Installation, Operation and Maintenance

PROPER SHEAVE AND DRUM DIAMETERS

Including groove diameters and relative merits of various materials for sheaves and drums.

GENERAL INFORMATION

In all applications of wire rope wherein the use of

sheaves and drums are involved, the design of these
sheaves and drums with respect to dimensions and
materials has considerable bearing on the service life
received from the wire rope operating on this
equipment. The actual service received may be
decreased by 50% or more where faulty equipment is
involved.
The four main factors to be considered from this
standpoint are:
1. Design
2. Materials Used
3. Alignment
4. Care of the equipment in service

For all elevator ropes, the tolerances shall be +1/64

minimum to +1/32 maximum.
The use of sheave groovers smaller than, or in excess
of, the above tolerances may result in materially
reduced service.
Maximum efficiency will be obtained from sheaves
whose flanges form an angle of approximately 15 with
the vertical as shown resulting in about 42% of the
circumference of the rope in contact with the groove of
the sheave. Grooves with vertical flanges are
unsatisfactory because they result in excessive chafing
of the rope.

Figure 8. Illustrates the various dimensions of a

sheave, and the use of a sheave gauge
(illustraton on left).

DIAMETER TOLERANCES FOR SHEAVE GROOVES

NOMINAL ROPE DIAMETER

GROOVE DIAMETER TOLERANCES

(INCHES)

MINIMUM

MAXIMUM

1/4 through 5/16

+ 1/64

+ 1/32

3/8 through 3/4

+ 1/32

+ 1/16

13/16 through 1-1/8

+ 3/64

+ 3/32

1-3/16 through 1-1/2

+ 1/16

+ 1/8

1-9/16 through 2-1/4

+ 3/32

+ 5/32

2-5/16 up

+ 1/8

+ 3/16

Installation, Operation and Maintenance

PROPER SHEAVE AND DRUM DIAMETERS

Recommended minimum tread diameters of sheaves and drums in inches for operating ropes.

6X7
(42D)
10-1/2
13-1/4
15-3/4
18-1/2
21
23-1/2
26-1/4
31-1/2
36-3/4
42
47-1/4
52-1/2
...............
...............
...............
...............
...............
...............

6 X 19 SEALE
18 X 17
NON-SPINNING
(34D)
8-1/2
10-3/4
12-3/4
15
17
19-1/4
21-1/4
25-1/2
29-3/4
34
38-1/4
42-1/2
46-3/4
51
55-1/4
59-1/2
63-3/4
68

6 X 16 FILLER WIRE
6 X 19 WARRINGTON
FLATTENED
STRAND (30D)
7-1/2
9-1/2
11-1/4
13-1/4
15
17
18-3/4
22-1/2
26-1/4
30
33-3/4
37-1/2
41-1/4
45
48-3/4
52-1/2
56-1/4
60

8 X 19 SEALE
6 X 19 FILLER WIRE
(26D)
6-1/2
8-1/4
9-3/4
11-1/2
13
14-3/4
16-1/4
19-1/2
22-3/4
26
29-1/4
32-1/2
35-3/4
39
42-1/4
45-1/2
48-3/4
52

6 X 37 SEALE
6 X 41 SHOVEL
(18D)
...............
...............
6-3/4
8
9
10-1/4
11-1/4
13-1/2
15-3/4
18
20-1/4
22-1/2
24-3/4
27
29-1/4
31-1/2
33-3/4
36

6 X 42
TILLER
(34D)
3-1/2
4-1/2
5-1/4
6-1/4
7
8
8-3/4
10-1/2
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............

GENERAL INFORMATION

ROPE
DIAMETER
(INCHES)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
1-5/8
1-3/4
1-7/8
2

SAFE LOADS - FACTORS OF SAFETY

Several points must be taken into consideration during installation.
In determining the factor of safety for any installation involving
the use of wire rope, there are several points which must be
taken into consideration including impact, normal and static
loads, acceleration, types of attachments used, types and
arrangement of sheaves and drums, economical rope life, the
reserve strength of the rope to be used, and the degree of
danger to life and property. Each and every one of these points
must be given due consideration in the determination of the
factors of safety and the rope to be used.

Derrick Guys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stack Guys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wrecking Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Towing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Logging Ropes
Spar Tree Guy . . . . . . . . . . . . . . . . . . . . . . . . . 2-1/2
Sky Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flying Yarders . . . . . . . . . . . . . . . . . . . . . . . . . 1-3/4

The factor of safety is determined by dividing the breaking strength

of the rope used by the maximum load to be applied thereon, i.e.,
the factor of safety of 1 inch 6 x 19 improved Plow Steel rope with
a breaking strength of 41.8 tons having a maximum applied load of
8.36 tons is 41.8 divided by 8.36 or 5 to 1.

