Transcript
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Wire rope products will break if abused, misused or overused. Consult industry recommendations and ASME Standards before using. Wirerope Works, Inc. warrants all BethlehemWire Rope and Strand products. However, any warranty, expressed or implied as to quality, performance or fitness for use of wire rope products is always premised on the conditionthat the published breaking strengths apply only to new, unused rope, that the mechanical equipment on which such products are used is properly designed and maintained, that suchproducts are properly stored, handled, used and maintained, and properly inspected on a regular basis during the period of use. Wirerope Works, Inc. expressly prohibits the resaleof worn, previously owned and used Bethlehem Wire Rope and Strand products. Immediately following removal from service, all wire rope products are to be properly disposed of inaccordance with applicable municipal, state, and federal guidelines. Manufacturer shall not be liable for consequential or incidental damages or secondary charges including but notlimited to personal injury, labor costs, and a loss of profits resulting from the use of worn, previously owned and used products. Manufacturer shall not be liable for consequential orincidental damages or secondary charges including but not limited to personal injury, labor costs, a loss of profits resulting from the use of said products or from said products beingincorporated in or becoming a component of any product.
Bethlehem Wire Rope and the Bethlehem Wire Rope reel logo are registered trademarks of Wirerope Works, Inc. Form-set and Lift-Pac are trademarks of Wirerope Works, Inc.Wirerope Works, Inc. 2007
2
Wire Rope SelectionWire Rope Construction ................... 3
Wire Rope Finish .............................. 3
Wire Grade ...................................... 3
Wire Rope Lay ................................. 3
Preformed Wire Rope ....................... 4
Wire Rope Core ................................ 5
Wire Rope Lubrication ...................... 5
The Modified X-chart ........................ 5
Rope Substitution............................. 5
Suggested Wire Rope
Constructions ................................... 6
Standard Wire Rope6x7 Class ......................................... 9
6x19 Class10
6x37 Class ....................................... 10
Alternate Lay Wire Rope .................. 12
Rotation-resistant Ropes
Safety Design Factors ....................... 13Handling And Installation ................ 13
8x19 Class ....................................... 14
19x7 ................................................ 14
SFP 19 ............................................. 15
Specialized Wire RopeGeneral Information ......................... 16
6-PAC ............................................... 17
6-PAC RV ......................................... 17
TRIPLE-PAC ....................................... 18
SFP 35 ............................................. 18
BXL .................................................. 19
Super-B ............................................ 20
Flattened Strand .............................. 21
Handling & InstallationMeasuring Rope Diameter ................ 22
Unreeling & Uncoiling ...................... 22
Kinks ............................................... 22
Drum Winding ................................. 22
Wire Rope Clips ............................... 23
Seizing Wire Rope ............................ 24
Installation ....................................... 24
Standard Operating Practices ........... 26
Wire Rope InspectionBasic Guidelines ............................... 27
Inspection Guidelines For
Specialized Wire Rope ...................... 28
Drums & Sheaves ............................. 30
Broken Wires In Wire Rope .............. 31
Troubleshooting Checklist ................ 32
Technical InformationWWW Specifications ........................ 33
WWW Markers ................................ 33
Wire Rope Tolerances ....................... 33
Rope Strength Design Factors .......... 33
Physical Properties ........................... 34
Effect Of Sheave Size ....................... 34
Block Twisting .................................. 34
Wire Rope SlingsBasic Hitches .................................... 36
D/d Ratios ........................................ 36
Sling Eye Designs ............................. 36
Effect Of Angles On Sling Capacities 36
Wire Rope Sling Inspection .............. 36
Recommended Operating Practices .. 37
Standard Products LIst ...................... 39
Table Of Contents
Wirerope Works, Inc. (WW) manufactures Bethlehem Wire Rope products in a wide variety of constructions, coresand steel grades. This catalog contains general information on wire rope constructions emphasizing the most com-mon applications, based upon new, unused wire rope. Abuse or failure to exercise proper care and maintenancecan significantly alter a wire ropes characteristics, particularly the breaking strength.
The technical data contained herein is based on accepted engineering practices and, where applicable, is inaccordance with Occupation Safety and Health Administration standards. In use, this data should be supplementedby the application of the professional judgement of qualified engineering personnel.
