruc-

tion

Steel Core

Approx. Weight(lb/ft)

EIPMinimum Breaking Strength(net tons)

EEIPMinimumBreaking Strength(net tons)

1 6 x 19 S 1.85 51.7 56.91-1/8 6 x 19 S 2.34 65 71.51-1/4 6 x 19 S 2.89 79.9 87.91-3/8 6 x 19 S 3.5 96 1061-1/2 6 x 19 S 4.16 114 125

1-5/8 6 x 19 S / 6 x 26 WS 4.88 132 146

1-3/4 6 x 19 S / 6 x 26 WS 5.67 153 169

1-7/8 6 x 26 WS 6.5 174 1922 6 x 26 WS 7.39 198 217

All drill lines have asphaltic lube, post lube, and are RRL.

Diameter(in.)

StandardConstruc-

tion

Fiber Core


Minimum Breaking Strength(net tons)

5/8 6 x 19 S 1.85 51.73/4 6 x 19 S 2.34 657/8 6 x 19 S 2.89 79.91 6 x 19 S 3.5 96

All cable lines have petroleum lube, are LRL and FC.

Diameter(in)

StandardConstruc-

tion

Fiber Core



3/8 6 x 7 .21 5.867/16 6 x 7 .29 7.931/2 6 x 7 .38 10.39/16 6 x 7 .48 139/16 6 x 7 Galv. .47 135/8 6 x 7 .59 15.9

All cable lines have petroleum lube, and are RRL.


706








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6 x 26 Tubing Line

Features: Excellent balance betweenfatigue and wear resistance

Oilfield & Natural Gas Drilling Products (Cont.)

Swaged Tubing Line

Features: Compacted rope

Riser Tensioner Ropes

Features: Special construction and multiple wire tensile increasing fatigue resistance

Diameter(in.)

StandardConstruc-

tion

Steel Core



7/8 6 x 19 WS 1.42 39.81 6 x 19 WS 1.85 51.7

1-1/8 6 x 19 WS 2.34 65

All tubing lines have petroleum lube, and are RRL.

Diameter StandardConstruc-

tion

Steel Core

Approx.Weight(lb/ft)

MinimumBreakingStrength(net tons)in. mm

1-3/4 45 6 x 49 1.42 39.81-7/8 48 6 x 49 1.85 51.7

2 52 6 x 49 2.34 652-1/8 54 6 x 49 2.35 662-1/4 58 6 x 49 2.36 672-3/8 60 6 x 49 2.37 682-1/2 64 6 x 49 2.38 692-5/8 67 6 x 57 2.39 702-3/4 70 6 x 57 2.40 71

All tensioners have asphaltic lube, and are RLL or LLL.

Diameter(in.)

StandardConstruc-

tion

Steel Core



7/8 6 x 26 WS 1.80 477/8 6 x 26 WS 1.82 471 6 x 26 WS 2.35 621 6 x 26 WS 2.26 62

All swaged tubing lines have petroleum lube, and are RRL or LRL.


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Flex-X® 19 Wire RopesFlex-X delivers extra value when you need high strength in a rotation-resistant wire rope. Its rotation-resistant construction provides a smooth, extremely compact wire rope withmore steel in the cross-section than conventional ropes.

Flex-X 19 is made from 19-wire Seale strands. Six strandsare laid around a core strand in one direction, then 12strandsarelaidaroundthisfirstoperationintheoppositedirection.

Because of its tightly compacted, smooth design, Flex-X 19 offers several advantages:

■ Morecrushresistancethanastandard19x7rope while providing the same rotation resistance.■ Higherstrength-to-diameterduetocompactedwires in the strands. With increased metallic area, it provides rope strengths equal to 6 strand XXIP IWRC ropes of the same diameter.■ Resistancetobendingfatigueduetotheuniformityof the wires within each strand. The strand’s outer surface is smooth, reducing contact pressures between the rope’s strands and radial pressures as it operates over sheaves and drums.■ Exceptionalstabilityduetothehigherdensitystrands coupled with the smooth outer surface.■ Improvedhandling,operatingandspooling characteristics.■ Reducedweartosheavesanddrums.

Flex-X has also demonstrated greater fatigue resistance to substantially reduce rope expense and extend rope service life. It’s ideal for single-part or multi-part hoist lines wherever you encounter spooling problems, drum crushing, block twisting or have fast line speeds.

Flex-X® 6 Wire Ropes■ Superior performance 6-strand rope ■ Increased service life ■ Less sheave and drum wear

Less sheave and drum wear Flex-X 6 users receive superior performance and increased service life in many applications compared to the ropes they had previously employed. When compared to conventional six strand ropes, Flex-X 6 ropes provide greater surface area and more steel per given diameter. This increases rope stability and strength. This results in a longer service life and less sheave and drum wear.

Flex-X® 19 & Flex-X® 6

Diameter(in.)

Flex-X 19 Flex-X 6

Approx.Wt. / Ft.

(lbs.)

Minimum Breaking

Force (Tons of

2,000 lbs.*)

Approx.Wt. / Ft.

(lbs.)

Minimum Breaking

Force (Tons

of 2,000 lbs.)

3/8 – – 0.32 8.8 7/16 0.43 11.2 0.41 11.9 1/2 0.49 14.6 0.55 15.3 9/16 0.69 18.5 0.70 19.3 5/8 0.78 22.7 0.86 22.7 3/4 1.16 32.4 1.25 32.4 7/8 1.58 43.8 1.67 43.8

1 2.05 56.9 2.18 56.91-1/8 2.57 71.5 2.71 71.51-1/4 – – 3.43 87.91-3/8 – – 4.25 1061-1/2 – – 5.01 125

* These strengths apply only when a test is conducted with both endsfixed.Wheninuse,thestrengthsoftheseropesmaybe significantlyreducedifoneendisfreetorotate.

Flex-X® 6Wire Ropes

Flex-X® 19Wire Ropes


Flex-X® vs. standard rope of similar construction:

Flex-X designs reduce drum scrubbing between the lead line and the previous wrap. The smooth contact creates less interference, less metal loss and wire deformation. The increased surface area of Flex-X can be seen in the comparison of the contact points of a standard 6 x 26WS and Flex-X as shown.


708








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General-purpose wire rope that delivers extra-long service life.

ThekeytoPFVandTuf-Kotewirerope’sbenefitslieinits exclusive patented fabrication. Standard, lubricatedMacwhyte® and Union® Wire Rope is used in the extrusionprocess where the “gaps” (or valleys) between the individualrope strands are impregnated with a sealing thermoplastic material.Eachstrand“valley”inthefinishedropeisfilledwithplastic.Thefinishedropemayhaveathin“skincoat-ing”ofplasticbutthishasnosignificanteffectontheoutsidediameter of the PFV and Tuf-Kote rope or its serviceability.

Result: PFV and Tuf-Kote wire rope is a balanced sealed-lubricated wire rope that delivers exceptional performance and service life on applications that produce severe operating conditions, such as: haulback lines in high lead logging systems, saw mill carriage lines, draglines, towing hawser and drilling lines. And there is less sheave and drum wear.

PFV® & Tuf-Kote®

M.B.F. = Minimum Breaking Forces are listed in Tons of 2,000 pounds.WT. = Approximate weight in pounds per foot.

RopeDiameter

(in.)

6 X 19 IWRC PREmium GRADE6 x 36 IWRC 7-Flex IWRC

M.B.F. WT. M.B.F. WT. M.B.F. WT.3/8 7.55 .27 7.55 .27 7.55 .27

7/16 10.2 .37 10.2 .37 10.2 .371/2 13.3 .49 13.3 .49 13.3 .49

9/16 16.8 .61 16.8 .61 16.8 .615/8 20.6 .76 20.6 .76 20.6 .763/4 29.4 1.09 29.4 1.09 29.4 1.097/8 39.8 1.49 39.8 1.49 39.83 1.491 51.7 1.94 51.7 1.94 51.7 1.94

1-1/8 65 2.46 65 2.46 65 2.461-1/4 79.9 3.03 79.9 3.03 79.9 3.031-3/8 96 3.67 96 3.67 96 3.671-1/2 114 4.37 114 4.37 114 4.311-5/8 132 5.12 132 5.12 132 5.121-3/4 153 5.94 153 5.94 153 5.941-7/8 174 6.82 174 6.82 174 6.83

2 198 7.76 198 7.76 198 7.772-1/8 221 8.77 221 8.77 221 8.272-1/4 247 9.83 247 9.83 247 9.882-3/8 274 10.9 274 10.9 – –

Note: Minimum breaking forces apply only to new, unused PFV wire rope. Any performance specifications are conditional on proper rope size, construction, and grade; on proper design and maintenance of mechanical equipment on which wire rope products are used; and on proper storage, handling, use, maintenance and periodic inspection of such products during the period of use.


RopeDiameter

(in.)

19 X 7

M.B.F. WT.5/16 4.3 .1773/8 6.15 .257/16 8.33 .351/2 10.8 .459/16 13.6 .585/8 16.8 .713/4 24 1.027/8 32.5 1.391 42.2 1.82

1-1/8 53.1 2.31-1/4 65.1 2.831-3/8 78.4 3.431-1/2 92.8 4.08


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Please contact a Lifting Specialist for details of Casar’s entire product line. Below is a sample of their most popular ropes.

Starlift Plus■ Availableinlangslayorregularlay.■ Isarotationresistant,flexiblehoistrope with a compacted steel core.■ Isfullylubricated.■ Hasahighbreakingload.■ Hasacoreinaspecialdesign,avoidingcrossovers between the strands of the core and reducing the danger of internal rope destruction.■ Isknownworldwideforitsexcellentservicelife.■ Isespeciallysuitedformulti-layerspooling.■ Availableinsizesfrom:3/8"to2"and10mm to 50 mm■ Minimumbreakingloadsfrom18,400lbs. to 524,460 lbs.

Eurolift■ Availableinlangslayorregularlay.■ Isarotationresistant,flexiblehoistropemadeoutof compacted steel core.■ Isfullylubricated.■ Hasanextremelyhighbreakingloadandaverygood resistance against drum crushing.■ Hasacoreinaspecialdesign,avoidingcrossovers between the strands of the core and preventing internal rope destruction.■ Isespeciallysuitedformulti-layerspooling.■ Availableinsizesfrom:7/16"to2"and10mmto50mm■ Availablein1770,1960and2160grades.■ Minimumbreakingloadsfrom18,364lbs.to581,234lbs.

Turboplast■ Availableinlangslayorregularlay.■ Isan8strandropemadeoutofcompacted outer strands.■ Isfullylubricated.■ Hasaplasticlayerbetweenthesteelcoreandthe outer strands, giving the rope a high structural stability, avoiding internal rope destruction and protecting the core against corrosive environment.■ Hasaveryhighbreakingloadandagoodresistance against crushing.■ Note: this rope may not be used with a swivel.■ Availableinsizesfrom:5/16"to2"and8mmto50mm■ Availablein1770and1960grades.■ Minimumbreakingloadsfrom11,243lbs.to510,437lbs.

Starlift Plus, Eurolift & Turboplast

Ask our Lifting Specialists for more details and a complete diameter and breaking load chart for these and other Casar ropes.



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Mobile Crane Ropes WARNING SEE WARNING INFORMATION ON PAGES 721 - 723.

SureLift 35

■ Highlyrotationresistant■ Speciallydesignedfor high performance cranes with long drops■ Highstrength-to-weightratio ensures high breaking loads■ Longlife,highflexibility, and excellent spooling properties■ Smoothsurfaceareafordecreasedwearonsheaves and drums■ Canbeusedwithaswivel■ Availableindiametersfrom10mmto44mm; with minimum breaking loads from 11 to 191 tons

Cushion-Pac 8

■ Excellentchoicefor production-oriented cranes■ Exceptionallylongservicelife for minimized downtime■ Highliftingcapacityandresistance to crushing■ Reduceddrumandsheavewear and good spooling properties■ Advancedcushionedcoreforsuperiorropelife■ Reverse-laycoreversionisavailable■ Availableindiametersfrom1/2"(13mm)to1-1/2"(38mm); with minimum breaking loads from 16 to 138 tons (EEIP) and 14 to 125 tons (EIP)

Cushion-Pac 18

■ Rotationresistantrope for hoisting applications■ Suitableforbothsingle-fall and multi-reeve applications■ Multi-strandconstructionwith specially selected wire tensiles■ DyPacdesignforincreased lifting capacity and crushing resistance■ Smoothouterstrandforefficiencyonhighspeedhoistinglines■ Advancedcushioncoreforsuperiorservicelife■ Excellentspoolingproperties■ Availableindiametersfrom3/8"(10mm)to1-1/2"(38mm); with minimum breaking loads from 8 to 133 tons

DyPac 6

■ Proven6-strandconstruction with special high tensile wires■ Exceptionaldurabilityensures high productivity■ DyPacdesignforhighbreaking loads and smooth outer surface■ Highcrushresistanceand enhanced drum spooling■ Availableindiametersfrom3/8"(10mm)to1-1/2"(38mm); with minimum breaking loads from 8 to 125 tons

Power-Pac 9


= Main Hoist Rope = Boom Hoist Rope


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Overhead Crane RopesCushion-Pac 8

■ Excellentchoicefor production-oriented cranes■ Exceptionallylongservicelife for minimized downtime■ Highliftingcapacityandresistance to crushing■ Reduceddrumandsheavewear and good spooling properties■ Advancedcushionedcoreforsuperiorropelife■ Reverse-laycoreversionisavailable■ Availableindiametersfrom1/2"(13mm)to1-1/2"(38mm); with minimum breaking loads from 16 to 138 tons (EEIP) and 14 to 125 tons (EIP)

Cushion-Pac 18

■ Rotationresistantrope for hoisting applications■ Suitableforbothsingle-fall and multi-reeve applications■ Multi-strandconstructionwith specially selected wire tensiles■ DyPacdesignforincreased lifting capacity and crushing resistance■ Smoothouterstrandforefficiencyonhighspeedhoistinglines■ Advancedcushioncoreforsuperiorservicelife■ Excellentspoolingproperties■ Availableindiametersfrom3/8”(10mm)to1-1/2”(38mm); with minimum breaking loads from 8 to 133 tons

DyPac 6



= Main Hoist Rope


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Galvanized Steel Strand

1 x 7 1 x 19

NominalDiameterof Strand

(in.)

Numberof

Wires

NominalDiameter of

Coated Wires(in.)

Approx. Wt. of Strand(lbs. / 1000 ft.)

Minimum Breaking Force of Strand (lb.)

UtilitiesGrade

HighStrength

Grade

Extra-HighStrength

Grade3/16 7 .062 73 – 2,850 3,9907/32 7 .072 98 – 3,850 5,4001/4 7 .080 121 – 4,750 6,6509/32 7 .093 164 – 6,400 8,9505/16 7 .104 205 – 8,000 * 11,200 *3/8 7 .120 273 11,500 * 10,800 * 15,400 *7/16 7 .145 399 18,000 14,500 * 20,800 *1/2 7 .165 517 25,000 18,800 * 26,900 *1/2 19 .100 504 – 19,100 26,7009/16 7 .188 671 – 24,500 35,0009/16 19 .113 637 – 24,100 33,7005/8 7 .207 813 – 29,600 42,4005/8 19 .125 796 – 28,100 40,2003/4 19 .150 1,155 – 40,800 58,3007/8 19 .177 1,581 – 55,800 79,7001 19 .200 2,073 – 73,200 104,500

* ASTM A 363 (Weldless) is also available in these sizes and grades upon request.



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Structural Wire ProductsGalvanized Structural Strand to ASTM A-586

■ Usuallysuppliedpre-stressed.■ Cut-to-lengthandpaintstriped.■ Parallelcontactcoreconstruction with amorphous polypropylene lubricant available.■ ClassAzinc-coatedwire.

