Wire Rope User S Manual AIS PDF

,-
\....;:::
WIRE ROPE
USERS MANUAL
COMMITTEE OF WIRE ROPE PRODUCERS
American Iron and Steel Institute
$2.50
This publication is a joint effort of the .
COMMITTEE OF WIRE ROPE PRODUCERS/
and the
WIRE ROPE TECHNICAL BOARD
The Wire Rope Technical Board (WRTB) is an association of engineers
representing companies that account for more than 90 percent of wire rope
produced in the United States; it has the following objectives:
To promote development of engineering and scientific knowledge relating to
wire rope;
To assist in establishing technological standards for military, governmental and
industrial use;
To promote development, acceptance and implementation of safety standards;
To help extend the uses of wire rope by disseminating technical and engineering
information to equipment manufacturers; and ""
To conduct and/,or underwrite research for the benefit of both industry and
user.
Data, specifications, architectural/engineering information and drawings presentep in
this publication have been delineated in accordance with recognized professional
principles and practices, and are for general information only. Suggested procedures
and products should not, therefore, be used without first securing competent advice with
respect to their suitability for any given application.
The publication of the material contained herein is not intended' as a warranty on the
part of American Iron and Steel Institute-or that of any person named herein-that
these data are suitable for any general or particular use, or of freedom from infringement
of any patent or patents. Any use of these data or suggested practices can only be
made with the understanding that American Iron and Steel Institute makes no warranty
of any kind respecting such use and the user assumes all liability arising therefrom.
COMMITTEE OF WIRE ROPE PRODUCERS
1000 16th Sfreet,N. W.
Wasl1!ngt9n, D.C. 20036
Copyright 1979 by American Iron'and Steel Institute
All rights reserved
Printed in U.S.A.
Permission to reproduce or quote any portion of this book as editorial
reference is hereby granted. When making such reproductions or quotations,
the courtesy of crediting this publication and American Iron and Steel
Institute will be appreciated.
J
1.
2.
3.
4.
5.
. 6.
APPENDIX A
APPENDIXB
APPENDIX C
APPENDIXD
APPENDIXE
APPENDIX F
CONTENTS
INTRODUCTION / 5
BASIC COMPONENTS / 7
WIRE ROPEIDENTIFICATION AND CONSTRUCTION / 9
HA'NDLINGWIREROPE /17
Receiving, Inspection and Storage /17
Wire Rope Installation / 18
Unreeling & Uncoiling / 19
Seizing Wire Rope / 22
Cutting Wire Rope / 24
End Attachments / 25
Efficiency ofEnd Attachments /25
Socketing/ 28
Wire Rope Clips / 29
How to Apply Clips / 29
Wedge Sockets / 33
Drums-Grooved / 34
Drums-Plain (Smooth) / 35
Drums-Multiple Layers / 36
OPERAnON AND MAINTENANCE OF WIRE ROPE / 37
Sheaves & Drums / 37
Bending Rope Over Sheaves & Drums / 39
Inspection of Sheaves and Drums / 42
The "X-Chart"-Abrasion Resistance vs. Bending-Fatigue Resistance / 44
Breaking in aNew Wire Rope /45
Wire Rope and Operations Inspection / 45
Strength Loss of Rope Over Sheaves or Stationary Pins / 47
Fleet Angle / 48
Factors Affectingthe Selection of Wire Rope / 49
Guideline to Inspections and Reports / 52
Field Lubrication / 68
Wire Rope Efficiency Over Sheaves. /70
PHYSICAL PROPERTIES /73.
Elastic Properties of Wire Rope / 73
Design Factors / 76
Breaking Strengths / 77 _
O"rdering Storing and Unreeling Wire Rope / 97
A Glossary of Wire Rope Terms /99
Wire Rope Fittings / 109
Socketing / 120
. Shipping Reel Capacity / 125
Weights of Materials / 126
CONTENTS IN ALPHABETICAL ORDER /128
3
r.
Acknowledgements
Tabular data and accompanying reference drawings for wire rope clips were
provided by The Crosby Group. All other illustrations used throughout were
.furnished by member companies of the Committee of Wire Rope Producers
(AISI). Drawings were prepared especially for this publication and are based
wholly or in part on graphic material that originally appeared in literature issued
separately by various member companies of the Committee.
Numericaland factual data, not otherwise credited, were obtained from
published and unpublished sources supplied by the Committee (AIS!) and by the
Wire Rope Technical Board (WRTB).
4
". ' ... ~ _
1Introduction
ma-chine: an assemblage of parts . .. that transmit forces, motion, and energy one
to another in some predetermined manner and to some desired end . ..
-Webster's Third New International Dictionary
In and of itself, wire rope is a machine. The geometry--{)r configuration--{)f its
cross-section and the method and material of its manufacture are precisely
designed to perform "in some predetermined manner and to some desired end."
Hence, as befits any useful machine, it is imperative that the rope's potential use
be fully recognized, that its functional characteristics be understood, and that
procedures for proper maintenance be scrupulously adhered to. By giving active
recognition to these generally accepted concerns, the user can be reasonably
certain that maximum service life and safety will be realized for every rope
installation or application.
Full recognition of the inherent use-potential for wire rope derives from a
realization of the great number and wide variety of ropes available for general and
special operating needs. Every particular style in all sizes, constructions, grades,
and cores is designed to meet some special set of functional requirements.
Fabricated to close tolerances, wire rope is inspected at all significant
manufacturing intervalsto assure the user of a uniformly high quality product.
Athoroughunderstandingof wire rope characteristics is, of course,a primary
essential. This involves intimate familiarity witlioperating conditions, load
factors, rope grades, and constructions.
Immediately after manufacture, wire rope care becomes an overriding,
necessity. At no point can aproper regard forcare and maintenance be neglected;
it must be exercised in handling, shipping, storage, and in installation. Then,
after the rope is put into operation, approved maintenance practices and rigorous
inspection (qf both the rope and its associated equipment) must be carried out
on a continuous basis. Only by strict adherence to these procedures can the rope
operate with safety and effiCiency throughout its entire life span.
Prepared for the long-time user as well as those unfamiliar with the product
or its technology, this publication represents a joint effort by the wire rope
industry. Those who already have a working knowledge of wire ropes will find
in these pages a comprehensive and convenient source of reference data on such
areas as properties and characteristics, handling, storage, operation and
maintenance-in short, a handy checklist.
As for the not-too-well informed or new user, this publication can serve
as a broad-ranging introduction. For these readers, the information provided can
help establish sound practices; practices of selection and application that are at
once safe, efficient and economic.
As a cooperative industry effort, this manual brings together a significant
portion of the enormous collection of data now scattered about in thefiles
and publications of many individual companies. The text offers many
recommendations, both explicit and implied. but these have been made solely
for the purpose of providing some initial judgment point from which ultimate
decisions as to design and use may be made. The reader is urged to consult with
the wire rope manufacturer as to the specific application planned. The
manufacturer's experience can then help the user make the most appropriate
5
Ii.
choice.' In the filial analysis, responsibility for design and use decisions rest with
the user. .
The selection of equipment or components is frequently influenced by the
special demands of an industry. An equipment manufacturer may, for reasons of
space, econom.y, etc., feeic0111pelled to depart from suggested procedures
given in these pages. It is important to remember that such variations from
recommended practices should be regarded as potential dangers. However, when
such circumstances are unavoidable they demand compensating efforts on the
part of the user. These "extras" should include (but not necessarily be limited to)
more frequent and more thorough inspections by skilled, specifically trained
personnel. Additionally, these circumstances may demand the keeping of special
lubrication and mainteriaricerecords, and the issuance of special warnings
regarding removal and replacement criteria.
\.
2 Basic Components
(STRAND
!;.;,.
Figure 1. The three basic components of a
typical wire rope.
Wire rope consists of three essential components. These, while fewin number',
vary in both complexity and configuration so as to produce ropes for specific
purposes or Basically, these three components of a standard wire
rope design are: 1) wires that form the strand, 2) a core, and 3) the multi-wire
strands laid helically around the core (Fig. 1).
Wire, for rope, is made in several materials and types; these include 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 appropriate for requirements of the finished
product.)
"iron"type wire is actuaEy :i j,jh'-carbon steel and has fairly limited use
except for older elevator installations. However, when iron is used for other than
elevator application, it is most frequently galvanized.
Steel wire strengths are appropriate to the particular grade of the wire rope in
which they are used. These grades of wire rope are traction steel, mild plow steel,
plow steel, improved plow steel, and extra improved plow steel. (While steel grade
names originated at the earliest stages of wire rope devt"lorment, they been
retained and serve as indicators of the strength of a particular size and grade of
rope). The strength of plow steel forms the basis for calculating the strength of all
steel rope wires, and the tensile strength of any grade is not constant, but varies
with the diameter-being highest for the smallest wires.
The most common finish for steel wire is "bright" or uncoated. Steel wires
may also be galvanized (zinc coated). "Drawn galvanized" wire has the same
strength as bright wire, but wire "galvanized at finished size" is usually 10%
lower in strength. In some special applications, tinned wire is used. but it should
be noted that tin provides no sacrificial (cathodic) protection for the steel
as does zinc.
Listed in order of frequency of use, stainless steel ropes are made of AISI
Types 302/304, 316, and 305. Contrary to general belief, hard-drawn stainless
Type 302/304 is magnetic. Type 316 is less magnetic and Type 305 has a
permeability low enough to qualify as non-magnetic.
Monel Metal wire is usually Type 400 and conforms to Federal
Specification QQ-N-281.
Bronze wire is usually Type A Phosphor Bronze (CDA#510) although
other bronzes are sometimes specified.
The core is the intrinsic foundation of wire rope; and is made of materials
that will provide proper support for the strands under normal bending and
loading conditions. Core materials include fibers (hard vegetable or synthetic) or
steel. The steel core consists either of stranded wires or of another independent
wire rope. The three most commonly used core designations are: fiber core
(FC), independent wire rope core (lWRC). and strand core (WSC) (Fig. 2).
Catalog descriptions of the various available ropes include these abbreviations
to identify the type of core.
Strands are made up of two or more wires, laid in one of many specific
geometric arrangements. or in a combination of steel wires with some other
materials such as natural or synthetic fibers. Although it is conceivable that a
7
strand can be made up of any number of wires, or that a rope can have any number
of strands, in the United States the majority of wire ropes are designed with six
strands. Major U.S. strand classifications are 7-, 19-,37-,61-,91-, and 127-wire.
Despite their numerical characteriiations, it should be noted that the
classifications do not necessarily refer "to the actual wire count in each strand.
In standard manufacturing practice, rope constructions do not necessarily have
the specific wire counts given by their respective classifications. The following
section, WIRE ROPE IDENTIFICATION," provides a complete description
of the construction of each classification.
To summarize: a wire rope consists, in most cases, of three components:
wires, strands, and a core (Fig. 2). To these may be added what may be
considered a fourth component: the wire rope's lubricant-a factor vital to the
satisfactory performance of most operating ropes.
FIBER (FC) INDEPENDENT
WIRE ROPE
CORE (IWRC)
WIRE
STRAND
(WSC)
Figure 2. The three basic wire rope cores. In
selecting the most appropriate core for a
given application, a qualified manufacturer
should be called upon for guidance, Fiber
cores, for example, are not recommended for
applications involving elevated temperatures
or high peak loads. ,
8
3 Wire Rope Identification and Construction
Wire rope is identified not only by its component parts, but also by ~ construction,
Le., by the way the wires have been laid to form strands, and by the way the
strands have been laid around the core.
In Figure 3, drawings "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 (drawings "b" and "d") are laid in the
opposite direction.
Again in Figure 3, the first two drawings ("a" and "b") show regular lay
ropes. Followingthese are the types known as lang lay ropes. 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 rope's are
made so that the direction of thewire lay in the strand is opposite to the direction
of the strand lay in the rope; lang lay ropes ("c" and "d") are made with both
strand lay and rope lay in the same direction. Finally, the type "e" called
alternate lay consists of alternating regular and lang lay strands.
a
b
,
d
,-
Fi!!llre 3. A comparison of typical wire rope Jays: a) right rl'gular ray, b) Il'ft rl'glliar ray,
c) right lang lay, d) Il'ftlang lay, e) right altanCltl' lay.
9
A-
REGULAR LAY
I
I
I
I
_-BI
:\1
. Of all wire rope types in current use, right regular lay is found in the widest
range of applications. Many applications related to excavation, construction
or mining, require lang lay rope. Currently, left lay rope is used less frequently.
In any case, where left lay and/or lang lay are required, the manufacturer/supplier
must be so informed before ordering. As for alternate lay ropes, these
are used for special applications.
Circumstances that favor the use of lang lay ropes derive from two unique
advantages over regular lay ropes. Lang lay ropes: 1) are more resistant to
bending fatigue, and 2) have a greater wearing surface per wire across the crown
of the strand. The total wearing surface area of the rope is, for practical purposes,
the same for both regular and lang lay ropes-with the same geometric
construction and depth of wear-the eventual wear on the equipment and the
service life of the rope favors laI1glay construction on applications where
fatigue or abrasion are controlling factors.
To illustrate this point, Figure 4 compares a regular lay with a lang lay rope,
each of which has been worn to the same amount of reduction in their
respective diameters.
Hence, it is not the total of the rope's worn surface area that governs the
life span of rope and equipment. It is, rather, the inherent characteristics of
properly used lang lay ropes that gives them a significant advantage in resistance
to both abrasion and fatigue.
However, lang lay ropes have some disadvantages. They are more
susceptible to damage resulting from: handling abuses, bending' over extremely
small sheaves, pinching in undersize sheave grooves, crushing when improperly
wound on drums, and they are subject to excessive rotation. In fact, this latter
tendency for the rope and the strands to unwind in the same direction, requires that
lang lay ropes should be secured at both ends to prevent unlaying or spinning out.
Preforming is a wire rope manufacturing process wherein the strands and
their wires are shaped-during fabrication-to the spiral form that they will
ultimately assume in the finished rope or strand.
As previously noted,wire rope strands are made up of a number of wires.
Figure 4. A comparison of wear characteristics hetween l(//IR lay and r{'Rular lay rdpes. The line a-b indicates the rope axis.
10
The wire' arrangeme'nt in the strands will determine the rope's functional
characteristics, i.e., its capacity to Dleet the operatjng conditions to which it wilI
be subjected. There are many basic'design constructions around which
standard wire ropes are built; some of these are shown in Figure 5.
Four typical strand cross-sections, designed around the Warrington, Seale
and Filler Wire basic constructions are shown in Figure 6.
Wire ropes are identified by a nomenclature that is referenced to: 1) the
number of strands in the rope, 2) the number (nominal or exact) and
arrangement of wires in each strand, and 3) a descriptive word or letter indicating
the type of construction. i.e., geometric arrangement of wires (Fig. 7).
Under the earlier section BASIC COMPONENTS, mention was made
concerning the manner in which wire rope constructions are grouped or classified.
The most widely used classifications are listed and described in Table 1.
At this point, it may be useful to discuss wire rope nomenclature in
somewhat greater detail. It is a subject that may easily generate some
misunderstanding. The reason for this stems from the practice of referring to
rope either by class or by its specific construction.
Ropes are classified both by the number of strands and the nurriber of wires
in each strand, e.g., 6x7, 6x 19, 6x37,8x J 9, J 9x7, etc. However, these are'nominal
classifications that mayor may not represent the actual construction: For example,
the 6x19 class commonly includes constructions such as 6x21 filler wire, 6,,25 filler
wire,and 6x26 Warrington Seale. Despite the fact that none of these have, 19
wires, they are designated as being in the 6x 19 classification.
Hence, a supplier receivingan order for 6x 19 rope may assume this to be a
class reference and is legally justified in furnishing any construction within this
category. But, if the job should require the special characteristics of 6x25 W, and
a 6x19 Seale (Fig. 5) is supplied in its stead, a shorter service life can be expected.
To avoid such misunderstanding, the safest procedure is to order a specific
construction if such geometry is essential for the intended purpose, or to order
, both by class and construction, e.g., 6x 19 (6x26 Warrington Seale).
Identifying wire rope in class groups facilitates selection on the basis of
strength, weight/ft. and price since aU ropes within a class have the same nominal
strength, weight/ft and price. As for other functional ,characteristics, these can
be obtained by referencing the specific construction within the class.
Only three wire ropes in the 6x 19 classification actually have 19 wires:
6x19 2 operation, 6x19 Seale, and6x19 Warrington. All the rest have different
counts. There is a greater proportion of 37-wire constructions in the 6x37 class
but these are infrequently produced. The more commonly available 6x37
'constructions include: 6x31 Seale. 6x31 Warrington Seale (WS). 6x36 WS,
6x4l Seale FiUerWire (SFW), 6x41. WS, 6x43 FW, '6x46 WS, etc,-none of
which contains 37 wires.
While a strand's interior has some significance. its important characteristics
relate to the number and, in consequence, the size of the outer wires. This is
discussed in somewhat greater detail in the section titled FACTORS AFFECTING
THE SELECTION OFWIRE ROPE (p. 49).
11
Wire rope nomenclature also defines: length, size (Le., diam.), type, direction
of lay, grade of rope, type of core. and whether it is preformed (p/f) or
non-preformed (np/f). If the direction and type of lay are omitted from the
rope description, it is presumed to be. a right regular lay. In addition, if no mention
is made as to preforming, this will be presumed as a requirement .for preforming.
On the other hand, an order for elevator rope requires an explicit statement
since p/f and np/f ropes are used extensively.
An example of a complete description would appear thus:
600 ft %" 6x25 FW Left lang lay
Improved plow IWRC
(Rope described above would be made PREFORMED.)
.....,.
...... .
...\'... ......,.
~ ';i.::'
..... " ,.'.....' ........ ..
t,::,,;>',:,
, ft
.. ,..:,..
.....,..
.. ..
6125 FW
,
\.. "j
.-
Figure 5. Basic constructions around which standard wire ropes are built.
:i\
!...!e.s.

e:eo:" :
.....:;...:..: .
.;:x:;:
..:-...,:-.....
0;' :.'i
..:..e:!ll
....r.\.
..~
6.21 SEALE WITH

WITH IWRC
~
.. ..
,\\t..!t::
4 ~ e.e:::-
:te
E : ~ :
. .... ~ .
.. ...~ ..:....
-::J.:;.
--te-
6.31 WARRINGTON
SEALE WITH IWRC
Figure 6. A fewcqmbinations of basic design constructions.
12
SEALE STRAND
19 WIRE SEALE
19 9
Figure 7. A single wire rope strand. Wire
rope is identified by reference to its number
of strands, as well as the number and geo-
metric arrangement of wires in the strand.
TABLE I' WIRE ROPE CLASSIFICATIONS
Based on the Nominal Number of Wires in Each Strand
'.-'
Classification
6x7
. 6x19
6x37
6x61
6x91
6x127
8x19
19x7
and
18x7
Description
Containing 6 strands that are made up of 3 through 14
wires, of which no more than 9 are outside wires.
wires, of which no more than 24 are wires,
. . ....
Containing 6 strands that are made up of 75 throughl 09
Containing 6 strands that are made up of 110 or more
Containing 19 strands, each strand is made up of 7 wires.
It is :!llanufactured by covering an inner rope of 7x7 left
langlay construction with 12 strands in right regular lay.
(Therotation-resistant property that characterizes this
highly specialized construction is a result of the counter
torques developed by the two layers.) When the steel wire
core strand is replaced by a fiber core, the decription
becomes 18x7.
/

When acenter wire is replaced by a strand, it is considered as a single wire,
and the rope classification remains unchanged.
There are, of course, many' other types of wire rope, but they are useful
only in a limited number of applications and, as such, are sold as specialties.
Usually designated according to their actual construction, some of these special
constructions are listed in Table 2 and shown in Figure 8.
13
5119 MARLINE CLAD 6142 TILLER ROPE
Figure 8. Three special purpose constructions that suggest wire rope's inherent
design potential.
TABLE 2 SPECIAL CONSTRUCTIONS
3x7 Guard Rail
3x19 Slusher
6x12 Running Rope
6x24 Hawsers
6x30 Hawsers
6x42 (6x6x7) TiIle.r Rope
6x3x19 Spring Lay
5x19 Marline Clad
6x19 Marline Clad
Table 2 is a much abbreviated listing of ropes designed for highly speciaiized
applications. Within the scope of this publication, it is not feasible to list the
many uses, nor to describe the possible design variations.
Cross-sections of wire rope shown in Figures 9 and 10 are among the most
commonly used, and they are arranged in their respective classification groups.
Because they are in greater demand, they are more generally available.
There is, however, one specialized wire rope category that requires some
discussion here-elevator rope. In this application, selecting the right rope
requires more than ordinary care.
Elevator rope can be obtained in four principal grades: 1) iron. 2) traction
steel, 3) high-strength steel, and 4) extra-high-strength steel. In addition. bronze
rope is sometirnesused for a limited number of functions within this category.
It should be noted that demand for the iron grade is decreasing markedly and
its use is gencralJy limited to older existing equipment.
...'.
14
"'-..
Figure 9. Cross-sections of some commonly
used wire rope constructions.
6,7 WITH FIBER CORE
6 x7 CLASSIFICATION
.. ..
eA- ' '

.:......,}'.:: ..:......
.. t ./.'.e! I!!"G;,&$.

.... f!..!i.:.
........ .
..: .
6,25B FLATIENED STRAND

TRIANGULAR CENTER WIRE.
., ... .......
..-:.. ..
..... ..,.: ,: .....
... .
... .
.......;.:..;......
......... ......
.. ....... ..
...... .....
.i'
6x30 GFLATTENED STRAND
BRANGLED CENTER
6 x19 CLASSIFICATION
.!
...:.:.
!.!
... ,-, .:e:
-
.
.
. :..: .
\e.:e -,' e:e:
.,.!...
.:!:
6xl9 SEALE WITH IWRC

.....:...
.! ...!
... ,', ...

.e!l.,.:i:::',::: .'1:.-
... '.. ...
..-:.:'..
.. ..
6,25 FILLER WIRE
WITH IWRC
6,26 WARRINGTON
SEALE WITH IWRC
.
....

. ..
... .:.:::.:......
:;:.:.:.:!:
0:':::',' .....
.....
.
.... ......,
6,31 FI.LLER WIRE

WITH IWRC
. .

.. ..:.
..:. ::i::e
...................
: :i::::i: :
:. .:...:::.\

..
. l5.
6,3i WARRINGTON SEALE
WITH'IWRC
..
......
. .... ......

..........'...
:-*;:.:=!: -.:.:
:::::::::
...... ........ ..
. !te....:
. .! ..
.. ...
.......
.. ...
6,41 SEALE FILLER
WIRE WITH IWRC
\!
....
'.". ., .
.!.
.:,.-:::::::::-1,
. : :. ..
........:...."...,
.' ..; ..........
.. '! .
:.!.P..

......
6,36 FILLER WIRE
WITH IWRC
.. .
.
.. :.-:.. .
: ...!' : .
.. :i: ..::
.:'::. :i::-::i:
..!': .
:..............
.... ...... ..
. .
.....:
... .
6,46 SEALE FILLER
WIRE WITH IWRC
6,49 FILLER WIRE SEALE
WITH FISER CORE
"Also manufactured as 6x27H and 6x25B.
""Also manufactured as 6x27V.
15
6:x37 CLASSIFICATION
The mostwidely used constructions forelevatoTT9pe are.6x25 FW, ..... ...
8xI9 Seale, and 8x25 FW. But,on occasion, anumber of other constructions are
, . ! ; ,I "
used. In any case, these ropes differ significantly from one another in their wear
and fatigue characteristics, thus they should not be inter-changed indiscriminately.
There are, in fact, some as governor rope-where the ropes
may not 'be interchanged either in grade or construction without re-qualification.
A special construction (6x42) is still used from time to time a hand rope
to control the elevator, and small diameter ropes (of 7x19 construction) are
used as control ropes for operating floor selection equipment.
From reel to reel, there are slight yet significant differences in the elastic
properties of wire rope. Because of such possible variations, it is strongly
suggested that all rope for a given elevator be obtained from a single reel.
Recognizing the need for such precaution, many codes and purchasing
specifications make this a standard requirement.
As noted, it is beyond the scope of this publication to discuss, in depth, design
and selection considerations for elevator rope. Information concerning sheave
diameters, design factors (ratio of nominal strength to working load), groove
contours, etc. can be found in the ANSI Code Al 7.1.
To obtain current data and sound technical guidance on elevator rope or
any other special requirements, a reputable wire rope should
be consulted.