If your specific wire rope needs or requirements are not shown in this catalog, please consult WWs sales or
engineering department for technical information and recommendations.Wire rope products will break if abused, misused or overused. Consult industry recommendations and appropriate Standards before using. Wirerope Works, Inc. warrants all Bethlehem WireRope and Strand products. However, any warranty, expressed or implied as to quality, performance or fitness for use of wire rope products is always premised on the condition that the pub-lished breaking strengths apply only to new, unused rope, that the mechanical equipment on which such products are used is properly designed and maintained, that such products are properlystored, handled, used and maintained, and properly inspected on a regular basis during the period of use. Wirerope Works, Inc. expressly prohibits the resale of worn, previously owned andused Bethlehem Wire Rope and Strand products. Immediately following removal from service, all wire rope products are to be properly disposed of in accordance with applicable municipal,state, and federal guidelines. Manufacturer shall not be liable for consequential or incidental damages or secondary charges including but not limited to personal injury, labor costs, and a lossof profits resulting from the use of worn, previously owned and used products. Manufacturer shall not be liable for consequential or incidental damages or secondary charges including butnot limited to personal injury, labor costs, a loss of profits resulting from the use of said products or from said products being incorporated in or becoming a component of any product.
Bethlehem Wire Rope, the Bethlehem Wire Rope reel logo and Super B are registered trademarks of Wirerope Works, Inc. Form-set, Purple, Purple Plus, Royal Purple, Royal Purple Plus, SFP19, 36DD, 6-PAC, 6-PAC RV, TRIPLE-PAC, BXL, SUPER-PAC, SKYBRITE, Roepac, Herringbone, En-Core, Bethpac, Maxi-Core, Phoenix, Z-nodes, wire rope colored purple and wire rope colored pinkare trademarks of Wirerope Works, Inc.
Wirerope Works, Inc. 1997, 2000, 2003, 2005, 2007
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3
Wire Rope Selection
Three Components of Wire Rope
Wire rope is a machine composedof a number of precise, moving parts,
designed and manufactured to bear avery definite relation to one another.In fact, some wire ropes contain more
moving parts than many complicatedmechanisms. For example, a 6-strand
rope with 49-wire strands laid aroundan independent wire rope core con-
tains a total of 343 individual wires.All of these wires must work togetherand move with respect to one another
if the rope is to have the flexibility
necessary for successful operation.Wire rope is composed of wires,
strands and a core. The basic unit of
wire rope is wire, which is carefullyprocessed and drawn from selected
grades of steel to predetermined physi-cal properties and sizes. A prede-termined number of finished wires
is then helically laid together in auniform geometric pattern to form
a strand. This process must be per-formed with precision and exactnessto form a strand of correct size and
characteristics. The required numberof suitably fabricated strands are laid
symmetrically with a definite length oflay around a core, forming the finished
wire rope. All Bethlehem Wire Ropeproducts are manufactured at WW's fa-cility in Williamsport, Pennsylvania.
Wire Rope ConstructionWire rope is identified by its con-
struction, or the number of strandsper rope, and number of wires in each
strand. For example, the construction6x25 denotes a 6-strand rope, with
each strand having 25 wires. Con-structions having similar weights andbreaking strengths are grouped into
wire rope classifications, such as the6x19 and 6x37 Classes.
Wire Rope FinishThe term brightrefers to a wirerope manufactured with no protectivecoating or finish other than lubricant.
Some applications do require morecorrosion protection than lubricantcan provide. In these instances, a
galvanized finish is provided. Consultwith WWs engineering department for
more information on galvanized wirerope.
Wire Grade
Purple grade wire (improved plowsteel) is a strong, tough, durablesteel that combines great strengthwith high resistance to fatigue. Its
minimum tensile strength varies from223 to 258 ksi, depending upon wire
diameter.Purple Plus is WWs trade name for
Extra Improved Plow (EIP) steel. Oncea specialty grade, Purple Plus is now
WWs grade for all standard wire rope.Minimum tensile strength varies from
245 to 284 ksi, depending upon wirediameter.
Royal Purple, or Extra ExtraImproved Plow (EEIP) steel, is a gradeused where a high breaking strength
is required. This grade typically pro-vides a breaking strength a minimum
of 10% higher than Purple Plus and isfound primarily as a standard grade for
specialized wire rope. However, RoyalPurple is available for standard wireropes upon request.