Recommended for:

■ Maincablesofsuspensionbridges.■ Boomsupports.■ Guysfortowers.■ Load-carryingmembersinbuildingstructures.

Galvanized Structural Bridge Rope to ASTM A-603

■ Goodmodulusofelasticity.■ Pre-stressedwhenrequired with a modulus of elasticity = 20,000,000 psi.■ ClassAzinc-coatedwire.

Recommended for:

■ Mainsupportcableson short-span suspension bridges.■ Suspensioncablesonlarge suspension bridges.■ Roofsupportsforlargebuildings.

7 x 7 6 x 25 IWRC

6 x 7 IWRC 6 x 41 IWRC



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Rope or Strand

Diameter

StrandApprox.

Metallic AreaApprox.Wt. / Ft.

RopeApprox.

Metallic AreaApprox.Wt. / Ft.

Class 'A' Coating

ThroughoutClass 'A' Coating

in. MBF Tons in. sq. lbs. MBF Tons in. sq. lbs.1/2 15 .15 .52 11.15 .119 .42

9/16 19 .19 .66 – – –5/8 24 .23 .82 18 .182 .68

11/16 29 .28 .99 – – –3/4 34 .34 1.18 26 .268 .95

13/16 40 .40 1.39 – – –7/8 46 .46 1.61 35 .361 1.28

15/16 54 .53 1.85 – – –1 61 .60 2.1 45.7 .471 1.67

1-1/16 69 .68 2.37 – – –1-1/8 78 .76 2.66 57.8 .596 2.11

1-3/16 86 .85 2.96 – – –1-1/4 96 .94 3.28 72.2 .745 2.64

1-5/16 106 1.03 3.62 – – –1-3/8 116 1.13 3.97 87.8 .906 3.21

1-7/16 126 1.24 4.34 – – –1-1/2 138 1.35 4.73 104 1.08 7.82

1-9/16 150 1.47 5.13 – – –1-5/8 162 1.59 5.55 123 1.27 4.51

1-11/16 176 1.71 5.98 – – –1-3/4 188 1.84 6.43 143 1.47 5.24

1-13/16 202 1.97 6.9 – – –1-7/8 216 2.11 7.39 164 1.69 6.03

1-15/16 230 2.25 7.89 – – –2 245 2.40 8.4 186 1.92 6.85

2-1/16 261 2.55 8.94 – – –2-1/8 277 2.71 9.49 210 2.17 7.73

2-3/16 293 2.87 10.05 – – –2-1/4 310 3.04 10.64 235 2.42 8.66

2-5/16 327 3.21 11.24 – – –2-3/8 344 3.38 11.85 261 2.69 9.61

2-7/16 360 3.57 12.48 – – –2-1/2 376 3.75 13.13 288 2.97 10.6

2-9/16 392 3.94 13.8 – – –2-5/8 471 4.13 14.47 317 3.27 11.62

2-11/16 432 4.33 15.16 – – –2-3/4 452 4.54 15.88 347 3.58 12.742-7/8 494 4.96 17.36 379 3.91 13.9

3 538 5.40 18.9 412 4.25 15.113-1/8 584 5.86 20.51 – – –3-1/4 625 6.34 22.18 475 5.04 183-3/8 673 6.83 23.92 – – –3-1/2 724 7.35 25.73 555 5.83 213-5/8 768 7.88 27.6 – – –3-3/4 822 8.44 29.53 640 6.67 243-7/8 878 9.01 31.53 – – –

4 925 9.60 33.6 730 7.59 27

Structural Wire Products(Continued)Galvanized Structural Strand and Bridge Rope


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Wire Rope LubricantWire ropes contain numerous moving parts which require lubrication. Each time the rope bendsorflexes,theinternalstrands rub together. Whitmore’s Wire Rope Lubricant coats these strands to prevent friction and wear. This results in longer wire rope life, less downtime for rope changes and more production.

Whitmore’s Wire Rope Lubricant quickly penetrates to the core. This ensures that the rope is lubricated throughout while providing a non-drying, non-tacky filmontheoutsideoftherope.This protects outer strands from corrosion, as well as lubricating the wire rope drums and sheaves.

Applications:Whitmore’s Wire Rope Lubricant is easily pumpable at temperatures down to -25°F (-35°C). Its nondrying filmremainsflexibleinthemostextremeweatherconditions,whicheliminatesflakingandpeeling.

Whitmore’s Wire Rope Lubricant can be used to lubricate all sizes of wire rope, as well as chains, leaf springs and other applications where penetrating oil is needed. It may be applied by hand or automatic lube system.

Benefits:■ Prolongs wire rope life—readily penetrates to the core and lubricates internal strands.■ Non-tacky—eliminates dirt pick-up and lubricant sling-off.■ Guards against rust and corrosion—displaces water as it penetrates.■ Extreme load carrying ability—extends wire rope life and minimizes downtime.■ Aerosol propellant is non-flammable—safe to use.

Recommended Application Rate:

■ Dripsystem:firstweek—3dropsperminute, per inch diameter rope. ■ Secondweekandthereafter—1dropperminute, per inch diameter rope.■ Spraysystem:every15minutesfor30seconds (on payout only).

Vitalife® products are the preferred wire rope lubricants in the industry because of their ability to penetrate into wire rope and displace water and contaminants, thus reducing wear and corrosion throughout the rope.

■ Availableinavarietyofcontainersizes.■ Providesinnerstrandpreservationandlubricity.■ Allowsforeasyvisualinspectionoftheropes.■ Reducesthefrictionbetweenthestrandsofthewire rope, thus extending rope life.■ Adherestosurfaceofstrands,forminganouterfilm which provides excellent corrosive protection.■ Non-tacky(willnotattractdust)■ Vitalife® in aerosol form is a regulated dangerous good. See MSDS sheet for shipping instructions.■ Vitalife® Bio-Lube has been developed especially for environmentally friendly applications.■ Vitalife® 500 has been developed exclusively for ski lifts and tramways.■ Vitalife® 600 has been developed exclusively for elevator applications.


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Kellems® Wire Management Products Pulling / Splicing GripsOverhead, Underground, Commercial Construction, SpecialtyKellems® Wire Rope Grips are made of high strength galvanized steel strand in a construction of triple, double and single weave for superior gripping ability. They are available with or without a rotating barrel, which will help eliminate twist in the old rope from being transferred to the new rope.

Flexible or rotating eyes will mate easily with line stringing swivels for attachment to pulling lines; they have great strength for trouble free pulling jobs.

Shoulder protectors contain the cable inside the grip and smooth the passage of the grip over line stringing blocks or conduit bends; they protect the leading edge of the grip from abrasion.

The galvanized steel mesh grip provides strength for securepullingjobsandaslimprofilewithlittlebuild-up;ithasflexibilitytofollowcablepath.

The multi-weave styles available add strength for big pulling jobs and provide positive gripping power.

Endless weave allows easy installation onto cable. It has asnag-freelowprofile;designedtobereusabletool.


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Kellems® Wire Management Products Pulling / Splicing Grips(Continued)Splicing Grips

Wire Rope SplicingKellems Wire Rope Grips are made of high strength galvanized steel strand in a construction of triple, double and single weave for superior gripping ability. They are available with or without a rotating barrel,which will help eliminate twist in the old rope from being transferred to the new rope.

ApplicationWire Rope Grips are used for changing wire rope on oil derricks, large cranes, overhead cranes and drag lines. They provide a quick, safe, inexpensive temporary splice. By installing the used wire rope in one end and the new rope in the other, the new wire rope can be pulled in as the old one is pulled out.

Benefits■ Highstrengthforsecurepulling.■ Easyinstallation.■ Flexibletopassthroughsheavesandblocks.Note: 1. During installation, each end of the grip should be banded and taped down securely over the rope to insure smooth passage through sheaves and to guard against accidental release.2. The rotating barrel is not a swivel and will not turn while under tension. It can turn to relieve pulling torque when tension is relaxed.

Cable SplicingSplicing Grips are made of galvanized steel in double or single weave mesh construction. They are available in various lengths and sizes to suit most applications.

ApplicationSplicing Grips are used as a temporary splice for rope, cable or wire rope. They can also be used as cable reinforcement, and can act as a shield to protect cables and hoses from abrasion.

Benefits■ Easilyinstalledorremoved.■ Galvanizedsteelconstructionforstrength.■ Flexibletofollowcablepath.Note: 1. During installation, each end of the splicing grip should be banded and taped down securely to the cable to insure smooth passage with the cable and guard against accidental release.

Wire Rope Splicing GripsTriple, Double, Single Weave, Galvanized Steel

Regular Wire Rope Grips

Cable Dia.Range

(in.)

Approx. BreakingStrength

(lbs.)

Approx. Lengthof Grip

(ft.)

CatalogNumber

9/16" to 5/8" 7,500 5.75 033160013/4" to 7/8" 12,500 6.75 033160021" to 1-1/8" 16,000 7.00 03316003

1-1/4" to 1-3/8" 20,000 8.00 033160041-3/8" to 1-1/2" 20,000 8.00 03316006

Rotating Wire Rope Grips

Cable Dia.Range

(in.)

Approx. BreakingStrength

(lbs.)

Approx. Lengthof Grip

(ft.)

BarrelDimensions

Length x O.D. (in.)

CatalogNumber

7/16" to 1/2" 5,000 5.33 3.00" x .87" 033170019/16" to 5/8" 7,500 5.83 4.25" x 1.00" 033170023/4" to 7/8" 12,500 6.50 4.25" x 1.00" 033170031" to 1-1/8" 16,000 8.67 5.50" x 1.37" 03317004

1-1/4" to 1-3/8" 20,000 9.00 5.50" x 1.37" 033170051-1/2" to 1-3/4" 20,000 11.00 5.50" x 1.37" 03317006

CAUTION SEE CAUTION INFORMATION ON PAGES 721 - 723.


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Kellems® Wire Management Products Pulling / Splicing Grips(Continued)Tools and Bands

Punch-Lok® BandsPunch-Lok Bands are applied over the tail of a grip to prevent the mesh from being tripped or pulled loose. Also, they assure full gripping action by locking the mesh of the tail in tight contact with the cable or rope.

When the tail of a grip is the leading end, the bands are particularly important to prevent accidental release caused by tripping on obstructions. A conductor-to-conductor (double-socking) pulling operation is a good example: where two grips connect two conductors to form a temporary splice. Bands should be applied to the ends of the grips as illustrated herein. It is also common practice to tape over the banded tail area to assure smooth passage through the sheaves. The conductor should be installed in the grip up to the elbows of the aluminum shoulders in order to assure full and complete gripping action.

SwivelsSwivelsareessentialtotheefficiencyandsafetyofanyhightensionapplication. They are particularly important where continuous pulls develophigherandhighertorquelevels.Torqueisintensifiedbythepull resistance of the cable itself and the resistance of the high tension controlling equipment regulating line sag.

Ball bearing swivels release torque and prevent it from reaching dangerous levels that can damage the cable and obstruct the lines as it passes through sheaves, wheels or blocks.

Punch-Lok BandsGrip

BandingRange

(in.)

Band Width(in.)

Band Inside

Diameter (in.)

Model CatalogNumber

1/4" to 1-1/8" 3/8" 1-3/8" 0-311 203200501-1/8" to 1-5/8" 3/8" 2" 0-316 203200511-5/8" to 2-1/4" 5/8" 2-1/2" 0-10 203200522-1/4" to 3-1/2" 5/8" 4" 0-16 20320053

3-1/2" to 5" 5/8" 6" 0-24 20320054

AccessoriesPunch-Lok Tools Catalog

NumberDescriptionP-1000 for use with 5/8" width Banding Tool. 20320048P-38 for use with 3/8" and 5/8" width Banding tool for tight spaces

20320047

Note: In all cases two Punch-Lok Bands should be double wrapped approximately 1" to 2" from the grip’s tail. Banding is required to ensure maximum reliability and guard against accidental release.

CAUTION SEE CAUTION INFORMATION ON PAGES 721 - 723.


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Klein Tools Pulling GripsForged-Steel Grips IntroductionKlein grips offer total wire and cable-pulling capability for the power utility, telecommunication and many other industries.

Klein “Chicago”® and "Haven"® Grips are widely used in the power, communicationsandgeneralconstructionfieldstopullwireandcable,and to maintain temporary tension until it can be permanently terminated. These grips are to be used for pulling up lines to tension only and are not to be used as anchors.

Klein has designed and built standard and custom grips of outstanding quality since 1885. They are proven dependable. The complete lineincludes a type and size for every application.

There is a Klein grip for virtually every type of wire and cable, including:■ Extra-high-strengthcables,messenger,guystrandandconductors■ Barewire■ Large-diameterconductors■ BareA.C.S.R.,aluminumandstranded-coppercables■ PVC-coveredconductors■ Weatherproofwire■ Telephonecable

Klein "Chicago" Grips have locking loop handles, standard on most grips and available on hot-line grips by ordering with spring. The locking fea-ture allows the jaws to be held in an open position for easier placement on wire or cable. Saves substantial time, makes grip positioning easier than with wedge or boil-on designs. To lock, open jaws and fold loop handle toward the side plates.

Klein "Chicago"® GripsHow to select the proper grip.Care should be taken in choosing grips to assure correct handling of wire and cable. Three basic factors determine the selection of the proper grip foreachspecificapplication:1. Type of wire or cable.2. Outside diameter of wire or cable.3. Maximum safe load required.

All three of these factors are included in the description of each Klein grip along with the type of inside jaw contour available. Correct selection of gripping jaws is essential to avoid damage to wire or cable. In pulling stranded wire, the jaws should be long enough to take a full lay of cable to avoid damage to the conductor.

The tables in this grip section are supplied to assist you in determining outside diameters and breaking points of the various types and sizes of wire and cable in general use.

For our recommendations of the proper grip to meet your needs, send exact cable description and pulling requirements.

Inside-Jaw Contours Klein "Chicago" Grips are offered with three types of jaw contour: Single V, Double V, and Round. Each grip comes with the proper inside-jaw contour for the type of wire or cable to be worked.

Single V. Simple three-point contact jaws designed for use on small-diameter bare wire and cable (solid and stranded).

Doubts V. Four-point contact provides greater gripping pressure and assures proper alignment of wire and cable within the jaws. Designed for high-strength steel guy wire and messenger wire, and extra high-strength cables and conductors.

Round. Round jaws provide maximum contact and gripping power to minimize conductor damage. This jaw design is recommended for use on bare aluminum, A.C.S.R., and copper conductors.

Repair or replace?Never repair any grip. Grip laws can sometimes be replaced if the grip is returned to Klein, but structural wow or damage cannot be safely corrected. Grips that are bent, misaligned or otherwise distorted should be discarded and replaced.

Before each use, check all grips for jaw condition, proper alignment of jaws and all parts, and possible distortion caused by exceeding safe-load specifications.Gripsshouldoperatesmoothly.Spring-loadedgripsshould lock open with loop handle in "Down" position and should dose automatically with loop handle "Up".

The Klein parallel jaw grip maybe tested by opening and closing the jaws by hand, exercising proper caution. All parts and rivets which may be distorted due to exceeding safe load should be checked.

Recommended Care and MaintenanceThe following guidelines have been established in order to maintain all grips in good condition:1. Clean the grip jaws. Use emery cloth or a clean wire brush to periodically clean the surfaces of grip jaws. Note: Aluminum-strand conductors may have a die-grease coating which can de¬posit on grip jaws. Now aluminum conductors should be wiped clean before grip application. Grip jaws should be wiped clean of all grease before use. Be sure to clean grip jaws before and after each use on wire or cable which has been galvanized or otherwise coated.

2. Clean aft working parts. Use Klein's Cinch Cleaner / Degreaser Cat. No. 51101 to clean all joints and moving parts, then apply Cinch Yellow No. 51045.

3. Check all parts. Look carefully for distortion or misalignment.

4. Never repair any grip. If there is ever any question about the safe condition of any grip, please consult us directly. Please remember this rule.