$ ....:l! !fI$ t;::.et::
'lSf
W
b
....':e l:iji"eO..:::
."... -O:!:-
1817 ROTATION RESISTANT 19>7 ROTATION RESISTANT
Willi FIBER CORE WITH WIRE STRANOCORE
a 1917 CLASSIFICATIONS
..\,.
.1::::.-:-:.
:er... .;:.it
.eM _\
-:.-:-.:- eif:-.
... . :::.:.:.::: .
.-:-.:.-:- ......
... e!.
"A'!
yti, W
8 I Z5 FILLER WIRE
WITH IWRC
8119 CLASSIFICATION
!.
.. ..
p4!
t!:. - .-.f.-
:- iJ!.:i:.-. -\.
.
....\..:.......:. .
.
-.............
' .. --:i:-- .,-
...,. ....
.;!:
....;.:...
8119 SEALE WITH

IWRC
Figure 10. Cross-sections of wire ropes designed for specific functions. Note that the two
rotation-resistant constructions are identical except for the core--one of which is wire strand
and the other fiber. The wire strand core increases the number of strands.from 18 to 19.
16
4 Handling Wire Rope
RECEIVING, INSPECTION AND STORAGE
The right time to start appropriate.care and handling procedures for wire rope,
is immediately on delivery. When th,e rope arrives it should be carefully checked
for size, construction and core, making certain that the delivered product matches
the description on the tags, requisition forms, packing slips, purchase order,
and invoice.
Following these preliminaries, the question of storage should be considered.
If the wire rope is to be held for a considerable time before being used, it must
be protected from the elements. A dry, well-ventilated building or shed is a
proper storage place. Avoid closed, unheated, tightly sealed buildings because
. condensation will form on the rope when warm, moist outside air envelops the
colder rope. Although wire rope is protected by a lubricant, this is nottotally
effective since condensation can still occur within the small interstices between
strands and wires, thereby creating corrosion problems.
If, on the other hand, the delivery site precludes the use of an inside storage
space and the rope must be kept outdoors, it should be suitably covered with
a waterproof material. Weeds and tall grass should be cut in the assigned,storage
area, and the reel itself should be on a platform, elevated so as to>keep it from
direct contact with the ground. Providing an adequate covering f()r the reel will
also prevent the original lubricant from drying out with a resuit;:;,rjt loss of
protection.
Wire rope should never be stored in areas subject to elevated temperatures.
Dust, grit or chemically laden atmosphere are also to be avoided. Although the
lubricant applied at the factory offers some degree of protection, every normal
precaution should be taken with each coil or reel of wire rope.
Whenever wire rope remains in position on an idle machine, cr'ane, hoist,
etc., it should be coated with an appropriate protective lubricant. In these
circumstances, as with ropes stored outside, moisture, in the form of condensation,
rain or snow, may form on the wire rope. Some of the moisture may easily
become trapped inside the rope and cause corrosion problems. .
If the wire rope is to be kept inactive for an extended period while wound
on the drum of the idle equipment, it may be necessary to apply a coating of
. lubricant to each layer as the rope is wound on the drum; Cleaning, inspection and
re-Iubrication should precede start-up of the equipment.
17
WIRE ROPE INSTALLATION
CHECKING THE DIAMETER
It is most important to check the diameter of the delivered rope before installation.:
This is to make certain that the rope diameter meets the specified requirements
for the given machine or equipment. With an undersize diameter rope, stresses
will be higher than designed for and the probability of breaking the rope will
be increased; an oversize diameter rope will wear out prematurely. This happens
because of abuse to the rope caused by pinching in the grooves of the sheave
and drum.
In checking, however, the "true" rope diameter must be measured. And this
is defined as the diameter of the circumscribing circle, i.e., its largest cross-sectional
dimension. To insure accuracy this measurement should be made with a wire
rope caliper using the correct method (b) shown in Fig. 11. For measuring
ropes with an odd number of outer strands, special techniques must be employed.
Design specifications for wire rope are such that the diameter is slightly larger
than the nominal size, accqrdingto the allowable tolerances shown in Table 3.
TABLE 3
OVERSIZE LIMITS OF WIRE ROPE DIAMETERS*
Nominal Rope Diameter Allowable Limits
I
i.
."
Thru ;;a" -0 +8%
Over Ih II thru -0 +7%
Over thru 1,4 II
-0 +6%
Over 1,4 /I and larger -0 +5%
*These limits have been adopted by the Wire Rope Technical
Board (WRTB). and are being considered for inclusion in the
forthcoming revised edition of "Federal Standard RR.W410."
In the case of certain special purpose ropes, such as aircraft
cables and elevator ropes, each has specific requirements.
"TRUE" DIAMETER

.
\
, .fI'::W" --......
lye.
"81
\ ... :l'",
\ /

---
A
B. CORRECT C. INCORRECT
Figure 1I. How to measure (or caliper) a wire rope correctly. Since the "true" diameter (a)
lies within the circumscribed circle, always measure the larger dimension (b).
18
UNREELING AND UNCOILING
Wire rope is shipped in cut lengths, either in coils or un reels. Great care should
be taken when the rope is removed from the shipping package since it can
be permanently damaged by improper unreeling or uncoiling. Looping the rope
over the head of the reel or pulling the rope off a coil while it is lying on the
ground, will create loops in the line. Pulling on a loop will, at the very least,
produce imbalance in the rope and may result in open or closed kinks (Fig. 12).
Once a rope is kinked, the damage is permanent. To correct this condition, the
kink must be cut out, and the shortened pieces used for some other purpose.
Figure 12. Improper handling will help create open (a) or closed (b) kinks. The open kink
will open the rope lay; the closed kink will close it. The starlin!! loop Cc): do not allow the rope
to form a small loop. If. however. a loop forms and is removed at the point shown, a kink will
be avoided. The kink Cd): here the looped rope has been put under tension, the kink has
formed, the rope is permanently damaged and is of little value.
19
PREFERRED
REEL
ALLOWABLE- IF NOT CLOSE COUPLEO

Figure 15. Winding wire rope from reel
to drum.
Unwinding wire rope from its reel also requires careful and proper procedure.
There a.re three methods to perform this step correctly:
1) The reel is mounted on a shaft supported by two jacks or a roller payoff
(Fig. 13). Since the reel is free to rotate, the rope is pulled from the reel by
"a workman, holding the rope end and walking away from the reel as it unwinds.
A braking device should be employed so that the rope is kept taut and the
reel is restrained from over-running the rope. This is necessary particularly
with powered equipment.
2) Another method involves mounting the reel on an unreeling stand (Fig. 14).
It is then unwound in the same manner as described above (I). In this case,
however, greater care must be exercised to keep the rope under tension
sufficient to prevent the accumulation of slack-a condition that will cause
the rope to drop below the lower reel head.
3) In another accepted method, the end of the rope is held while the reel itself
is rolled along the ground. With this procedure the rope will payoff properly;
however, the end being held will travel in the direction the reel is being rolled.
As the difference between the diameter of the reel head and the diameter of
the wound rope increases, the speed of travel will increase.
i3. The wire rope teeI is mounted ona Shaft supported by jacks. This permits the reel
to rotate freely. and the rope can be unwound either manually or by a powered mechanism.
20
Figure 14. A vertical unreeling stand.
When r ~ r l i n wire rope from a horizontally supported reel to a drum, it is
preferable for the rope to travel from the top of the reel to the top of the
drum; or, from the bottom of the reel to the bottom of the drum (Fig. 15).
Re-reeling in this manner will avoid putting a reverse bend into the rope
as it is being installed. If a rope is installed so that a reverse bend is induced,
it may cause the rope to become livelier and, consequently, harder to handle.
When unwinding wire rope from a coil, there are two suggested methods for
carrying out this procedure in a proper manner:
1) One method involves placing the coil on avertical unreeling stand.
The stand consists of a base with a fixed vertical shaft. On this shaft there
is a "swift," consisting of a plate with inclined pins positioned so that the coil
may be placed over them. The \vhole swift and coil then rotate as the rope
is pulled off. This method is particularly effective when the rope is to be
wound on a drum.
2) The most common as well as the easiest uncoiling method is merely to hold
one end of the rope while rolling the coil along the ground like a hoop (Fig. 16).
Figures 17 and 18 show unreeling and uncoiling methods that are most
likely to provide kinks. Such improper procedures should be strenuously avoided
in order to prevent the occurrence of loops. These loops, when pulled taut, will
inevitably result in kinks. No matter how a kink develops, it will damage strands
and wires, and the kinked section must be cut out. Proper and carefiirliandIing
will keep the wire rope free from kinks.
Figure 16. Perhaps the most common and
easiest uncoiling method is to hold one end of
the rope while the coil is rolled along the
ground.
Figure 17. Illustrating a wrong method of
unreeling wire rope.
21
Figure 18. Illustrating a wrong method of
uncoiling wire rope.
Figure 19. METHOD A: Lay one end of the
seizing wire in the groove between two strands;
wrap the other end lightly in a close helix over
n position of the groove using a seizing iron
(a rOl,lnd bar 1/2 " to %" diam. x 18" long) as
shown above. Both ends of tbe seizing wire
should be twisted together tightly, and tbe
finished appearance as shown below. Seizing
widths should not be less than the rope
diameter. METHOD B: The procedure
illustrated at right is the second of the two
(A and B) accepted methods for placing
seizing on wire rope.
SEIZING WIREROPE
While there are numerous ways to cut w ~ rope, in every case. certain precautions
'must be observed. For one thing, proper se'izings are always applied on both
sides of the place where the cut is to be made. In a wire rope, carelessly or
inadequately seized, ends may become distorted and flattened. and the strands
may loosen. Subsequently, when the rope is put to work. there may be an uneven
distribution of loads to the strands; a condition that will significantly shorten
the life of the rope.
There are two widely accepted methods of applying seizing (Fig. 19). The
seizing itself should be a soft, or annealed wire or strand. The seizing wire diameter
and the length of the seize will depend on the diameter of the wire rope. But
the length of the seizing should never be less than the diameter of the rope being
seized. For preformed rbpes, one seizing on each side of the cut is normally
sufficient. But for those that are not preformed. a minimum of two seizings is
recommended (Fig. 20). Seizings should be spaced 6 rope diameters apart.
Table 4 lists seizing lengths and seizing wire diameters suggested for use
with some commonly used wire ropes.
"
(
TABLE 4 SEIZING
Suggested Diameters and Lengths::
. ... ..:;".
Rope Diameters Seizing Wire Diameters* Seizing Lengths
inches mm inches mm inches mm
3.5-8.0 .032 0.813 6.0
9.5-14.5 .048 1.21
1,6
13.0
0/8 _10/10
16.0-24.0 .063 1.60 % 19.0
1-1 26,0-33.0 .080 2.03 11.4 32.0
1%-111;10 '35.0-43.0 .104 2.64 1% 44.0
1%-21,6 45.0-64.0 .124 3.15
21,6 64.0
.;;
65.0-89.0 .124 3.15 3
t
h 89.0
*The diameter of seizing wire for elevator ropes is generally smaller than indicated in this
table. The wire rope manufacturer should be consulted for recommended,sizes.
23
CUTTING WffiE ROPE "
Wire rope after being properly (Fig. 20). Cutting is a reasonably
simple operation provided appropriate tools are used. There are several types of
cutters and shears commercially available. These are specifically designed to
cut wire rope.
Portable hydraulic and mechanical rope cutters are available. In remote
areas, however, it may at times be necessary to use less desirable cutting methods.
For example, using an axe or hatchet must be recognized as dangerous.
NONPREFORMED

BEFORE CUTTING
.J

AFTER CUTTING

PREFORMED I

BEFORE CUTTING I

AFTER CUTTING
Figure 20. Seizings, either on non-preformed or preformed wire rope, are applied
before cutting.
24
END ATTACHMENTS
For a number as tight openings in drums. or other
complicated reeving systems-there, may be a need for making special end
preparations. Wh'en these are required, there are about four basic designs (and
combinations) to choose from (Fig. 21 ) .
Becket loops are used when another rope is needed to pull the new rope into
place. The rope end must be fastened to the mechanism so that force and motion
. are transferred efficiently. End fittings thus become items of great importance
for transferring these forces. Each basic type of end fitting has its own individual
characteristics. Thus, one type will usually fit the needs of a given installation
better than the others (Fig. 22).
THE EFFICIENCY OF END ATTACHMENTS
It should be noted that not all end attachments will develop the full strength of
the wire rope used. To lessen the possibility of error, the wire rope industry
has determined terminal efficiencies for various types of end attachments.
Table 5-listing these efficiencies-permits calculation of the holding: power
of the more popular end fittings for any size, grade and constFuction ofi:wire rope.
A
PAD EYE
B
LINK
BECKET
c
TAPERED
8 WELDED
END
o
TAPERED
END WITH
LOOP
-""
f<
Z:::.:;
Figure 21. Beckets. or end preparations. are used on wire rope ends when another rope is
needed to puJl the operating rope into place. Four commonly used beckets are illustrated.
25

WIRE ROPE SOCKET SPELTER OR RESIN ATTACHMENT'
WIRE ROPE SOCKET -SWAGED

MECHANICAL SPLICE- LOOP OR THIMBLE ATTACHMENT
WEDGE SOCKET,
CLIPS - NUMBER OF CLIPS VARIES WITH ROPE SIZE

LOOP OR THIMBLE SPLICE- HAND TUCKED
Figure 22. End fittings. or attachments. are available in many designs. some of which were
developed for particular applications. The six shown are among the most commonly used.
26
.' ....... "'-", ..
TABLE 5 TERMINAL EFFICIENCIES (APPROXIMATE)
Efficiencies are based on nominal :strengths
Method of Attachment
. Efficiency
Rope with IWRC* Rope with FC**
Wire Rope Socket-Spelter
or Resin Attachment
'. Swaged Socket
Mechanical Spliced Sleeve
1" dia. and smaller
11A3" dia. thru 1% "
2" dia. and larger
100%
95%
95%
92
I
h%
90%
100%
(Not established)
92V2%
90%
87'iZ %
90%
89%
88%
87%
86%
84%
82%
80%
80%
79%
78%
77%.
76%'
74%
72%
70%
Loop or Thimble Splice-Hand Spliced (Tucked)
(Carbon Steel Rope)'

0/16"
%"

'iZ"
%"
%"
%"thru2'iZ"
Loop or Thimble Splice-Hand Spliced (Tucked)
(Stainless Steel Rope)

l}16"
%"
%6"
Ih"
0/8 "
%"
%"
Wedge Sockets***
(Depending on Design) 75% to 90%
Clips***
(Number of clips varies with size of rope) 80%
. *IWRC = Independent Wire Rope Core **FC = Fiber Core
***Typical values when applied properly. Refer to fittings
manufacturers for exact values and method.
27
90%
89%
88%
87%
86%
84%
82%
80%
75% to 90%
80%
U-BOLT '''IST'GRIP
SOCKETING
Impropetly attached wire rop'e te;:rminals lead to serious-possibly unsafe-
conditicms. To perform'properly"alI wire rope elements must be held securely
by the terminal. If this is not accomplished. the strands will "loaf on the job"
and there is every likelihood that a strand will become "high". A high strand
condition is illustrated in Figure42. In the case shown. selective abrasive
wear of the loose strand will necessitate early removal of the rope.
Poured Sockets-SpeIter or Resin
When preparing a wire rope for socketing. it is of extreme importance to follow
recommended procedures. (See Appendix D: SOCKETING PROCEDURES.)
Procedures other than those stipulated here. may develop the required strength
but this cannot be pre-determined without destructive tests. It is far safer-
and ultimately less costly-to follow well-established practices.
There are many ways to go wrong in socketing procedures. Some of the
more common pitfalls that should be guarded against include:
I ) Turning back the strands-inward or outward-before the "broom" is
inserted into the socket;
2) Turning back the strands and seizing them to the body of the rope;
3) Turning back the strands and tucking them into the body of the rope;
4) Tying a knot in the rope;
5) Driving nails, spikes, bolts, and similar objects into the socket after the rope
is in, so as to "jam" it tight; this is particularly dangerous-and ruinous.
To avoid these and many other dangeroLls practices, play it safe by following
correct' procedures.
WIRE ROPE CLIPS
Wire rope clips are widely used for attaching wire rope to haulages, mine cars,
hoists, and for joining two ropes.
Clips are available in two basic designs; the V-bolt and fist grip (Fig. 23).
The efficiency of both types is the same.
When using V-boll clips. extreme care must be exercised to make certain
that they are attached correctly. i.e., the V-bolt must be applied so that the "U"
section is in contact with the dead end of the rope (Fig. 24). Also. the
tightening and retightening of the nuts must be accomplished as required.
Fil:ure 23. Wire rope clips are obtainable
in two basic designs: V-bolt and fist grip.
Their efficiency is the same.
HOWTO APPLY CLIPS
U-BOLT CLIPS (Table 6, page 30)
Recommended Method of Applying U-Bolt Clips to Get Maximum
Holding P6""ier of the Clip
1) Turn back the specified amount of rope from the thimble. Apply the first clip
one base width from the dead end of the wire rope (U-bolt over dead end-live
end rests in clip saddle). Tighten nuts evenly to recommended torque.
2) Apply the next clip as near' the loop as possible. Turn on nuts firm but do
not tighten.
3) ,Space additional clips if required equally between the first two. Turn on nuts-
take up rope slack'---tighteh alI nuts evenly on alI clips to recommended torque.
4) NOTICEl Apply the initial load and retighten nuts to the recommended torque.
Rope will stretch and shrink in diameter when loads are applied. Inspect
periodically and retighten. .
A termination made in accordance with the above instructions, and using
the number of clips shown has an approximate 80% efficiency rating. This rating
is based upon the catalog breaking strength of wire rope. 1f a pulley is used in
place of a thimble for turning back the rope, add one additional clip.
The.number of clips shown is based upon using right regular or lang lay
wire rope, 6 x 19 class or 6.x 37 class, fibre core or IWRC, IPS or XIPS. If Seale
. construction or similar large outer wire type construction in the 6 x 19 class
is to be used for sizes 1 inch and larger, add one additional clip.
The number of clips shown also applies to right regular lay wire rope,
8x 19 class, fibre core, IPS, sizes 1
1
12 inch and smaller; and right regular lay wire
rope, 18 x 7 class, fibre core, IPS or XIPS, sizes 1
3
,4 and smaller.
For other classes of wire rope not mentioned above, it may be necessary to
add additiqnal clips to the number shown.
If a greater number of clips are used than shown in the table, the amount of
rope turnback should be increased proportionately. ABOVE BASED ON
USE OF CLIPS ON NEW ROPE.
IMPORTANT: Failure to make a termination in accordance with
aforementioned instructions, or failure to periodically check and retighten"lOthe
recommended torque, will cause a reduction in efficiency rating.
RIGHT WAY FOR MAXIMUM ROPE STRENGTH
WRONG WAY: CLIPS STAGGERED
WRONG WAY: CLIPS REVERSED
Figure 2';, The correCI way 10 attach U-bolts is shown at the top: the "U" section is in contact
with the rope's dead end.
29
\,
TABLE 6*
Min. no. Amount of Torque
Clip of rope to in Weight
Size A B C D E F G H
:tlips turn back Ib/ft Ib/100
~ .22 .72 .44 .47 .41 .38 .81 .94 2 ~ 4.5 5
~ 6 .25 .97 .56 .59 .50 .44 .94 1.16 '2 3% 7.5 9
~ .31 1.03 ,50 .75 .66 .56 1.19 1.44 2 4% 15 18
\,
~
.,
%6 .38 1.38 .75 .88 ..72 .69 1.31 1.69 2 5 ~ 30 30
% .44 1.50 .75 1.00 .91 .75 1.63 1.94 2 6 ~ 45 42
%6 .50 1.88 1.00 1.19 1.03 .88 ' 1.81 2.28 2 7 65 70
~ .50 1.88 1.00 1.19 1.13 .88 1.91 2.28 3 l ~ 65 75
%6 .56 2.25 1.25 1.31 1.22 .94 2.06 2.50 3 12 95 100
% .56 2.38 1.25
. 1.31
1.34 .94 .2.06 '2.50 3 12 95 100
% .63 2.75 1.44 1.50 1.41 1.06 2.25 2.84 4 18 130 150
'Va .75 3.13 1.63 1.75 1.59 1.25 2.44
. 3.16 4 19 225 240
1 .75 3.50 1.81 1.88 1.78 1.25 2.63. 3.47 5 26 225 250
~ .75 3.88 2.00 2.00 1.91 1.25 2.81 3.59 6 34 225 310
~ .88 4.25 2.13 2.31 2.19 1.44 3.13 4.13 6 37 360 460
1% .88 4.63 1.31 2.38 2.31 1.44 3.13 4.19 7 44 360 520
~ .88 4.94 2.38 2.59 '2..53 1.44 3.41 4.44 7 48 360 590
10/8 1.00 5.31 2.63 2.75 2.66 1.63 3.63 4.75 7 51 430 730
1% 1.13 5.75 2.75 3.06 2.94 1.81 3.81 5.28 7 53 590 980
2 1.25 6.44 3.00 3.38 3.28 2.00 4.44 5.88 8 71 750 1340
2
1
,4 1.25 7.13 3.19 3.88 . 3.94 2.00 4.56 6.38 8 73 750 1570
2
I
h 1.25 7.69 3.44 4.13 4.44 2.00 4.69 6.63 9 84 750 1790
2% 1.25 8:31 '3.56 4.38 4:88 2,00 5.00 6.88 10 100 750 2200
3 1.50 9.19 3.88 4.75 5.34 2.38 5.3i 7.63 10 106 1200 3200
"From The Crosby Group
30
FIST GRIP CLIPS (Table 7, on following page)
RECOMMENDED METHOD OF APPLYING FIST GRIP CLIPS
1) Turn back the specified amount of rope from the thimble. Apply the first clip
one base width from the dead end of the wire rope. Tighten nuts evenly to
recommended torque.
2) Apply the next clip as near the loop as possible. Turn on nuts firmly but do
not tighten.
3) Space additional clips if required equally between the first two. Turn on nuts-
take up rope slack-tighten all nuts evenly on all Clips to recommended torque.
4) NOTICEl Apply the initial load and retighten nuts to the recommended torque.
Rope will stretch and shrink in diameter when loads are applied. Inspect
periodically and retighten.
A termination made in accordance with the above instructions, and using
the number of clips shown has an approximate 80% efficiency rating. This rating
is based upon the catalog breaking strength of wire rope. If a pulley is used in
place of a thimble for turning back the rope, add one additional clip.
The number of clips shown is based upon using right regular Or lahg lay
wire rope, 6 x 19 class or 6 x 37 class, fibre core or IWRC, IPS or EIPS. If Seale
construction or similar large outer wire type construction in the 6 x 19 class
is to be used for sizes 1 inch and larger, add one additional clip.
The number of clips shown also applies to right regular lay wire rope,
8 x 19 class, fibre core, IPS, sizes IIh inch and smaIIer; and right re'gular lay wire
rope, 18 x 7 class, fibre core, IPS or EIPS, sizes 1
1
/2 and smaIIer.
For other classes of wire rClpe not mentioned above, it may be necessary ,
to add additional clips to the number shown.
If a greater number of clips are used than shown in the table, the amount
of rope turnback should be increased proportionately. ABOVEBASED ON
USE OF FIST GRIP CLIPS ON NEW WIRE ROPE.
1MPORTA NT: Failure to make a termination in accordance with
aforementioned instructions, or failure to periodically check and retighten to the
recommended torque, will cause a reduction in efficiency rating.
31
t- A T.. L
1 rET
,-
, ,.
TABLE 7*
Min. no. Amount of Torque
Clip L of rope to in Weight
Size A B C D E F G H Approx. M N clips turn back Ib/ft Ib/l00
.25 1.25 .34 .94 .38 .50 1.28 .22 1.63 .69 1.47 2 4 30 21
\
I