Developed by WW for the federal
government, Royal Purple Plus is thehighest strength grade availableto Bethlehem Wire Rope customers.
Royal Purple Plus provides a breakingstrength 35% higher than Purple Plus,
and is available in WWs TRIPLE-PAChoist rope.
It is the grade of wire which deter-
mines the nominal breaking strengthfor each diameter and construction.
Note, the acceptance strength listedin the various tables for Bethlehem
Wire Rope products is 2-1/2% below
the nominal strengths listed.Other grades are available to meet
specific requirements. Some grades arecovered by wire rope standards while
others may be specially tailored. Con-sult WWs engineering department for
further information.
Wire Rope LayThe helix or spiral of the wires and
strands in a rope is called the lay. Regular lay denotes rope in which
the wires are twisted in one direc-tion, and the strands in the opposite
direction to form the rope. The wiresappear to run roughly parallel to the
center line of the rope. Due to thedifference in direction between thewires and strand, regular lay ropes are
less likely to untwist or kink. Regularlay ropes are also less subject to failure
from crushing and distortion becauseof the shorter length of exposed outer
wires.
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Wire Rope Selection
4
Lang lay is the opposite; the wiresand strands spiral in the same direc-
tion and appear to run at a diagonal tothe center line of the rope. Due to the
longer length of exposed outer wires,Lang lay ropes have greater flexibilityand abrasion resistance than do regu-
lar lay ropes. Greater care, however,must be exercised in handling and
spooling Lang lay ropes. These ropesare more likely to twist, kink and crush
than regular lay ropes. Right or left lay refers to thedirection in which the strands rotate
around the wire rope. If the strandsrotate around the rope in a clockwise
direction (as the threads do in a righthand bolt), the rope is said to be right
lay. When the strands rotate in a coun-terclockwise direction (as the threadsdo in a left hand bolt), the rope is left
lay.
Right regular lay is furnishedfor all rope applications unlessotherwise specified.
When a lay-length is used as aunit of measure, it refers to the lineardistance a single strand extends in
making one complete turn aroundthe rope. Lay-length is measured in
a straight line parallel to the center
line of the rope, not by following thepath of the strand. The appropriatetime to replace a wire rope in service isfrequently determined by counting the
number of broken wires in the lengthof one rope lay.
Preformed Wire RopeForm-set is WW's trade name for
preformed wire rope. Form-set meansthat the wires and strands have been
preset during manufacture into thepermanent helical form they take inthe completed rope.
Unless otherwise specified,
Bethlehem Wire Rope products arefurnished Form-set.
Preformed wire rope has definitecharacteristics which are advanta-
geous on most wire rope applications.Preforming greatly reduces internal
stresses, eases rope handling, andgives more equal distribution of loadon the wires and strands. Preformed
rope runs smoother and spools more
uniformly on a drum than non-pre-formed, has greater flexibility and
gives longer service life in bending.Preformed wires tend to remain in
position after breaking. This reduces
the tendency for them to protrude anddamage adjacent wires. Because the
wires do not protrude, we strongly sug-gest greater care and more thorough
inspection to detect broken wires in aForm-set rope.
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Wire Rope Selection
5
Wire Rope CoreMost wire ropes are supplied with
either a fiber or steel core. The coreis the foundation ot a wire rope. Its
primary function is to support the
wire strands of the rope, maintainingthem in their correct relative positionsduring the operating life of the rope.
Fiber cores are ropes made fromfibers formed into yarns, then intostrands and finally into the finished
core form. There are two general typesof fiber: natural vegetable material,
such as sisal, and synthetic filaments,such as polypropylene.
Steel cores may be an indepen-dent wire rope (IWRC) or, in the caseof small diameter ropes and some ro-
tation-resistant ropes, a wire strandcore (WSC). These steel cores providemore support than fiber cores to theouter strands during the ropes oper-
ating life. Steel cores resist crushing,are more resistant to heat, reduce theamount of stretch, and increase the
strength of the rope.
Wire Rope LubricationDuring the manufacture of Beth-
lehem Wire Rope products, WW applies
heated lubricant to individual wiresduring the stranding operation. Upon
customer request, additional lubricant
may be applied during the closingoperation as well.