Please order grips by description and specifications only. Actual product may vary from photo.


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Klein Tools Pulling Grips (Continued)When pulling EHS (extra-high-strength) galvanized steel cable, the galvanizing has a tendency to coat the jaws of any grip, causing the cable to slip. To reduce the possibility of slippage and damage to the cable, the jaws of this grip are milled on a curve with a double “V” contour.

Catalog Number

Minimum Cable Size

in. (mm)

MaximumCable Size

in. (mm)

Maximum Safe Load lbs. (kg)

Approx. Weight Each

lbs. (kg)Jaw Length

in. (cm)

1684-74 .218 (5.54) .55 (13.97) 8,000 (3,629) 6.25 (2.83) 5 (12.7)

Catalog Number

Minimum Cable Size

in. (mm)

MaximumCable Size

in. (mm)

Maximum Safe Load lbs. (kg)

Approx.Weight Each

lbs. (kg)1604-10 14 B&S .06 (1.52) 2 B&S .25 (6.35) 2,500 (1,136) 1 (.45)1604-20 8 B&S .125 (3.18) Steel Strand .50 (12.70) 5,000 (2,272) 2.5 (1.14)1604-20L 8 B&S .125 (3.18) Steel Strand .50 (12.70) 5,000 (2,272) 2.5 (1.14)1625-20 1 B&S .28 (7.11) Wire Rope .75 (19.05) 8,000 (3,636) 3.5 (1.59)

1625-20, 7/8 .38 (9.65) Wire Rope .88 (22.35) 8,000 (3,636) 3.5 (1.59)1625-20, 1 .50 (12.70) Wire Rope 1.00 (25.40) 8,000 (3,636) 3.5 (1.59)

Designed for use when light, compact grip is desired andwhere conductor damage is not a factor. Gripping pressureof the knurled jaw is applied to 1/4" (6.35 mm) cable area.1604-20L and 1625 series have a swing latch to help holdcableinthejaw.1625-20canbefurnishedtofit7/8"(22.2 mm) or 1" (25.4 mm) cable on special order.

Caution:Proper maintenance and field inspection of all grips is necessary before each use. Check to be sure there is no accumulation of foreign material in the jaws which might cause slippage. Check mechanical condition of entire grip. Check grip to be sure it is correct size and type for the application. Clean and lubricate. Do not lubricate gripping surfaces of jaws. Check all parts for distortion or misalignment.

OSHA requires that all hand tools and equipment be maintained in good working order and that they be free from damage caused by wear or abuse (OSHA Part 1910, Subpart P, Section 1910.242).

In addition, OSHA Part 1926 Subpart V, Section 1926.955 paragraph 7 (ii) and 8 specifically state that: “That manufacturer’s load rating shall not be exceeded for stringing lines, pulling lines, sock connections and all load bearing hardware and accessories.”

“Conductor grips shall not be used on wire rope unless designed for this application.”

Grip-Cleaning Brush SetSet of four wire-bristle brushes designed for cleaning Klein wire- and cable-pulling grips.

Brushes have stiff wire bristles.Available in round and square shapes and two lengths for efficientcleaningofdifferentjawconfigurations.Semi-flexiblesteel shafts set into comfortable wooden handles provide the necessary reach into grip jaws.Illustrated general grip care and maintenance instructions are included.

Contains: Round-bristle 3/8" x 3" (10 x 76 mm), 12" (305 mm) long; Square-bristle 3/8" x 3" (10 x 76 mm), 12" (305 mm) long; Round-bristle 1-9/16" x 5" (40 x 127 mm), 14" (356 mm) long; Square-bristle 1-9/16" x 5" (40 x 127 mm), 14" (356 mm) long.

Inside Jaw Contour



721

Wire RopeProduct Warnings

& Cautions


722

Wire Rope TechnicalBoard Warning

Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused.

Wire Rope failure may cause serious injury or death!

Protect yourself and others:■ ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.■ NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED.■ NEVER OVERLOAD a wire rope.■ INFORM YOURSELF: Read and understand manufacturer's literature or "Wire Rope and Wire Rope Sling Safety Bulletin".*■ REFER TO APPLICABLE CODES, STANDARDS and REGULATIONS for INSPECTION REQUIREMENTS and REMOVAL CRITERIA.*

* For additional information or the BULLETIN, ask your employer or wire rope supplier.

WARNING


For complete warning and application information, see Wire Rope Technical Board at www.wireropetechnicalboard.org

For complete warning and application information, see Bridon American at www.bridonamerican.com

For complete warning and application information, see Bethlehem / Wire Rope Works, Inc. at www.wwwrope.com

For complete warning and application information, see WireCo / Union Wire Rope at www.unionrope.com

For complete warning and application information, see Wire Rope Industries at www.wirerope.com

For complete warning and application information, see Casar at www.casar.de/en


723

Klein Tools Pulling GripsWarnings ■ Before each use, clean jaw area and inspect grip for

proper operation to avoid slippage.■ When used on/near energized lines, ground, insulate, or isolate grip before pulling.■ Do not exceed rated capacity.■ Always match proper size and type of grip to application.■ Grips are to be used for temporary installation, not for permanent anchorage.

WARNING

For complete warning and application information, see Klein Tools, Inc. at www.kleintools.com

Safety and Working Load Factors For Wire Mesh Grips

The broad application of Kellems grips on a wide variety of objects requires that adequate safety factors be used to establish working loads. The approximate breaking strength of a Kellems grip represents an average calculation based on data established from actual direct tension testing done in our engineering laboratories.

It is impossible to catalog or guarantee a safety factor suitable for all applications as operating conditions are never the same. The tension, diameter, movement, number of objects gripped, gripping surface, and the attachments used are just some of the factors which vary with each application. These factors, together with the effects of abrasion, corrosion, prior use or abuse and any other variables of a specific application, must be considered by the user and the grip replaced as appropriate. Where the conditions of the application are not well defined or known, or where risk of injury to persons or property is involved, a greater safety factor should be utilized.

Under normal conditions, Kellems’ recommended factor of safety is five for catalog listed pulling grips, and ten for catalog listed support grips. Any warranty as to quality, performance or fitness for use of grips is always premised on the condition that the published breaking strengths apply only to new, unused grips, and that such products are properly stored, handled, used, maintained and inspected by the user at a frequency appropriate for the use and condition of the grip.

Kellems® Wire Management Products Pulling / Splicing Grips Cautions & Warnings

It is very important to comply with all of the following precautions. Failure to do so may result in property damage, personal injury or death.

1. Pulling grips are to be installed by a qualified individual in accordance with all applicable national and local safety, electrical and rigging codes.2. Ensure that the correct grip is selected for your specific needs.3. Do not use a pulling grip for any application other than pulling cable.4. Thoroughly examine the grip for damage. Do not use a damaged grip.5. Ensure that the recommended work load of the grip is suitable for the application. Never use grips at their approximated rated breaking strength. A safety factor of 5 is recommended for pulling grips.6. Do not alter grips in any way. For example, do not modify pulling eyes, shoulders, fittings or lugs.7. Do not attach any type of pulling hardware to any point on the grip other than the pulling eye. The pulling eye is the only acceptable means of attachment to external hardware.8. Always apply 2 bands at 1" and 2" respectively, from the tail end of the mesh to guard against accidental release of the grip. Accidental release can occur if an object contracts and pushes against the tail end of the mesh, thereby expanding and releasing it’s hold.

CAUTION

For complete warning and application information, see Hubbell Incorporated at www.hubbell.com


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Wire Rope Assemblies& End Fittings IndexSteel Swage Buttons .....................................726Wedge Ferrules Buttons ................................727Terminal Efficiencies ......................................728Boom Pendant Inspection .............................729Boom Pendant Thimbles ...............................730Boom Pendants .............................................731, 733Spelter Socket Assemblies ............................731Open & Closed Spelter Sockets ....................732Swaged Socket Assemblies ..........................733Open & Closed Swage Sockets ....................734Forged Wire Rope Clips ................................735Fist Grip® Wire Rope Clips ............................736Wedge Socket ...............................................737Super Terminator® Wedge Socket .................738Threaded Sleeve ...........................................739Threaded Stud ...............................................740Wire Rope Terminals .....................................741 - 743Copper Oval & Copper Stop Sleeves ............744 Nickel Plated Copper Oval Sleeves...............745 Stainless Steel Oval Sleeves.........................745Aluminum Oval Sleeves ................................746Cutter Tools ...................................................747 - 750Wire Rope Cutters .........................................751Precision Cable Cutters .................................752Movable Bridge Cable Assemblies ................753Security, Barrier and Guardrail Cable Assemblies & Fittings ...................754

WarningsProduct Warnings ..........................................755 - 757

For the complete catalog index, refer to the front of the book.

MazzellaCatalog13_WireRopeAssemblies.indd 724 7/3/13 10:11 AM

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Every Order Made toPurchaser’s SpecificationsHow to order:

We can produce any assembly to fit your specifications precisely. When ordering, please consider the following:

■ Diameter of the wire rope.■ Wire rope classification or construction.■ Rope material (stainless, galvanized, bright, etc.).■ Rated capacity required.■ Length as described by reference points (see diagram below).■ Fitting material required.■ For threaded fittings, specify the type, length and hand of thread.■ For terminals, such as forks and eyes, please specify how they should be positioned relative to each other —same plane or opposite planes.■ The number of completed assemblies required.

How to measure reference points for specifying your assemblies.

Here are several examples of various assemblies. The dotted vertical lines indicate the reference points. Please specify these reference points when youorder. If you need a customized assembly notshown here, please call us and we’ll supply you what you need.


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Steel Swage Buttons

Wire Rope Size(in.)

After SwagingDiameter

(in.)Long(in.)

1/8 3/8 5/85/32 7/16 3/43/16 1/2 7/87/32 9/16 11/4 9/16 1-3/16

9/32 11/16 1-1/45/16 3/4 1-3/83/8 3/4 1-3/47/16 1 21/2 1-1/8 2-3/16

9/16 1-1/4 2-7/165/8 1-3/8 2-7/83/4 1-1/2 3-1/47/8 1-3/4 3-7/81 2 4-3/8

1-1/8 2-1/4 4-13/161-1/4 2-1/2 5-7/161-3/8 2-3/4 61-1/2 3 6-1/2



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Wedge Type FerrulesESCO ferrules are made of high strength alloy steel and feature a two-piece wedge that is rifled to provide more gripping surface on the wire rope strands and greater holding power.

ESCO machined wedge-type ferrules permit the make up or repair of chokers and winch lines in minutes—no molten socket metal or swaging equipment is required. Wedge type ferrules may be applied with ESCO Socketfast.

Wedge-type ferrules are intended only for use with new 6 x 19 class or 6 x 37 class, right regular lay, EIP, IWRC rope made to U.S. specifications.


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Terminal Efficiencies (Approximate)Efficiencies are based on nominal strengths.

Type of TerminationEfficiency

Rope with IWRC * Rope with FC ** Profile

Wire Rope Socket (Spelter or Resin) 100% 100%

Swaged Socket (Regular Lay Ropes Only)

(Regular Lay Ropes Only) 100% (Not established)

Mechanical Spliced Sleeve1" dia. and smaller 95% 92-1/2 %Greater than 1" dia. through 2" 92-1/2% 90%Greater than 2" dia. through 3-1/2" 90% (Not established)

Loop or Thimble Splice-Hand Spliced (Tucked) (Carbon Steel Rope)1/4" 90% 90%5/16" 89% 89%3/8" 88% 88%7/16" 87% 87%1/2" 86% 86%5/8" 84% 84%3/4" 82% 82%7/8" thru 2-1/2" 80% 80%

Loop or Thimble Splice-Hand Spliced (Tucked) (Stainless Steel Rope)1/4" 80% –5/16" 79% –3/8" 78% –7/16" 77% –1/2" 76% –5/8" 74% –3/4" 72% –7/8" 70% –

Wedge Sockets ***

(Depending on Design) 75% to 80% 75% to 80%

Clips ***

(Number of clips varies with size of rope) 80% 80%

* IWRC = Independent Wire Rope Core ** FC = Fiber Core.*** Typical values when applied properly. Refer to fittings manufacturers for exact values and method.

For terminal efficiencies on Premium High Performance Ropes, contact local customer service representative.


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Boom Pendant InspectionBoom pendant inspection is vital for proper use.

General guide to boom pendant inspection:

1. Measure the diameter of the rope at several points along the pendant, especially near the end fittings. Measurements below the rope's nominal diameter may mean that the core is deteriorating, even if the outside wires and strands appear to be in good condition.

2. Inspect the outside wires and strands for damaging rust or abrasive wear caused by loss of lubrication, or by the rope’s contact with the boom or other structures on the crane.

3. Inspect the rope for broken wires—especially near the end fittings. Even one broken wire near an end fitting may be a sign that the rope is deteriorating and may be near failure. Any “valley breaks,” that is, wires that have broken in the valley between two strands may also be a sign that there is serious vibration fatigue in the core.

4. Inspect the fitting attachments.

Hand spliced: look for slippage in the splice or any tucks that may have pulled out.

Poured zinc or thermo-set resin sockets: look at the base of the sockets for any signs that the wires may be pulling out of the zinc or thermo-set resin. Look at the top of the cone for any sign that the zinc or thermo-set resin is cracked or is chipping or flaking off.

Returned loop swaged: look for any sign that the sleeve may be cracked, crushed or peeling back. Look for any sign that the rope may be pulling out of sleeve.

Flemish eye swaged: look for any sign that the sleeve may be cracked, crushed or peeling back.

Swaged sockets: look for any signs of a cracked or bent shank. Look for any sign that the rope may be pulling out of the socket.

5. Inspect the end fittings: inspect the fittings for any signs of cracking or distortion. Pay particular attention to the area around the pin holes and along the ears of open sockets.

Inspect the pin holes for any signs of elongation or excessive wear.

Inspect the socket pins for any signs of bending or excessive wear.

Note: If any of the above conditions exists, the pendant should be removed from service and inspected or tested further.

This is intended to be a general guide only. Contact the manufacturer of the equipment, the pendants and/or the end fittings to get specific retirement criteria.

Reference to ASME Standard B30.9.

Watch for brokenwires in this area

This assemblymust be replaced.


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Boom Pendant ThimblesIllustrated below is a NEWCO Boom Pendant fabricated with a flemish eye splice and swaged steel sleeves which fit around a pendant fitting that is either open or closed. Available In sizes from 9/16" to 2-3/8". Pendants are not to be used for any other purpose other than Boom Pendant application. NEWCO Pendant Thimbles are interchangeable with standard sockets. Weight on open pendant includes pin (D) and cotter.

Wire RopeDiameter

(in.)

Closed Dimensions & Data (in.) Est. Weight(lbs.)A B C D E F G

9/16 to 5/8 4-3/2 3-1/8 1-1/4 1-1/16 1-1/16 11/16 2-1/8 1.73/4 4-27/32 3-5/8 1-7/16 1-5/16 1-3/16 13/16 2-1/2 2.67/8 5-5/16 4-1/8 1-11/16 1-1/2 1-3/8 15/16 2-3/4 3.51 5-31/32 4-9/16 2-1/16 1-3/4 1-5/8 1-1/8 3 4.6

1-1/8 6-3/8 5-1/16 2-5/16 2 1-3/4 1-1/4 3-1/4 5.61-1/4 to 1-3/8 7-3/8 6-1/8 2-9/16 2-1/4 2-1/8 1-1/2 4 9.6

1-1/2 8-3/16 6-3/4 2-13/16 2-1/2 2-3/8 1-5/8 4-1/2 141-5/8 10-7/16 8 3-1/16 2-5/8 2-1/2 1-3/4 5-1/2 29

1-3/4 to 1-7/8 12-5/16 9-3/4 3-9/16 3-1/8 3 2 7 412 to 2-1/8 13 10-1/2 3-13/16 3-7/16 3-1/4 2-1/4 7-1/2 57

2-1/4 to 2-3/8 17-5/16 11-3/4 4-3/8 3-7/8 3-5/8 2-1/2 8-1/2 76

Wire RopeDiameter

(in.)