0/10 .31 1.34 ,44 1.06 .38 .63 1.47 .19 1.94 .69 1.56 2 5 30 26
'"
% .38 1.59 .50 1.06 ,44 .75 1.81 .25 2.38 .75 1.88 2 45 37
.50 1.88 .56 1.25 .50 1.00 2.19 .28 2.75 .88 2.19 2 6
1
12 65 60
.50 1.88 .56 1.25 .. .50 1.00 2.19 .28 2.75 .88 2.19 3 11 65 60
%0 .63 2.28 .69 1.50 .63 1.25 2.69 .28 3.50 1.06 2.63 3 12% 130 110
% .63 2.28 .69 1.50 .63 1.25 2.69 .28 3.50 1.06 2.63 3 130 110
% .75 2.69 .88 1.81 .75 1.50 2.94 .31 3.75 1.25 3.06 3 16 225 140
'Va .88 2.97 .97 2.13 .75 1.75 3.31 .38 4.13 1.25 3.14 4 26 225 220
1 1.00 3.06 1.19 2.25 .75 2.00 3.72 ,41 4.63 1.25 3.53 5 37 225 270
Bis 1.13 3.44 1.28 2.38 .88 2.25 4.19 ,44 5.25 1.44 3.91 5 41 360 300
114 1.25 3.56 1.34 2.50 .88 2.50 4.25 .50 5.25 1.44 4.03 6 55 360 410
1% 1.50 4.13 1.56 3.00 1.00 3.00 5.56 .56 7.00 1.63 4.66' 6 62 500 680
1Y.z 1.50 4.13 1.56 3.00 1.00 3.00 5.56 .56 7.00 1.63 4.66 6 66 500 680
*From The Crosby Group
32
WEDGE SOCKETS
One of the more popular end attachments for wire rope is the wedge socket.
For field, or on the job attachment, It is easily instaIJed and quickly dismantled.
The procedure is simple: '
1) Inspect the wedge and socket; all rough edges or burrs, that might damage the
rope, should be removed.
2) If the end of the rope is welded, the welded end should be cut off. This will
allow the distortions of the rope strands, caused by the sharp bend around the
wedge, to adjust themselves at the end of the line. If the weld is not cut off, the
distortions will be forced up the working line. This may result in the
development of high strands and wavy rope.
3) Place the socket in an upright position and. bring the rope around in a large,
easy to handle, loop. Care must be taken to make certain that the live-Ioaded-
side of the rope is in line with the ears (Fig. 25).
4) The dead end of the rope should extend from the socket for a distance
approximately nine times the rope diameter. The wedge is now placed in the
socket, and a wire rope clip is placed around the dead end by clamping a
short, extra piece of rope to the tail. (Do not clamp to the live part.) The V-bolt
should bear against the tail; the saddle of the clip should bear against the short
extra piece. i'
5) Secure the ears of the socket to a sturdy support and carefully take a strain on
thelive side of the rope. Pull the wedge and rope into position.. with tension
sufficiently tight to hold them in place.
6).After final pin connections are made, increase the loads gradually until the
wedge is properly seated. Avoid sudden shock loads.
The foregoing is the recommended procedure. If variations are made to
suit special conditions, they should be carefully evaluated beforehand.
B
WRONG
A
RIGHT
LIVE END---....
Figure 25. The wedge socket is a very
popular end attachment; it is easily installed
and quickly dismantled. But it must be
applied correctly (A).
33
DRUMS-GROOVED
Drums are the means by which power is transmitted to the rope and thence to the
object to be moved. For the wire rope. to pick up this power efficiently and to
transmit it properly to the working end, installation must be carefully controlled.
If the drurn is grooved, the winding conditions should be closely supervised
to assure adherence to the following recommended procedures:
1) the end of the rope must be secured to the drum by such means as will
give the end attachment at least as much strength as is specified by the
equipment manufacturer.
2) Adequate tension must be maintained on the rope while it is being wound
so that the winding proceeds under continuous tension.
3) The rope must follow the groove.
4) There should be at least three dead turns remaining on the drum when the rope
is unwound during normal operation. Two dead turns are a mandatory
requirement in many codes and standards.
If the wire rope is carelessly wound and, as a result, jumps the grooves,
it will be crushed and cut where it crosses from one groove to the other. Another,
almost unavoidable problem is created at the drum flange; as the rope climbs
to a second layer there is further crushing and the wires receive excessive abrasion.
Riser and filler strips may help remedy this condition.
34
\.
DRUMS-PLAIN (SMOOTH)
Installation of a wire rope on a (smooth) face drum requires a great
deal of care. The starting position s1.?ould be at the drum end so that each tum
of the rope will wind tightly against the preceding turn (Fig. 26). Here too,
close supervision should be maintained all during installation. This will help make
. certain that:
1) the rope is properly attached to the drum,
2) appropriate tension on the rope is maintained as it is wound on the drum,
3) each turn is guided as close to the preceding turn as possible, so that there
are no gaps between turns,
4) and that there are at least two dead turns on the drum when the rope is fully
unwound during normal operating cycles.
Loose and uneven winding on a plain- (smooth-) faced drum, can and
usually does create excessive wear, crushing and distortion of the rope. The results
of such abuse are lower operating performance, and a reduction in the rope's
effective strength. Also, for an operation that is sensitive in terms of moving
and spotting a load, the operator will encounter control difficulties the rope will
pile up, puU into the pile and faU"from the pile to the drum surface;: The .
ensuing shock can break or otherwise damage the rope.
L- -R
UNDERWIND LEFT TO RIGHT
USE LEFT LAY ROPE
L- -R
----++{1-
OVERWIND LEFT TO RIGHT
USE RIGHT LAY ROPE
LEFT LAY
UNDERWOUND
I
RIGHT LAY
OVERWOUND
L- -R
-H-----
OVERWIND RIGHT TO LEFT
USE LEFT LAY ROPE
L-- -R
++-----
UNDERWIND RIGHT TO LEFT
USE RIGHT LAY ROPE
LEFT LAY
OVERWOUND
I
R1GHT LAY
UNDERWOUND
26. By holding the right or left hand with index finger extended. palm up or palm
down, the proper procedure for installing lefT- and righT-lay rope on a smooth drum can be
easily determined.
35
L- -R
CROSS OVER
Figure 27. After the first layer is wound
on a drum. the point at which the rope winds
back for each turn is called the cross-over.
The proper direction of winding the first layer on a smooth drum can be
determined by standing behind the drum and looking along the path the rope
travels, and then following one oLthe procedures illustrated in Figure 26.
The diagrams show: the correct relationship that should be maintained between
the direction of lay of the rope (right or left), the direction of rotation of the
drum (overwind or underwind), winding from left to right or right to left.
DRUMS-MULTIPLE LAYERS
Many installations are designed with requirements for winding more than one layer
of wire rope on a drum. Winding multiple layers presents some further problems.
The first layer should wind in a smooth, tight helix which, if the drum is
grooved, is already established. The grooves allow the operator to work off the
face of the drum, and permit the minimum number of dead turns.
A smooth drum presents an additional problem, initially, as the wire rope
must be wound in such a manner that the first layer will be smooth and uniform and
will provide a firm foundation for the layers of rope that will be wound over it.
The first layer of rope on the smooth drum should be wound with tension sufficient
to assure a close helix--each turn being wound as close as possible to the
preceding turn-and most, if not all, of the entire layer being used as dead turns.
The first layer then acts as a helical groove which will guide the successive
layers. Unlike wire ropes operating on groove drums, the first layer should not
be unwound from a smooth-faced drum with multiple layers.
After the rope has wound completely across the face of the drum (either
smooth or grooved), it is forced up to a second layer at the flange. The' rope then
winds back across the drum in the opposite direction, lying in the depression
between the turns of the rope on the first layer. Advancing across the drum on
the second layer, the rope, following the "grooves"'formed by the rope on the first
layer, actually winds back one turn in each revolution of the drum. The rope
must then cross two rope "grooves" in order to advance acrOss the drum for
each turn. The point at which this occurs is known as the cross-over.
Cross-over is unavoidable on the second, and all succeeding layers. Figure 27
illustrates the winding of a rope on the second layer from left to right, and
from right to left-the direction is shown by the arrows.
At these cross-over points, the rope is subjected to severe abrasion and
crushing as it is pushed over the two rope "grooves" and rides across the crown of
the first rope layer. The scrubbing of the rope, as this is happening, can
easily be heard.
There is, however, a special drum grooving available that will greatly
minimize the damage that can occur atcross-over points.
Severe abrasion can also be reduced by applying the rule for the correct rdpe
lay (right- or left-lay) to the second layer rather than to the first layer. It is for
thiS reason that the first layer of a smdoth drum should be wound tight and
used as dead turns.
36
'"
5 Operation and Maintenance of Wire Rope
37
TABLES
MAXIMUM ALLOWABLE RADIAL BEARING PRESSURES OF ROPES'ON
VARIOUS SHEAVE MATERIALS (pOUNDS PER SQUARE INCH--PSI):'
>',OJ
,
Regular Lay Rope, psi Lang Lay Rope, psi
Flattened
Strand
Lang Lay,
Material 6x7 6 x 19 6x37 8 x 19 6x7 6 x 19 6 x 37 psi Remarks
Wood 150 250 300 350 165 275 330 400
On end grain of
beech, hickory, gum.
Cast tron 300 480 585 680 350 550 660 800
Based on minimum
Brinell hardness of 125.
30-40 Carbon. Based
Carbon Steel Casting 550 900 1,075 1,260 600 1,000 1,180 1,450 on minimum Brinell
hardness of 160.
Not advised unless
Chilled Cast Iron 650 1,100 1,325 1,550 715 1,210 1,450 1,780 surface is uniform
\ .....
in hardness.
Grooves must be ground
Manganese Steel 1,470 2,400 3,000 3,500 1,650 2,750 3,300 4,000 and sheaves balanced
for high-speed service.
38
Values for the allowable unit radial pressures given in Table 8 are intended
solely as a user's guide. And use of these figures does not guarantee prevention
of any trouble. Further, the values should not be taken as restrictive with regard to
other or new materials. There are, for example, certain elastomers in current
use that are apparently providing excellent service, but since there is insufficient
data to support specific recommendations, such products are not mentioned.
BENDING WIRE ROPE OVER SHEAVES AND DRUMS
Sheaves, drums and rollers must be oia 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
.. difficult to identify the one specific size of sheave or drum most economical
for every application.
The rule to follow is this: the most economical design is the one that most
closely accommodates the limiting factors imposed by the operating conditions
and the manufacturer's recommendations.
All wire ropes operating over sheaves and drums are subjected to cyclic
bending stresses, hence the rope wires will eventually fatigue. The magnitude of
these stresses depends-all other factors being constant-uponthe.ratioof
the diameter oithesheaveor drumto the diameter of the rope. Frequently,
fatigue from cyclic, high-magnitude bending stress is the principalEeason for
shortened rope service.
To illustrate, in order 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 ofthe rope, the
distance being greater along the top side than it is on the underside next to
the groove. Proper rope action (and service) is adversely affected if shifting the
wires cannot compensate for this situation. Also, there can be additional
motion retardation because of excessive pressure caused by a sheave whose groove
diameter is too small, or by a lack of lubrication. Changing the bending direction
from one sheave to another should be scrupulously avoided as this reverse
bending still further accelerates wire fatigue.
The relationship between sheave diameter and rope diameter is a critical
factor that is used to establish the rope's fatigue resistance or relative service life.
It is expressed in the tread D/ d ratio mentioned earlier in which D is the tread
diameter of the sheave and d is the diameter of the rope. Table 9 lists "suggested"
and "minimum" values for this ratio for various rope constructions. Tables 10
and 11 show the effect of rope constructions and D/ d ratios on service life.
39
TABLE 9 ,
RECOMMENDED SHEAVE AND DRUMRATIOS
Suggested Minimum
Construction D/d* ratio D/d* ratio
6x 7 72 42
19 x 7 or 18 x 7 51 34
6 x 19 Seale 51 34
6x25B 45 30
6x27H 45 30
6x30G 45 30
6 x 21 filler wire 45 30
6 x 31 Warrington Seale 39 26
8 x 19 Seale 41 27
6 x 42 Tiller 21 14 I
\",
*D =tread diameter of sheave d =nominal diameter of rope
To find any recommended or minimum sheave tread diameter
from the above table, the ratio for the construction rope to
be used is multiplied by its nominal diameter (d). For example:
The minimum sheave tread diameter for a Y2" 6 x 21 FW rope
would be Vz inch (nominal diameter) x 30 (minimum ratio)
Or 15 inches.
Note: These values are for reasonable service. Other, different.
values are permitted by various standards such as ANSI.
API, PCSA, etc. Smaller values mean shorter life.
40
.. )
TABLE 10
RELATIVE BENDINGLIFE
Rope
Construction
6x7
18 x 7
6 x 19 S
6 x 30 Style G
6 x 25 Style B
6 x 21 FW
6x25FW
Factor
.57
.67
.80
.80
.80
.92
1.00
Rope
Construction
6 x 31 WS
6 x 36 WS
8 x 25 FW
6 x 41 SFW
6 x 43 FWS
6 x 49 SWS
6 x 42 Tiller
Factor
1.09
1.31
1.39
1.39
1.54
1.54
2.00
If a change in construction is being considered as a means of obtaining longer service on a rope
influenced principally by bending stresses. the table of factors may be useful. For example: a
change from a 6 x 25 FW with a factor of 1.00 to a 6 x 36 WS with a factor of 1.31 would mean
the service life could be expected to increase 1.31 times or 31 %.
It must be pointed out however that these factors apply only for bending stresses. Other factors
which may contribute to rope deterioration have not been considered.
. SERVICE LIFE CURVE FOR VARIOUS Old RATIOS
!
I I I
!
!
I
i
I
/ 1
I i 1
I
!
I
I
!
I
I
!/
.!
I
!
! I
!
! I
I
I I !
i I i I
i

1
I
I I
I
I :/ !
j
,
i
! /
!
I
/i i !
I
I I

/
,
i !
I
i
,
/ i ! I
I i/ !
/1 i
i '/
I
! /
;
,
/1 !
i
i V
I
!
i
V I !
..v- I I
i
i
Figure 28. This service life curve only takes
into account bending and tensile stresses. Its
applicability can be illustrated by the
following example: A rope working with
a Did ratio of 26 has a relative service life
of 17. If the same rope works over a sheave
that increases its Did ratio to 35, the
service life increases to 32. In short, this
rope used on a larger sheave, increases its
service life from 17 to 32--or 88%.
100
90
eo
70
w
u.
:::i
w
u 60
>
a:
w
II)
w50
Q..
o
a:
w
> 40
!i
...J
W
a: 30
20
10
41
10 20 30
Old RATIO
40 50 60
Figure 29. Cross-sections illustrating 3
sheave-groove conditions revealed by the
metric arrangement of wires in the strand.
tight; and C is too loose.
B
B
A
A
c
c
(
\
INSPECTION OF SHEAVES AND DRUMS
Under normalconditions, machines receive periodic inspections, and their over-all
condition is recorded. Such inspections 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.
The very first item to be checked when examining sheaves, rollers and drums,
is the condition of the grooves (Figs. 29,30, and 31). To check the size, contour
and amount of wear, a groove gage is used. As shown in Figure 29, the gage
should contact the groove for about 150
0
of arc.
. Two types of groove gages 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.
For new or re-machined grooves, the groove gage is nominal plus the full
oversize percentage. The gage carried by most wire rope representatives today is
used for worn grooves and is made nominal plus the oversize percentage.
This latter gage is intended to act as a sort of "no-go" gage. Any sheave with
a. groove smaller than this must be re-grooved or, in all likelihood, the existing
rope will be damaged.
When the sheave is re-grooved it should be machined to the dimensions for \,
"new and machined" grooves given in Table 11. This table lists the requirements for
new or re-machined grooves, giving the groove gage diameter in terms of the
nominal wire rope diameter plus a percentage thereof. Similarly; the size of the
"no-go" gage 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.
o
Figure 30. Th.ese sheave-groove cross-
sections represent 3 wire rope seating
conditions: A. a new rope in a new groove;
B. a new rope in a worn groo"e; and C. a
worn rope in a worn groove. (See also Figs;
29 and 31.)
GROOVE
GAGE
Figure 31. 11Iustrating the various dimensions of a and the lise of gage.
42
TABLE 11
MINIMUM SHEAVE- AND DRUM-GROOVE DlMENSIONS*
~ ~
Nominal
Groove Radius
Rope Diameter New Worn
1 2 3 4 5 6
inches mm inches mm inches mm
;I.;
6.5 .137 3.48 .129 3.28
0/16 8.0 .167 4.24 .160 4.06
% 9.5 .201 5.11 .190 4.83
i!J.6 11 .234 5.94 .220 5.59
'h 13 .271 6.88 .256 6.50
~ 6 14.5 .303 7.70 .288 7.32
% 16 .334 8.48 .320 8.13
34 19 .401 10.19 .380 9.65
% 22 .468 11.89 .440 11.18
1 26 .543 13.79 .513 13.03
PAl 29 .605 15.37 .577 14.66
1;1.; 32 .669 16.99 .639 16.23
1% 35 .736 18.69 .699 17.75
1'h 38 .803 20.40 .759 19.28
1% 42 .876 22.25 .833 21.16
134 45 .939 23.85 " .897 22.78
IV!! 48 1.003 25.48 .959 24.36
2 51 1.070 27.18 1.019 25.88
2;.s
54 1.137 28.88 1.079 27.41
2;1.;
58 1.210 30.73 1.153 29.29
2% 61 1.273 32.33 1.217 30.91
2lh 64 2.338 33.99 1.279 32.49
2% 67 1.404 35.66 1.339 34.01
234 71 1.481 37.62 1.409 35.79
2% 74 1.544 39.22 1.473 37.41
3 77 1.607 40.82 1.538 39.07
3;.s 80 1.664 42.27 1.598 40.59
3
1
,4 83 1.731 43.97 1.658 42.11
3% 87 1.807 45.90 1.730 43.94
*Values given are applicable to grooves in 3
1
h 90 1.869 47.47 1.794 45.57
sheaves and drums: they are not general1y
suitable for pitch design since this may
334 96 1.997 50.72 1.918 48.72
involve other factors.
4 103 2.139 54.33 2.050 52.07
Further. the dimensions do not apply to
4;1.; 109 2.264 57.51 2.178 55.32
traction-type elevators: in this circumstance.
4
1
h
" 115
2.396 60.86 2.298 58.37
drum- and sheave-groove tolerances should
4
3
4 122 2.534 64.36 2.434 61.82
conform to the elevator manufacturer's
specifications.
67.64 2.557 64.95 5 128 2.663
Modern drum design embraces extensive
5
1
,4 135 2.804 71.22 . 2.691 68.35
considerations heyond the scope of this
5lh 141 2.929 74.40 2.817 71.55
puhlication. It should also be noted that
'<.:.::::-
drum grooves are now produced with a
534 148 3.074 78.08 2.947 74.85
number of oversize dimensions and pitches 6 154 3.198 81.24 3.075 78.16
applicable to certain service re"quirements.
43
THE "XCHART"-ABRASION RESISTANCE
VS. BENDINGFATIGUE RESISTANCE
While there is a possibility, there is little likelihood that an application can be
found for which there is a precisely suitable wire rope--one that can satisfy
every indicated requirement.
As with all engineering design probll::ms, feasible solutions demand
compromise to some degree. At times, it becomes necessary to settle for less than
optimum resistance to abrasion in order to obtain maximum flexibility; the
latter being a more important requirement for the given job. A typical example of
this kind of trade-off would be in selecting a highly flexible rope on an overhead
crane. Conversely, in a haulage installation, a rope with greater resistance to
abrasion would be chosen despite the fact that such ropes are markedly
less flexible.
Two compelling factors that govern most decisions as to the selection of a
wire rope are: abrasion resistance, and resistance to bending fatigue. Striking
a proper balance with respect to these two important characteristics demands
judgment of a very high order. A graphic presentation of just such comparison of
qualities between the most widely used rope constructions and others is given
by means of the X-chart (Fig. 32).
Referring to this chart when selecting a rope, the mid-point (at the X)
comes closest to an even balance between abrasion resistance and resistance to
bending fatigue. Reading up or down along either leg of the X, the inverse
relationship becomes more apparent as one quality increases and the other
decreases.
Fijture 32. The wire rope inuusth' refers to
this as the X-chl/rl. It servesto illustr:ite the
inverse relationship hetween ahrasion
resistance :md resistance to henuing fatigue in
a representative numher of the most widely
lIszJ ....ire ropes.
o 6
z
<1
0::
1--
9
(f)
0::10
W
a.

0::
3:12
oW
'00
i/i,12
I--
::::>
014
o
. 0:: 16
W
OJ
:2
0::::>
Z 18
44

e,"
_U',>-
"tv_

.,,'V'

U'/U'

1-
0
.
,0
e,
/: t<;-'V'
o 'V'<Q
s-

0
:,,0
<v G'

,,'V' /Q
e,.(:J
-0

'V'''' <7r
v<V
611.7
611.195
611.2\ FW
FLATTENED
STRAND
6x25 FW
6x31 WS
6x36 WS
611.41 SFVJ
6x49SWS

The term flexibility is frequently thought of as being synonymous with
resistance to bending fatigue. This is not true. Flexibility refers to the capability of
flexing or bending. While a high degree of fatigue resistance may sometimes
accompany the flexibility characteristic, it does not necessarily follow that this is so.
A fiber core rope, for example, is more flexible than an IWRC rope. Yet, when
the IWRC rope is bent around undersize sheaves at relatively high loads, it will
usually perform better than the more flexible fiber core rope. The reason for
this lies in the. ability of IWRC rope to retain its roundness and freedom of internal
movement. Under the same conditions, a fiber core rope will flatten and
inhibit free internal adjustment, thereby leading to early failure.
As noted earlier, a design choice is almost invariably the result of compromise.
Ultimately, what issought is an efficient, economical solution, hence whatever
the compromise, it must help achieve this goal.
BREAKING IN A NEW WIRE ROPE
A new wire rope requires careful installation and close adherence to following
all the appropriate procedures previously noted. After the rope has' been..'installed
and the ends secured in the correct manner, the mechanism should be started
carefully and then permitted to run through a cycle of operation at very slow
speed. During this trial operation, a very close watch should be kept on all
working parts-sheaves, drums, rollers-to make certain that the rope"Juns
freely, and 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 run-throughs of the normal operational cycle under light load and at
reduced speed. This procedure allows the component parts of the new rope to make
a gradual adjustment to the actual operating conditions.
WIRE ROPE AND OPERATIONS INSPECTION
To assure a high level of safety while keeping the annual cost of wire rope at a
reasonably low level, it is essential to maintain a well-planned program of
periodic inspection. Frequently, there are statutory and/ or regulatory agencies
whose requirements must be adhered to, but whether or not these exist in a given
locale, the wire rope user can be guided by the suggested procedures that follow.
A brasion, bending and crushing represent the ABC's of wire rope abuse,
.and iUs the primary goal of good inspection practice to discover such conditions
early enough so that corrections can be made or ropes replaced safely and
with minimum effort. When any degradation indicates a loss of original rope
strength, a decision must be made quickly as to allowing the rope to remain in
service. But such a decision can only be made by an experienced inspector.
And his determination will be based_on:
---.
I.) Details of the equipment's operaTion: Will the rope break?
2) Frequency of inspection: Will it be safe until the next scheduled inspection?
3) Maintenance history: How rapid is the degradation?
4) Consequences of failure: Will it present hazards to humans?
5) Historical records of similar equipment
To make certain that sufficient information is obtained. following are
guidelines. that should be adhered to:
45
:: '
If the fleet angle (Fig. 34) is large, it may be necessary to accept a smaller
arc of contact at the throat; 1300 for exa.mple instead of 150
0
. This is done
to avoid scrubbing the rope on the flange of the sheave.
As previously noted, the groove size is evaluated on the basis of how the
gage leaf fits the groove. Daylight under the gage is not tolerable when using the
worn groove gage. If a full over-size gage is used, some daylight may be acceptable,
but this really must be judged by relating the measurement to the actual size
of the rope.
For new rope, extra caution should be observed as to its fit in the groove.
Characteristically, ropes become smaller in diameter immediately after being
placed in service. As a result, they would operate satisfactorily in a "worn"
g r o o v ~ cine that was gaged OK by the "worn" groove gage. Nonetheless, in some
cases, a rope may not "pull down," and if this happens, abnormal wear may occur.
It is important to remember that a tight groove not only pinches and
damages the rope but that the pinching prevents the necessary adjustment of
the wires and strands. On the other hand, a groove that is too large will not
provide sufficient support; in this case, the rope will flatten and thereby restrict
the free sliding action cif the wires and strands.
The size of the groove is not the only critical item to be examined closely.
The condition of the groove is also an important factor of concern. Is it smooth or
imprinted? If the groove is imprinted then it must be re-machined or, if it is
imprinted too deeply, it means that sheave, roller or drum must be replaced.
If replacement is indicated, a larger sheave or drum should be installed if
possible, or a harder material should be specified for the replacement.
Groove examination should also concern itself with how the groove is wearing.
If it is worn off-center, thereby forcing the rope to undercut or to rub against
the flange, it then becomes necessary to correct the alignment of the reeving
system, and to specify a harder material.
When checking the grooves, the bearings of the sheaves and rollers should
also be examined. They should turn easily. If not, each bearing must be properly
lubricated. "Wobble" in the sheave-from broken or worn bearings-is not
acceptable. Bad bearings will set up vibrations in the wire rope that can cause
rapid deterioration unless the condition is remedied. Bad bearings also increase
the force on the rope that is needed to move a given load, since friction
forces will be greatly increased.
Sheaves with broken flanges may allow the rope to jump from the sheave
and become fouled in the machinery. When this happens, the rope is cut;
curled, and the crowns of the wires in the strands are burred. There is ample
evidence to support then.lle that shea.ves with broken flanges must be
replaced immediately.
A sheave or'drumwitha flat spot can induce a "Whip" into the line. This
\vhip. or wave. travels until it is stopped by the end terminal, at which point the rope
may bend severely. This condition helps to accelerate the fatigue breakage
of wires. Sometimes the reeving is such that the whip or wave is arrested by a
sheave. or the drum itself. In these circumstances. the whipping will cause
wire breaks along the crowns of the strands. Obviously, sheaves or drums that
exCite vibrations of this sort, must ~ repaired or replaced.
46
".\
In addition to the items listed above. inspection should also focus on any and
all conditions that could cause wear and eventual damage to the wire rope.
For example, plain-face (smooth) drums can develop grooves or rope
impressions that will prevent the rope from winding properly. Imprinting is
. greatest at the pickup point when the machine is accelerating. If this happens,
the surface should be repaired by machining or replaced. The winding should be
checked to make sure that the rope is winding "thread wound" (Fig. 27).
Excessive wear in grooved drums should be checked for variations either
in the depth or pitch of the grooves. This condition is particularly critical
when double drums are used because a differential force will be set up that can
break the drum and shear the shaft.
No matter what type of drum is in use, excessive drum wear will usually result
in rapid rope deterioration, This condition will accelerate rapidly when winding
in multiple layers.
STRENGTH LOSS OF WIRE ROPE OVER
STATIONARY SHEAVES OR PINS
Rope breaking strength is determined in a standard test wherein fittings are
attached to the ends of the rope and the rope is pulled in a straight line.
If, however, the rope passes over acurved surface (such asa sheave or pin)
its strength "is decreased." The amount of such reduction will depend on the
severity of the bend as expressed by the Did ratio. For example, a rope bent
around a pin of its own diameter will have only 50% of the strength attributed to
it in the standard test. This is called "50% efficiency" (Fig. 33) . Even at
Did ratios of 40, there may be a loss of up to 5% . At smaller bid ratios, the
loss in strength increases quite rapidly.
The angle of bend need not be I 80
0
90
0
, or even 45
0
; relatively
small bends can cause considerable loss.
All discussion of strength pre-supposes a gradually applied load not
in excess of 1" /minute.
38 34 30 26 16 22
Old RATIO
14 10 6 2
I I I. I
I
!
I i
I
I
I i I I I

I i
I I
i
i I I
I
,
i\J
I
I
I ! !
i
I
i
I I I I I
I 1\..1
I I I. ! i.
I
!
I
i I
I 1
,
I I
I ! N.. I i
I
,
1
:
i I
i I I
I i
j
I
I
I
I I
[
!