Operation Ropes on

While arbitrary values for factors of safety cannot be definitely

set for various classifications of service due to the considerable
number of variables as described above in each installation, the
following minimum safety factors have been established
through considerable experience as being satisfactory under
normal conditions.

Hot Ladle Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Clamshell Buckets . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mine Hoists, Refuse Planes
and Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Industrial Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Elevators
Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 10
High Speed Traction . . . . . . . . . . . . . . . . . 10 to 12
Suspension Bridge
Main Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

On special installations, may we suggest that you contact our

engineering department for information as to safe loads and
desirable factors of safety.

Suspender Ropes . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cableway Track Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation, Operation and Maintenance

SHOCK LOADS
Several points must be taken into consideration during installation.
EXAMPLE OF SHOCK

TAKING UP SLACK AT FULL SPEED

STRESS ON THE ROPE

TOTAL LOAD AT REST

TAKING UP 3" SLACK

GENERAL INFORMATION

TAKING UP 6" SLACK

TAKING UP 12" SLACK

6,375 lbs.

11,200 lbs.
C
D

12,250 lbs.
15,675 lbs.

If Safety Factor of 5 was provided for Condition A

WHAT FACTOR DO YOU HAVE LEFT WHEN CONDITION CHANGED TO D?

HOW CAN YOU AVOID SHOCK

LOADS?

T H E O P E R AT O R I S A L L I M P O R TA N T

1. Make sure there is no slack and no jerking of the

rope at the start of the loading.

Provided the equipment is in good condition, and the

correct rope is properly installed, the responsibility lies
squarely on the operator to avoid shock loads. A good
operator is a good ropes best friend, and when this
friendship ceases, the rope might just as well be cut up
with a torch or emery wheel. An operator can make or
break a wire rope. There is no substitute for experience
in handling rope and a desire to get the most out of it.

2. Watch carefully the loads hoisted to see that they are

not beyond the ropes proper working load.
3. Do not allow rope to become fouled or jammed either
on the drum or by jumping a sheave.
4. Start load carefully. Too fast acceleration overloads
the rope. Watch how the rope takes it on the pick-up.
Apply power smoothly and steadily.

10

Installation, Operation and Maintenance

SUMMARY OF SUGGESTIONS
Obtaining the maximum possible service from wire rope.
NEVER ALLOW ROPES TO KINK
OR BIRDCAGE AS THEY WILL BE
P E R M A N E N T LY D A M A G E D

Wire rope, being made of steel, is subject to rapid

deterioration through exposure to acid fumes, excessive
heat, or moisture. Should the type of installation require
that it be exposed to any or all of these conditions, it
should be protected accordingly and extreme care
should be taken to ensure the proper type of rope being
recommended for this type of installation.

A permanent kink or bird-cage cannot be repaired.

Either of these conditions, almost invariably caused by
improper handling, results in greatly decreased service
or immediate removal of the rope. In addition, the kink
or bird-cage is a weak spot in the rope and greatly
reduces the tensile strength of the rope.

SELECT THE PROPER SIZE,

GRADE AND CONSTRUCTION OF
ROPE
This is the prime factor in obtaining maximum service
from wire rope. In order to ensure the initial installation
of the proper type rope, we maintain a staff of competent,
experienced wire rope engineers who are at all times
available to serve you in recommending proper types of
rope for any and all types of rope-using equipment.
A LWAY S K E E P Y O U R R O P E S
P R O P E R LY L U B R I C AT E D

GENERAL INFORMATION

DO NOT SUBJECT ROPES TO

A C I D F U M E S , E X C E S S I V E H E AT
OR MOISTURE

USE PROPER SIZE AND TYPE OF

SHEAVES AND DRUMS
The use of the proper size and type of sheaves and drums
will provide greatly increased rope service, far out of the
proportion to the cost of installation of proper equipment.
WHERE END FITTINGS ARE
U S E D , U S E S TA N D A R D
PRESCRIBED METHODS OF
A P P LY I N G S A M E
A chain is no stronger than its weakest link. The same
statement may be applied to wire rope with end fittings.

A wire rope is in reality a machine with its component

wires constituting its moving parts, therefore it should
be treated as a machine with regards to lubrication
during periods of service. While it is true that all ropes
are treated at the factory with the very best available
lubricants, these lubricants in many instances cannot be
expected to last throughout the service life of the rope.
For this reason, strict attention to the requirements of
lubrication of wire rope while in service will result in
greatly improved performance and service obtained.
K E E P R O P E S P R O P E R LY S E I Z E D
AT A L L T I M E S T O P R E V E N T H I G H
S T R A N D S A N D U N L AY I N G O F R O P E
An improperly seized non-preformed rope is subject not
only to the loss of the portion of rope which will fray out
or unlay if the seizing becomes loose, but in addition,
may result in one or more high strands which will work
back into the rope resulting in early destruction of the
rope due to concentrated wear on these high strands.

11