Open Dimensions & Data (in.) Est. Weight(lbs.)A B C D E F G H J L P R

9/16 to 5/8 8-3/64 2-3/8 1-1/4 1-3/16 15/32 11/16 2-1/8 3-1/8 2-17/32 4-1/4 2-9/32 9/16 5.33/4 9-3/32 2-13/16 1-1/2 1-3/8 17/32 13/16 2-1/2 3-5/8 3-1/32 4-3/4 2-3/4 21/32 7.57/8 10-5/16 3-1/4 1-3/4 1-5/8 5/8 15/16 2-3/4 4-1/8 3-1/4 5-1/4 3-1/4 3/4 12.51 11-11/16 3-3/4 2 2 3/4 1-1/18 3 4-9/16 3-11/16 5-7/8 3-7/8 7/8 19

1-1/8 12-25/32 4-1/4 2-1/4 2-1/4 7/8 1-1/4 3-1/4 5-1/16 3-27/32 6-17/32 4-7/16 1 261-1/4 to 1-3/8 15-1/32 4-3/4 2-1/2 2-1/2 15/16 1-1/2 4 6-1/8 4-5/16 8 4-15/16 1-1/8 39

1-1/2 17-1/8 5-3/8 3 2-3/4 1-1/16 1-5/8 4-1/2 6-3/4 4-13/16 9-1/8 5-5/8 1-3/16 561-5/8 20-1/2 5-5/8 3 3 1-3/16 1-3/4 5-1/2 8 6-7/16 10-5/8 6-1/8 1-5/16 78

1-3/4 to 1-7/8 24-1/16 6-5/8 3-1/2 3-1/2 1-5/16 2 7 9-3/4 7-7/16 12-3/4 6-7/8 1-9/16 1252 to 2-1/8 27 7-5/8 4 3-3/4 1-11/16 2-1/4 8 10-3/4 9-3/4 13-1/4 7-1/8 1-13/16 166


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Spelter Socket Assemblies (Boom Pendants)Molten zinc is standard as the bonding medium surrounding wires inside the socket, but epoxy compound may be specified.

Both mediums have same capacity ratings. Steel forgings are used for rope sizes 1/2" through 4", and cast steel fittings for larger sizes. Larger than 4" available on special order. Assembly length is measured from centerline of pin for open sockets and bearing point for closed sockets.

Wire rope assemblies with fittings permanently attached at ends are customfabricated for use as boom pendants, guylines, raising lines, backstays,lifting bridles, etc. These are offered in both poured or spelter sockets and mechanically swaged sockets.

Wire RopeDiameter

(in.)

Closed Spelter Socket Dimensions & Data (in.)

A B C D F G H J K L1/4 4.50 .50 1.50 .88 .38 .69 1.56 2.25 .50 1.75

5/16 to 3/8 4.88 .62 1.69 .97 .50 .81 1.69 2.25 .69 27/16 to 1/2 5.44 .69 2 1.16 .56 .94 1.88 2.50 .88 2.259/16 to 5/8 6.31 .81 2.63 1.41 .69 1.12 2.38 3 1.00 2.50

3/4 7.56 1.06 3 1.66 .81 1.25 2.75 3.56 1.25 37/8 8.75 1.25 3.63 1.88 .94 1.50 3.25 4 1.50 3.501 9.88 1.38 4.13 2.30 1.13 1.75 3.75 4.44 1.75 4

1-1/8 11 1.50 4.50 2.56 1.25 2.00 4.13 5 2.00 4.501-1/4 to 1-3/8 12.12 1.63 5.30 2.81 1.50 2.25 4.75 5.50 2.25 5

1-1/2 13.94 1.94 5.33 3.19 1.63 2.75 5.25 6 2.50 61-5/8 15.13 2.13 5.75 3.25 1.75 3.00 5.50 6.50 2.75 6.50

1-3/4 to 1-7/8 17.25 2.19 6.75 3.75 2 3.13 6.38 7.50 3 7.562 to 2-1/8 19.50 2.44 7.63 4.38 2.25 3.75 7.38 8.50 3.25 8.56

2-1/4 to 2-3/8 21.13 2.63 8.50 5 2.50 4 8.25 9 3.63 9.502-1/2 to 2-5/8 23.50 3.12 9.50 5.50 2.88 4.50 9.25 9.75 4 10.622-3/4 to 2-7/8 25.38 3.12 10.75 6.25 3.12 4.88 10.19 11 4.88 11.25

3 to 3-1/8 27 3.25 11.50 6.75 3.38 5.25 11.50 12 5.25 11.753-1/4 to 3-3/8 29.25 4 12.25 7.25 3.62 5.75 12.25 13 5.75 12.253-1/2 to 3-5/8 31 4 13 7.75 3.88 6.50 13 14 6.25 13

3-3/4 to 4 33.25 4.25 14.25 8.50 4.25 7.25 14.25 15 7 14

Wire RopeDiameter

(in.)

Open Spelter Socket Dimensions & Data (in.)

A C D F G H J L M N1/4 4.56 .91 .69 .38 .69 1.56 2.25 1.56 1.31 .36

5/16 to 3/8 4.84 .81 .81 .50 .81 1.69 2.25 1.75 1.50 .447/16 to 1/2 5.56 1 1 .56 .94 1.88 2.50 2.00 1.88 .509/16 to 5/8 6.75 1.25 1.19 .69 1.13 2.25 3 2.50 2.25 .56

3/4 7.94 1.50 1.38 .81 1.25 2.62 3.50 3 2.62 .627/8 9.25 1.75 1.63 .94 1.50 3.25 4 3.50 3.13 .801 10.56 2 2 1.13 1.75 3.75 4.50 4 3.75 .88

1-1/8 11.81 2.25 2.25 1.25 2 4.12 5 4.62 4.12 11-1/4 to 1-3/8 13.19 2.50 2.50 1.50 2.25 4.75 5.50 5 4.75 1.13

1-1/2 15.12 3 2.75 1.63 2.75 5.25 6 6 5.38 1.191-5/8 16.25 3 3 1.75 3 5.50 6.50 6.50 5.75 1.31

1-3/4 to 1-7/8 18.25 3.50 3.50 2 3.13 6.38 7.50 7 6.50 1.562 to 2-1/8 21.50 4 3.75 2.25 3.75 7.38 8.50 9 7.00 1.81

2-1/4 to 2-3/8 23.50 4.50 4.25 2.50 4 8.25 9 10 7.75 2.132-1/2 to 2-5/8 25.50 5 4.75 2.88 4.50 9.25 9.75 10.75 8.50 2.382-3/4 to 2-7/8 27.25 5.25 5 3.12 4.88 10.50 11 11 9 2.88

3 to 3-1/8 29 5.75 5.25 3.38 5.25 11.12 12 11.25 9.50 3.003-1/4 to 3-3/8 30.88 6.25 5.50 3.62 5.75 11.88 13 11.75 10 3.123-1/2 to 3-5/8 33.25 6.75 6 3.88 6.50 12.38 14 12.50 10.75 3.25

3-3/4 to 4 36.25 7.50 7 4.25 7.25 13.62 15 13.50 12.50 3.50

Rated Capacity—Tons

Wire RopeDiameter

(in.)

6 x 19 & 6 x 36IWRC

EIP EEIP1/2 2.7 2.9

9/16 3.4 3.75/8 4.1 4.53/4 5.9 6.57/8 8 8.81 10 11

1-1/8 13 141-1/4 16 181-3/8 19 211-1/2 23 251-5/8 26 291-3/4 31 341-7/8 35 38

2 40 432-1/8 44 492-1/4 49 542-3/8 55 602-1/2 60 662-5/8 66 732-3/4 72 792-7/8 78 86

3 85 943-1/8 92 1013-1/4 98 1093-3/8 106 1163-1/2 113 124



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Open & ClosedSpelter Sockets

Wire RopeDiameter

(in.)

Closed Spelter Socket Dimensions & Data (in.)

A B C D F G H J K L1/4 4.50 .50 1.50 .88 .38 .69 1.56 2.25 .50 1.75

5/16 to 3/8 4.88 .62 1.69 .97 .50 .81 1.69 2.25 .69 27/16 to 1/2 5.44 .69 2 1.16 .56 .94 1.88 2.50 .88 2.259/16 to 5/8 6.31 .81 2.63 1.41 .69 1.12 2.38 3 1.00 2.50

3/4 7.56 1.06 3 1.66 .81 1.25 2.75 3.56 1.25 37/8 8.75 1.25 3.63 1.88 .94 1.50 3.25 4 1.50 3.501 9.88 1.38 4.13 2.30 1.13 1.75 3.75 4.44 1.75 4

1-1/8 11 1.50 4.50 2.56 1.25 2.00 4.13 5 2.00 4.501-1/4 to 1-3/8 12.12 1.63 5.30 2.81 1.50 2.25 4.75 5.50 2.25 5

1-1/2 13.94 1.94 5.33 3.19 1.63 2.75 5.25 6 2.50 61-5/8 15.13 2.13 5.75 3.25 1.75 3.00 5.50 6.50 2.75 6.50

1-3/4 to 1-7/8 17.25 2.19 6.75 3.75 2 3.13 6.38 7.50 3 7.562 to 2-1/8 19.50 2.44 7.63 4.38 2.25 3.75 7.38 8.50 3.25 8.56

2-1/4 to 2-3/8 21.13 2.63 8.50 5 2.50 4 8.25 9 3.63 9.502-1/2 to 2-5/8 23.50 3.12 9.50 5.50 2.88 4.50 9.25 9.75 4 10.622-3/4 to 2-7/8 25.38 3.12 10.75 6.25 3.12 4.88 10.19 11 4.88 11.25

3 to 3-1/8 27 3.25 11.50 6.75 3.38 5.25 11.50 12 5.25 11.753-1/4 to 3-3/8 29.25 4 12.25 7.25 3.62 5.75 12.25 13 5.75 12.253-1/2 to 3-5/8 31 4 13 7.75 3.88 6.50 13 14 6.25 13

3-3/4 to 4 33.25 4.25 14.25 8.50 4.25 7.25 14.25 15 7 14

Wire RopeDiameter

(in.)

Open Spelter Socket Dimensions & Data (in.)

A C D F G H J L M N1/4 4.56 .91 .69 .38 .69 1.56 2.25 1.56 1.31 .36

5/16 to 3/8 4.84 .81 .81 .50 .81 1.69 2.25 1.75 1.50 .447/16 to 1/2 5.56 1 1 .56 .94 1.88 2.50 2.00 1.88 .509/16 to 5/8 6.75 1.25 1.19 .69 1.13 2.25 3 2.50 2.25 .56

3/4 7.94 1.50 1.38 .81 1.25 2.62 3.50 3 2.62 .627/8 9.25 1.75 1.63 .94 1.50 3.25 4 3.50 3.13 .801 10.56 2 2 1.13 1.75 3.75 4.50 4 3.75 .88

1-1/8 11.81 2.25 2.25 1.25 2 4.12 5 4.62 4.12 11-1/4 to 1-3/8 13.19 2.50 2.50 1.50 2.25 4.75 5.50 5 4.75 1.13

1-1/2 15.12 3 2.75 1.63 2.75 5.25 6 6 5.38 1.191-5/8 16.25 3 3 1.75 3 5.50 6.50 6.50 5.75 1.31

1-3/4 to 1-7/8 18.25 3.50 3.50 2 3.13 6.38 7.50 7 6.50 1.562 to 2-1/8 21.50 4 3.75 2.25 3.75 7.38 8.50 9 7.00 1.81

2-1/4 to 2-3/8 23.50 4.50 4.25 2.50 4 8.25 9 10 7.75 2.132-1/2 to 2-5/8 25.50 5 4.75 2.88 4.50 9.25 9.75 10.75 8.50 2.382-3/4 to 2-7/8 27.25 5.25 5 3.12 4.88 10.50 11 11 9 2.88

3 to 3-1/8 29 5.75 5.25 3.38 5.25 11.12 12 11.25 9.50 3.003-1/4 to 3-3/8 30.88 6.25 5.50 3.62 5.75 11.88 13 11.75 10 3.123-1/2 to 3-5/8 33.25 6.75 6 3.88 6.50 12.38 14 12.50 10.75 3.25

3-3/4 to 4 36.25 7.50 7 4.25 7.25 13.62 15 13.50 12.50 3.50

Notice: All cast steel spelter sockets 1-5/8" and larger are magnetic particle inspected and ultrasonic inspected. Proof testing available on special order.

Note: Above drawing illustrates one groove used on sockets 1/4" thru 3/4". Sizes 7/8" thru 1-1/2" use 2 grooves. Sizes 1-5/8" and larger use 3 grooves.

Note: Above drawing illustrates one groove used on sockets 1/4" thru 3/4". Sizes 7/8" thru 1-1/2" use 2 grooves. Sizes 1-5/8" and larger use 3 grooves.


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Swaged Socket Assemblies(Boom Pendants)In mechanically swaged fittings, high pressure swagers and precision dies cause metal of the socket to flow around wires and strands tooffer the ultimate in compactness and strength with minimum weight.

Normally, only regular lay rope is used. Swaged assemblies are interchangeable with poured sockets up through 2" rope diameters. Assembly length is measured from centerline of pins for both open and closed sockets.

Indicate choice of end fittings on purchase orders by the suffixes “OS” or “CS” after the stock number, for open or closed type fittings. Pins and cotters are supplied as standard on open fittings, but assemblies may be specified without pins. Fittings will be assembled in the same plane unless specified otherwise on the order.

Wire RopeDiameter

(in.)

Closed Swage Socket Dimensions & Data (in.)

A B C D E F H L1/4 4.31 .50 1.38. .75 .27 2.12 .50 3.505/16 5.44 .77 1.62 .88 .34 3.19 .67 4.503/8 5.44 .77 1.62 .88 .41 3.19 .67 4.507/16 6.91 .98 2.00 1.06 .48 4.25 .86 5.751/2 6.91 .98 2.00 1.06 .55 4.25 .86 5.759/16 8.66 1.25 2.38 1.25 .61 5.31 1.13 7.255/8 8.66 1.25 2.38 1.25 .67 5.31 1.13 7.253/4 10.28 1.55 2.88 1.44 .80 6.38 1.31 8.637/8 11.94 1.70 3.12 1.69 .94 7.44 1.50 10.131 13.56 1.98 3.63 2.06 1.06 8.50 1.75 11.50

1-1/8 15.03 2.25 4.00 2.31 1.19 9.56 2.00 12.751-1/4 16.94 2.53 4.50 2.56 1.33 10.63 2.25 14.381-3/8 18.63 2.80 5.00 2.56 1.45 11.69 2.25 15.751-1/2 20.12 3.08 5.50 2.81 1.58 12.75 2.50 17.001-3/4 23.56 3.69 6.25 3.56 1.86 14.88 3.00 20.00

2 27.62 3.94 7.25 3.81 2.11 17.00 3.25 23.00

Wire RopeDiameter

(in.)

Open Swage Socket Dimensions & Data (in.)