WW utilizes two standard lu-bricants during the manufacture of
general purpose ropes. WWs N-lubeis a petrolatum-based lubricantused primarily in the manufacture
of standard wire rope. This type oflubricant prevents rust and corrosion
and lubricates against internal wear.W-lube, the standard lubricantused for specialty wire rope, is anasphaltic-based lubricant and rustpreventative compound with a large
percentage of water-displacing addi-tives and corrosion inhibitors. W-lube
is ideal for offshore and land cranes,and logging winch lines.
The Modified X-chartTwo factors governing most de-
cisions in selecting wire rope are
abrasion resistance and resistanceto bending fatigue. A graphic pre-sentation of the balance between
these properties has traditionallybeen given by means of the X-chart.
However, new designs of wire rope,such as 6-Pac and Triple-Pac, do not
follow the X-chart model as they aredesigned to provide both abrasion
resistance and resistance to bending
fatigue. WW, therefore, developed theModified X-chart.
To read the Modified X-chart, the
position of each rope construction
must be considered in relation toboth the X and Y axes, or AbrasionResistance and Resistance to Bending
Fatigue, respectively. For example, theconstruction 6x41 (6x49) is in theupper left quadrant, ranking high on
the bending fatigue scale. However, itsposition in abrasion resistance is very
low. Therefore, it can be said that a6x41 (6x49) construction offers ex-
cellent resistance to bending fatigue,but poor resistance to abrasion. Atthe other end of the spectrum is a 6x7
construction, located in the lower righthand corner of the chart. A 6x7 offers
excellent abrasion resistance, but verypoor resistance to bending fatigue.
Rope SubstitutionMany equipment manufacturers
have established standard or speci-fied wire ropes for their products.
Rope substitution is acceptableprovided the end user follow the basic
design specifications established by
the equipment manufacturer: Always use the specified
rope diameter. Ensure that the breaking
strength of the substituterope meets or exceeds that
of the rope specified. Always substitute a rope
with the same basiccharacteristics, such asrotation resistance.
ASME B30.5-1995 Addenda5-1.7.2(a) states: The ropes shall be
of a construction recommended bythe rope or crane manufacturer or
person qualified for that service.
High
Low
ResistancetoBendingFatigue
Triple-Pac 6x41 (6x49) 6-Pac
6x36
6x31
6x25 6x27 FlatStrand
6x21
6x19
Super B
6x7
LowHighAbrasion Resistance
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6
Suggested Wire Rope Constructions
NOITACILPPA SNOITIDNOCLARENEG SNOITIDNOCEREVES
SENARC
SLLABPORD
seniLdaoL CRWIRR52x6 CAP-6
SENARCYRTNAG
tsioHniaM CRWIRRssalC73x6;CRWIRR52x6 DD63;91PFS;CAP-6
tsioHyrailixuA CRWIRR52x6 DD63;91PFS;CAP-6
edulcnisepytenarcyrtnaG ocnarKdnaenoK,gameD,H&P:
SENARCEVITOMOCOL
tsioHniaM CRWIRR52x6 CAP-ELPIRT;CAP-6
tsioHyrailixuA CRWIRR52x6 CAP-ELPIRT;CAP-6
tsioHmooB CRWIRR52x6 CAP-ELPIRT;CAP-6
seniLgaT CFRRelaeSnotgnirraW33x6 a/n