: , ,
: i
I
I I I
I
;
! I I
!
I I
I
I
I
1

I ;
, ,
! !
I i I !
i
i
i
i
i I
,
I
I
j
i i
I
I
I i I ! 1
i
I
i
I
I
90
100
60
EFFICIENCY OF WIRE ROPE WHEN BENT OVER SHEAVES OR PINS OF VARIOUS SIZES
50
!!
13 70
z
w
U

60
Figure 33. Derived from standard test data.
this curve relates rope strength efficiency to
various Did ratios. The curve is based on
static loads only and applies to 6 x 19 and
6 x 17 class ropes.
47
FIXED
SHEAVE
II
1'\
/1\
I \
, \
I \
I \
I \
,--r FLOATING
I "",---SHEAVE
-1 r--
I \
I \
I \
I \
I \
I \
I \
I \
, \
I \
I \
I \
I \
I \
I 1/20MIN IlZoMiN \
11i(2MAX IIIZOMAX \
1\.
,.... f1 "" 0;
I LEFT RIGHT \
I FLEET FLEET \
I ANGLE ANGLE \
Figure 34. This illustration of wire rope
running from a fixed sheave. over a floating
sheave. and then oil to n smooth drum.
graphically defines the '
FLEET ANGLE
The achievement of even windirigorta smooth faced drum is closely related
to the ma.gnitude ofthe D/ d ratio, the speed of rotation, load on the rope, and the
fleet angle. Of all these factors,the one that exerts perhaps the greatest
influence on winding characteristics. is the fleet angle.
The schematic drawing (Fig. 34) shows an installation where the wire
rope runs from a fixed sheave. over a floating sheave. and then on to the surface
of a smooth drum. The fleet angle (Fig. 34) may be defined as the included
angle between two lines; one line drawn through the middle of the fixed sheave
and the drum-and perpendicular to the axis of the drum and a second line drawn
from the flange of the drum to the base of the groove in the sheave.
(The drum flange represents the farthest position to which the rope can travel
across the drum.) There are left and right fleet angles. measured to the left
or right of the center line of the sheave, respectively.
It is necessary to restrict the fleet angle on installations where wire rope
passes over the lead or fixed sheave and onto a drum. For optimum efficiency
and service characteristics. the angle here should not exceed 1
1
/2 for a smooth
drum, nor 2for a grooved drum. Fleet angles larger than these suggested
limits can cause such problems as bad winding on smooth drums, and the rope
rubbing against the flanges of the sheave grooves. Larger angles also create
situations where there is excessive crushing and abrasion of the rope on the drum. "-., / 1
Conversely, small fleet angles-less than lh o-should also be avoided since
too small an angle will cause the rope to pile up.
FACTORS AFFECTINGTHE SELECTION OF WIRE ROPE
The key to choosing the rope best suited for the job, lies in an accurate estimation
of the important requirements. Correct appraisal of the following will simplify
the selection process:
1) Strength-resistance to breaking
2) Resistance to bending fatigue
3) Resistance 10 vibrational fatigue
4) Resistance to abrasion
5) Resistance to crushing
6) Reserve strength
It is well-nigh impossible for any single rope to have top values in all of the
above qualities. The rule, in fact, seems to be that a high rating in one almost
_always means lower ratings in others. The first task is to make a careful analysis of
the job requirements, establishing priorities among these requirements, and
then selecting the rope on a trade-off basis. This will provide the best possible
balance by sacrificing the least essential advantages in order to obtain
maximumbenefits in the most important requirements.
Following, are brief explanations ofthe six factors previously listed:
1) Strength-resistance to breaking .,
As has been noted at the very outset. a wire rope is a machine-a fairly, complex
deviCe that transmits and modifies force and motion. Thus, the very first
consideration in choosing a "machine," is to determine the potential work
load. Stated in tenus of wire rope, this means establishing the actual16ad
that is to be moved. To this known dead weight, there must be added those
loads that are caused by abrupt starts (acceleration), sudden stops,
shock loads, high speeds, friction of sheave .bearings. Another item in this
equation is the loss of efficiency that occurs when the rope is bent over
sheaves. All of these loads must be summed up in order to determine the true
total load that will ultimately be handled.
For an average operation, this figure is generaliy multiplied by a "design
factor" of 5. For increased mobility or design space economy, a design
factor of less than 5 is used at times. but if the load is especially valuable,
or if there is danger to human life, a larger design factor (up to 8 or 9) is used
in some instances. A still larger factor is sometimes found to be desirable.
The factored load is now used to choose the size, grade, and core of the wire
rope to be considered. (An extended discussion of Design Factors can be
found on page 76.)
2) Resistance to bending fatigue
To describe this, a close analogy can be made with a paper clip. If it is
repeatedly bent back and forth at one point. it will eventually break. The reason
for this is a phenomenon called "metal fatigue." To some degree, the same
thing happens when a wire rope is bent around sheaves. drums, and rollers,
The sharper-or more acute-the bend. the quicker the fatigue factor
does its work. Accelerating the rate of travel also speeds up fatigue; close-
coupled re\'erse bending will speed it up at an even greater rate.
But fatigue can be greatly reduced if sheaves and drums have, at the
49
very least, the recommended minimum diameter (Table 9). As for the rope,
there is one governing overall rule: the greater the number of wires in each
strand, the greater the resistance of the rope to bending fatigue.
The subject of metal fatigue is covered by a large and extensive body of
literature. It is not the intent of this publication to discuss, even in broad
terms, the theoretical concepts of the phenomenon. It will simply be noted
here that the concept of fatigue as a cause of metal "crystallization" is
incorrect since all metals are at all times crystalline in structure. The crystalline
appearancein many fractures is not indicative of "crystallization."
3) Resistance to vibrational fatigue
Vibration, from whatever source, sends shock waves through the rope. These
waves are a form of energy that must be absorbed at some point. This point
may appear at various places-'-the end attachment, the tangent where the rope
contacts the sheave, or at any other place where the waves are arrested and
the energy absorbed.
In the normal operation of a machine or hoist, wire ropes develop a
Wave action that can be observed either as a low frequency or as a sharp, high
frequency cycle. A good example of this is found in shaft hoists. When the
cage is just starting up, the rope has a very slow swing within the shaft. But,
by the time the cage reaches the top of the shaft, the initially low frequency
has become a high frequency vibration. The result is eventual breakage of the
wires at the attachment of the cage.
Another type of vibrational fatigue is found in operations where there is
cyclic loading. Such loadings would be found, for example, in the boom
suspension systems of draglines. Here, the energy is absorbed at the end
fittings of the pendants or at the tangent point where the rope contacts the
sheave. In this case, the "vibration" is torsional as well as transverse.
4) Resistance to abrasion
Abrasion is one of the most common destructive conditions to which wire rope
is exposed. It will occur whenever a rope either rubs against or is dragged
through any soil or other material. It happens whenever a rope passes around
a sheave or drum. And, it takes place within the rope itself whenever it is
loaded or bent. Abrasive action weakens the rope simply by removing metal
from both inside and outside wires.
When excessive wear is encountered in an operation, the problem
usually stems from faulty sheave alignment, incorrect groove diameters, an
inappropriate fleet angle, or improper drum winding. There may, however, be
other causes. If, on investigation, none of these common conditions are
found to be causative factors. the solution may lie in changing to a more
suitable rope construction. In making such a change, it is helpful to
remember that larger oliter wires alld lang-lay ropes are more abrasion resistant
than regular-lay ropes. (See p.lO for limitations of lang-lay ropes,)
5) Resistance to crushing
Rope can be crushed I ) by its own pressure against a sheave. 2) from
improperly sized grooves. and 3) from overwinding on a drum.
The pressure of rope against a sheave is determined by the sheave
diameter and the load. The pressure of rope to a drum is influenced in great
50
measure by"the support of the groove; smooth drums have a more adverse
"effect than those that are g r o o v ~
Overwinding is also a cause of wear even when the winding is done in an
ordeiIy (thread-winding) manner. Irregular or scramble winding is an
even greater cause of damage.
Obviously, in each of these cases, reducing the load will ease the condition.
If, however, this is not feasible, offending sheaves should be replaced with
sheaves that have larger tread diameters. Unsuitable drums and/ or winding
conditions should be corrected. Otherwise, the rope will have to be replaced
by one with a construction better designed to resist the abuse.
If the original rope has a fiber core, the replacement should have a steel
core because a steel core rope will provide greater physical support. And
here it is well to remember that regular-lay ropes are better able to resist
crushing than lang-lay ropes.
6) Reserve strength
The reserve strength of a wire rope is defined as the combined strength of all the
wires it contains, except those in the outside layer of the strands. . -.
The foHowing listing (Table 12) gives the percent of reserve strength for
6- or 8-strand wire rope relative to the number of outside wires ineach strand:
TABLE12
Number
of
Outside
Wires
3'
4
5
6
7
8
9
10
12
14
16
18
51
Percent
of
Reserve
Strength
o
5
13
18
22
27,
32
36
43
49
54
58
r.,
'GUIDELINE TOINSPECTIONSAND REPORTS FOR EQUIPMENT,
WIRE ROPE AND WIRE ROPE SLINGS
1) Maintain all inspection records and reports for the length of time deemed
appropriate.
2) Prior to each daily use, the following procedure should be followed.
a. Check all equipment functions.
b. Lower load blocks and check hooks for deformation or cracks.
c. During lowering procedure and the following raising cycle, observe the rope
and the reeving. Particular notice should be paid to kinking, twisting or
. other deformities. Drumwinding conditions should also be noted.
d. Check wire rope and slings for visual signs of anything that can cause them
to be unsafe to use, i.e., broken wires, excessive wear, kinking or twisting,
and marked corrosion. Particular attention should be given to any new
damage during operation.
3) Monthly inspections are recommended with a signed report by an authorized
competent inspector. The Monthly Reports should include inspection of
the following:
a. All functional operating mechanisms for excessive wear of components,
brake system parts and lubrication.
b. Limit switches.
c. Crane hooks for excess 'throat opening or twisting along with a visual
for cracks.
d. Wire rope and reeving for conditions causing possible removal.
e: Wire rope slings for excessive wear, broken wires, kinking, twisting and
mechanical abuse.
f. All end connections suchas hooks, shackles, turnbuckles, plate clamps,
sockets,'etc. for excessive wear, and distortion.
4) An Annual Inspection withsigned report must be made for the following:
a. Crane hook for cracks.
b. Hoist drum for wear or cracks.
c. Structural members for cracks, corrosion and distortion.
d, For loose structural connections such as bolts, rivets, and weldments.
. WIRE ROPE INSPECTION
The following is a fairly comprehensive listing of critical inspection 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) Abrasion
Rope abrades when it moves through an abrading medium or 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.
\.
-'",
J
. ,
52
. .. ~
2) Rope stretch
All ropes will stretch when loads are initially applied. For an extended
discussion of stretch, see pp. 73 and following.
As rope deteriorates from wear, fatigue, etc. (excluding accidental
damage), continued application ofa load of constant magnitude will produce
varying amounts of rope stretch. A "stretch" curve plotted for stretch vs.
time (Fig. 35) displays three discrete phases:
Phase I. 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.
On the plotted curve-stretch vs. time-this portion would almost be a
horizontal straight line inclined slightly upward from its initial level.
Phase 3. Thereafter, the stretch begins to increase at a quicker rate. This means
that the rope is reaching the point of rapid deterioration; a of
prolonged subjection to abrasive wear, fatigue, etc. This secoridupturn of
the curve is a warning indicating that the rope should soon be removed.
::l:
U
....
W
a::
to
w
Q.
o
a::
....
o
Vl
....
z
::>
I
I w
I I a::
I I
3-
::l:
I
I
,
,

I
"'-
a:
I I Z
.... I
I :;:
'-.Vl
I
g- ..J
I
I
NORMAL LljE STRETCH
I
I
g:-
f-e
I
'j
u
I
I
I
::>
I
I
a:
I
f-t;;
z
1
I
I
11-, 0 I
U I
I
I
I
I
I 1

I
....
I ::>
I
;5-
J
I I
I I
/
I
I
I
I I
/
I
I
I
I I
V
I
I
I
I
I
UNITS OF ROPE LIFE
Figure 35. This curve is plotted to show the relationship of wire rope stretch to the various
stages of a rope's life.
53
"j
3) Reduction in rope diameter ,
Any marked reduction in rope indicates degradation. Such reduction
may be attributed to:
excessive external abrasion
internal or external corrosion
loosening or tightening of rope lay
inner wire breakage
rope stretch
ironing or milking of strands
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 has undergone significant modification.
Previously, a decrease in the rope's diameter was compared with published
standards of minimum diameters. The amount of change in diameter is,
of course, useful in assessing a rope's condition. But, comparing this figure
with a fixed set of values is, for the most part, useless. These long-accepted
minima are not, in themselves, of any serious significance since they do
not take into account such factors as: 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 a combination
of both; and 3) the actual original diameter of the rope rather than its
nominal value.
As a matter of fact, all ropes will show a significant reduction in diameter
when a load is applied. Therefore, a rope manufactured close to its nominal
size may, when it is subjected to loading, undergo a greater reduction
in diameter than that stipulated in the minimum diameter table. Yet,
these circumstances, the rope would be declared unsafe although 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 the upper limits of allowable size. If the
diameter has reached a reduction to nominal or slightly below that, the tables
would show this rope to be safe: But it should, perhaps, be removed.
Today, evaluations of the rope diameter are first predicated on a
comparison bf the original diameter-when new and subjected to a known
load-with the current reading under like circumstances. Periodically,
throughout the life of the rope, the actual diameter should be recorded when
the rope is under equivalent loading and in the same operating section.
This procedure, if followed carefully, reveals a common 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 more rapid
reduction in diameter and when observed it is time for removal.
Deciding whether or not a rope is safe is not always a simple matter.
A number of different but interrelated conditions must be evaluated. It would be
54
dangerously unwise for an inspector to declare a rope safe for continued
service simply because its diameter had not reached the minimum arbitrarily
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) Corrosion
Corrosion, while difficult to evaluate, is a more serious cause of degradation
than abrasion. Usually, it signifies a lack of lubrication. Corrosion will
often occur internally before there is any visible external evidence on the rope
surface. Pitting of wires is a cause for immediate rope removal. Not only
does it attack the metal wires. but it also prevents the rope's component parts
from moving smoothly as it is flexed. 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 r p ~ s immediate removal from service. When a
rope shows more than one wire failure adjacent to a terminal fitting,,it should
be removed immediately. To retard corrosive deterioration, the rope
should be kept well lubricated. In situations where extreme corrosive action
can occur, it may be necessary to use galvanized wire rope.
5) Kinks
Kinks are permanent distortions caused by loops drawn too tightly.:Ropes
with kinks must be removed from service.
6) "Bird Caging"
Bird caging results from torsional imbalance that comes about because of
mistreatments such as sudden stops, the rope being pulled through tight
sheaves, or wound on too small a drum. This is cause for rope replacement
unless the affected portion can be removed.
7) Localized Conditions
Particular attention must be paid to wear at the equalizing sheaves.
During normal operations this wear is not visible. Excessive vibration, or whip
can cause abrasion and/ or fatigue. Drum cross-over and flange point
areas must be carefully evaluated. All end fittings. including splices, should
be examined for worn or broken wires, loose or damaged strands,
cracked fittings, worn or distorted thimbles and tucks of strands.
8) Heat Damage
After a fire, or the presence of elevated temperatures, there may be metal
discoloration. or an apparent loss of internal lubrication; fiber core ropes are
particularly vulnerable. Under these circumstances the rope should
be replaced.
9) Protruding Core
If. for any cause. the rope core protrudes from an opening between the
strands the rope is unfit for service.
55
10) Damaged End Attachments
Cracked, bent, or broken end fittings must be eliminated. 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 15% over normal
nor should twisting be greater than 10.
11) Peening
Continuous pounding is one of the causes of peening. The rope strikes
against an object such as some'structural part of the machine, or it beats
against a roller, or it hits itself. Often, this can be avoided by placing protectors
between the rope and the object it is striking. Another common cause
of peening is continuous passage-under high tension-over a sheave or
drum. Where peening action cannot be controlled, it is necessary to
have more frequent inspections and to be ready for earlier rope replacement.
Figure 36 shows the external appearance of two ropes, one of which
has been abraded and the other peened. Also shown are the cross-section of
both wires in these conditions.
abrasion peening
Figure 36. These plan views and r s ~ sections show the effects of abrasion and peening on
wire rope. Note that a crack has formed as a result of heavy peening.
56
12) Scrubbing
Scrubbing refers to the displacement of wires and strands as a result of rubbing
around or against an object. This, in turn, causes wear and displacement of
wires and strands along one side of the rope. Corrective measures should
be taken as soon as this condition is observed.
13) Fatigue Failure
Wires that break with square ends and show little surface wear, have usually
failed as a result of fatigue. Such failures can occur on the crown of the
strands, or in the valleys between the strands where adjacent strand contact
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, a more
flexible rope should be used. But, if the rope in use is already of maximum
flexibility, the only remaining course that wiil help prolong its service life is to
move the rope through the system by cutting off the dead end. By moving
the rope through the system, the fatigued sections are moved to less fatiguing
areas of the reeving. This technique is most frequently used in rotary drilling.
14) Broken Wires
The number of broken wires on the outside of a wire rope are 1) an index
of 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 Table 13. Such action must be taken without;,;,
regard to the type of fracture.
On occasion, a single wire will break shortly after installation.
However, if no other wires break at that time, there is no need for concern.
On the other hand, should more wires break, the cause should be
carefully investigated.
. _On any installation, valley breaks-i.e., where the wire ruptures between
strands-should be given serious attention. When two or more such
conditions are found, the rope should be replaced immediately.
It is well to remember that once broken wires appear-,-in a normal
rope operating under normal conditions-a good many more will show up
within a relatively short period. Attempting to squeeze the last measure
of service from a rope beyond the allowable number of broken wires
(Table 13), will create an intolerably hazardous situation. _
A diagnostic guide to some of the most prevalent rope abuses is given in
Table 14, On the following pages these abuses are illustrated and described.
57
TABLE 13 WHEN TO REPLACE WIRE ROPE-BASED ON NUMBER QF BROKEN WIRES
Number Broken Wires Number Broken Wires
. InRunning Ropes In Standing Ropes
ANSI In One In One In One At End
No. Equipment Rope Lay Strand Rope Lay Connection
B30.2 Overhead & Gantry Cranes 12 4
Not
Specified
B30.4 Portal, Tower & Pillar Cranes 6 3 3 2
B30.5 Crawler, Locomotive & Truck Cranes 6 3 3 2
B30.6 Derricks 6 3 3 2
B30.7 Base Mounted Drum Hoists 6 3 3 2
B30.8 Floating Cranes and Derricks 6 3 3 2
AlO.4 Personnel Hoists 6* . 3 2* 2
AlO.S 'Material Hoists 6*
Not Not
Specified Specified
'" Also remove for 1 valley break.
i ~ t 37. A wire that has broken under a tensile load in excess of itsstrength. is recognized
by the "cup and cone" configuration at the fracture point (A). The necking down of the wire at
point of failure shows that failure occurred while the wire retained its ductility. A fatigue
break is usually characterized by squared-off ends perpendicular to the wire either straight
across or Z-shaped (B & C).
58
TABLE 14 DIAGNOSTIC GUIDE TO COMMON WIRE ROPE ABUSES
,.
\...::/
Abuse
Fatigue
Tension
Abrasion
Cut or Gouged
or Rough Wire
Torsion or
Twisting
Mashing
Corrosion
Abrasion
plus Fatigue
Abrasion
plus Tension
Symptoms
Wire break is transverse--either straight across
or Z shape. Broken ends will appear grainy.
Wire break reveals predominantly cup and
cone fracture with some 45
0
shear breaks.
Wire break mainly displays outer wires
worn smooth to knife edge thinness. Wire
broken by abrasion in combination with
another factor will show a combination break.
Wire ends are pinched down, mashed and/or
cut in a rough diagonal shear-like manner.
Wire ends show evidence of
twist and/or cork-screw effect.
Wires are flattened and spread at broken ends.
Wire surfaces are pitted with break showing
evidence either of fatigue tension or abrasion.
Reduced cross-section is broken off
square thereby producing a chisel shape.
Reduced cross-section is necked down
as in a cup and cone configuration. Tensile
break produces a chisel shape.
59
Possible Causes
Check for rope bent around too small. a radius;
vibration or whipping; wobbly sheaves; rollers too
small; reverse bends; bent shafts; tight grooves;
corrosion; small drums & sheaves; incorrect rope
construction; improper installation; poor end
attachments. All running rope if left in service
long enough will eventually fail by fatigue.
Check for overloads; sticky, grabby clutches;
jerky cortditions; loose bearing on drum; fast
starts, fast stops, broken sheave flange; wrong
rope size & grade; poor end attachments.
Check for too great a strain on rope after factors
of deterioration have weakened it.
Checkfor change in rope or sheave size; change
in load; overburden change; frozen or stuck
sheaves; soft rollers, sheaves or drums; excessive
fleet angle; misalignment of sheaves; kinks; .. .
improperly attached fittings; grit & sand; objects
imbedded in rope; improper grooving..
Check on all the above conditions for mechimical
abuse, or either abnormal or accidental forces
during installation.
Check on all the above conditions for mechanical
Check on all the above conditions for mechanical
Indicates improper lubrication or storage.
A long term condition normal
to the operating process,
A long term condition normal
to the operating process.
,.,.,....... ,,-
I
Figure 38. An example of interstrand and core-to-strand nicking. A strand (upper member) \.
has been removed from the rope (lower member) to show the equivalent lines of nicking where
strands are in contact with one another, as well as with the core.
i ~ ~ r 39. A cork-screll'('d rope: the condition Came about asa result of the rope being pulled . -,"
around an ohject having a small diameter.
60
,"

/
Figure 40. When a reel has been damaged in transit, it is a safe assumption that irreparable
damage has b.een.dane to the rOj?e.
Figure 41. Wire rope abuses during shipment create serious problems. One of the more
common causes is improper fastening of rope end to reel. e.g., nailing Ihro/lgh the rope end.
These photos show two acc('prab!(' methods: A) one end of a wire "noose" holds the rope.
and the other end is secured to the reel: and B) the rope end is held in place by a l-bolt or
V-bolt that is fixed to the reel.
61
Figure 42. An example of "high strand". The excessive wear of a single strand is caused by improper
socketing.
Figure 43. This rope was damaged by being rolled over some sharp object.
Figure 44. These damages were the result of bad drum winding.
62
...
Figure 45. This effect of drum crushing is evidence of bad winding conditions.
Figure 46. A deeply corrugated sheave.
Figure 47. This rope condition is called a dog leg.
63
Figure 48. An occurrence that is called a popped core.
Figure 49. This is a typical bird cage condition.