A B C D E F H L M N1/4 4.81 .50 1.38 .69 .27 2.13 .69 4.00 .38 1.50

5/16 6.25 .77 1.62 .81 .34 3.19 .81 5.31 .47 1.753/8 6.25 .77 1.62 .81 .41 3.19 .81 5.31 .47 1.75

7/16 7.81 .98 2.00 1.00 .48 4.25 1.00 6.69 .56 2.001/2 7.81 .98 2.00 1.00 .55 4.25 1.00 6.69 .56 2.00

9/16 9.50 1.25 2.38 1.19 .61 5.31 1.25 8.13 .68 2.255/8 9.50 1.25 2.38 1.19 .67 5.31 1.25 8.13 .68 2.253/4 11.56 1.55 2.75 1.38 .80 6.38 1.50 10.00 .78 2.757/8 13.41 1.70 3.13 1.62 .94 7.44 1.75 11.63 .94 3.251 15.47 1.98 3.69 2.00 1.06 8.50 2.00 13.38 1.06 3.75

1-1/8 17.31 2.25 4.06 2.25 1.19 9.56 2.25 15.00 1.19 4.251-1/4 19.06 2.53 4.50 2.50 1.33 10.63 2.50 16.50 1.22 4.751-3/8 20.94 2.80 5.00 2.50 1.45 11.69 2.50 18.13 1.38 5.251-1/2 22.88 3.08 5.50 2.75 1.58 12.75 3.00 19.75 1.69 5.751-3/4 26.63 3.39 6.69 3.50 1.86 14.88 3.50 23.00 2.11 6.75

2 31.44 3.94 8.00 3.75 2.11 17.00 4.00 26.88 2.37 8.00

Rated Capacity—Tons

Wire RopeDiameter

(in.)

6 x 19 & 6 x 36IWRC

EIP EEIP1/4 .68 .74

5/16 1.1 1.23/8 1.5 1.7

7/16 2 2.21/2 2.7 2.9

9/16 3.4 3.75/8 4.1 4.53/4 5.9 6.57/8 8 8.81 10 11

1-1/8 13 141-1/4 16 181-3/8 19 211-1/2 23 251-3/4 31 34

2 40 43


OS-OS CS-CS OS-CS

PinsSamePlane

PinsOpposite

Plane

PinsSamePlane

PinsOpposite

Plane

PinsSamePlane

PinsOpposite

Plane


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Open & Closed Swage Sockets■ Forged from special bar quality carbon steel, suitable for cold forming.■ Hardness controlled by spheroidize annealing.■ Swage Socket terminations have an efficiency rating of 100% based on the catalog strength of wire rope.■ Stamp for identification after swaging without concern for fractures (as per directions in National Swaging Brochure).

Note: S-502 Swage Sockets are recommended for use with 6 x 19 or 6 x 36, IPS or XIP (EIP), XXIP (EEIP), RRL, FC or IWRC wire rope.

S-502 Closed Swage Socket SpecificationsWire

Rope Dia. (in.)

WeightEach (lbs.)

Before Swage Dimensions (in.)

A B C D E F H L1/4 .33 4.31 .50 1.38 .75 .27 2.12 .50 3.50

5/16 .75 5.44 .77 1.62 .88 .34 3.19 .67 4.503/8 .72 5.44 .77 1.62 .88 .41 3.19 .67 4.507/16 1.42 6.91 .98 2.00 1.06 .48 4.25 .86 5.751/2 1.42 6.91 .98 2.00 1.06 .55 4.25 .86 5.75

9/16 2.92 8.66 1.25 2.38 1.25 .61 5.31 1.13 7.255/8 2.85 8.66 1.25 2.38 1.25 .67 5.31 1.13 7.253/4 5.00 10.28 1.55 2.88 1.44 .80 6.38 1.31 8.637/8 6.80 11.94 1.70 3.12 1.69 .94 7.44 1.50 10.131 10.40 13.56 1.98 3.63 2.06 1.06 8.50 1.75 11.50

1-1/8 14.82 15.03 2.25 4.00 2.31 1.19 9.56 2.00 12.751-1/4 21.57 16.94 2.53 4.50 2.56 1.33 10.63 2.25 14.381-3/8 28.54 18.63 2.80 5.00 2.56 1.45 11.69 2.25 15.751-1/2 38.06 20.12 3.08 5.50 2.81 1.58 12.75 2.50 17.001-3/4 51.00 23.56 3.39 6.25 3.56 1.86 14.88 3.00 20.00

2 89.25 27.62 3.94 7.25 3.81 2.11 17.00 3.25 23.00

S-501 Open Swage Socket SpecificationsWire

Rope Dia. (in.)

WeightEach (lbs.)

Before Swage Dimensions (in.)

A B C D E F H L M N1/4 .52 4.81 .50 1.38 .69 .27 2.13 .69 4.00 .38 1.50

5/16 1.12 6.25 .77 1.62 .81 .34 3.19 .81 5.31 .47 1.753/8 1.30 6.25 .77 1.62 .81 .41 3.19 .81 5.31 .47 1.75

7/16 2.08 7.81 .98 2.00 1.00 .48 4.25 1.00 6.69 .56 2.001/2 2.08 7.81 .98 2.00 1.00 .55 4.25 1.00 6.69 .56 2.00

9/16 4.67 9.50 1.25 2.38 1.19 .61 5.31 1.25 8.13 .68 2.255/8 4.51 9.50 1.25 2.38 1.19 .67 5.31 1.25 8.13 .68 2.253/4 7.97 11.56 1.55 2.75 1.38 .80 6.38 1.50 10.00 .78 2.757/8 11.52 13.41 1.70 3.13 1.62 .94 7.44 1.75 11.63 .94 3.251 17.80 15.47 1.98 3.69 2.00 1.06 8.50 2.00 13.38 1.06 3.75

1-1/8 25.25 17.31 2.25 4.06 2.25 1.19 9.56 2.25 15.00 1.19 4.251-1/4 35.56 19.06 2.53 4.50 2.50 1.33 10.63 2.50 16.50 1.22 4.751-3/8 43.75 20.94 2.80 5.00 2.50 1.45 11.69 2.50 18.13 1.38 5.251-1/2 58.50 22.88 3.08 5.50 2.75 1.58 12.75 3.00 19.75 1.69 5.751-3/4 88.75 26.63 3.39 6.69 3.50 1.86 14.88 3.50 23.00 2.11 6.75

2 146.25 31.44 3.94 8.00 3.75 2.11 17.00 4.00 26.88 2.37 8.00

Before using any National Swage fitting with any other type lay, construction or grade of wire rope, it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured.

In accordance with ASME B30.9, all slings terminated with swage sockets shall be proof loaded.


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Forged Wire Rope ClipsG-450 Crosby® Clips ■ Each base has a Product Identification Code (PIC) for material traceability, the name CROSBY or CG, and a size forged into it.■ Based on the catalog breaking strength of wire rope, Crosby wire rope clips have an efficiency rating of 80% for 1/8" - 7/8" sizes, and 90% for sizes 1" through 3-1/2".■ Entire Clip-Galvanized to resist corrosive and rusting action.■ Sizes 1/8" through 2-1/2" and 3" have forged bases.■ All Clips are individually bagged or tagged with proper application instructions and warning information.■ Clip sizes up through 1-1/2" have rolled threads.■ Meets or exceeds all requirements of ASME B30.26 including identification, ductility, design factor, proof load and temperature requirements. Importantly, these wire rope clips meet other critical performance requirements, including fatigue life, impact properties and material traceability, not addressed by ASME B30.26.■ Look for the Red-U-Bolt®, your assurance of Genuine Crosby Clips.

* Electro-plated U-Bolt and Nuts.

** 2-3/4" and 3-1/2" base is made of cast steel.

G-450 Crosby® Clips

Rope Size G-450Stock No.

Std.Package

Qty.

WeightPer 100

(lbs.)

Dimensions (in.)

in. mm A B C D E F G H1/8 * 3-4 * 1010015 100 6 .22 .72 .44 .47 .37 .38 .81 .99

3/16 * 5 * 1010033 100 10 .25 .97 .56 .59 .50 .44 .94 1.181/4 6-7 1010051 100 19 .31 1.03 .50 .75 .66 .56 1.19 1.43

5/16 8 1010079 100 28 .38 1.38 .75 .88 .73 .69 1.31 1.663/8 9-10 1010097 100 48 .44 1.50 .75 1.00 .91 .75 1.63 1.94

7/16 11 1010113 50 78 .50 1.88 1.00 1.19 1.13 .88 1.91 2.281/2 12-13 1010131 50 80 .50 1.88 1.00 1.19 1.13 .88 1.91 2.28

9/16 14-15 1010159 50 109 .56 2.25 1.25 1.31 1.34 .94 2.06 2.505/8 16 1010177 50 110 .56 2.25 1.25 1.31 1.34 .94 2.06 2.503/4 18-20 1010195 25 142 .62 2.75 1.44 1.50 1.39 1.06 2.25 2.847/8 22 1010211 25 212 .75 3.12 1.62 1.75 1.58 1.25 2.44 3.161 24-26 1010239 10 252 .75 3.50 1.81 1.88 1.77 1.25 2.63 3.47

1-1/8 28-30 1010257 10 283 .75 3.88 2.00 2.00 1.91 1.25 2.81 3.591-1/4 32-34 1010275 10 438 .88 4.44 2.22 2.34 2.17 1.44 3.13 4.131-3/8 36 1010293 10 442 .88 4.44 2.22 2.34 2.31 1.44 3.13 4.191-1/2 38 1010319 10 544 .88 4.94 2.38 2.59 2.44 1.44 3.41 4.441-5/8 41-42 1010337 Bulk 704 1.00 5.31 2.62 2.75 2.66 1.63 3.63 4.751-3/4 44-46 1010355 Bulk 934 1.13 5.75 2.75 3.06 2.92 1.81 3.81 5.24

2 48-52 1010373 Bulk 1300 1.25 6.44 3.00 3.38 3.03 2.00 4.44 5.882-1/4 56-58 1010391 Bulk 1600 1.25 7.13 3.19 3.88 3.19 2.00 4.56 6.382-1/2 62-65 1010417 Bulk 1900 1.25 7.69 3.44 4.13 3.69 2.00 4.69 6.63

** 2-3/4 ** 68-72 1010435 Bulk 2300 1.25 8.31 3.56 4.38 4.88 2.00 5.00 6.883 75-78 1010453 Bulk 3100 1.50 9.19 3.88 4.75 4.44 2.38 5.31 7.61

** 3-1/2 ** 85-90 1010426 Bulk 4000 1.50 10.75 4.50 5.50 6.00 2.38 6.19 8.38

Crosby Clips, all sizes 1/4" and larger, meet the performance requirements of Federal Specification FF-C-450 TYPE 1 CLASS 1, except for those provisions

required of the contractor.


SS-450 Stainless Steel Wire Rope Clips

Rope Size SS-450Stock No.

Std.Package

Qty.

WeightPer 100

(lbs.)

Dimensions (in.)

(in.) (mm) A B C D E F G H1/8 3-4 1011250 Bulk 6 .22 .72 .44 .47 .41 .38 .81 .99

3/16 5 1011261 Bulk 10 .25 .97 .56 .59 .50 .44 .94 1.161/4 6-7 1011272 Bulk 20 .31 1.03 .50 .75 .66 .56 1.19 1.443/8 9-10 1011283 Bulk 47 .44 1.50 .75 1.00 .91 .745 1.63 1.941/2 12-13 1011305 Bulk 77 .50 1.88 1.00 1.19 1.13 .88 1.91 2.285/8 16 1011327 Bulk 106 .56 2.38 1.25 1.31 1.34 .94 2.06 2.50

SS-450 Stainless Steel Wire Rope Clips ■ Each base has a Product Identification Code (PIC) for material traceability, the name CROSBY or “CG”, and a size forged into it.■ Entire clip is made from 316 Stainless Steel to resist corrosive and rusting action.■ All components are Electro-Polished.■ All Clips are individually bagged or tagged with proper application instructions and warning information.

SS-450

G-450


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Fist Grip® Wire Rope Clips■ Entire clip is Galvanized to resist corrosive and rusting action.■ Based on the catalog breaking strength of wire rope, Crosby wire rope clips have an efficiency rating of 80% for 3/16"— 7/8" sizes, and 90% for sizes 1" through 1-1/2".■ Bolts are an integral part of the saddle. Nuts can be installed in such a way as to enable the operator to swing the wrench in a full arc for fast installation.■ All sizes have forged steel saddles.■ All Clips are individually bagged or tagged with proper application instructions and warning information.■ Meets or exceeds all requirements of ASME B30.26 including identification, ductility, design factor, proof load and temperature requirements. Importantly, these wire rope clips meet other critical performance requirements, including fatigue life, impact properties and material traceability, not addressed by ASME B30.26.■ Assembled with standard heavy hex nuts.

Fist Grip® wire clips meet or exceed the performance requirements of Federal Specification FF-C-450 Type III, Class 1, except for those

provisions required of the contractor.

* Sizes through 5/8" incorporate New Style Design.


G-429 Fist Grip® Clips

Rope Size G-429Stock No.

Std.Package

Qty.

WeightPer 100

(lbs.)

Dimensions (in.)

in. mm C D E G N3/16 - 1/4 5-7 1010471 100 23 .40 .94 .38 1.41 1.44

5/16 8 1010499 100 28 .47 1.06 .38 1350 1.543/8 10 1010514 50 40 .51 1.06 .44 1.84 1.78

7/16 - 1/2 11 - 13 1010532 50 62 .59 1.25 .50 2.21 2.159/16 - 5/8 14 - 16 1010550 50 103 .72 1.50 .63 2.72 2.57

3/4 18 - 20 1010578 25 175 .86 1.81 .75 2.94 2.677/8 22 1010596 25 225 .97 2.12 .75 3.31 2.861 24 - 26 1010612 10 300 1.13 2.25 .75 3.72 3.06

1-1/8 28 - 30 1010630 10 400 1.28 2.38 .88 4.22 3.441-1/4 32 - 34 1010658 10 400 1.34 2.50 .88 4.25 3.56

1-3/8 to 1-1/2 36 - 40 1010676 Bulk 700 1.56 3.00 1.00 5.56 4.12

NEW STYLEFIST GRIP® CLIPS

3/16" - 5/8"FIST GRIP® CLIPS

3/4" - 1-1/2"


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S-421T Wedge Socket■ Wedge socket terminations have an efficiency rating of 80% based on the catalog strength of XXIP wire rope. ■ Meets or exceeds all requirements of ASME B30.26 including identification, ductility, design factor, proof load and temperature requirements. Importantly, these sockets meet other critical performance requirements, including fatigue life, impact properties and material traceability, not addressed by ASME B30.26.■ Type Approval and certification in accordance with ABS 2006 Steel Vessel Rules.1-1-17.7, and ABS Guide for Certification of Cranes.■ Basket is cast steel and individually magnetic particle inspected.■ Pin diameter and jaw opening allows wedge and socket to be used in conjunction with closed swage and spelter sockets.■ Secures the tail or “dead end” of the wire rope to the wedge, thus eliminates loss or “Punch out” of the wedge.■ Eliminates the need for an extra piece of rope, and is easily installed.■ The TERMINATOR™ wedge eliminates the potential breaking off of the tail due to fatigue.■ The tail, which is secured by the base of the clip and the wedge, is left undeformed and available for reuse.■ Incorporates Crosby’s patented QUIC-CHECK® “Go” and “No-Go” feature cast into the wedge. The proper size rope is determined when the following criteria are met: 1. The wire rope should pass thru the “Go” hole in the wedge. 2. The wire rope should NOT pass thru the “No-Go” hole in the wedge.

* Nominal Note: For intermediate wire rope sizes, use next larger size socket. The S-423T Super TERMINATORTM wedge is designed to be assembled only into the Crosby S-421T TERMINATORTM socket body.

IMPORTANT: The S-423TW for sizes 5/8" through 1-1/8" (14mm through 28mm) will fit respective size standard Crosby S-421T basket.

The 1-1/4" (30-32mm) S-423TW will only fit the Crosby S-421T 1-1/4" basket marked with “ TERMINATORTM ”.

Wire RopeDiameter S-421T

StockNo.

WeightEach(lbs.)

S-421TWStock No.

Wedge Only

Wedge OnlyWeightEach(lbs.)

Optional G-4082Bolt, Nut & Cotter

G-4082 Stock No.

Weight Each (lbs.)(in.) (mm)

3/8 9-10 1035000 3.18 1035555 .50 1092227 .381/2 11-13 1035009 6.15 1035564 1.05 1092236 .695/8 14-16 1035018 9.70 1035573 1.79 1092254 1.153/4 18-19 1035027 14.50 1035582 2.60 1092281 1.917/8 20-22 1035036 21.50 1035591 4.00 1092307 3.231 24-26 1035045 30.75 1035600 5.37 1092325 5.40

1-1/8 28 1035054 45.30 1035609 7.30 1092343 7.501-1/4 30-32 1035063 64.90 1035618 10.60 1092372 10.34

■ Utilizes standard Crosby Red-U-Bolt® wire rope clip.■ The 3/8" thru 1-1/8" standard S-421 wedge socket can be retrofitted with the new style TERMINATOR™ wedge.■ Available with Bolt, Nut and Cotter Pin.■ U.S. patent 5,553,360, Canada patent 2,217,004 and foreign equivalents.■ Meets the performance requirements of EN 13411-6: 2003.■ Assembly includes Socket, Wedge, Pin and Wire Rope Clip

Wire RopeDiameter S-421T

Stock No.

Dimensions(inches)

(in.) (mm) A B C D G H J* K* L P R S T U V3/8 9-10 1035000 5.69 2.72 .81 .81 1.38 3.06 7.80 1.88 .88 1.56 .44 2.13 .44 1.25 1.381/2 11-13 1035009 6.88 3.47 1.00 1.00 1.62 3.76 8.91 1.26 1.06 1.94 .50 2.56 .53 1.75 1.885/8 14-16 1035018 8.25 4.30 1.25 1.19 2.12 4.47 10.75 1.99 1.22 2.25 .56 3.25 .69 2.00 2.193/4 18-19 1035027 9.88 5.12 1.50 1.38 2.44 5.28 12.36 2.41 1.40 2.63 .66 3.63 .78 2.34 2.567/8 20-22 1035036 11.25 5.85 1.75 1.63 2.69 6.16 14.37 2.48 1.67 3.13 .75 4.31 .88 2.69 2.941 24-26 1035045 12.81 6.32 2.00 2.00 2.94 6.96 16.29 3.04 2.00 3.75 .88 4.70 1.03 2.88 3.28

1-1/8 28 1035054 14.38 6.92 2.25 2.25 3.31 7.62 18.34 2.26 2.25 4.25 1.00 5.44 1.10 3.25 3.561-1/4 30-32 1035063 16.34 8.73 2.62 2.50 3.56 9.39 20.48 2.94 2.34 4.50 1.06 6.13 1.19 4.62 4.94

Wedge sockets meet the performance requirements of Federal Specification RR-S-550D, Type C, except those provisions required of the contractor.



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S-423T Super TerminatorTM Wedge Socket■ Wedge socket terminations have a minimum efficiency rating on most high performance, high strength, compacted strand, rotation resistant wire ropes of 80% based on the catalog breaking strength of the various ropes. **■ Patent Pending design eliminates the difficulty of installing high performance wire rope into a wedge socket termination.■ Proper application of the Super TERMINATOR™ eliminates the “first load” requirement of conventional wedge socket terminations.■ S-423TW Wedge Kit can be retrofitted onto existing Crosby S-421T TERMINATOR™ wedge sockets.■ Wedge and accessories provided with a zinc finish.■ Meets the performance requirements of EN13411-6:2003.■ Meets or exceeds all requirements of ASME B30.26 including identification, ductility, design factor, proof load and temperature requirements. Importantly, these sockets meet other critical performance requirements, including fatigue life, impact properties and material traceability, not addressed by ASME B30.26.■ Basket is cast steel and individually magnetic particle inspected.■ Pin diameter and jaw opening allows wedge and socket to be used in conjunction with closed swage and spelter sockets.■ Secures the tail or “dead end” of the wire rope to the wedge, thus eliminates loss or “punch out” of the wedge.■ Eliminates the need for an extra piece of rope, and is easily installed.■ The TERMINATOR™ wedge eliminates the potential breaking off of the tail due to fatigue.■ The tail, which is secured by the base of the clip and the tension device, is left undeformed and available for reuse.

Wedge sockets meet the performance requirements of Federal Specification RR-S-550D, Type C, except those provisions required of the contractor.

Meets the performance requirements of EN13411-6:2003.

■ Available with Bolt, Nut and Cotter Pin. ■ Assembly includes Socket, Wedge, Pin, Wire Rope Clip, Tensioner, Bolts and Secondary Retention Wire.

** NOTICE: Due to the unique construction of various ropes, Crosby cannot make a broad general statement that all current and future design of ropes, when properly assembled with the Super TERMINATORTM, will achieve a minimum 80% termination efficiency. Contact wire rope manufacturer or Crosby Engineering (918-834-4611) to determine efficiency rating for a specific rope.

* Nominal Note: For intermediate wire rope sizes, use next larger size socket. The S-423T Super TERMINATORTM wedge is designed to be assembled only into the Crosby S-421T TERMINATORTM socket body.

IMPORTANT: The S-423TW for sizes 5/8" through 1-1/8" (14mm through 28mm) will fit respective size standard Crosby S-421T basket.

The 1-1/4" (30-32mm) S-423TW will only fit the Crosby S-421T 1-1/4" basket marked with “ TERMINATORTM ”.

Wire RopeDiameter

S-423T Assembly with Round Pin and Cotter Pin

S-423TB Assembly with Bolt, Nut and Cotter Pin

S-423TW **Wedge Kit

(in) (mm) S-423TStock No.

S-423T Weight Each S-423TBStock No.

S-423TB Weight Each S-423TWStock No.

S423TW Weight Eachlbs. kg lbs. kg lbs. kg

5/8 14-16 1035123 12.7 5.8 1035218 13.1 5.9 1034018 5.2 2.43/4 18-19 1035132 19.4 8.8 1035227 19.1 8.7 1034027 7.2 3.37/8 20-22 1035141 28.8 13.1 1035236 27.8 12.6 1034036 10.3 4.71 24-26 1035150 39.2 17.8 1035245 37.3 16.9 1034045 11.9 5.4

1-1/8 28 1035169 57.1 25.9 1035254 57.9 25.9 1034054 19.9 9.01-1/4 30-32 1035178 88.6 40.2 1035272 88.1 39.9 1034063 33.8 15.3

Wire RopeDiameter

S-421TStock No.

Dimensions(inches)

(in) (mm) A B C D G F G H J * L P R S T U V5/8 14-16 1035123 8.25 4.50 1.25 1.19 3.00 4.06 2.13 4.61 12.31 1.22 2.25 .56 3.25 .75 6.88 2.603/4 18-19 1035132 9.88 5.20 1.50 1.38 3.25 4.81 2.44 5.37 14.69 1.40 2.62 .66 3.63 .88 7.65 3.027/8 20-22 1035141 11.25 5.88 1.75 1.63 3.81 5.73 2.69 6.16 16.98 1.67 3.13 .75 4.31 1.00 9.47 3.471 24-26 1035150 12.81 6.56 2.00 2.00 3.81 5.73 2.94 7.05 18.54 2.01 3.75 .88 4.70 1.13 10.41 3.82

1-1/8 28 1035169 14.38 6.94 2.25 2.25 4.00 6.85 3.38 7.81 21.23 2.26 4.25 1.00 5.44 1.25 11.83 4.221-1/4 30-32 1035178 16.34 8.63 2.62 2.50 4.50 7.76 3.57 9.38 24.10 2.34 4.50 1.06 6.62 1.38 13.87 5.82

** Kit contains Wedge, Wire Rope Clip and Bolts, Tensioner, Tensioner Bolt and Secondary Retention Wire.



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Threaded SleeveWhen you want to maximize the length adjustment of your assembly at the point where a wire rope is attached, the threaded sleeve is ideal.

The sleeve is made to meet your requirements. The standard sleeve material is carbon steel, but stainless steels and higher strength steels are also available on request.

We furnish the sleeves without wrench flats unless specified on the order.

You should also measure the length of the assembly,using the maximum dimensions (from the outside end of the sleeve).

To determine the thread length (TL), use the minimum dimensions needed. This allows us to use existing qualified designs. The standard thread used is Right Hand National Course Class 2A, but other threads are available on request.

You may order custom designs with different fitting lengths if you want, but that may reduce the assembly’s overall rated capacity. Call our Customer Service Department to evaluate all the possibilities.

Wire RopeDiameter

ThreadLength (TL) Thread

UNCThread

UNC

Wrench Flat(Optional)

After Swage(AS) Diameter

LengthB

in. in. in. in. in.3/32 * .75 1/4" - 20 1/4" - 20 7/32" x 1/4" .25 1.251/8* .75 1/4" - 20 1/4" - 20 7/32" x 1/4" .25 1.25

5/32 * 1 5/16" - 18 5/16" - 24 9/32" x 1/4" .3125 1.53/16 * 1.25 3/8" - 16 3/8" - 24 11/32" x 1/4" .375 1.757/32 * 1.75 7/16" - 14 7/16" - 20 3/8" x 3/8" .4375 2.381/4 * 1.75 1/2" - 13 1/2" - 20 7/16" x 3/8" .5 2.389/32 1.75 9/16" - 12 9/16" - 18 1/2" x 3/8" .5625 2.505/16 2.50 5/8" - 11 5/8" - 18 9/16" x 1/2" .625 3.253/8 3 3/4" - 10 3/4" - 16 11/16" x 1/2" .75 3.75

7/16 3.25 7/8" - 9 7/8" - 14 13/16" x 1/2" .875 41/2 3.75 1" - 8 1" x 14 7/8" x 1/2" 1 4.59/16 4 1-1/8" - 7 1-1/8" - 12 1" x 3/4" 1.125 55/8 5 1-1/4" - 7 1-1/4" - 12 1-1/8" x 3/4" 1.25 63/4 5.75 1-1/2" - 6 1-1/2" - 12 1-3/8" x 1" 1.5 77/8 6.75 1-3/4" - 5 1-3/4" - 12 1-5/8" x 1" 1.75 81 7.75 2" - 4.5 2" - 12 1-7/8" x 1-1/4" 2 9.25

* Galvanized Aircraft Cable


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Threaded StudWhen your application requires a simple threaded assembly, the threaded stud is the most economical choice. You can depend on the tolerances with this assembly.

Materials available:

■ Carbon Steel (standard)■ Stainless Steel■ Higher Strength Steels■ Zinc Plating, also available

We furnish the studs without wrench flats unlessspecified on the order.

When measuring the thread length, use the minimum dimensions to make use of existing qualified designs.

Thread length may be increased if desired. The standard thread used is Right Hand National Course Class 2A, but other threads are available on request.

The B and A fitting dimensions are needed, alongwith the maximum length of the assembly measuredusing the outside end of the stud.

Custom designs with different fitting lengths andthread diameters are available, but that may reducethe assembly’s ultimate rated capacity. Pleasecheck with our Customer Service Department.

Wire RopeDiameter

ThreadLength C Thread

Wrench Flat(Optional)

After SwageA

LengthB

in. in. in. in. in.3/32 * 3 1/4" - 20 3/16" x 3/16" .22 4.251/8* 3 1/4" - 20 3/16" x 3/16" .22 4.25

5/32 * 6 5/16" - 18 7/32" x 1/4" .25 7.633/16 * 6 3/8" - 16 9/32" x 1/4" .31 7.887/32 * 6 7/16" - 14 11/32" x 3/8" .38 8.751/4* 6 1/2" - 13 3/8" x 1/2" .44 99/32 6 9/16" - 12 7/16" x 1/2" .5 9.55/16 6 5/8" - 11 1/2" x 1/2" .56 9.753/8 6 3/4" - 10 9/16" x 1/2" .63 10.25

7/16 6 7/8" - 9 11/16" x 1/2" .75 111/2 6 1" - 8 3/4" x 1/2" .875 11.59/16 6 1-1/8" - 7 7/8" x 1/2" 1 12.255/8 6 1-1/4" - 7 1" x 1/2" 1.13 12.753/4 6 1-1/2" - 6 1-1/8" x 3/4" 1.25 14.257/8 7 1-3/4" - 5 1-3/8" x 3/4" 1.5 16.51 8 2" - 4.5 1-5/8" x 1" 1.75 19

1-1/8 9 2-1/4" - 4.5 1-7/8" x 1" 2 21.51-1/4 10 2-1/2" - 4 2-1/8" x 1" 2.25 24

* Galvanized Aircraft Cable


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Single Shank Ball MS 20664—Corrosion Resistant Specifications

Part Number

Cable Dia.

ADia.

AsDia.

BDia.

Bs Sphere

Dia.Cs D

E Rad Ref

L N Dia.

MS Max Rad

Lbs. Per

Piecein. in. in. in. in. in. in. in. in. in. in.MS20663C2 1/16 .132 .112 .212 .190 .156 .114 .0825 .2685 .073 .014 .0019MS20664C3 3/32 .168 .143 .282 .253 .234 .152 .110 .384 .104 .019 .005MS20663C4 1/8 .223 .190 .350 .315 .313 .1895 .137 .500 .139 .023 .0075MS20664C5 5/32 .259 .222 .424 .379 .391 .227 .165 .616 .169 .028 .01MS20664C6 3/16 .298 .255 .492 .442 .469 .264 .192 .730 .201 .033 .015MS20664C7 7/32 .352 .302 .560 .505 .547 .3025 .220 .846 .233 .038 .025MS20664C8 1/4 .406 .348 .629 .567 .625 .3395 .247 .962 .264 .042 .03MS20664C9 9/32 .444 .382 .699 .632 .750 .3775 .275 1.078 .297 .046 .05MS20664C10 5/16 .480 .413 .768 .694 .813 .4145 .302 1.193 .328 .046 .066

Wire Rope TerminalsPlain Ball BA3—Corrosion Resistant Specifications

Part Number

Cable Dia. A B C D E

Sphere Dia.

F

Min Breaking Strength

Lbs.

Lbs. Per

Piecein. in. in. in. in. in. in.

BA3-1 1/32 .211 .035 .141 .026 .083 .1905 60 .002.208 .038 .137 .016 .073 .1875

BA3-2 1/16 .211 .076 .141 .026 .083 .1905 385 .0017.208 .073 .137 .016 .073 .1875

BA3-3 3/32 .288 .106 .174 .041 .099 .253 735 .004.284 .102 .170 .031 .089 .250

BA3-4 1/8 .355 .143 .190 .041 .142 .317 1,200 .006.351 .139 .184 .031 .132 .312

BA3-5 5/32 .429 .175 .227 .041 .170 .380 1,680 .009.425 .171 .220 .031 .160 .375

BA3-6 3/16 .498 .207 .264 .041 .197 .442 2,520 .01.493 .203 .259 .031 .187 .437

Double Shank Ball MS 20663 —Corrosion Resistant Specifications

Part Number

Cable Dia.

ADia.

AsDia.

BDia.

Bs Sphere

Dia.D L

± .0075Ls

RefN

Dia.

RS Max Rad

Lbs. Per

Piecein. in. in. in. in. in. in. in. in. in.MS20663C2 1/16 .127 .112 .207 .190 .114 .362 .390 .073 .014 .0016MS20663C3 3/32 .163 .143 .277 .253 .152 .525 .578 .104 .019 .0032MS20663C4 1/8 .218 .190 .345 .315 .1895 .688 .765 .139 .023 .0094MS20663C5 5/32 .254 .222 .419 .379 .227 .850 .953 .169 .028 .0125MS20663C6 3/16 .293 .255 .487 .442 .264 1.012 1.140 .201 .033 .025MS20663C7 7/32 .347 .302 .555 .505 .3025 1.175 1.328 .233 .038 .032MS20663C8 1/4 .401 .348 .624 .567 .3395 1.337 1.515 .264 .042 .040MS20663C9 9/32 .439 .382 .694 .632 .3775 1.497 1.7119 .297 .046 .042

MS20663C10 5/16 .475 .413 .763 .694 .4145 1.664 1.875 .328 .046 .043


742








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Wire Rope Terminals (Continued)

Fork End MS 20667—Corrosion Resistant Specifications

Part Number

Cable Dia.