, Figure 50., Here the strand wires were snagged.
64
,
,
Figure S1. A very bad condition (spiralling) brought about when the rope jumped from
the sheave.
65
'.
Figure 52. This is the appearance of a typical tension break; a result of overloading.
A
B
Figure 53. A) Serious wear resulting from excessive bending. and B) localized wear brought
about by poor cut-off practice.
Figure 54. This is an illustration of a seriolls condition where the rope slides over or
against itself.
i ~ r 55. An illustration of \'Olley type fatigue breaks. Flexing the rope exposes broken
wires hidden in valleys between strands.
66
-\
\ )
0'
r'"

ROPE INSPECTION SUMMARY
Any wire rope that has broken wires, deformed strands, variations in diameter, or
any change from its normal appearance, must be considered for replacement.
It is always better to replace a rope when there is any doubt concerning its
condition or its ability to perform the required task. The cost of wire rope
replacement is quite insignificant when considered in terms of human injuries,
the cost of down time, or the cost of replacing broken structures.
Wire rope inspection includes examination of basic items such as:
1) Rope diameter reduction
2) Rope lay
3) External wear
4) Internal wear
5) Peening
6) Scrubbing
7) Corrosion
8) Broken wires
Some sections of rope can break up without any prior warning. Already
discussed in some detail as to cause and effect, sections where this occurs are
ordinarily found at the end fittings, and at the point where the rope enters or
leaves the sheave groove of boom hoists, suspension systems, or other semi-
operational systems. Because of the "working" that takes place: at these sections,
no appreciable wear or crown breaks will appear. Under such an operation,
the core fails thereby allowing the strands to notch adjacent strands.;However,
when this happens, valley breaks will appear. As soon as the first vaHey break
is detected, the rope should be removed immediately.
If preventive maintenance, previously described, is diligently
performed, the rope life will be prolonged and the operation will be safer.
Cutting off a given length of rope at the end attachment before the core
deteriOI:ates and valley breaks appear, effectively eliminates these sections
as a source of danger.
EQUIPMENT INSPECTION
Any undetected fault on a sheave, roller, or drum-be it of relatively major or
minor significance-can cause a rope to wear out many times faster than the wear
resulting from normal operations. As a positive means of minimizing abuses
and other-than-normal wear, the procedures here set forth should be adhered to.
Every observation and measurement should be carefully recorded and kept in
some suitable and accessible file.
1) Give close examination to the method by which the rope is attached both to the
drum and to the load. Make certain that the proper means of attachment
is applied correctly, and that any safety devices in use are in satisfactory
working order.
67
2) Carefully check the groove and working surface of every sheave, roller, and
drum, to determine whether each (groove and surface) is as near to the
~ o r r t diameter and contour as circumstances will permit, and whether all
surfaces that are in contact with the rope are smooth and free of corrugations
or other abrasive defects.
3) Check sheaves and rollers to determine whether each turns freely, and whether
they are properly aligned with the travel ofthe rope. All bearings must be
in good operating condition and furnish adequate support to the sheaves and
rollers. Sheaves that are permitted to wobble will create additional forces
that accelerate the deterioration rate of the rope.
4) If starter, filler, and riser strips on drums are used, check their condition and
location. shouid these be worn, improperly located or badly designed, they
will cause poor winding, dog legs, and other line damage.
5) Wherever possible, follow the path that the rope will follow through a complete
operating cycle. Be on the lookout for spots on the equipment that have
been worn bright or cut into by the rope as it moves through the system.
Ordinarily, excessive abrasive wear on the rope can be eliminated at these
points by means of some type of protector or roller.
FIELD LUBRICATION
During fabrication, ropes receive lubrication; the kind and amount depending
on the rope's size, type, and anticipated use. This in-process treatment will provide
the finished rope with ample protection for a reasonable time if it is stored
under proper conditions. But, when the rope is put into service, the initial
lubrication may be less than needed for the full useful life of the rope. Because of
this possibility, periodic applications of a suitable rope lubricant are necessary.
Following, are the important characteristics of a good wire rope lubricant:
1) It should be free from acids and alkalis,
2) It should have sufficient adhesive strength to remain on the ropes,
3) It should be of a viscosity capable of penetrating the interstices between
wires and strands,
4) It should not be soluble in the medium surrounding it under the actual
operating conditions,
5) It should have a high film strength, and
6) It should resist oxidation.
68
Before applying lubrication, accumulations of dirt or other abrasive material
should be removed from the rope., Cleaning is accomplished with a stiff wire
.brush and solvent, and compressed,air or live steam. Immediately after it is
cleaned, the rope should be lubricated. When it is normal for the rope to operate
in dirt, rock or other abrasive material, the lubricant should be selected with
great care to make certain that it will penetrate and, at the same time, will not pick
up any of the material through which the rope must be dragged.
As a general rule, the most efficient and most economical means to do field
lubrication/protection is by using some method or system that continuously
applies the lubricant while the rope is in operation. Many techniques are used;
these include the continuous bath, dripping, pouring, swabbing, painting, or
where circumstances dictate, automatic systems can be used to apply lubricants
either by a drip or pressure spray method (Fig. 56).
PAINTING
I
SWABBING
POURING
SPRAY NOZZLE DRIPPING
CONTINUOUS BATH
..
,
i ~ r 56. Lubricant application methods in general use today include continuous bath,
dripping, pouring, swabbing, painting, and spraying. The arrows indicate the direction in which
the rope is moving.
69
WIRE ROPE EFFICIENCY OVER SHEAVES
(TACKLE BLOCK SYSTEM) "
Some portion of a wire rope's strength---:'when operating over sheaves-is
expended in turning the sheaves and in flexing. This lost strength is not available
to lift the load, and in a multi-part tackle block system (Fig. 57) this loss
factor can be significant.
The load "seen" by the lead line (fast Ilne) under static (no-movement)
conditions can be readily calculated if the load is divided by the number of parts
of line as expressed in the following fbrmula:
F 1
1 d Total load (incl. slings, contain.ers, etc.)
ast me oa = .
No. of parts of line
For example, in a four-part system (Fig. 57d) to lift 6000 Ib, the lead line
load will equal: .
6000 or 1500 Ib
4
.-'." ..
, ~
A. ONE PART LINE B. TWOPART LINE C. THREE PART LINE D. FOUR PART UNE E. FNE-PART LINE
Figure 57;' Commonly, used single- and multiple-sheave blocks (tackles). Static loading on the
rope is: A) equal to, B)Y.2of. C)V., of. D) l,4 of. and E) lis of the supported load.
70
N=4
5=4
Figure 58. Schematic representation of a
four-part reeving system. N =the number of
parts of line supporting the load (W), and
S =the number of rotating sheaves.
Moreover, if this system has ball or roller bearings in the s h v s ~ the lead
line load will increase to 1651 lb when the load starts to move. On the other
hand, if the sheaves have plain bearings such as bronze bushings, the lead line load
will increase to 1851 lb.
In an 8-part system with plain bearings, the lead line load jumps from
750 lb to 10861b-an increase of 45%! Derricks often use 8 or more parts in the
boom support system. The schematic diagram (Fig. 58) shows 4-part reeving.
This system has the same number of sheaves as there are parts of line.
The following procedure presumes this condition throughout. Provision
for extra lead sheaves are given at the end of this discussion.
To calculate the lead-line load, the combined load of the container, contents
_and lifting attachments is multiplied by the lead line factor as follows:
Lead line load = lead-line factor x load
TABLE 15 LEAD-LINE FACTORS*
Parts With Plain With Roller
of Line BearingSheaves Bearing Sheaves
1 .917 .962
2 .568 .530
3 .395 .360
4 .309 .275
5 .257 .225
6 .223 .191
7 .199 .167
8 .181 .148
9 .167 .135
10 .156 .123
11 .147 .114
12 .140 .106
13 .133 .100
14 .128 .095
15 _.124 .090
*In using this table. the user should note that it is based on
the as:umption that the number of parts of line (N) is equal to
the number of sheaves (5). When S exceeds N, refer to the text.
71
EXTRA
SHEAVE
N'4
5'5
Figure 59. Schematic representation of a
4-part reeving system with an extra (idler)
sheave.
. 'Fig: 59showsasimilar4-part system with an additional lead-in sheave;
In such cases, for each additiorial sheave the tabulated value is multiplied by 1.09
for plain bearings, or L04 for ariti-frictio)1bearings. r .
Example: What is the lead-line factor for a plain bearing tackle block system
of 5 parts of line and two extra lead-in sheaves? The tabulated value is .257.
Since there are two additional sheaves, the computation is:
.257 x 1.09 x 1.09 = .305
What is the lead-line load on this system 'Yhen the load is 5000 Ibs?
5000 x .305 - 1525 lb
It should be emphasized that the."dead-end" also may "see" this
augmented load.
Systems in which both rope ends are attached to a drum such as may be founa
in overhead cranes are not within the planned scope of this manual. It is
suggested, therefore, that information on such systems be obtained directly
from a wire rope manufacturer.
72
6 Physical Properties
ELASTIC PROPERTIES OF WIRE ROPE
Wire rope, an elastic member, derives its normal stretch characteristics from two
sources:
1) the inherent elasticity of its metal components, and
2) the compaction process ofits wires, strands and core.
There is, moreover, a third source of elongation-under-Ioad: the rope's
tendency to rotate and its associated lengthenings of the lay. This rather complex
process has potentially dangerous consequences and must be avoided. A discussion
elongation brought about by rotation is not included here since it is not
within the scope of this publication.
Constructional stretch occurs when the rope's elements are compressed,
or pulled together, as the load is applied. The result is a slight decrease in
diameter and increase in length. This may be likened to the familiar effect known
as the "Chinese Finger Trap." As would be expected, ropes that have more
compressible cores (e.g., fiber cores) than IWRC or strand core ropes (e.g., 7 x 19
aircraft cable) will exhibit greater constructional stretch.
Usually, constructional stretch in IWRC or strand core ropes becomes
permanent after several loadings leaving the rope with very little resiliency or
recovery. However, fiber core ropes if lightly loaded (elevator ropes) may
retain some degree of resiliency throughout most of their service life.
The rope's construction, particularly its type of core and the. number of
strands, will have a significant effect on constructional stretch. For example,
an 8-strand rope has a core diameter averaging 22% greater than that of a
6-strand rope. The 8-strand rope's constructional stretch is about 50% greater.
As to the effect of core type, a 6-strand rope with IWRC has about half (50%)
of the constructional stretch of a 6-strand fiber core rope.
The load range will also influence the overall stretch. When constructional
stretch just about reaches a maximum at 20% loading, the elastic portion will
remain almost straight-line up to around 65 % .
Total stretch, therefore, as a percent of length is greater from 0 to 20%
than from 20 to 65 % because constructional stretch contributes very little
above 20%..
To gain some idea of the amount of constructional stretch that may be
expected, the following brief tabulation shows some of the percentages:
Rope Construction
6 strand fiber core
6 strand IWRC
8 strand fiber core
*Depends on loading.
73
Approx. Range of Stretch*
lh%-%%
%%_11'2%
%%-1%
Despite the fact that stretchcannofbe calculated precisely, the following
formula will provide a close sufficient for most situations.
Ch . I . h (ft) . 'Change (lb) x Length (ft)
ange 10 engt = Area (inches:!) x Modulus of Elasticity
It should be noted that this formula does not take rotation into account.
Example: What approximate elongation per foot may be expected in a
"-6 x 41 Warrington Seale Construction IPS IWRC if the load changes
from 20% to 30% of its nominal strength?
Change in load =Nominal strength x (.3 -.2) = 23,000 x (.3 -.2)
= 23,000 x.l = 2300lb
Modulus of Elasticity (fromTable 15) = 14,000,000
Area (from Table 16) -.4902 x (lIz)2 = .1225
Change in length = 2300 xI _ 0013 ft
.1225 x 14,000,000 - .
Note: A 100 ft piece would stretch 100 times this figure or .13 ft (1.61 inches).
Tables 16 and 17 provide approximate modulus of elasticity and metallic
area for a number of rope classifications and diameters.
TABLE 16 APPROXIMATE MODULUS OF ELASTICITY
(pounds per square inch)
Rope Classification
6 x 7 with fiber core
6 x 19 with IWRC
6 x 37 with IWRC
74
Zero to 20% Loading
11,700,000
,10,800,000
9,900,000
8,100,000
13,500,000
12,600,000
20% to 65% Loading
13,000,000
12,000,000
11,000,000
9,000,000
15,000,000
14,000,000
TABLE 17
APPROXIMATE METALLIC AREAS OF VARIOUS CONSTRUCTIONS
Based on 1.03 diameter. If marked by an asterisk (*), area is based on exact
nominal diameter.
Fiber
Construction Centerless Core IWRC
1x2 .3927
1 x 3* .5075
1 x 7* .5930
1 x 19* .5827

3 x 7* .3708
5x7 .3903 .4566
6x6 ' .3198 .3861
6x7 .3843 .4506
6x12 .2319
6x1912/7 .3756 .4419
6 x 19 S .4035 .4698
6x19W .4156 .4819
6x21 FW .4115 .4778
6x21 S .4107 .4770
6x2415/9 .3292
6x25 FW .4167 .4830
6x26WS .4092 .4755
6x27 S
6x29FW .4197 .4860
6x3112/9 .3852 .4515
6x31 S
6 x 31 WS .4144 .4807
6x33 FW .4232 .4895
6x 36 WS .4185 .4848
6x3718/19W .3925 .4588
6x37FW .4268 .4931
6x41 SFW .4246 .4909
6x41 WS .4239 .4902
6 x 42 Tiller .2313
6x43 FWS .3920 .4583
6x46SFW .4253 .4916
6x 46 WS .4257 .4920
6x61 FWS .4075 .4738
7x7 .4706
7x1912/7 .4662
7x 19W .5051
8x7 .3427 .4740
8x 1912/7 .3325 .4638
8x 19 S .3588 .4715
NOTE: Values given are based on 3% 8x 19W .3659 .4972
oversize because this is a common
design "target." But, this figure
8x25FW .3675 .4988
often varies and is not to be
18 X 7 .4215
considered a standard. Wire sizes
19 X 7 .4526
in specific constructions alw vary,
6 X 3 X 19 .1220
.'
thus the given values are approxi-
.'
7x7x7 .3425 .;
mate. They are, however, within
..
the range of accuracy of the entire
7 X 7 X 19 .3614
method that is, in itself, approximate.
75
Where it is necessary to have precise data on elastic.characteristics, aload vs.
elongation test must be performed on a representative sample of the rope
under consideration.
For certain applications, ropes may be pre-stretched in order to remove
some of the constructional stretch. Frequently, this treatment is used on structural
members such as bridge rope and strand. In some cases, pre-stretching is
applied to operating ropes where elongation may present problems, e.g., elevator
and skip hoist ropes.
While a pre-stretching technique has value, some of the benefit is lost in
reeling and handling.
DESIGN FACTORS
Earlier, in this publication, the design factor was defined as the ratio of the
nominal breaking strength of a wire rope to the total load it is expected to carry.
Hence, the design factor that is selected plays an important part in determining
the rope's service life. Excessive loading, whether continuous or sporadic,
will greatly impair its serviceability. Usual1y, the choice of a certain wire rope size
and grade will be based on static loading and, under static conditions, it is
sufficient for its task. However, where a machine is working and dynamic loads
. are added to the static load, it is quite possible to exceed the material's elastic limit.
As was noted in the earlier discussion, a "common" design factor is 5.
Figure 60, the Wire Rope Relative Service Life Curve, shows how the service life is
reduced as operating loads are increased. A change in the design factor from
5 to 3 decreases its life expectancy index from 100 to 60-a drop of 40%!
9 e 7 5 6
OESIGNFACTOR
4 2
I
I
I ~
I i I ~
i
~
i
;
./y
~ ~ ~ ~
./
; ... ,. /1
~ !
/" i
1/
I
./I
!
/' I
,
! I
/ :
/ !
I
V , , I I I I
170
160
150
140
130
'" !!: 120
..J
tjllO
~ 100
'" en 90
'"8
...
~ 70
'" "'60
50
40
30
20
10
o
I
Figure 60. This graph is called the Rrltllil'c' S",l'ic(' Lifc' CUrI'c'. Ii relates the service life to
operating loads, A design factor of 5 is chosen mqs\ frequently,
7(>
BREAKING STRENGmS
The breaking strength is the ultimate load registered on a wire rope sample
during a tension test. ~ ; :
The nominalstrengths given (Tables 18 through 36), have been
calculated by a standardized, industry-accepted procedure, and manufacturers
design wire rope to these strengths. When making design calculations, it should be
noted that the given figures are the static strengths. All discussion of strength
is predicated on the assumption of there being a gradually applied load less than
1" /minute. Designers should base their calculations on these strengths.
A minimum acceptance strength, 21/z % lower than the published nominal
breaking strengths, was established as the industry tolerance. It serves to offset
testing variables that occur during the actual physical test of a wire rope sample.
This tolerance is used in the basic wire rope governmental specifications.
Wire rope testirig, whether it is performed for the purpose of determining
grade or for adherence to specifications, requires the sample to be tested to
meet certain standards: For example: the sample's length must not be less than
. 3 ft (0.91 m) between sockets for ropes with diameters of from ys,jnch
(3.2 mm) through 3 inches (77 mm); on ropes with larger (over 3 inches)
diameters, the clear length must be at least 20 times the rope diameter. The test
is considered valid only if failure oCcurs 2 inches (51 mm) Or morefrom
either of thesockets, or from the holding mechanism.
77
,j."
,
i
""-..:.;;;/
TABLE19 NOMINAL STREN:GTHS OF WIRE ROPE
6 x 7 Classification/Bright IWRC
Nominal Diameter Approximate Mass Nominal Strength*
Improved Plow Steel
inches mm Ib/ft kg/m tons metric tonnes
;4
6.5 0.10 0.15 2.84 2.58
lh6 8 0.16 0.24 4.41 4.0
% 9.5 0.23 0.34 6.30 5.72
11.5 0.32 0.48 8.52 7.73
Ih
13 0.42 0.63 11.1 10.1
14.S 0.53 0.79 14.0 12.7
% 16 0.65 0.97 17.1 15.5
% 19 0.92 1.37 24.4 22.1
Y8 22 .
1.27 1.89 33.0 29.9
1 26 1.65 2.46 42.7 38.7
B/s 29 2.09 3.11 53.5 48.5
1;4 32 2.57 3.82 65.6 59.5
1% 35 3.12 4.64 78.6 71.3
1;,z 38 3.72 5.54 92.7 84.1
*To convert to Kilonewtons (kN).multiply tons (nominal
. breaking strength) by 8.896; lIb =4.448 newtons (N).
79
"r
TABLE20 NOMINAL OF WffiE ROPE
6 x 19 Classification/Bright J.<'iber Core
Nominal Diameter Approximate Mass Nominal Strength*
.,",
Jmproved Plow Steel
inches mm lb/ft kg/m tons metric tonnes
;4 6.5 0.11 0.16 2.74 2.49
8: 0.16 0.24 4.26 3.86
% 9.5 0.24 0.35 6.10 5.53
11.5 0.32 0.48 8.27 7.50
ih
13 0.42 0.63 10.7 9.71
%'a 14.5 0.53 0.79 13.5 12.2
% 16 0.66 0.98 16.7 15.1
% 19 0.95 1.41 23.8 21.6
U! 22 1.29 1.92 32.2 29.2
1 26 1.68 2.5 41.8 37.9
-,L-
Ph 29 2.13 3.17 52.6 47.7
32 2.63 3.91 64.6 58.6
1% .35 3.18 4.73 77.7 70.5
Ph 38 3.78 5.63 92.0 83.5
.<'}
1% 42 4.44 6.61 107 97.1
1% 45 5.15 7.66 124 112
1% 048 5.91 8.8 141 128
2 51 6.72 10.0 160 145
2% 54 7.59 11.3 179 162
2
1
,4 57 8.51 12.7 200 181
2% 61 9.48 14.1 222 201
2
1
12 64 10.5 15.6 244 221
2% 67 11.6 17.3 268 243
2% 70 12.7 18.9 292 265
"'To convert to Kilonewtons (kN), multiply tons (nominal
breaking strength) by 8.896; 1 lb .= 4.448 newtons (N).
80
)
\
-
-- ----------------
-, TABLE 21 NOMINAL STRENGTHS OF WIRE ROPE
6 x 19 Classification/Bright IWRC
Nominal Approximate
Diameter Mass Nominal Strength*
Improved Extra Imp.
Plow Steel Plow Steel
metric metric
inches mm lb/ft kg/m tons tonnes tons tonnes
;4
6.5 0.12 0.17 2.94 2.67 3.40 3.08
%6 8 ' 0.18 - 0.27 4.58 4.16 5.27 4.78
% 0.26 0.39 6.56 5.95 7.55 6.85
11.5 0.35 0.52 8.89 8.07 10.2 9.25
;6
13 0.46 0.68 11.5 10.4 13.3 12.1
14.5 0.59 0.88 14.5 13.2 16.8 15.2.,
% 16 0.72 1.07 17.7 16.2 20.6 18.7
% 19 1.04 1.55 25.6 23.2 29.4 26.7
% 22 1.42 2.11 34.6 31.4 39.8 36.1
'1 -26 1.85 2.75 44.9 40.7 51.7 46.9
Ph 29 2.34 3.48 56.5 51.3 65.0 59.0
1;4 32 2.89 4.30 69.4 63.0 79.9 72.5
1% 35 3.5 - 5.21 83.5 75.7 96.0 87.1
1;6-
-38 4.16 6.19 98.9 89.7 114 103
1% 42 4.88 7.26 115 104 132 120
1% 45 5.67 8.44 ]33 ]21 153 ]39
1% 48 6.5 9.67 152 138 174 158
2
- 51,
7.39 11.0 172 156 198 180
2Vt! 54 - 8.35 12.4 192 174 22] 200
2% 57 9.36 13.9 215 195 247 224
2% 61 10.4 15.5 239 217 274 249
2;6 64 11.6 17.3 262 238 302 274
2%
67,
12.8 19.0 288 261 331 300
2% 70 14.0 20.8 314 285 361 327
*To convert to Kilonewtons (kNL multiply tons (nominal

breaking strength) by 8.896: 1 lb =4.448 newtons (N).
!

TABLE 22 NOMINAL STRENGTHS.OF WIRE ROPE
6x 37 Classification/Bright (Uncoated), Fiber Core
Nominal Strength*
Nominal Diameter Approximate Mass Improved Plow Steel
1,4
6.5 0.11 0.16 2.74 2.49
%.6 8 0.16 0.24 4.26 3.86
% 9.5 0.24 0.35 6.10 5.53
11.5 0.32 0.48 8.27 7.50
1h 13 0.42 0.63 10.7 9.71
1)16 14.5 0.53 0.79 13.5 12.2
% 16 0.66 0.98 16.7 15.1
% 19 0.95 1.41 23.8 21.6
22 1.29 1.92 32.2 29.2
\.
',;
1- 26 1.68 2.50 41.8 37.9
Ph 29 2.13 3.17 52.6 47.7
11,4 32 2.63 3.91 64.6 58.6
1% 35 3.18 4.73 77.7 70.5
11h 38 3.78 5.63 92.0 83.5
1% 42 4.44 6.61 107 97.1
1% 45 5.15 7.66 124 112
48 5.91 8.8 141 128
2 51 6.72 10.0 160 145
2% ..
54 7.59 11.3 179 162
21,4 57 8.51 12.7 200 181
2% 61 9.48 14.1 222 201
21h 64 10.5 15.6 244 221
2% 67 11.6 17.3 268 243
2.i 70 12.1 18.9 292 265
74 13.9 20.7 317 287
3 77 15.1 22.5 344 312
3% 80 16.4 24.4 371 336
31,4 83 17.7 26.3 399 362
"'To convert to Kilonewtons (kN). mUltiply tons (nominal
breaking strength) by 8.896; 1 Ib =4.448 newtons (N).