ADia.

AsDia.

DDia.

F +.010 -.005

G ± .003 H

L +.020 -.000

Ls Ref

NDia.

UDia.

ZMin

Lbs. Per

Piecein. in. in. in. in. in. in. in. in. in. in. in.MS20667-2 1/16 .160 .138 .190 .218 .093 .500 1.572 1.75 .078 .344 .600 .01MS20667-3 3/32 .218 .190 .190 .254 .108 .670 1.945 2.06 .109 .438 .757 .02MS20667-4 1/8 .250 .219 .190 .383 .195 .735 2.352 2.61 .141 .547 .914 .0325MS20667-5 5/32 .297 .250 .250 .406 .202 .800 2.665 3.00 .172 .688 .967 .05MS20667-6 3/16 .359 .313 .313 .543 .260 .880 3.071 3.24 .203 .781 1.133 .09MS20667-7 7/32 .427 .375 .313 .625 .296 .970 3.440 3.74 .234 .906 1.252 .15MS20667-8 1/4 .494 .438 .375 .688 .313 1.070 3.806 4.10 .265 .969 1.368 .20MS20667-9 9/32 .563 .500 .438 .719 .327 1.170 4.120 4.48 .297 1.156 1.432 .30MS20667-10 5/16 .635 .563 .438 .765 .348 1.268 4.438 4.86 .328 1.265 1.5 .3812MS20667-12 3/8 .703 .625 .500 .830 .380 1.525 5.033 5.74 .390 1.5 1.895 .575MS20667-14 7/16 .781 .688 .562 .830 .380 1.776 6.402 6.57 .468 1.75 2.164 .775MS20667-16 1/2 .844 .750 .625 1.035 .473 1.903 6.938 7.50 .531 1.875 2.313 1.625

Terminal—Cylindrical ST 24 Specifications

PartNumber

CableDia. A B C D C=As Die

Size Lbs. PerPiecein. in. in. in. in. in. in.

ST24-2 1/16 .224 .221 .190 .076 .190 3/32 .0019.214 .217 .185 .073

ST24-3 3/32 .333 .252 .219 .107 .219 1/8 .005.323 .248 .214 .104

ST24-4 1/8 .416 .298 .250 .146 .250 5/32 .0075.406 .294 .245 .141

ST24-5 5/32 .510 .377 .313 .177 .313 3/16 .01.500 .373 .303 .172

ST24-6 3/16 .635 .439 .315 .208 .375 7/32 .114.625 .435 .370 .203

Strap Fork Ends—Corrosion Resistant—MIL Spec. NAS 1435-K Specifications

PartNumber

NAS Number

CableDia. A B C D E F Lbs.

PerPiecein. in. in. in. in. in. in.

SP 2-2 NAS 1435K-2 1/16 1-1/16 .454 .188 .042 3/8 .093 .006SP 2-3 NAS 1435K-3 3/32 1-1/2 .616 .188 .049 7/16 .108 .013SP 2-4 NAS 1435K-4 1/8 1-5/8 .638 .188 .093 1/2 .195 .303SP 2-5 NAS 1435K-5 5/32 1-31/32 .699 .25 .096 9/16 .202 .042SP 2-6 NAS 1435K-6 3/16 2-3/16 .75 .313 .125 11/16 .260 .083

Strap Eyes—Corrosion Resistant—MIL Spec. NAS 1435-E Specifications

PartNumber

NAS Number

CableDia. A B C D E Lbs. Per

Piecein. in. in. in. in. in.

SP 2-2 NAS 1435K-2 1/16 1-1/16 .454 .188 .042 3/8 .006SP 2-3 NAS 1435K-3 3/32 1-1/2 .616 .188 .049 7/16 .013SP 2-4 NAS 1435K-4 1/8 1-5/8 .638 .188 .093 1/2 .303SP 2-5 NAS 1435K-5 5/32 1-31/32 .699 .25 .096 9/16 .042SP 2-6 NAS 1435K-6 3/16 2-3/16 .75 .313 .125 11/16 .083

Also known as “Stop Buttons”, “Sleeves”, “Boeing Buttons”, these Stainless Steel Terminals have had a multitude of uses. When properly applied, they will hold the breaking strength of the wire rope.


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Eye End MS 20668—Corrosion Resistant Specifications

Part Number

Cable Dia.

ADia.

AsDia.

C ± .020

DDia. J

L +.020 -.000

Ls Ref

NDia. P

U+.025 -.010Dia.

Y ZMin

Lbs. Per

Piecein. in. in. in. in. in. in. in. in. in. in. in. in.

MS20668-2 1/16 .160 .138* .523 .190 .088 1.631 1.809 .078 1.042 .359 .072 .662 .009MS20668-3 3/32 .218 .190* .707 .190 .103 2.043 2.160 .109 1.261 .438 .092 .856 .018MS20668-4 1/8 .250 .219* .738 .190 .190 2.337 2.593 .141 1.511 .500 .103 .900 .035MS20668-5 5/32 .297 .250* .831 .250 .197 2.684 3.029 .172 1.761 .640 .131 .997 .050MS20668-6 3/16 .359 .313* .903 .313 .255 3.019 3.187 .203 2.011 .781 .155 1.082 .090MS20668-7 7/32 .427 .375** 1.007 .313 .291 3.382 3.678 .234 2.261 .813 .187 1.195 .135MS20668-8 1/4 .494 .438** 1.133 .375 .307 3.763 4.062 .265 2.511 .968 .221 1.326 .200MS20668-9 9/32 .563 .500*** 1.257 .438 .322 4.153 4.512 .297 2.761 1.109 .251 1.465 .250MS20668-10 5/16 .635 .563*** 1.373 .438 .343 4.546 4.969 .328 3.011 1.218 .281 1.609 .400MS20668-12 3/8 .703 .625*** 1.688 .500 .375 5.562 5.968 .390 3.511 1.50 .320 2.124 .575MS20668-14 7/16 .781 .688*** 1.968 .562 .375 6.398 6.867 .468 4.011 1.75 .350 2.460 .790MS20668-16 1/2 .844 .750**** 2.115 .625 .468 7.323 7.886 .531 4.698 1.875 .406 2.698 1.050

Wire Rope Terminals (Continued)

* +.000 / -.005** +.000 / -.007

*** +.000 / -.008**** +.000 / -.009

Clevis Pins PI 1 —Corrosion Resistant Specifications

PartNumber

Fits MS No. Indicated

CableDia. A B C D E L F Lbs.

PerPiecein. in. in. in. in. in. in. in.

P11-2 MS-20667-2 1/16 3/16 1/4 3/64 3/64 .076 25/64 9/32 .004P11-3 MS-20667-3 3/32 3/16 1/4 3/64 3/64 .076 25/64 9/32 .004P11-4 MS-20667-4 1/8 3/16 5/16 3/64 3/64 .076 17/32 13/32 .005P11-5 MS-20667-5 5/32 1/4 3/8 1/16 1/16 .076 17/32 13/32 .009P11-6 MS-20667-6 3/16 5/16 7/16 1/16 5/64 .106 23/32 9/16 .017P11-7 MS-20667-7 7/32 5/16 7/16 1/16 5/64 .106 7/8 11/16 .020P11-8 MS-20667-8 1/4 3/8 1/2 3/32 5/64 .106 31/32 13/16 .033P11-9 MS-20667-9 9/32 7/16 9/16 1/8 3/32 .106 1-3/32 7/8 .040

P11-10 MS-20667-10 5/16 7/16 9/16 1/8 3/32 .106 1-3/32 7/8 .040P11-12 MS-20667-12 3/8 1/2 5/8 5/32 7/64 .140 1-1/4 1 .050

Cotter Pin SpecificationsPart Number A (in.) B (in.) C (in.)

PI 5-1 .062 .75 1/8PI 5-2 .093 1.00 3/16

Marine Eye EY1—Corrosion Resistant Steel Specifications

Part Number

Cable Dia.

C+.460 -.065

D+.010 -.010

E+.000 -.005

F +.006 -.000

J±

1/32L P

U +.041 -.078

AfterSwage

ES+.042-.079

AfterSwage

LSRef

Lbs. Per

Piece

in. in. in. in. in. in. in. in. in. in. in.EY1-2 1/16 .500 .264 .160 .078 .218 1.50 1.063 .594 .138 1.809 .015EY1-3 3/32 .500 .264 .218 .109 .218 1.758 1.188 .594 .190 2.070 .028EY1-4 1/8 .500 .264 .250 .141 .218 2.088 1.50 .594 .219 2.401 .033EY1-5 5/32 .580 .327 .297 .172 .281 2.355 1.688 .75 .25 2.709 .055EY1-6 3/16 .710 .389 .359 .201 .359 2.750 2 .875 .313 3.147 .090EY1-7 7/32 .800 .452 .427 .228 .406 3.220 2.313 1 .375 3.787 .015EY1-8 1/4 .900 .514 .494 .265 .468 3.625 2.5 1.125 .438 4.282 .025EY1-9 9/32 .990 .514 .563 .295 .468 3.795 2.688 1.125 .500 4.514 .330EY1-10 5/16 1.080 .640 .635 .325 .593 4.495 3.25 1.375 .563 5.274 .50EY1-12 3/8 1.150 .640 .703 .390 .593 4.930 3.5 1.375 .625 5.659 .670EY1-14 7/16 1.240 .765 .781 .468 .719 6.375 4.125 1.625 .688 6.750 1EY1-16 1/2 1.290 .890 .844 .531 .844 7.375 4.750 1.875 .750 7.187 1.25


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Copper Oval & Copper Stop Sleeves

Copper Oval Sleeves

CableSize

Nicopress OvalSleeve Stock No. Nicopress

Hand ToolStock No.

Approx.Weight Per

1000 Sleeves(lbs.)

SleeveLength BeforeCompressed

Approx.

SleeveLength AfterCompressed

Approx.Plain

CopperZinc-Plated

Copper1/32" 17-1-B 27-1-B 17-BA * 0.6 1/4" 5/16"3/64" 18-11-B4 28-11-B4 51-B4-887 2 3/8" 7/16"1/16" 18-2-C 28-1-C 51-C-887 3 3/8" 7/16"3/32" 18-2-G 28-2-G 51-G-887 5 3/8" 7/16"1/8" 18-3-M 28-3-M 51-M-850 17 9/16" 3/4"5/32" 18-4-P 28-4-P 51-P-850 23 5/8" 7/8"3/16" 18-6-X 28-6-X 51-X-850 49 15/16" 1-3/16"7/32" 18-8-F2 28-8-F2 51-F2-850 56 7/8" 1-1/16"1/4" 18-10-F6 28-10-F6 3-F6-950 80 1-1/8" 1-1/2"

5/16" 18-13-G9 28-13-G9 3-G9-950 114 1-1/16" 1-3/8"No. 635 Hydraulic Tool Dies

3/8" 18-23-H5 18-23-H5 Oval H5 153 1-1/4" 1-5/84"7/16" 18-24-J8 18-24-J8 J8H6 302 1-3/4" 2-5/16"1/2" 18-25-K8 18-25-K8 Oval K8 410 1-7/8" 2-1/2"

9/16" 18-27-M1 18-27-M1 Oval M1 551 2" 2-5/8"5/8" 18-28-N5 18-28-N5 Oval N5 802 2-3/8" 3-1/8"

Copper Stop Sleeves

CableSize

NicopressStop SleeveStock No.

NicopressHand ToolStock No.

OutsideDiameterof Sleeve

Approx.Weight Per

1000 Sleeves(lbs.)

SleeveLength BeforeCompressed

Approx.

Typical HoldingStrength ofStop Sleeve

(lbs.) **1/32" 871-32-B 17-BA * 1/8" 3/4 1/4" 1203/64" 871-12-B4 51-B4-887 11/64" 1-1/2 7/32" 2401/16" 871-1-C 51-C-887 13/64" 2 7/32" 4301/16" 871-1-Q *** 51-q929 1/4" 2 5/32" 4253/32" 871-17-J (Yellow) 51-MJ 21/64" 8 5/16" 6003/32" 871-3-Q *** 51-Q-929 1/4" 2 5/32" 551/8" 871-18-J (Red) 51-MJ 21/64" 8 5/16" 900

5/32" 871-19-M 51-MJ 27/64" 13 5/16" 12003/16" 871-20-M (Black) 51-MJ 27/64" 12 5/16" 16007/32" 871-22-M 51-MJ 7/16" 20 5/8" 25001/4" 871-23-F6 3-F6-950 21/32" 60 11/16" 35005/16" 871-26-F6 3-F6-950 21/32" 60 11/16" 4000

NicopressOval Sleeve

FinishedEye Splice

NicopressStop Sleeve

Finished Stop

* Formerly 17-1 Tool** Holding strengths shown are based on use of galvanized aircraft cable.*** Electro Galvanized Steel Sleeves


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Nickel PlatedCopper Oval Sleeves

Stainless Steel Oval Sleeves

CableSize

NicopressOval Sleeve

StockNumber

Nicopress ToolsWeight(lbs.)

Per 1000SleevesApprox.

SleeveLengthBefore

Compres-sion

Approx.

SleeveLengthAfter

Compres-sion

Approx.

Single Groove

Hand ToolStock

Number

Multi-Groove

Hand ToolStock

Number

Number 635HydraulicTool Die

3/64" 428-1.5-VB4 51-B4-887 33V-CGB4 Oval B4 2 3/8" 7/16"

1/16" 428-25-VC 51-C-887 33V-CGB4 or 64-CGMP Oval C 3 3/8" 7/16"

3/32" 428-3-VG 51-G-887 33V-CGB4 or 64-CGMP Oval G9 6 3/8" 7/16"

1/8" 428-4-VM 51-M-850 33V-CGB4 or 64-XPM Oval M 17 9/16" 3/4"

5/32" 428-5-VP 51-P-850 33V-CGB4 or 64-XPM Oval P 23 5/8" 7/8"

3/16" 428-6-VX 51-X-850 63-XPM Oval X 49 15/16" 1-3/16"7/32" 428-7-VF2 51-F2-850 – Oval F2 59 7/8" 1-1/16"1/4" 428-8-VF6 3-F6-950 – Oval F6 81 1" 1-3/8"5/16" 428-105-VG9 3-G9-950 – Oval G9 120 1-1/16" 1-3/8"3/8" 428-12-VH5 – – Oval H5 155 1-3/16" 1-1/2"

7/16" 428-14-VJ8 – – Oval J8 310 1-3/4" 2-5/16"1/2" 428-16-VK8 – – Oval K8 420 1-7/8" 2-9/16"

9/16" 428-18-VM1 – – Oval M1 565 2" 2-13/16"5/8" 428-20-VN5 – – Oval N5 822 2-3/8" 3-1/4"

The 428 Series oval sleeves are made from special materials and are specifically designed for use with stainlesssteel aircraft cable. The nickel plating gives this Nicopress sleeve a distinctive appearance.

CableSize

Nicopress Oval Sleeves Nicopress Tool Selection

Sleeve Stock Number

Weight (lbs.) Per 1000 Sleeves

Approx.

Sleeve Length Before

Compression Approx.

Hand ToolNumber 35

Hydraulic Tool Die

1/32" 168-1-VB 1/2 1/4" 31-B –3/64" 168-1.5-VB4 1-1/2 3/8" 31-B4-887 Oval B41/16" 168-2-VB4 1-1/2 3/8" 31-B-887 Oval B43/32" 1683-VC 2-1/4 3/8" 31-C-887 Oval C1/8" 168-4-VG 3-3/4 3/8" 31-G-887 Oval BG5/32" 168-5-VM 14 23/32" 51-M-850 Oval M3/16" 168-6-VP 17 3/4" 51-P-850 Oval P7/32" 168-7-VX 31 7/8" – Oval X1/4" 168-8-VF2 44 1-1/8" – Oval F2

Conform to military standard (MS-51844).