TABLE 23 NOMINAL STRENGTHS OF WIRE ROPE
6 x 37 Classification/Bright (Unc'Oated), IWRC
Nominal Strength*
Improved Extra Imp.
Nominal Approximate Plow Steel Plow Steel
Diameter Mass
metric metric
inches mm lb/ft kg/m tons tonnes tons t6nnes
1;4
6.5 0.12 0.17 2.94 2.67 3.4 3.08
'316 8 0.18 0.27 4.58 4.16 5.27 4.78
% 9.5 0.26 0.39 6.56 5.95 7.55 6.85
~ 6 11.5 0.35 0.52 8.89 8.07 10.2 9.25
Ih
13
'"
0.46 0.68 11.5 10.4 13.3 12.1
%6 14.5 0.59 0.,88 14.5 13.2 16.8 15.2
% 16 0..72 1.07 17.9 16.2 20.6 18.7
% 19 1.04 1.55 25.6 23.2 29.4 26.7
~ 22 1.42 2.11 34.6 31.4 39.5 ..- 35.9
1 26 1.85 2.75 44.9 40.7 51.7 . 46.9
11;8 29 2.34 3.48 56.5 51.3 65.0 59.0
11;4 32 2.89 4.30 69.4 63.0 79.9 72.5
1% 35 3.50 5.21 83.5 75.7 96.0 87.1
Ph 38 4.16 6.19 98.9 89.7 114 1'03
1% 42 4.88 7.26 115 104 132 120
1% 45 5.67 8.44 133 121 153 139
~ 48 6.5 9.67 152 138 174 158
2 51 7.39 11.0 172 156 198 ]80
2% 54 8.35 12.4 192 ]74 221 200
21;4 57 9.36 13.9 215 195 247 224
2% '
61 10.4 15.5 239 217 274 249
2%, 64 ] 1.6 17.3 262 238 302 274
2% 67 12.8 19.0 288 26] 331 300
2% 70 14.0 20.8 314 285 361 327
2% 74 15.3 22.8 341 309 392 356
3 77 16.6 24.7 370 336 425 386
3% '
80 18.0 26.8 399 362 458 415
31;4 83 19.5 29.0 429 389 492 446
3% 86 21.0 31.3 459 416 529 480
3
1
h 90 22.7 33.8 491 445 564 512
3%' 96 24.3 36.2 523 458 602 528
3% 103 26.0 38.7 557 505 641 581
*To convert to Kilonewtons (kN). mUltiply tons (nominal
,
.-. breaking strength) by 8.896: 1 Ib =4.448 newtons (N) .
~ ~
\z.:.7i
S3
6 x 61 Classification/Bright (Uncoated)", Fiber Core
. t"
Nominal Strength*
inches mm 1b/ft kg/m tons metric tonnes
1 26 1.68 2.5 39.8 36.1
;Ills 29 2.13 3.17 50.1 45.4
1% 32 2.63 3.91 61.5 55.8
. 1%
35 3.18 4.73 74.1 67.2
~ 38 3.78 5.63 87.9 79.7
1% 42 4.44 6.61 103 93.4
1% 45 5.15 7.66 119 108
1% 48 5;91 8.80 136 123
2 51 6.77
10.1 .
154 140
2lis 54 7.59 11.3 173 157
2% 57 8.51 12.7 193 175
2% 61 9.48 14.1 214 194
2
1
h 64 10.5 15.6 236 214
t',
2% 67 11.6 17.3 260 236
2% 70 12.7 18.9 284 258
2% 74 13.9 20.7 309 280
3 77 15.1 22.5 335 304
3% 83 17.7 26.3 390 354
'3% 86 19.1 28.4 419 380
3 ~ 90 20.6 30.7 449 407
.- (
'3% 96 23.6 35.1 511 464
4 103 26;9 40.0 577 523
4% 109 '. 30.3 45.1 646 586
41/.2 115 34.0 50.6 719 652
4% 122 .37.9 56.4 794 720
5 128 42.0 62.5 872 791
: ~ 4 "'To convert to Kilonewtons (kN). multiply tons (nominal
breaking strength) by 8.896; I Ib =4.448 newtons (N).
TABLE 26 NOMINAL STRENGTHS" OF WIRE ROPE
6 x 91 Classification/Bright (Uncmited), "Fiber Core
Nominal Strength*
2 51 6.77 to. 1 146 132
: ~
.2;.g 54 7.59 11.3 164 149
~ 57 8.51 12.7 183 166
2% 61 9.48 14.1 203 184
2th 64 to.5 15.6 225 204
2% 67 11.6 17.3 247 224
2% 70 12.7 18.9 270 245
3 77 15.1 22.5 318 288
(
"-
3
1
,4 83 17.7 26.3 371 337
./. n
3th 90
20.6 .
30.7 426 386
*To convert to Kilonewtons (kN), multiply tons (nominal
breaking strength) by 8 ~ 9 6 ; lIb =4,448 newtons (N).
,..
')1;
\
J
87
.- ;l . ~
J ~
, ~ i /
.
"
TABLE 2S NOMINAL STRENGTHS OF WIRE ROPE
6x30, 6x 30G, 6 x25B,& 6 x27H
-.,""
" i ~
Flattened Strand/Fiber Core
Nominal Strength*
inches mm lb/f( kg/m tons metric tonnes
~ 13 0.45 0.67 11.8 10.8
%6 14.5 0.57 0.85 14.9 13.5
.% 16 0.70 1.04 18.3 16.6
% 19 1.01 1.50 26.2 23.8
'Va 22 1.39 2.07 35.4 32.1
1 26 1.80 2.68 46.0 41.7
1'h 29 2.28 3.39 57.9 52.5
1'4 32 2.81 4.18 71.0 64.4
I
\
" ..
1% 35 3.40 5.06 85.5 77.6
1 ~ 38 4.05 6.03 101 91.6
1% 42 4.75 7.07 118 107
, i% 45
551 ' 8.20 136 123
h', 1'% 48 6.33 ' 9.42 155 141
2 51 7.20 10.70 176 160
;
breaking strength) by 8.896; 1 Ib ='4.448 newtons (N).

,I,;..
-8 x 19 (Uricoafedj;Fiber Core
-.1.)i,'
Nominal Strength
"
'4 6.5 0.10 0.15 2.35 2.13
8 0.15 0.22 3.65 3.31
}Is 9.5 0.22 0.33 5.24 4.75
11.5 0.30 0.45 7.09 6.43
1h 13 0.39 0.58 9.23 8.37
l}lo
14.5 0.50 0.74 11.6 10.5
% 16 0.61 0.91 14.3 13.0
% 19 0.88 1.31 20.5 18.6
(
';:;i\
\..
22 1.20 1.79 27.7 25.1
1 26 1.57 2.34 36.0 32.7
BIs 29 1.99 2.96 45.3 41.1
1'4 32 2.45 3.65 55.7 50.5
His 35 2.97 4.42 67.1 60.7
I1h 38 3.53 5.25 79.4 72.0
breaking strength) by 8.896; 1 Ib =4.448 newtons (N).
90
8x19 Classification/Bright IWRC
91
92
93
TABLE 34 NOMINAL STRENGTHS, OF WIRE ROPE
6x 7 Classification/Galvanized, Fiber C6re*
Nominal Strength**
1,4
6.5 0.09 0.14 2.38 2.16
l}16 8 0.15 0.22 3.69 3.35
% 9.5 0.21 0.31 5.27 4.78
'M6 11.5 0.29 0.43 7.14 6.48
.........
In 13 0.38 0.57 9.27 8.41
91n 14.5 0.48 0.71 11.7 10.6
% 16 0.59 0.88 14.3 13.0
% 19 0.84 1.25 20.4 18.5
'Va 22 1.15 1.71 27.6 25.0

1 26 1.50 2.23 35.7 32.4
Pis 29 1.90 2.83 44.8 40.6
114 32 2.34 3.48 54.9 49.8
1% 35 2.84 4.23 65.8 59.7
Ph 38 3.38 5.03 77.6 70.4
For ropes with an IWRC, add 7th % to their respective
nominal strengths and 10% to their approximate mass
(weights). Fiber cores consist either of polypropylene or
natural fiber.
"To convert to Kilonewtons (kN), multiply tons (nominal
breaking strength) by 8.896; lIb. =4.448 newtons (N).
94
..... ,
.'
TABLE 35 NOMINAL OF WIRE ROPE
6 X12 Construction/ Galvanized,'Fiber
Nominal Strength**
inches rom lb/ft kg/m tons metric tonnes
%6 8 0.10 0.14 2.34 2.12
% 9.5 0.15 0.22 3.36 3.05
%6'
11.5 0.20 0.30 4.55 4.13
13 0.26 0.39 5.91 4.71
%.6 14.5 0.33 0.49 7.45 6.76
% 16 0.41 0.61 9.16 8.31
% 19 0.59 0.88 13.1 11.9
21 0.69 1.03 15.3 13.9
va 22 0.80 1.19 17.7 16.1
1 26 1.05 1.56 23.0 20.9
*Fibercores consist either of polypropylene or natural fiber.
**To convert to Kilonewtons (kN), multiply tons (nominal
breaking strength) by 8.896; 1 lb =4.448 newtons (N).
95
6 x 24 Construction/Gaivanb;ed, Fiber Core':'
Nominal Strength**
inches mm Ib/ft kg/m tons metric tonnes
% 9.5 0.19 0.29 4.77 4.33
1;12 .
13 0.35 0.52 8.40 7.62
0/16 14.5 0.44 0.65 10.6 9.62
% 16 0.54 0.80 13.0 1l.8
% 19 0.78 1.16 18.6 16.9
'Va 22 1.06 1.58 25.2 22.9
1 26 1.38 2.05 32.8 29.8
Big 29 1.75 2.60 41.2 37.4
114 . 32 2.16 3.21 50.7 46.0
","
1% 35 2.61 3.88 61.0 55.3
11;12 38 3.ll 4.63 72.3 65.6
1% 42 3.64 5.42 84.5 76.7
it;
,.
..';;.
1%
45' 4.23 6.30 97.5 88.5
:'".i<"t
1Y!l 48 4.85 7.22 III 101
-h;'
2 51 5.52 8.21 126 ll4
*Fiber cores consist either of polypropylene or natural fiber.
**To convert to Kilonewtons (kN), multiply tons (nominal
breaking strength) by 8.896; 1 lb =4.448 newtons (N).
': "
'{:::;'
Appendix A
ORDERING, STORING AND UNREELING WIRE ROPE
A. Ordering
When ordering wire rope, it mustbe described as completely as possible.
The generally accepted nomenclature conventions, defined elsewhere in this
publication, should be carefully noted. These, along with other applicable
information will not only enable the rope manufacturer to satisfy the
purchaser's requests, but will also provide data for technical advice or
suggestions. Following, is a check list of these data:
1. The application for which the wire rope is intended.
2. Description of the rope itself:
a. Length-standard or tape measured
b. Diameter-measured as shown on page 14 .
.. c. Construction--e.g., "6 x 19 Seale"
d. Lay-Right or Left; Regular or Lang Lay
e. Grade-:-improved plow steel, extra improved plow steel,
traction steel, other
f. Finish-bright, galvanized, or tinned
g. Core-independent wire rope (IWRC) , wire strand, or fiber
h. Preformed or non-preformed
i. Lub!"ication-standard or special
3. Describe end attachments (ifrequired)
4. Special spooling or reel requirements
B. Storing .
No matter how the delivered rope is packaged, it should always be kept away
from moisture. This means storing under a weatherproof cover overhead,
and no direct contact with the ground or floor. Ocean spray, acid fumes,
or similarly corrosive atmospheres should be avoided. When reels will
remain stored for long periods, the supplier should be asked to ship the ropes
with a p.x:otective wrapping. Where this has not been done, the outer layers
of rope should be coated with an approved lubricant.
. When a rope is to be removed from service and stored, it should be
thoroughly cleaned. lubricated, and carefully coiled on a reel. In this case, the
same storage conditions that are required for new rope, should be maintained.
Ambient temperature for rope in storage should be low. Elevated
temperatures tend to liquefy or thin out rope lubricants. Thus, wire rope
storage areas should not only be normally cool spaces, but possible
sources of high heat should be kept at some distance.
97
C. Unreeling
Wire rope must always be handled w ~ ~ care. This is particularly important
when teeIs or coils are 'receh/ed' moved'about, unreeled or uncoiled.
Reels or coils should never be dropped. When this happens, the rope may
s'hift and cause the reel to collapse and thus the rope itself may be damaged.
Removing rope from a collapsed reel may often result in rope damage.
Coiled rope, if dropped on the edge of the coil, can sustain a permanent bend.
Coils and reels should only be rolled on relatively smooth, hard surfaces.
Rolling through loose dirt, standing water, or across sharp, hard objects, or
over uneven surfaces can cause deformations or harm the lubricant protection.
Careful handling beforeinstaIlation and proper maintenance procedures
afterward will ensure the longest possible service life for wire rope.
Improper handling can prove quite costly for the user, yet, for the
most part, abuse is easily avoidable.
Appendix B
A GLOSSARY OF
WIRE ROPE TERMS
ABRASION Frictional surface wear on
the wires of a wire rope.
ACCELERATION STRESS h e ~
additional stress that is imposed on a
wire rope as a result of an increase in the
load velocity. (See DECELERATION
STRESS).
AGGREGATE AREA See AREA,
METALLIC.
AGGREGATE BREAKING
STRENGTH The breaking strength
derived by totalling the individual
breaking strengths of the elements of the
strand or rope. This strength does not
give recognition to the reduction in
strength resulting from the angularity of
the elements in the rope nor other factors
which may affect efficiency.
AIRCRAFT CABLES Strands, cords
and wire ropes made of special-strength
wire, designed primarily for use in various
aircraft industry applications.
ALBERTS LAY See LAY, TYPES.
ALTERNATE LAY See LAY, TYPES.
AREA, METALLIC Sum of the cross-
sectional areas of all the wires either in
a wire rope or in a strand.
BAIL a) V-shaped member of a bucket,
or b) V-shaped portion of a socket or
other fitting used on wire rope.
BAILING LINE In well drilling, it is
the wire rope that operates the bailer that
removes water and drill cuttings.
BARNEY CAR A relatively small car
permanently attached to a haulage rope
that pushes cars along a haulage system.
BASKET OF SOCKET The conical
portion of a socket into which a broomed-
rope-end is inserted and then secured
either with zinc or resin.
BECKET An end attachment to
facilitate wire rope installation.
99
BECKET LOOP A loop of small rope or
strand fastened to the end of a large
wire rope. Its function is to facilitate wire
rope installation.
BACK-STAY Wire rope or strand guy
used to support a boom or mast; or that
section of a main cable, as on a suspension
bridge, cableway, etc., leading from
the tower to the anchorage.
BENDING STRESS Stress that is
imposed on the wires of a wire rope by a
bending or curving action.
BICABLE A term usually applied to a
wire rope aerial tramway that has a fixed
cable or strand to support the load, as
well as a traction or haul rope that moves
the load about the system.
BIRDCAGE A colloquialism
descriptive of the appearance of a wire
rope forced into compression. The outer
strands form a "cage" and, at times,
displace the core.
BLOCK A term applied to a wire rope
pulley enclosed in side plates and fitted
with some attachment such as a hook or
shackle.
BOOM HOIST LINE Wire rope that
operates the boom hoist of derricks,
cranes, draglines, shovels, etc.
BOOM PENDANTS A non-operating
rope or strand with terminations to
support the boom.
BREAKING STRENGTH
Breaking Strength is the ultimate load
at which a tensile failure occurs in the
sample of wire rope being tested. (Note:
The term breaking strength is synonymous
with actual strength.)
Minimum Acceptance Strength is that
strength which is 2\12 % lower than the
catalog or nominal strength. This
tolerance is used to offset testing variables
which exist when the test is made to
determine the breaking strength of a
specific sample of wire rope. Its use
originated with the basic government
wire rope specification.
BREAKING STRENGTH (cont,)
Nominal Strength is the published
(catalog) strength calculated by a
standard procedure and accepted by the
wire rope industry. The wire rope
manufacturer designs wire rope to this
strength, and the user should consider
this to be the minimum strength when
making design calculations.
BRIDGE CABLE The all-metallic wire
ropes or strands used as the catenary and
suspenders on a suspension bridge.
BRIDGE SOCKET A wire rope fitting
of forged or cast steel that is designed with
baskets-having adjustable bolts-for
securing rope ends. There are two styles:
1) the closed type has a V-bolt with or
without a bearing block in the V of the
bolt, and 2) the open type has two
eye-bolts and a pin.
BRIDLE SLING A multipart wire
rope sling.
BRIGHT ROPE Wire rope fabricated
from wires that are not metallic coated.
BRONZE ROPE Wire rope fabricated
from bronze wires.
BULL WHEEL A term applied to a
large-diameter wire rope sheave; e.g., the
sheaveS at the end of a ski lift.
BUTTON CONVEYOR ROPE
Wire ropes to which buttons or discs are
attached at regular intervals to move
material as in a trough.
CABLE . A term loosely applied to wire
r o p ~ wire strand and electriCal
conductors.
,
CABLE-LAID WIRE ROPE A type of
wire rope consisting of several wire ropes
laid into a single wire rope. Example: .
6 x 42 (6 x 6 x 7) tiller rope.
CABLE TOOL DRILLING LINE
The wire rope used to operate the cutting
tools in the "cable tool" drilling method
(i.e., rope drilling).
100
CABLEWAY Aerial conveying system
. for transporting single loads along Ii
s,uspended track cable.
CASING LINE Wire rope used to
install oil well casings.
CATENARY The curve formed by a
. wire rope when supported horizontally
between two fixed points; e.g., the main
spans on a suspension bridge.
CENTERS Wire, strand or fiber at the
center of a strand around which the wires
are laid.
CHOKER ROPE A short wire rope
sling that forms a slip noose around an
object that is to be moved or lifted.
CIRCUMFERENCE Measured
perimeter of a circle that circumscribes
either the wires of a strand or the strands
of a wire rope.
CLAMPS, STRAND A fitting for
forming a loop at the end of a length of
strand, consisting of two grooved plates
and bolts.
CLASSIFICATION Group or family
designation based on wire rope con-
structions with strengths and weights
jointly lisied under the broad designation.
CLEANING OUT LINE Wire rope
used in conjunction with tools that are
used to clean an oil well.
CLEVIS See SHACKLE.
CLIP Fitting for clamping two parts of
wire rope to each other.
CLOSED SOCKET A wire rope end
fitting consisting of basket and bail made
integral.
CLOSER A machine which lays (winds)
strand around a central core to form rope.
CLOSING LINE Wire rope that per-
forms two functions: 1) closes a clamshell
or orange peel bucket, and 2) operates
as a hoisting rope.
COARSE LAID ROPE Term generally
used in oil fields to designate a 6 x 7.
wire rope.
COIL Circular bundle or package of
wire rope that is not affixed to a reel.
COMEALONG Device for making a
temporary grip on a wire rope.
CONICAL DRUM Grooved hoisting
drum with a varying diameter. See
DRUM.
CONSTRUCTION Geometric design
description of the wire rope's cross section.
This includes the number of STRANDS,
the-number of WIRES per strand and the
pattern of wire arrangement in each
STRAND.
CONTINUOUS BEND Reeving of wire
rope over sheaves and drums so that it
bends in one direction, as opposed to
REVERSE BEND.
CONVEYOR ROPE Endless wire rope
used to carry material. See BUTTON
CONVEYOR ROPE.
CORD Term applied to small size wire
ropes or strands.
CORE The central member of a wire
rope about which the strands are laid.
It can be made of fiber, a wire strand or
an independent wire rope.
CORING LINE Wire rope used to
operate the coring tool that is used to take
core samples during oil well drilling.
CORROSION Chemical decomposition
of the wires in a rope through the action
of moisture, acids, alkalines or other -
destructive agents.
CORROSION-RESISTING STEEL
Chrome-nickel steel alloys designed for
increased resistance to corrosion.
CORRUGATED Term used to describe
the grooves of a sheave or drum after
these have been worn down to a point
where they show an impression of a
wire rope.
101
COlTON CENTER See FIBER
CENTERS.
COTTON CORE See FIBER CORES.
COUPLING (track strand) Device for
joining the ends of two lengths of
track strand.
COVER WIRES Outer layer of wires.
CRACKER Manila rope spliced or
otherwise attached to the end of a wire
drilling line.
CREEP The unique movement of a
wire rope withrespect to a drum surface
or sheave surface resulting from the
asymmetrical load between one side of the
sheave (drum) and the other; It is not
dissimilar from the action of a caterpillar-
moving over a flat surface. It should be
distinguished from slip which is yet
another type of relative movement
between rope and the sheave or drum
surface.
CRITICAL DIAMETER For any given
wire rope, it is the diameter oJ the smallest
bend that permits both wires and strands
to adjust themselves by relative movement
while retaining their normal cross-secti9n
position.
CROSS LAY See LAY, TYPES.
CROWD ROPE A wire rope used to
drive or force a power shovel bucket into
the material that is to be handled.
CYLINDRICAL DRUM A hoisting
drum of uniform diameter. See DRUM.
DEAD-LINE In drilling, it is the end of
the rotary drilling line fastened to the
anchor or dead-line clamp.
DECELERATION STRESS
The additional stress that is imposed on
a wire rope as a result of a decrease
in the load velocity.
DEFLECTION a) The sag of a rope in
a span. Usually measured at mid-span
as the depth from the chord "joining the
tops of the two supports. b) Any
deviation from a straight line.
DESIGN FACTOR In a wire rope, it
is the ratio of the listed breaking strength
to the total working load.
DIAMETER A line segment which
passes through the center of a circle and
whose end points lie on the circle. As
related to wire rope it would be the
diameter of a circle which circumscribes
the wire rope.
DOG-LEG Permanent short bend or
kink in a wire rope caused by improper
use or handling.
DRAGLINE a) Wire rope used for
pulling excavating or drag buckets, and
b) name applied to a specific type of
excavator.
DRILLING LINE See CABLE TOOL
DRILLING LINE and ROTARY
DRILLING LINE.
DRUM A cylindrical flanged barrel,
either of uniform or tapering diameter, on
which rope is wound either for operation
or storage. Its surface may be smooth or
grooved.
EFFICIENCY Ratio of a wire rope's
measured breaking strength and the
aggregate strength of all individual wires
tested separately-usually expressed
as a percentage.
ELASTIC LIMIT Stress limit above
which permanent deformation will take
place within the material.
ELLIPTIC SPOOL An endless-rope
drive drum with a face in the shape of an
elliptic arc.
ELONGATION See STRETCH.
ENDLESS ROPE Rope whose two ends
are spliced together to. form a single
continuous loop.
~
EQUALIZING SHEAVE The sheave
at the center of a rope system over which
. -no rope movement occurs other than
equalizing movement. It is frequently
overlooked during crane inspections, with
diasastrous consequences. It can be the
source of severe fatigue deterioration.
EQUALIZING SLINGS Multiple-leg
slings composed of wire rope and fittings
that are designed to help distribute the
load equally. See SLING.
EQUALIZING THIMBLES Special
type of load-distributing fitting used as
a component of certain wire rope slings.
EXTRA FLEXIBLE WIRE ROPE
An ambiguous and archaic term some-
times applied to describe wire ropes in
the 8 x 19 class and 6 x 37 class. The term
is so indefinite as to be meaningless and
is in disfavor today.
EXTRA HIGH-STRENGTH STRAND
A grade of galvanized or bright strand.
EXTRA IMPROVED PLOW STEEL
ROPE A specific wire rope grade.
EYE OR EYE SPLICE A loop, with or
without a thimble, formed at the end
of a wire rope.
FACTOR OF SAFETY A term origin-
ally used in the wire rope industry to
state the ratio of nominal strength to the
total working load. The term is no longer
used since it implies the permanent
existence of this ratio when, in actuality.
the rope strength begins to reduce the
moment it is placed in service.
See DESIGN FACTOR.
FATIGUE In wire rope the term is
usually applied to the process of progres-
sive fracture. from bending. of the
individual wires. These fractures may and
usually do occur at bending stresses well
below the ultimate strength of the
material: it is not an abnormality although
it may be accelerated due to conditions in
the rope such as rust or lack of lubrication.
: .. ,
FERRULE A metallic button, usually
cylindrical in shape, normally fastened to
a wire rope by swaging but sometimes by
spelter socketing.
FERRY ROPE Refers to wire rope that
is suspended over water for the purpose
of guiding a boat.
FIBER CENTERS Cords or rope made
of vegetable or synthetic fiber that are
used as the center of a strand.
FIBER CORES Cords or rope made of
vegetable of synthetic fiber that are used
as the center of a wire rope.
FILLER WIRE Small auxiliary wires
within a strand whose primary purpose is
to position and support other wires.
FIITING Any functional accessory
attached to a wire rope.
FLAG Marker placed on a rope so as
to locate the load position.
FLAT ROPE Wire rope that is made of
a series of parallel, alternating right-lay
and left-lay ropes, sewn together with
relatively soft wires. '
FLAITENED STRAND ROPE
, Wire rope that is made either of oval or
triangular shaped strands in order to'
form a flattened rope surface.
FLEET ANGLE That angle between
the rope's position at the extreme end
wrap on a drum, and 'a line drawn perpen-
dicular to the axis of the drum through
the center of the nearest fixed sheave.
See DRUM and SHEAVE.
FLEXIBLE WIRE ROPE An archaic
and imprecise term to differentiate one
rope construction from another; such as,
6 x 7 (least flexible) and 6 x 19 classifi-
cation (somewhat more flexible). See
EXTRA FLEXIBLE WIRE ROPE.
GALVANIZED Hot-dipped (occasion-
ally electro-chemical) zinc coating for
corrosion resistance.
GALVANIZED ROPE Wire rope made
up of galvanized wire.
103
GALVANIZED STRAND Strand made
up of galvanized wire.
GALVANIZED WIRE Zinc-coated wire.
GRADE Wire rope or strand classifica-
tion by strength and/ or type of material-
i.e., Improved Plow Steel, Type 302
Stainless, Phosphor Bronze, etc. It does
not imply a strength of the basic wire used
to meet the rope's nominal strength.
GRADES, ROPE Classification of wire
rope by the wire's metallic composition
and the rope's breaking strength.
GRADES, STRAND Classification of
strand by the wire's metallic composition
and the strand's breaking strength. In the
order of increasing breaking strengths,
the grades are Common, Siemens Martin,
High-Strength and Extra-High Strength.
A Utilities grade strength is also made
to meet special requit.ements and its
strength is usually greater than high-:
strength.
GRAIN SHOVEL ROPE 6 x 19
Marline clad rope used for. handling
grain in scoops.
GROMMET An endless 6-strand wire
rope with a strand core made of one
continuous length of strand.
GROOVED DRUM Drum with a
grooved surface that accommodates the
rope and guides it for proper winding and
un-winding.
GROOVES Depressions-helical or
parallel-in the periphery of a sheave or
drum that are shaped to position and
support the rope.
GUY LINE Strand or rope, usually
galvanized, for stabilizing or maintaining
~ s ~ r u t u r in fixed-position.
HAULAGE ROPE Wire rope used for
pulling movable devices such as cars that
roll on a track.
HAWSER Wire rope. usually galvan-
ized, used for towing or mooring marine
vessels.
,;>
. HERRINGBONE See LAY, TYPES.
HI'GHSTRENGTH STRAND
Grade of galvanized or bright strand.
See GALZANIZED and BRIGHT ROPE.
HOLDING LINE Wire rope on a
clamshell or orange peel bucket that acts
as a restraint on the bucket while the
closing line is released to dump its load.
IDLER Sheave or roller used to guide
or support a rope. See SHEAVE.
IMPROVED PLOWSTEEL ROPE
A specific grade of wire rope.
INCLINE ROPES Ropes used in the
operation of cars on an inclined haulage.
INDEPENDENT WIRE ROPE CORE
Wire rope that is used as the core within
a larger rope. In rope specifications,
it is usually denoted by the abbreviation
IWRC.
INNER WmES AIl wires of a strand
except the outer or cover wires.
INTERNALLY LUBRICATED
Wire rope or strand having all of its wire
components coated with lubricant.
mON ROPE A specific grade of
wire rope.
mONING See MILKING.
IWRC See INDEPENDENT WIRE
ROPE CORE.
KINK A unique deformation of a wire
rope caused by a loop of rope being pulled
down tight. It represents irreparable
damage to the rope and an indeterminable
loss of strength.
LAGGING a) External wood covering
on a reel to protect the wire rope or strand,
or b) the grooved shell of a drum.
LANG LAY ROPE See LAY, TYPES.
LAY a) The manner in which the wires
in a strand or the strands in a rope are
helically laid, or b) the length, parallel to
"the longitudinal axis, in which a wire
104
makes one complete turn about the axis of
. the strand or a strand about the axis of
Ii rope. In this connection lay is also
referred to as lay length or pitch.
LAY,TYPES
1) Right Lay: product in which the
, elements are laid in a right hand helix.
2) Left Lay: product in which the
elements are laid in a left hand helix.
3) Cross Lay: product in which one or
more laying or closing operations are
performend in opposite directions. A
multiple operation product is named
according to the direction of the outside
layer.
4) Regular Lay: wire rope in which the
wires in the strands and the strands in the
rope are laid in opposite directions. The
crowns of the wires appear to line up
with the axis of the rope.
5) Lang Lay: wire rope in which the
wires in the strands and the strands in the
rope are laid in the same direction. The
crowns of the wires make an angle with
the axis of the rope.
6) Alternate Lay: lay of a wire rope in
which the strands are alternately regular
and lang lay.
7) Alberts Lay: an old, now rarely used,
term for lang lay.
8) Reverse Lay: another term for
alternate lay.
9) Spring Lay: this is not actually a
unique lay and more properly refers to a
wire rope construction. See MOORING
LINES and SPRING LAY.
10) Herringbone: an unusual construction
consisting of 4 Lang Lay strands, each
pair of which is separated by a
Regular Lay strand. See LAY.
LAY LENGm See LAY (b).
LEAD LINE That part of a rope t ~ l e
leading from the first, or fast, sheave to
the drum. See DRUM and SHEAVE.
LEFT LAY See LAY, TYPES.
LINE Term used synonymously with
WIRE ROPE.
LOCKED COIL STRAND Smooth-
surfaced strand ordinarily constructedof
shaped, outer wires arranged in concentric
layers around a center of round wires.
LOOP A 360
0
change of direction in the
course of a wire rope which when pulled
down tight will result in a kink. See EYE
and EYE SPLICE.
MARLINE-
A pre-lubricated fiber material.
MARLINE-CLAD ROPE Rope with
individual strands spirally wrapped
with Marline.
MARLINE SPIKE Tapered steel pin
used as a tool for splicing wire rope.
MARTENSTITE A micro-constituent
of steel that becomes extremely brittle
when the steel is heated above the critical
temperature and rapidly quenched; This can
occur in wire ropes as a result of frictional
heating and the mass cooling effect of the
cold metal beneath. Martenstite cracks
very easily when bent and such cracks
propagate through the entire structure
below.
MESSENGER STRAND Galvanized
strand used to support telephone and
electrical cables.
METALLIC CORES See WIRE
STRAND CORE and INDEPENDENT
WIRE ROPE CORE.
MILD PLOW See GRADES, ROPE.
MILKING Sometimes called ironing, it
is the progressive movement of strands
along the axis of the rope 'that results from
its movement through a restricted passage
such as a tight sheave. '
MODULUS OF ELASTICITY
Mathematical quantity expressing the
ratio, within the elastic limit, between a
definite range of unit stress on a wire rope
and the corresponding unit elongation.
MONOCABLE A term usually applied
to an aerial tramway designed with a
single wire rope that not only supports the
load but conveys it as well.
105
MOORING LINES Galvanized wire
rope, usually 6 x 12, 6 x 24, or 6 x 3 x 19
spring lay for holding ships to dock.
NON-ROTATING WIRE ROPE
An abandoned reference to 19 x 7 or
18 x 7 rope. See ROTATION
RESISTANT.
NON-SPINNING WIRE ROPE
See NON-ROTATING WIRE ROPE.
OPEN SOCKET A wire rope fitting that
consists of a "basket" and two "ears"
with a pin. See FITTING.
OUTER WIRES See COVER WIRES.
PEENING Permanent distortion
resulting from cold plastic flow of the
outer wires. Usually caused by pounding
against a sheave or machine member or by
heavy operating pressure between rope
and sheave, rope and drum, or rope and
adjacent wrap of rope.
PITCH See LAY (b).
PLOW STEEL See GRADES, ROPE.
PREFORMED STRANDS Strand in
which the wires are permanently shaped
before fabrication into strand to the
helical form they assume in the strand.
PREFORMED WIRE ROPE
Wire rope in which the strands are
permanently shaped before fabrication
into the rope to the helical form they will
assume in the wire rope.
PRESSED FITTINGS Fittings which
are attached to wire rope by cold forming
the fitting onto the rope by means of a
rotary swager or a press. See SWAGED
FITTINGS.
PRE-STRESSING An incorrect
reference to prestretching.
PRESTRETCHING Subjecting a wire
rope or strand to tension prior to its
intended application, for an extent and
over a period of time sufficient to remove
most of the constructional stretch.
SIEMENS-MARTIN STRAND
A grade of galvanized strand.
See GALVANIZE.
SHACKLE A D- or anchor-shaped
fitting with pin.
SHEAVE A grooved
plll1ey for wire rope.
SEWING WIRES See FLAT ROPE.
SERVE To cover the surface of a wire
rope or strand with a fiber cord or wire
wrapping.
SEIZE To make a secure binding at the
end of a wire rope or strand with seizing
wire or strand. See SEIZING WIRE.
SEIZING STRAND Small strand
usually made up of 7 soft wires.
See SEIZE.
SEIZING WIRE A soft wire.
See SEIZE.
SASH CORD Small, 6 x 7 wire ropes,
commonly made of iron wires, are
referred to by this tcrm.
SEALE The name for a type of strand
construction that is characterized by:
1) covcr wires of a single size, 2) the same
number of one size of wires in the
adjacent layer and 3) each layer having
the same length and direction of lay.
The most common construction of this
type has one center wire, nine inner wires
and nine cover wires.
SAG See DEFLECTION.
SAND LINE See BAILING LINE.
PROPORTIONAL LIMIt As used in SAFETY FACTOR
the rope industry this term is virtually the See DESIGN FACTOR.
Same as elastic limit. It is the end of the" ":,w
SAFE WORKING LOAD Potentially
load versus elongation relationship at
misleading. this term is in disfavor.
which an increase in load no longer
Essentially, it means the portion of the
prodllces a proportional increase in
nominal rope strength that can be applied
elongation and from which point recovery
" to nlove or Sllstal'n a load. It )'s misleadl'ng
to the rope's original length is unlikely.
because it is valid only when the rope
is new and equipment is in good condition.
See RATED CAPACITY.
RATED CAPACITY The load which a
wire rope or wire rope sling, when new,
may handle under given operating condi-
titms and at an assumed design fattor.
REEL A flanged spool on which wire,
rope or strand is wound for storage or
shipment.
REEVE To pass a rope through a hole
or around a system of sheaves.
ROTATION-RESISTANT ROPE
A wire rope consisting of an inner layer
of'strand laid in one direction covered-by
a layer' of strand laid in the opposite
direction. This has the effect of counter-
acting torque by reducing the tendency
of the finished rope to rotate.
RUNNING ROPE Term used to
describe 6x 12 galvanized wire rope.
REGULAR LAY ROPE
See LAY, TYPES.
RESERVE STRENGTH The strength
of a rope exclusive of the outer wires;
refers to all ropes that exhibit some type of
rotation-resistant quality or characteristic.
REVERSE BEND Reeving a wire rope
over sheaves and drums so that it bends
in opposing directions. See REEVE.
REVERSE LAY See LAY, TYPES.
RIGHT LAY See LAY, TYPES.
ROLLERS Relatively small-diameter
cylinders, or wide-faced sheaves, that
serve as support for ropes.
ROTARY LINE On a rotary dri11ing rig,
itis the wire rope used for raising and
lowering the drill pipe, as well as for
, controlling its position.
106
~
SLINGS Wire rope or ropes made into
forms, with or without fittings, for:
handling loads and designed to permit the
attachment of an operating rope.
SLING, BRAIDED Aflexible sling,
the body of which is made up of two or
more wire ropes braided together.
See SLINGS.
SMOOTH-COIL TRACK STRAND
Strand composed of concentric layers of
round wires, used as an aerial conveyor
track cable. See STRAND.
SMOOTH-FACED DRUM Drum with
a plain, ungrooved surf;;;:e. Sec DRUM.
SOCKET Generic name for a type of
wire rope fitting. See BRIDGE SOCKETS,
CLOSED SOCKETS, OPEN SOCKETS
and WEDGE SOCKETS.
SPECIAL FLEXIBLE WIRE ROPE'
Term sometimes used to describe 6 x 37
classification wire rope.
SPIN RESISTANT An abandoned
term referring to a rotation-resistant rope
of the 8 x 19 type.
See ROTATION RESISTANT.
SPIRAL GROOVE A continuous
helical groove that follows a path on and
around a drum face, similar to a screw
thread. See DRUM.
SPLICING Making a loop or eye in the
end of a rope by tucking the ends of the
strands back into the main body of the
rope. The term is also applied to, the
formation of loops or eyes in a rope by
means of mechanical attachments pressed
onto the rope. The term also relates to
the joining of two rope ends so as to form
a long or short splice in two pieces of rope.
. -
SPRING LAY See LAY, TYPES.
STAINLESS STEEL ROPE Wire rope
made up of corrosion-resisting steel wires.
STANDING ROPE See GUY LINE.
STIRRUP The U-bolt or eyebolt
attachment on a bridge socket.
See SOCKET.
107
STONE SAWING STRAND A 2-wire
or 3-wire strand used in stone and slate
quarrying operations.
STONE SAWING WIRE A shaped and
twisted wire used in stone and slate
quarrying operations.
STRAND A symmetrically arranged
and helically-wound assembly of wires.
STRAND CENTER See CENTERS.
STRAND CORE See CORES.
STRESS The force or resistance within
any solid body to alteration of form; in
the case of a soEd \vire it ',,",QuId be the Io:'.d
on the rope divided by the area of the wire.
STRETCH The elongation of a wire
rope under load.
SWAB LINE
See CLEANING OUT LINE.
SWAGED FITTINGS' Fittings into
which wire rope can be inserted and then
permanently attached by cold pressing
(swaging) the shank that encloses the rope.
See FITTING.
TAG LINE A small wire rope used to
prevent rotation of a load.
TAPERED DRUM
See CONICAL DRUM.
TAPERING AND WELDING
Reducing the diameter of a wire rope at
its end, and then welding the wires so as to
facilitate reeving. See REEVE.
THIMBLE Grooved metal fitting to
protect the eye, or fastening loop of
a wire rope.
TILLER ROPE A highly flexible rope
constructed by cable-laying six 6 x7 ropes
around a fiber core.
TINNED WIRE Wire that is coated
with tin. See WIRE.
TRACK CABLE On an aerial conveyor
it is the suspended wire rope or strand
along which the carriers move.
TRACTIoN ROPE On an aerial
conveyor or haulage system it is the wire
rope that propels the carriages.
TRACTION STEEL A special grade of
wire rope used for various funCtions
of an elevator system.
See GRADES, ROPE.
TRAMWAY An aerial conveying
system for transporting multiple loads.
TURN Synonymous with the term
WRAP; it is one wrap around a drum.
TURNBACK POINT That point in the
traverse of a rope across the face of
the drum where it reaches the flange,
reverses direction and begins forming the
next layer.
WARRINGTON The name for a type
of strand construction that is characterized
by having one of its wire layers (usually
the outer) made up of an arrangement
of alternately large and small wires.
1015
WEDGE SOCKET Wire rope fittings
()herein the rope end is secured by a
wedge. See FITIINGS.
WHIPPING An alternate term for
seizing. Also, it has been suggested as
punishment for those who neglect the
cautionary rules in this publication.
WIRE (round) A single, continuous
length of metal, with a circular cross-
section, that is cold-drawn from rod.
WIRE (shaped) A single, continuous
length of metal with a Z- or H-shaped
cross-section that is either cold-drawn or
cold-rolled from rod.
WIRE ROPE A designed assembly of
symmetrically arranged and helically
wound strands. See CORE and STRAND.
WRAP See TURN.
\
,
Appendix C WIRE ROPE FITTINGS
CLOSED WIRE ROPE SOCKETS
(POURED)
TABLE 37 DIMENSIONS (inches)

Approx.
Rope Wt
Diam. A B C D .G J R T Lb

1,4
2 1% \.16 1%0
!)1r. . 1h
1116
10/16 0.5
916& % 2 2 lJ.1r. 4!)16 1!)16
3,4
% 1
11
hr.
1%.6
0.9
\.16&
:yz
2
1
h 21,4 11h6 5\.1r. His 10/16 % 2 1118 1.5
%6& % 3 2:YZ 1t16 6%; 2% 1Ys 1 2% 1% 3.0
% 3:YZ 3 7% 2% 11,4 11,4 3 1% 4.5
'Vs 4 3lh 11,4 8% 31,4 1:YZ 1:YZ 3% 1% 7.0
1 4
1
h 4 1% 9'Vs 3% 1% 1% 4':18 21,4 11.0
1Ys 5 4
1
h 1:YZ 11 4
1
18 2 2 4
1
h 2:YZ 16.0
11,4 & 1% 5lh 5 1% 12Ys 4% 21,4 21,4 5 2% 22.0
1:YZ 6 6 1
1
0/16 13
1
0/16 51,4 2
3
,4 2:YZ 5% 3Ys 28.0
1% 6Y2 6% 2Ys 15% 5
1
h 3 2% 5% 31,4 36.0
1%&1% 7lh 7
1
%; 20/1.6 17lh 6% 3Ys 3 6% 3
1
%2 58.0
2 &2':18 8
1
h 8
1
0/1.6 2Y16 19% 7% 3% 31,4 7% 3
2
%2 80.0
21,4 & 2% 9 9% 2% 21% 81,4 4 3% 8lh 4%2 105.0
2:YZ & 2% 9% 10
5
18 3Ys 23
1
h 9
1
,4 4lh 4 9
1
h 4
2
%2 140.0
2
3
,4 & 2% 11 11lh 3 25
1
h 10% 4'Vs 4% 10
3
,4 5Y.32 220.0
3 &3
1
18 12 11% 31,4 27 11:YZ 5% 51,4 l1lh 5%2 276.0
31,4 & 3% 12 11% 31,4 27 11
1
h 5% 51,4 l1lh 5
17
1.32 276.0
3:YZ & 3
5
18 14 13 4 31 13 6lh 61/.+ 13 6Y.32 400.0
3%-4 15 14 41,4 331,4 141,4 71,4 7 141,4 540.0
NOTE: Dimensions are for reference only. Consult your supplier of the specific fittings for
exact details.
109
, l > ..
OPEN WIRE ROPE SOCKETS
(POURED)
TABLE 38 DIMENSIONS (inches)
Approx.
Rope Wt
Diam. A B C D E G J K L N P Lb
,
%;& 14'
2 1 31'4
1
31'4
lYJll FiSr.
l1Afi
0.9
.}
& 3/
8 2 1% 'Vs 40/s
1!Jt,t; 1:!1r. 31'4 ' 1
Ph
10/1r.
1.1
'Vlr.& liz 2Y2 2 ,i
1
"n 51'u
1'Vs '
1
1%,0
1 liz lYs , 1 2.3
1)10 & s/s 3 2Y2 IJ,4 6
3
1'4 21,4 111'4, P/s PA 'Hli 2v.. 1:1111 3.8
% 3Y2 3 . 11111
2% 1Y2, IJ,4 Ph % 2% 1% ,6.0
'Vs 4 3
1
/2 1% 9
1
,4 3%' 1%
,
1112 13..4 % 3
1
/s 1% 10.0
':".;,;r.'/.'
15.0 1 4liz 4 ' 10
u
'i,i 3% 2 1% 2 'Vs 3% 2
1V8 5 4liz
Ill::,!,;
4 2% 2 2.J,4 1 4
1
/s 2
1
1'4 23.0
11,4&1% 5
1
/2 5
211.
1
,; 13:);1n
4% 2
3
1'4 2
1
1'4 2Y2 1
1
/8 4
3
1'4 2Y2 32.0
1
1
/2, 6 6 31/8' 15Ys 5% 3
23,4 3
1:t
1li 5% 2%
;47:0
,1% 6
1
/2 6
1
/2 3
1
,4 16
1
,4 5
1
12 31,4 3 3 1ilti 5% 3 55.0
1%&I'Vs 711z 7 3% 18
1
,4 6% 3Ys 31/lj 31/2
l!J.1tj
6
1
12 3
1
12 85.0
2 & 21/8 8
1
12 9 4 211/2 7% 41,4 33..4 4
1
1
:1
111 7 3% 125.0
2
1
,4 & 2
3
18 9 10 4
1
12 23
1
12 8
1
,4 4
3
/s 4 4
1
/2 .21/8 7%"
4
1
,4 165.0
21/2 & 2% 9
3
,4 10
3
1'4
:; 2'5Vi' 91,4 4
1
/2 5 2% 81/2 4
3
,4 252.0
2
3
1'4 & 2'Vs 11 11 5
1
,4 27
1
,4 10
3
1'4 4'Vs 4Y8 5
1
1'4 2'Vs 9 5 315.0
3 & 31/8 12 1JI,4 5:}4 29 11
1
/2 5 5
1
,4 53..4 3 91/2 5
1
,4 380.0
3
1
,4 & 3% 13 1 6
J
/M 30% 12
1
'4
53,4 53,4' 6
1
/4 31/8 10 51/2 434.0
31/2 14 121/2
33
1
,4 13 6
1
,4 61/2 M4 31,4 103,4 6 563.0
3%-4 15 13Y2 7% 36
1
1.1 14
1
/.i 7 7
1
,4 71/2 3lj2 7 783.0
'i{;';
'NOTE: DifuensidJisatefot,reference6rtly. Consult your supplier of the specific fittings for
exact details.
lID
OPEN SWAGED WIRE ROPE
SOCKETS
TABLE 39 DIMENSIONS (inches) (after swaging)
After, Jaw Pin
Rope Swaging opening diam. Approx.
diam. A B C D E F H L wt/lb
W % Ph 1% 4 .52

. Hj'b 10/16 10/16 1% 10/16 1% 1.12
% 1%2 10/16 10/16 13,4
19,j(j
1% 5%6 1.07
Ylfl % %6 1 1 2 P/s 2 2.08
1/
2 % %6 1 2 1Ys 2 6
11
/16 2.08
% lYs
,1%2 lw, H1G 2w 1% 2% 8Ys 4.28
% 1% 1
1
/2 1% 2% 1%6 2% 10 7.97
'Vs lY2 % 1% 1% 3
1
/:' 1
2
ry{{2 llVs 11.3
1 13.4 % 2 2 3
3
,4 2%2 13% 17.8
1% 2 1 2w
2'IA
4w 2')16 15 26.0
2w P/s 2
1
12 2g'16 4
1
h 16
1
12 34.9
1% 2
1
12 P/s 2
1
12 5
l
A 5 18
1
/s 44.4
B-2 2% H16 3 5% 3Ys 5
1
12 19% 58.0
1% 3 ,,1%6 3
1
12 3
1
12 6% 3% 6w 23 87.5
2 1
6
1;(;4 4 3% 8 4%6 8 26% 150
exact details.
II I
OPEN SWAGED STRAND
SOCKETS
TABLE 40 DIMENSIONS FOR AND 37WIRE STRAND
(inches) (after swaging)
L@=r
Fj-l
r k B
---r
c
-L
i, .. jJ;
Approx.
(.
Jaw Pin wt/1b
Strand opening diarn. without
diam; A B C D E F H L Pin
1,4&%6 l1/s
5/
S 11;4 1716 21;4 2
1
12 8
3
/.; 3.5
% 1% % 1112 Ph 2% 1
1
710 3 10
1
/2 6.25
',c\;,.
1
716
&% 11,4 . 1%
1% 3
1
/.; 2 3% 121;4 9.25
1710 &% P/.; 1132 2 2 3% 2% 4 14 14.5
1%6 &1 2 21;4 21;4 4
1
/.; 2!)1n 4
1
12 15
3
/.; 20.5
1710 &1
1
/8 21;4 21,4 21h 4% 5 17V2 29.25
1710 &11;4 2,1/2 Hio 21h 2
1
12 51;4 3Vs
51/.; 191;4 38.25
1%6 &1% 2
3
/.; mu. 3 2% 5% 31h 5.% 21 45.0
exact details.
:
"
.," '
112

CLOSED SWAGED WIRE ROPE
SOCKETS
.. __...
TABLE 41 DIMENSIONS (inches) (after swaging)
.' .....f----L I !
t \ r-E-+-F-l
C(! [i : i n
After Eye Hole Approx.
Rope Swaging thickness diam. wt
diam. A B C D E F L (lb)
'/.4 i-5.6
1h
1% % 1% 31/2 .32
0/16 17:16 40/64 1% % 10/16 1%6 41/2 .77
% 17:16 40/64 . 1%
Ys 10/16 4Y2. .72
i-5.6 Ys 50/64 2 Fh6 P/2 1ij-:12 5% 1.42
1/2 Ys 50/64 2 B:1f1 Ph Bob 5
3
;.4 1.35
-E.
1% lVs 2% 1'/.4 1
1
%6 1% 7
1
/4 2.85
% 1% 1%6 2% 1i-5.G 2
1
/4 1 8% 4.90
Ys Ph l1/2 3va . P7:16 2
1
YJ.6 lOlls 7.28
1 1% 1% 3% 27:1(; 3 11
1
h 10.3
Iva 2 2 4. 2%G 30/16 12% 14.4
1'/.4 2
1
,4 .2'/.4 4Y2. 2%G 3% 20/16 14% 21.4
1% 2Y2. .2'/.4 5 2716 47:16 2"Vs 15% 27.9
Ph 2% 2
1
h 51/2 4JA 3va 17 36.0
1% 3 3 6'/.4 3!j16
5va
3!YJ.r,
20 51.0
2 3
1
h 3'/.4 7% 3
1
0/1\l 6 4% 23 90.0
113
CLOSED SWAGED STRAND
SOCKETS
TABLE 42 DIMENSIONS FOR 19WffiE AND 37WIRE STRAND
(inches) (after swaging)
Eye Hole Approx.
\-.
Strand thickness diam. wt
diam. A B C D E F L (lb)
1/2 & }I/s }I/s 21h 114 2Ys 7
1
12 2.75
% 1% mo 3
2% 1% 9 5.0
11Ao & 34
11h I1h 3th 3
1
;8 2 11 7.25
l:}lo & % }3;4 1% 4 2:1112 3% 2
1
4 12Y2 11.0
.. & 1 2 2 4Y2 3
3
;4 2Y2 13
1
12 16.0
IIA.. & 1
1
/s 2% 2
1
4 5 2
1
%2 4
1
4 2% 15 23.0
l=})o & 1% 2
1
12 2% 5% 4
1
12 31/s 161/2 29.0
l
r
il.. & 1% 2% 2th 5th 2% 4% 3% 18 35.5
exact details.
114
OPEN SWAGED SOCKETS
TABLE43 DIMENSIONS OF SOCKETS (inches)
A
.., ]
Center of pin Opening Diameter
Diameter' hole to end' between of Approximate
of of socket ears pin hole wt
rope A B C (lb)
!l
sh
2.5
5Vz % 2.5
%', 7 1!l 1% 5
% 7
1
/2 1% 1% 9
'Va 9 13,4 1% 15
1 9% ISh 1% 20
, I1h'
10% 1% 23
1% 11% 13,4 21h 32
1% 11% 1% 2Y8 32
13
1
,4 3Y8 52
1% 13% 31h 52
OPEN WIRE ROPE
WEDGETYPE SOCKETS
These wedge-type sockets are easily and
quickly attached in the field by bending the
rope end around the tapered wedge. This
type of socket is normally furnished
without pins.
exact details.
115
.. (."
WIRE ROPE ASSEMBLIES
When ordering wire rope ;"'ith fittings
attached. lengths-as shown-should
be specified. Additionally, the load at
which this measurement is taken
should be specified, i.e., at no load, at
a percentage of catalog breaking
strength etc.
The accompanying drawings do
not show all possible combinations of
fittings; in any case, the same
measuring methods should be
followed.'
I)
a
Zinc-attached closed wire rope socket at (Jne end; zihc;.attached open wire rbpi
socket at other end. : ~
Measurement: Pull of closed socket to centerline of open socket pin.
b
Closed swaged wire rope socket at one end; open swaged wire rope socket at
other end.
Measurement: Centerline of.,pin to centerline of pin.
c
Closed bridge socket attached to one end; open bridge socket attached to other end.
Measurements: Centerline of closed socket pin to centerline of open socket pin;
include two of the three values: takeup, contraction, and expansion. The values of
C and 0 are also required.
d
Thimble spliced at one end.
Measurement: Pull of thimble to end of rope.
e
Link'spliced atone end,' hook spliced at other end.
Measurement: Pull of link to pull of hook.
f
Thimble spliced at one end; loop spliced at other end.
Measurements: Pull of thimble to base of loop, and circumference of loop.
116
\.. . '.;.
a
b