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Aluminum Oval Sleeves

Size ofCable

NicopressOval Sleeves

Stock No.

NicopressHand ToolsStock No.

Nicopress Oval Sleeves

Approx. WeightPer 1000

Sleeves (lbs.)

Sleeve LengthBefore

CompressedApprox.

Sleeve LengthBefore

Compressed

1/16" 118-2-VC 51-C-887 1 3/8" 7/16"3/32" 188-3-VG 51-G-887 2.8 9/16" 5/8"1/8" 188-4-VM 51-M-850 6.1 5/8" 13/16"5/32" 188-5-VP 51-P-850 9 3/4" 1-1/32"3/16" 188-6-VX 51-X-850 15 7/8" 1-3/16"1/4" 188-8-VF6 3-F6-950 27 1-1/8" 1-7/16"

Number 635 Hydraulic Tool Dies5/16" 188-10-VG92 VG92 48 1-3/8" 1-11/16"3/8" 188-12-VJ8 Oval J8 104 1-7/8" 2-3/8"7/16" 188-14-VK8 Oval K8 115 1-7/8" 2-3/8"1/2" 188-16-VM1 Oval M1 169 2-1/8" 2-3/4"

For Steel Cable

Size ofRope

NicopressOval Sleeves

Stock No.

Nicopress Oval Sleeves

NicopressHand ToolsStock No.

Approx. Weightper 1000

Sleeves (lbs.)

Sleeve LengthBefore

CompressedApprox.

1/16" 1700-C 51-C-887 1 3/8"1/8" 1700-M 51-M-850 7 11/16"

3/16" 1582-P 51-P-850 9 1"1/4" 1700-X 51-X-850 20 1-1/4"

Number 635 Hydraulic Tool Dies5/16" 1700-G3 1700-G3 30 1-1/8"3/8" 1700-H5 1700-H5 63 1-9/16"1/2" 1700-J8 1700-J8 110 2"

For Fiber Ropes

Note: Mechanical hand tools and bench tools are available for compressing sleeves onto cable 1/32" to 5/16". Larger cable sizes require use of the Nicopress #635 hydraulic tool with pressing dies. Information on power press dies for high speed production will be furnished upon request.



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Nicopress No. 64-CGMPCutter Tool with Cable Cutter

Tool Length: 20"Actual Weight: 5-1/2 pounds

The Nicopress 64-CGMP/Cutter Tool combinestwo important functions…cable cutting and oval sleeve pressing. The 64-CGMP/Cutter Tool eliminates the handling of two separate tools. Engineered for field conditions, this tool is made from drop-forged alloy steel; the working surfaces are heat treated and specially hardened. Toggle action provides high mechanical force and results in low cutting effort. Cutting blades can be reversed for long useful life. This versatile field and shop tool cuts mechanical cable sizes up thru 7/32".

The 64-CGMP/Cutter Tool presses Nicopress Oval Sleeves 1/16" (C), 3/32" (G), 1/8" (M) and 5/32" (P). In addition, the 1/16" stop sleeve can be pressed with the C groove.

This tool cuts mechanical steel cable as large as 7/32", the cutting surfaces surround and support the cable while it is being cut. There are no frayed cable ends and cable cuts are clean and round.

Cutter Tools

Cuts Cable

Very low cutting effort is required to cut mechanical steel cable up thru 7/32". Hardened cutter blades surround and support the cable during the cutting action, which results in round, clean-cut cable ends.

Eye Splices Cable

This single tool will cut and eye splice steel cable, eliminating the need for two separate tools. The 64-CGMP/Cutter Tool eye splices four cable sizes— 1/16", 3/32", 1/8" and 5/32".


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No. 32-VC: VG Tool

Tool Length: 11-1/2"Shipping Weight: 2-1/2 pounds

A small hand tool with two sleeve-pressing grooves in the head. It is used for splicing with Nicopress Oval and Stop Sleeves having "C" or "G" letters in their Stock Numbers.

Cutter Tools (Continued)

No. 51 Tools

Tool Length: 18-1/4" Shipping Weight: 5-1/4 pounds

Each tool has a single sleeve-pressing groove for the size of cable. Rangeaccommodated—3/64" through 7/32".

Types No. 63 and No. 64 Tools

Tool Length: 20"Shipping Weight: 6 pounds

These are multiple sleeve-pressing groove hand tools. The No. 63V-XPM has three grooves and is used only with Oval Sleeves. For cable sizes 1/8", 5/32" and 3/16".


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Cutter Tools (Continued)NO. 51 Tools forStop Sleeves


The No. 51-MJ hand tool with two sleeve-pressing grooves is used for all M and J lettered Nicopress Stop Sleeves for cable sizes 3/32" through 7/32". The "M" groove of this tool can also be used for the No. 18-3-M and No. 28-3-M Oval Sleeves.

The No. 51-Q-929 single-groove tool is used for galvanized steel Stop Sleeves No. 871-1-Q and No. 871-3-Q.

Number 33V-CGB4Nicopress Tool


When several small diameter cables are being used, we recommend this multi-groove tool.The 33V-CGB4 has three pressing grooves, which press oval sleeves 3/64" (B-4), 1/16" (C) and 3/32" (G).

Splices made with these tools typically hold military specification grade aircraft control cable in tension until the cable breaks. To ensure good splices, make the proper number of presses in each sleeve. Applications that require continuous and frequent sleeve pressing call for the use of our larger toggle action tools, or power press equipment.


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Cutter Tools (Continued)Model 510 Bench Tool

Tool Length: 21" Approx. Weight: 6 pounds

Will accommodate the following interchangeable tool heads: 51-B4-887; 51-C-887; 51-G-887; 51-X-850; 51-F2-850; 64-CGIVIP; 51-M-850; 51-P-850; 63V-XPM; 51-MJ.

Designed to speed up bench type cable assembly work by allowing for one hand operation of bench press thereby freeing up other hand to position sleeve and cable. Available in two sizes.

Note: Heads may be removed from No. 51, No. 63 and No. 64 type hand tools and used in No. 510 Bench Mount.

Model 300 Bench Tool

Tool Length: 35" Approx. Weight: 19 pounds

Will accommodate the following interchangeable tool heads: 3-C-887; 3-G-887; 3-M-850; 3-P-850; 3-X-850; 3-F2-850; 3-F6-950; 3-G9-950; 3V-CGMP; 3V-F6XM; 3-MJ.

The advantage of using these heads is that fewer presses are required per splice as compared to the No. 51 tools. For cable sizes 1/8" through 5/32" only, one press is made per splice.

Note: Hoods may be removed from No. 3 Type Hand Tools and used in No. 300 Bench Mount.

Model 3512 Hydraulic Compression Tool

Length: 23"Weight: 13 poundsOutput: 12 Ton

The 3512 NICOPRESS® Hand Compression Tool is precision engineered for TROUBLE-FREE application of Nicopress sleeves: on-site, in-the-field or at the plant. The Nicopress Model 3512 is match-mated for Nicopress sleeves to lower your total installation costs.

Features:

■ Range accommodated: 1/32" through 1/2" diameter cable.■ Swivel Head pivots 180° for hard to reach splices.■ Install all but the largest Nicopress Splicing Sleeves— “in-the-field.”■ Quick-Change compression dies.


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Wire Rope CuttersMO-ST®—Models 1, 1A and 2The impact type wire rope cutters are the original portabletools invented by Morse-Starrett to cut wire rope. The cutters are actuated by striking with a hammer, they are easy to operate and do a superior cutting job with only a few blows of a hammer. These cutters are precision engineered to deliver a cut without affecting the original roundness of the wire rope. The blades and dies are made of the finest tool steel available, heat treated and ground to close tolerances. The impact style cutters are available in three sizes and cutting capacities. The Model 1 has a 3/4" capacity, the Model 1A a 1-1/16" capacity and the Model 2 has a 1-1/2" capacity. Replacement blades are also available.

HYDRASHEAR®—Models W-075,P-1125 and C-1750 The self-contained hydraulic cable cutter is a precision- engineered tool designed to give a clean cut with minimum effort. Just pump the handle...no outside power is required. This self-contained portable tool can be easily carried and is used by contractors, rigging lofts and elevator repairmen. All three models will operate under water. The Pell HYDRASHEAR® is recommended by wire rope manufacturers and used by industries throughout the world. The blades and die sets are made of the finest tool steel available, heat treated and ground to close tolerances. This means a long life for the blades, as well as superior performance. The hydraulic cutters are available in three sizes and capacities. The Model W-075 has a 3/4" capacity, the Model P-1125 a 1-1/8" capacity and the ModelC-1750 has a 1-3/4" capacity.

HYDRASHEAR®—Models POC-1125,POC 1750 and POC2500The power-operated cutters require an external hydraulicpower source for operation. These models can beactivated by any electric, gasoline, hand, battery or airoperated hydraulic pump capable of developing 10,000PSI and having free flow return through the pressure line.The pumps are hose-connected to the HYDRASHEARbody. The power-operated cutters are available in threesizes and cutting capacities. The Model POC1125 has a1-1/8" capacity, the Model POC1750 a 1-3/4" capacityand the Model POC2500 has a 2-1/2" capacity.


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Precision Cable CuttersSwiss Made Felco cutters are recognized around the world for their precision manufacturing and cutting capabilities. Lightweight enough for overhead cutting, yet strong enough for underwater work. Plastic coated handles afford a firm, comfortable grip. Replacement parts are available from stock. All cutters are tested before leaving the factory.

Type C-7Length: 8" / Weight: 10 oz.A cable, when crushed or deformed in cutting, is difficult touse with fittings. These cable cutters, with unique triangularjaws, never leave a frayed end. Cutters range from the lightweight Type C-7—Capacity: 3/16" diameter and smaller.

Type CP Cutters—For Steel Strapping and BandingLength: 8" / Weight: 10 oz.CP cutters are indispensable for cutting steel strapping and banding. They are also especially good for cutting string, twine, rope, tin and many other materials with ease. The red plastic handle is fitted to the hand to make cutting comfortable. A thumb catch locks the cutter when not in use.

Type C-9Length: 13" / Weight: 1.5 Ibs.Fills the gap between C-7 and C-12—cuts 1/4"steel cable. Ideal for the tool kit.

Type C-108Length: 22" / Weight: 4.5 Ibs.Simple construction with all parts protected against rust and salt water. Designed as an indispensable part of boat equipment. Especially suited for quick, easy cutting of shrouds, stays, halyards and other rigging of high-tensile wire rope or cable up to 5/16" diameter. Inexpensive insurance for that rare time when a mast breaks. The C-108will cut virtually any material, including steel rods up to 5/16" diameter and tempered steel spring wires up to 1/4" diameter.

Type C-112Length: 29" / Weight: 8.25 Ibs.Like the C-108, this cutter also has maximum force transmission, which applies the maximum leverage justat the right moment. This, coupled with Swiss precision blades, make the C-112 and the C-108 amazingly easy to use. The C-112 will handle a maximum capacity of 1/2" hitensile strands.

Type C-12Length:19" / Weight: 3 Ibs.Capacity: 3/8" diameter and smaller.

Type C-16Length: 23" / Weight: 5 lbs.Capacity: 5/8" diameter and smaller.

Type C-16E (Electrical)Length: 23" / Weight: 5 lbs.Cuts ACSR cable up to 3/4".


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Moveable Bridge Cable Assemblies■ Up-haul, Down-haul, Counterweight Cables and Special Assemblies.

■ Adherences to tight tolerances.

■ As required, meets AASHTO, AREMA and other related bridge specifications.

■ Your Quality Control People, Engineers and Government Auditors are welcome to our state-of-the-art facility during any part of your job.

■ Can produce standard and special end fittings.

■ We pre-stretch and proof-test in-house— our ISO Certified processes ensure quality and accuracy.

■ We have in-house engineering.


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Security, Barrier & Guardrail Cable Assemblies & Fittings■ Wire Rope—Turnbuckles

■ Wire Rope Clips—Thimbles

■ Domestic

■ Buy America Act

■ Buy American Act

Highway Guardrail CableAssemblies


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Wire Rope AssembliesProduct Warnings


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S-421T Wedge Socket Warnings

■ Loads may slip or fall if the Wedge Socket is not properly installed.■ A falling load can seriously injure or kill.■ Read and understand these instructions before installing the Wedge Socket.■ Do not side load the Wedge Socket.■ Apply first load to fully seat the Wedge and Wire Rope in the socket. This load should be of equal or greater weight than loads expected in use.■ Do not interchange wedges between S-421T and US422T or between sizes.■ Do not assemble an old style 1-1/4" S-421W wedge into an S-421T 1-1/4" TERMINATORTM basket.■ Do not assemble an old style UWO-422 wedge into a US-422T TERMINATORTM basket.

WARNING

Wire Rope Technical Board Warning:Spelter & Swage Socket (Boom Pendants)

Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused.

Wire Rope failure may cause serious injury or death!

Protect yourself and others:■ ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.■ NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED.■ NEVER OVERLOAD a wire rope.■ INFORM YOURSELF: Read and understand manufacturer's literature or "Wire Rope and Wire Rope Sling Safety Bulletin".*■ REFER TO APPLICABLE CODES, STANDARDS and REGULATIONS for INSPECTION REQUIREMENTS and REMOVAL CRITERIA.*

* For additional information or the BULLETIN, ask your employer or wire rope supplier.

WARNING


For complete warning and application information, see Wire Rope Technical Board at www.wireropetechnicalboard.org

For complete warning and application information, see The Crosby Group at www.thecrosbygroup.com

Button lengths and wall thickness are directly related to rope capacity. If a shorter button length is required, the shorter button may not achieve the full holding capacity of the rope. Special size buttons—per your specifications are available—ask a Lifting Specialist for more details.

WARNING

Steel Swage ButtonsWarnings



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Fist GripClips Warnings

■ Failure to read, understand, and follow these instructions may cause death or serious injury.■ Read and understand these instructions before using clips.■ Match the same size clip to the same size wire rope.■ Do not mismatch Crosby clips with other manufacturer's clips.■ Prepare wire rope end termination only as instructed.■ Do not use with plastic coated wire rope.■ Apply first load to test the assembly. This load should be of equal or greater weight than loads expected in use. Next, check and retighten nuts to recommended torque.

WARNING

Drop Forge ClipsWarnings

■ Failure to read, understand, and follow these instructions may cause death or serious injury.■ Read and understand these instructions before using clips.■ Match the same size clip to the same size wire rope.■ Prepare wire rope end termination only as instructed.■ Do not use with plastic coated wire rope.■ Apply first load to test the assembly. This load should be of equal or greater weight than loads expected in use. Next, check and retighten nuts to recommended torque.

WARNING



Nicopress® Aluminum Oval Sleeves Warnings

Aluminum sleeves may not develop 100% holding power (swaging efficiency). Testing is recommended prior to use to determine the holding power for any particular application, especially when the possibility of personal injury or property damage exists.

WARNING

For complete warning and application information, see Nicopress Products at www.nicopress.com

S-423T Super Terminator®

Wedge Socket Warnings

■ Loads may slip or fall if the Wedge Socket is not properly installed.■ A falling load can seriously injure or kill.■ Read and understand these instructions before installing the Wedge Socket.■ Do not side load the Wedge Socket.■ Apply recommended torque to tensioner and clip bolts, and properly install wire to securely lock tensioner bolt to tensioner.■ Do not assemble the S-423 Wedge in any brand or model socket basket other than the Crosby S-421T TERMINATORTM.■ The size is marked on the socket basket and wedge, do not interchange wedge between sizes.

WARNING



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