I-! .. -----------------LENGTH------------------......-I!
c
""""'11"'''''''
HTAKE UP

i
J------------------LENGTHI------------------_.. '
TAKE UP, ICONTRACT10N)+ (EXPANSION)
d
e
117
,:'.'
BOOM PENDANTS WITH
SWAGED FITTINGS
SINGLE-ROPE LEGS AND OPEN SWAGED SOCKETS I
I , .
<Q:=:---'--;-1
: 11
*
. ] R W
I SINGLE-ROPE LEGS AND OPEN AND CLOSED SWAGED SOCKETS I

: W1
@:=.----I.*,...... =: ! I! )4
I
SINGLE- ROPE LEGS AND CLOSED SWAGED SOCKETS
I I -L
\-I-! .....'---.-!..;.,..""-1) K
I T
(--.!-;-I! ,,--,@
...-..,.._------LENGTHOF PENDANT (SL)-, I
BOOM PENDANTS WITH SWAGED FITTINGS
Length of Pendant is measured as indicated on sketches.
Note: When ordering, customer should specify parallel or right
angle (90) socket pins.
118
119
Appendix D SOCKETING
C.l
C.2
C.3
SOCKETING PROCEDURES
Zinc-Poured Socketing
The following steps, in the order given. sh0l!Id be careful1y adhered to. '
1. Measure the Rope Ends to be Socketed
The rope end should be of sufficient length so that the ends of the unlaid wires
(from the strands) will be at the top of the socket basket. (Fig. C.1 ).
2. Apply Serving at Base of Socket ,
Apply a tight wire serving band, at the point where the socket base will be,
for a length of two rope diameters. (Figs. C.2 & C.3).
3. Broom Out Strand Wires
Unlay and straighten the individual rope strands and spread them evenly so
that they form an included angle of approximately 60, Unlay the w n ~ s of.each
, individual strand for the full length of the rope end-being careful not to
disturb or change the Jay of the wires and strands under the serving band.
Unlay the wires of an independent wire rope core in the same manner.
A fiber core should be cut out and removed as close to the serving band
as possible (Fig. C.3).
4. Clean the Broomed-Out Ends
A suggested cleaning solvent for this step is SC-5 Methyl Chloroform. It is also
known under the names Chlorothane VG and 1-1-1 Trichlorethane.
CAUTION: Breathing the vapor of this solvent is harmful;
it should only be used in a well-ventilated area. Be sure to follow the
solvent manufacturer's instructions, and carefitlly observe all
,instructions printed on the hlbel.
Swish the broomed-out rope end in the solvent. then brush vigorously to
remove all grease and dirt-making certain that the wires are clean to the
very bottom close to the serving band (Fig. C.4). Additional1y. a solution of
muriatic acid may also be used. If. however. acid is used thebroomed-out
ends should be rinsed in a solution of bicarbonate of soda so as to neutralize any
acid that may remain on the rope. Care should be exercised to prevent aCid
from entering the core; this is particularly important if the rope has a fiber
core. Where it is feasible. the best and preferred cleaning method for rope
ends prior to socketing is ultrasonic cleaning. After this cleaning step, place
the broomed-out end upright in a vise al10wing it to remain until all
solvent has evaporated and the wires are dry.
Solvent should never be permitted to remain on the rope or on the serving
band since it v,'ill run down the wires when the rope is remo\'ed from the vise.
5. Dip the Broomed-Oll/ Rope Ends in Flux
Prepare a hot solution of zinc-ammonium chloride flux comparable to Zaclon K.
Use a concentration of 1 Ib of zinc-ammonium chloride to I gallon of water;
maintain this at a tempera'ture of 180
0
to 200
0
F. Swish t ~ broomed-out
end in the flux solution. then place the rope end upright in the vise until such
time as the wires have dried thoroughly (Fig, C. 5).
6. Close Rope Ends and Place .'iacket
Use clean wire to compress the broomed-out rope end into a tight bundle
that will permit the socket to be slipped on easily over the wires (Fig. C. 6).
Before placing the socket on the rope. make certain that the socket itself
120
\.
C.4
e.s
m
is clean and heated. This heating is necessary in order to dispel any residual
moisture, and to prevent the zinc from cooling prematurely. A word of
caution: Never heat a socket after it is placed on the rope. To do so may
cause heat damage to the rope.
After the socket ison the rope end. the wires should be distributed evenly
in the socket basket so that zinc can surround each wire. Use extreme care
in aligning the socket with the rope's centerline. and in making certain that
there is a minimum vertical length of rope, extending from the socket,
that is equal to about 30 rope diameters (Fig. e. 7).
Seal the socket base with fire clay or putty but make certain that this
material does not penetrate into the socket base. Should this occur, it would
prevent the zinc from penetrating the full length of the socket basket
there by creating a void that would collect moisture after the socket is placed
in service.
7. Pour the Zinc
The zinc used should meet ASTM Specification designation B6-49 Grade (1 )
High Grade, and Federal Specification 00-Z-35l-a Amendment 1. interim
Amendment 2. Pour the zinc at a temperature of 950 to 970 F (Fig. e.8);
make allowances for cooling if the zinc pot is more than 25 ft from the socket.
A word of caution: Do not heat zinc above 1100 F or its bonding properties
will be lost. The zinc temperature may be measured with a portable pyrometer.
or a Tempilstik.Remove all dross before pouring. Pour the zinc in one
continuous stream until it reaches the basket top and all wire ends are covered;
there should be no "capping" of the socket.
8. Remove Serving
Remove the serving band from the socket base; check to make certain that
zinc has penetrated to the socket base (Fig. e.9) .
. 9. Lubricate the Rope
Apply wire rope lubricant to the rope at the socket base. and on any rope
section where the original lubricant may have been removed.
C.6 C.7
J21
e.s e.9
thermo-Set Resin
Before proceeding with a thermo-set resin socketing procedure, check
manufacturer's instructions carefully. Give particular attention to selecting
sockets that have been specifically designed for resin socketing. Follow the steps,
outlined below, or manufacturer's directions, in the order given.
1. Seizing and Cutting the Rope
Follow rope manufacturer's directions for a particular rope size or construction
with regard to the number, position, length of seizings and the seizing wire
size. The seizing, located at the base of the installed fitting, must be positioned
so that the ends of the embedded wires will be slightly below the level of the top
of the fitting's basket. The best means to cut the rope is with an abrasive wheel.
2. Opening and Brooming the Strand Wires
Before opening the rope end, place a short temporary seizing directly above
the seizing that represents the broom base. Temporary seizing prevents
brooming the wires the full length of the basket and also prevents loss of lay
in the strands and rope outside the socket. Remove all seizing between
the end of the rope and the temporary seizing. Unlay the strands comprising
the rope. Starting with the IWRC, or strand core, open each strand of
the rope and broom or unlay the individual wires. (Note: A fiber core in the
rope may be cut at the base of the seizing; some prefer to leave the core in.
Consult the manufacturer's instruction.) When the brooming is completed,
wires should be distributed evenly within a cone so that they form an included
angle of approximately 60. Some types of sockets will require a somewhat
different brooming procedure, in which case the manufacturer's instructions
should be followed.
3; Cleaning the Wires and Fittings
Different types of resin with different characteristics require varying degrees
of cleanliness. In some cases, merely using a soluble cleaning oil has been
found effective. For one type of polyester resin, on which over 800 tensile tests
on ropes in sizes 114 /I to 3
1
12 /I diameter were made without failure in the
resin socket attachment, the cleaning procedure was as follows:
Clean wires thoroughly so as to obtain resin adhesion. Ultrasonic
cleaning in recommended solvents such as trichloroethylene or
1-1-1 trichloroethane or other non-flammable grease-cutting solvents is
the preferred method of cleaning the wires in accordance with OSHA
Standards. Where ultrasonic cleaning is not available, brush or dip-cleaning
in trichloroethane may be used; but fresh solvent should be used for each
. rope and fitting and discarded after use. After cleaning, the broom should be
dried with clean compressed air or in other suitable fashion before
proceeding to the next step. The use of acid to etch the wires before resin
socketing is unnecessary and not recommended. Also, the use of a flux
on the wires before pouring resin should be avoided since this adversely
affects resin bonding to the steel wires. Since there is much variation in
the properties of different resins, manufacturers' instructions should
be carefully followed.
4. Close Rope Ends and Place Socket
Place rope in a vertical position with the broom end up. Close and compact
..
. I
the broom to permit insertion of thebroomed end into the base ofthefitting.
Slip the fitting on, removing anytemporary banding or seizing as required.
Make certain the broomed wires are uniformly spaced in the basket, with
wire ends slightly below the top edge of the basket, and that the axis of the rope
and the fitting are aligned. Seal the a:qnular space between the base of the
fitting and the exiting rope to prevent leakage of the resin from the basket.
A non-hardening butyl rubber-base sealant is satisfactory for this purpose.
Make sure that the sealant does not enter the base of the socket so that the
resin will be able to fiIl the complete depth of the socket basket.
5. Pouring the Resin
ControIled heat-curing (no open flame) at a temperature rangeof 250-300 F
is recommended. If ambient temperatures are less than 60 F, this is required!
When controIled heat curing is not available and ambient temperatures are
not less than 60 F the attachment should not be disturbed and tension should
not be applied to the socketed assembly for at least 24 hours.
6. Lubrication After Socket Attachment
After the resin has cured, re-Iubricate the wire rope at the base of the socket
to replace any lubricant that may have been removed during the cleaning
operation.
7. Acceptable Resin Types
CommerciaIly-available resin properties vary considerably. Hence, it is
important to refer to the individual manufacturer's instructionsbefore using
anyone type. General rules cannot, of course, be established.,
When properly formulated, most thermoset resins are acceptable for
socketing. These formulations, when mixed, form a pourable material which
will harden at ambient temperatures, or upon the application of moderate
heat. No open flame or molten metal hazards exist with resin socketing since
heat-curing when necessary, requires a relatively low temperature (250-300 F)
obtainable by electric resistance heating.
Tests have demonstrated that satisfactory wire rope socketing performance
can be obtained with resins having characteristics and properties as follows:
General Description
The resin shall be a liquid thermoset material that will harden after being
mixed with the correct proportion of catalyst or curing agent.
A. Properties of Liquid (Uncured) Material
Resin and catalyst are normally supplied in two separate containers.
After thoroughly mixing them together, the liquid can be poured into the
socket basket. Liquid resins and catalysts shall.have the following properties:
. 1) Viscosity of the Resin-Catalyst Mixture
30-40,000 CPS at 75 F immediately after mixing. Viscosity wiIl increase
at lower ambient terriperatures and resin may need warming prior to
mixing in the catalyst if ambient temperatures drop below 40 F.
2) Flash Point
Both resin and catalyst shall have a minimum flash point of 100F.
3) Shelf Life
Unmixed resin and catalyst shaH have a minimum of 1 year
shelf life at 70 F.
123
4) Pot Life and Cure Time
After mixing, the resin-catalyst blend shall be pourable for a minimum
of eight minutes at 60
0
F and shall harden in 15 minutes. Heating
of the resin in the socket to a maximum temperature of 250
0
F is
permissible to obtain full cure.
B. Properties of Cured Resin
1) Socket Performance
Resin shall exhibit sufficient bonding to solvent-washed wire in typical
wire rope end fittings to develop the nominal strength of all types and
grades of rope. No slippage of wire is permissible when testing resin-filled
rope socket assemblies in tension. After testing, however, some
"seating" of the resin cone may be apparent and is acceptable.
Resin adhesion to wires shall be capable of withstanding
tensile-shock loading.
2) Compressive Strength
The minimum allowable compressive strength for fully cured resin
is 12,000 psi.
3) Shrinkage
Maximum allowable shrinkage is 2 %. To control shrinkage, an inert
filler may be used in the resin provided that viscosity requirements as
specified above (A.l) for the liquid resin are met.
4) Hardness
The desired hardness of the resin is in the range of BarcoI40-55.
Resin Socketing Compositions
Manufacturer's directions should be followed in handling, mixing and pouring
the resin composition.
Performance of Cured-Resin Sockets
Poured-resin sockets may be moved after the resin has hardened. Following the
ambient- or elevated-temperature cure, recommended by the manufacturer,
resin sockets should develop the nominal strength of the rope, and have the
capability of withstanding shock loading to a degree sufficient to break
the rope. without cracking or breakage. Manufacturers of resin socketing
material shall be required to test these criteria before resin materials will
be approved for rope socketing use.
A final note of caution: the foregoing discussion is a generalized description
of but one of many commercially available thermo-set resins suitable for wire rope
socketing. Characteristics of these products vary significantly and each must be
handled differently. ThLiS, as noted earlier, specific information of any kind
concerning any resin must be obtained from the individual manufacturer before
setting up a resin socketing

Appendix E SHIPPING REEL CAPACITY
SHIPPING REEL CAPACITY
While it is virtually impossible to calculate the precise length of wire rope
that can be spooled on a reel or drum, the following formula provides a sufficiently
close approximation.
The'formula* is: L = (A+D) A B K
D
K
H
x =
I....t-------L-- B----<.I
fl
H J
Lf---J-------1
where: L = length of rope (ft)
A = depth of rope space on drum (inches)
B width of drum between
flanges (inches)
drum barrel diameter (inches)
comtant for given rope diameter
(see table below)
diameter of reel flanges (inches)
clearance
TABLE 45'
"K"
(0.2618 ..;- rope diameter
2
)
Diam. Diam.
(inches) K (inches) K
1A.6 49.8
112
0.925
23.4 !XI; 0.741
Ys 13.6 O/S 0.607

8.72
l1A.6
0.506
.. 6.14 % 0.428
1f.l2 4.59
. 10/1(;
0.354
'1.4 3.29 . 'VB 0.308
'hI> 2.21 1 0.239
*
1.58 1Ys 0.191
'Yi6 1.19 11.4 0.152
*This formula is based on uniform rope winding on the reel.
. It will not give correct results if the winding is non-uniform.
The formula also assumes that there will be the same
number of wraps of rope in each layer. While this is no: strictly
correct. there is no appreciable error in the result unless
the traverse of the reelis quite small relative to the flange
diameter ("H").
*"*The values given for "K" factors take normal rope oversize
into account. Clearance ("x") should be about 2 inches
unless rope-end fittings require more.
125
Diam.
(inches) K
1*
0.127
1 0.107
1% 0.0886
1% 0.0770
1'Vs 0.0675
2 0.0597
2
1
/s 0.0532
21.4 0.0476
2*
0.0419
2
1
/2 0.0380
Appendix F WEIGHTS OF
''''='''
*Weights are derived from average specific
gravities. except where noted as bulk, heaped
or loose material. etc.
.Substance
METALS, ALLOYS, ORES
Aluminum,
Aluminum, bronze ,.....
Antimony ..
Arsenic ;.;; .
Bismuth .
Brass, cast-rolled .
Bronze (gun metal)-
cOpper 88, tin 10,
zinc 2% ..
Bronze (Phosphor)-
copper 80, tin 10.
lead 10% ..
Chromium ..
Cobalt ; .
Copper, cast-rolled ..
Copper, ore, pyrites .
Gold, cast-hammered .
Iron. cast, pig ..
Iron, wrought ..
Iron, Spiegel-eisen .
Iron, ferro-silicon ..
Iron, ore, hematite ..
Iron, ore, hematite in bank
Iron, ore. hematite loose .
Iron, ore, limonite .
Iron, ore, magnetite ..
Iron, slag ..
Lead ; .
Lead ore, galena ,.
Magnesium ..
Manganese ..
Manganese or(f, pyrolusite
Mercury .
Molybdenum .
Nickel ..
Nickel monel metal ..
Platinum. cast-hammered ..
Silver, cast hammered ,.
Steel ..
Tin. cast-hammered ..
Tin. babbitt metal .
Tin. ore, cassiterite .
Tungsten .
Vanadium ..
Zinc. cast-rolled .
Zinc, ore. blende ..
Weight
(Ib/ft
3
)
165
481
416
358
608
534
544
562
428
552
556
262
1205
450
485
468
437
325
160-180
130-160
237
315
172
706
465
109
456
259
.848
562
545
556
1330
656
490
459
443
418
1180
350
440
253
Substance
'(.
'. VARIOUS SOLIDS
Carbon, amorphous,
graphitic .
Cork .
Ebony .
Fats .
Glass, common, plate ..
Glass, crystal ..
Glass, flint .
Phosphorous, white ..
Porcelain, china ..
Resins, Rosin, Amber .
Rubber, caoutchouc ..
Silicon ..
Sulphur, Amorphous .
Wax .
TIMBER, U.S. SEASONED
Ash, white ..
Beech ..
Birch, yellow .
Cedar, Port Orford ..
Cedar, white, red .
Chestnut .
Cypress, southern ..
Douglas Fir, coast type ..
Douglas Fir, mountain ..
Elm, American ..
Hemlock, eastern, western
Hickory, bigleaf .
Hickory, pignut .
Larch, western ..
Maple, red, black ..
Maple, silver : ..
Oak, Oregon white .
Oak, red ..
Pine, red ..
Pine, white, yellow,
western .
Poplar, yellow .
Redwood .
Spruce, black, red ..
Spruce, Engelmann ..
Tamarack .
\Valnut .
Moisture Contents:
Seasoned timber 12%
Green timber up to 50%
Weight
(Ib/ft
3
)
129
15
76
58
160
184
220
114
150
67
58
155
128
60
41
44
43
\
..i
29
..
22-23
30
32
34
30
35
28
48
53
36
38-40
33
51
44
33
27-28
28
30
28
23
37
39-40
GASES
Air, OC, 760mm 08071
Ammonia 0478
Carbon dioxide .1234
Carbon monoxide 0781
Gas, illuminating 028-.036
Gas, natural : 038-.039
Hydrogen .00559
Nitrogen .0784
Oxygen .0892
MINERALS
Asbestos 153
Barytes 281
Basalt 184
Bauxite 159
Borax 109
Chalk 137
Clay, marl 137
Dolomite 181
Feldspar, orthoclase :...... 159
Granite, gneiss 172
Greenstone, trap 187
Gypsum, alabaster 159
Hornblende 187
Limestone, crystalline ......160
Limestone, oolitic 144
Magnesite 187
Marble 168
Phosphate rock, apatite 200
Porphyry 172
Pumice, natural................ 40
Quartz, flint 165
Sandstone, bluestone 147
Substance
VARIOUS LIQUIDS
Alcohol, 100% .
Acids, Muriatic 40% .
Acids, nitric 91 % .
Acids, sulphuric 87% .
Lye, soda 66% .................
Oils, vegetable .
Oils, mineral, lubricants .
Petroleum .
Gasoline .
Water, 4C, max. densilY ..
Water, 100C .
Water, ice .
Water, snow, fresh fallen ..
Water, sea water .
Weight
(Ib/ft
3
)
49
75
94
112
106
58
57
55
42
62.428
59.830
56
8
64
Substance
Slate, shale ..
Soapstone, talc .
STONE, QUARRIED,
PILED
Basalt, granite, gneiss .
Limestone, marble, quartz
Sandstone "..
Shale .
Greenstone, hornblende .
BITUMINOUS
SUBSTANCES
Asphaltum ..
Coal, anthracite : .
Coal, bituminous .
Coal, lignite .
Coal, peat, turf, dry .
Coal, charcoal, pine ..
Coal, charcoal, oak .
Coal, coke ..
Graphite .
Paraffine .
Petroleum, crude : .
Petroleum, refined ..
Petroleum, benzine .
Petroleum, gasoline .
.Pitch .
Tar, bituminous .
COAL AND COKE, PILED
Coal, anthracite .
Coal, bituminous, lignite ..
Coal, peat, turf .
Coal, charcoal ..
Coal, coke ..
ASHLAR MASONRY
Granite, gneiss ..
Limestone, crystalline ..
Limestone, oolitic ..
Marble' :.: .
Sandstone, bluestone .
MORTAR RUBBLE
MASONRY
Granite, gneiss .
Limestone, crystalline ..
Limestone, oolitic ..
Marble .
Sandstone, bluestone ..
127
Weight
(Ib/ft
3
)
172.
169
96
95
82
92
107
81
97
84
78
47
23
33
75
131
56
55
50
46
42
69
75
47-58
40-54
20-26
10-14
23-32
172
160
144
168
147
165
156
138
162
140
Substance
BRICK MASONRY
.Pressed brick .
Common brick .
Soft brick ..
CONCRETE
Cement, stone, sand .
Cement, slag, etc .
Cement, cinder, etc .
VARIOUS BUILDING
MATERIAL
Ashes, cinders .
Cement, Portland, loose .
Cement, Portland, set .
Lime, gypsum, loose .
Mortar, set .
Slags, bimk slag ..
Slags, bank, screenings ..
Slags, machine slag .
Slags, slag sand ..: .
EARTH, ETC.,
EXCAVATED
Clay, dry .
Clay, damp, plastic .
Clay and gravel, dry ..
Earth, dry, loose .
Earth, dry, packed ..
Earth, moist, loose .
Earth, moist, packed .
Earth, mud, flowing ..
Earth, mud, packed .
Riprap, limestone ..
Riprap, sandstone .
Riprap, shale .
Sand, gravel, dry, loose .
Sand, gravel, dry, packed..
Sand, gravel, wet .
EXCAVATIONS IN
WATER
Sand or gravel :; .
Sand or gravel and clay ..
Clay ..
River mud _ .
Soil .
Stone riprap ..
Weight
(Ib/ft
3
)
140
120
100
144
130
100
40-45
90
183
65-75
103
67-72
98-117
96
49-55
63
110
100
76
95
78
96
J08
115
80-85
90
105
90-105
100-120
118-120
60
65
80
90
70
65
CONTENTS IN ALPHA:BETICAL ORDER'
BasitComponents /.7
Bending Rope Over Sheaves & Drums / 39
Breaking ina New Wire Rope /45
Breaking Strengths / 77
Clips, How to Apply /29
Cutting Wire Rope / 24
Design Factors /76
Drums: Grooved / 34
Multiple Layers /36
Plain (Smooth) / 35
Efficiency of End Attachments / 25
Elastic Properties of Wire Rope / 73
End Attachments / 25
Factors Affecting the Selection of Wire Rope / 49
Field Lubrication / 68
Fleet Angle / 48
Glossary of Wire Rope Terms (Appendix B) / 99
Handling Wire Rope /17
Inspections and Reports, Guidelines to / 52
Introduction / 5
Operation and Maintenance of Wire Rope / 37
Ordering, Storing and Unreeling Wire Rope (Appendix A) / 97
Physical Properties /73
Receiving, Inspection and Storage / 17
Seizing Wire Rope / 22
Sheaves & Drums / 37
Sheaves & Drums, Inspection of / 42
Shipping Reel Capacity (Appendix E) / 125
Socketing / 28
Socketing Procedures (Appendix D) / 120
Strength Loss of Rope Over Sheaves or Stationary Pins / 47
Unreeling & Uncoiling / 19
Wedge Sockets/ 33 "
Weights. of M,lterials p p ~ n d i x F) / 126
Wire Rope: Clips / 29
Efficiency Over Sheaves / 70
Fittings (Appendix C) / 109
Identification / 9
Installation /18
Operations Inspection/ 45
"X-Chart": Abrasion Resistance. vs. Bending-Fatigue Resistance / 44

Wire Rope User S Manual AIS PDF

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Wire Rope User S Manual AIS PDF

Transféré par

Droits d'auteur :

Formats disponibles

,-

6.21 SEALE WITH

eA- ' '

6,25B FLATIENED STRAND

6xl9 SEALE WITH IWRC

6,31 FI.LLER WIRE

8119 SEALE WITH

ALLOWABLE- IF NOT CLOSE COUPLEO

Vous aimerez peut-être aussi