)SEGRABDNASMROFTALP,SGIRGNILLIRD(SENARCLATSEDEPEROHSFFO
tsioHmooB CRWIRR52x6 CAP-ELPIRT;VRCAP-6;CAP-6
seniLtsioH 7x91;CRWIRR91x8 DD63;91PFS
seniLyrailixuA 7x91;CRWIRR91x8 DD63;91PFS
edulcnisepytenarclatsedeperohsffO ,drofrehtaeW,lanoitaN,tleB-kniL,reniraMtinU,enarcerohsffO,natiT,sciluardyHdeilppA:.tigakSdnaeniraMrekaB,naciremA,edylC,sulituaN,uaeruoTeL,rrehbeiL,OCVAF,gniKaeS,eirE-surycuB,xetinaM,cawotinaM
SENARCGNILEVARTDAEHREVO
seniLtsioH CRWIRRssalC73x6;CRWIRRssalC91x6 DD63;91PFS;CAP-6
,SENARCKCURTMOOBECITTALDNACIPOCSELET,NIARRETLLA,NIARRETHGUORSRELWARCNOITCIRFMOOBECITTALDNASRELWARCCILUARDYHMOOBECITTAL
tsioHmooB CRWIRRssalC73x6;CRWIRR52x6 CAP-ELPIRT;VRCAP-6;CAP-6
seniLtsioH CRWIRRssalC73x6;CRWIRR52x6 DD63;91PFS;CAP-ELPIRT;CAP-6
seniLyrailixuA 7x91;CRWIRR91x8 DD63;91PFS
stnadnePmooB CRWIRR52x6 CAP-ELPIRT;CAP-6
:edulcnisepytenarclateniarrethguoR ,gameD,rrehbeiL,onadaT,MPP,H&P,gnirheoK,niaroL,tleB-kniL,evorG,noilaGkralCdna,lanoitaN,xetinaM,cawotinaM,naciremA
SROTCARTMOOBEDIS
seniLtsioH CRWIRR52x6 CAP-ELPIRT;CAP-6
seniLmooB CRWIRR52x6 CAP-ELPIRT;CAP-6
SENARCKCIRREDGNIVLOVERDNASKCIRREDGELFFITS
seniLtsioH CRWIRR52x6 CAP-ELPIRT;CAP-6
seniLyrailixuA CRWIRR52x6 DD63;91PFS;CAP-ELPIRT;CAP-6seniLmooB CRWIRR52x6 DD63;91PFS;CAP-ELPIRT;CAP-6
edulcnisepytenarckcirreD cawotinaMdnaedylC,naciremA,EDYLCMA:
SENARCREWOT
seniLdaoL 7x53;7x91 DD63;91PFS
senilyellorT CRWIRR52x6 a/n
SENARCYELRIHW
tsioHniaM CRWIRR52x6 DD63;91PFS;CAP-6
tsioHyrailixuA CRWIRR52x6 DD63;91PFS;CAP-6
tsioHmooB CRWIRR52x6 CAP-6
:edulcnisepytenarcyelrihW edylCdnaOCVAF,naciremA,EDYLCMA
Gantry crane types include: P&H, Demag, Kone and Kranco
Offshore pedestal crane types include: Applied Hydraulics, Titan, Offshorecrane, Unit Mariner, Link-Belt, National, Weatherford,Manitowac, Manitex, Bucyrus-Erie, SeaKing, FAVCO, Liebherr, LeToureau, Nautilus, Clyde, American, Baker Marine and Skagit
Rough terrain et al crane types include: Galion, Grove, Link-Belt, Lorain, Koehring, P&H, Tadano, Liebherr, Demag,American, Manitowac, Manitex, National, and Clark
Derrick crane types include: AMCLYDE, American, Clyde and Manitowac
Whirley crane types include: AMCLYDE, American, FAVCO and Clyde
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Suggested Wire Rope Constructions
7
NOITACILPPA SNOITIDNOCLARENEG SNOITIDNOCEREVES
GNIGDERD
SEGDERDREPPID
seniLtsioH CRWILRssalC73x6;CRWILRssalC91x6 VRCAP-6;CAP-6
seniLgnikcaBdnagnigniwS CRWILRssalC73x6;CRWIRRssalC91x6 CAP-6
seniLdupS CRWILRssalC73x6;CRWILRssalC91x6 CAP-6
SEGDERDLLEHSMALC
seniLgnisolCdnagnidloH CRWILRssalC91x6 CAP-6
seniLgniwS CRWILRssalC73x6;CRWIRRssalC91x6 CAP-6
seniLtsioHmooB CRWILRssalC91x6 VRCAP-6;CAP-6
seniLrohcnAronretS CRWIRRssalC91x6 CAP-6
seniLdupS CRWILRssalC73x6;CRWILRssalC91x6 CAP-6
SEGDERDTEKCUBNIAHCROREDDAL
seniLreddaL CRWILRroRRssalC91x6 CAP-6
seniLnretSdnawoB CRWILRssalC73x6;CRWIRRssalC91x6 CAP-6
seniLdupS CRWILRssalC73x6;CRWILRssalC91x6 CAP-6
SEGDERDNOITCUS
seniLreddaL CRWILRroRRssalC91x6 CAP-6
seniLgniwS CRWIRRssalC91x6 CAP-6
seniLdupS CRWILRssalC73x6;CRWIRRssalC91x6 CAP-6
seniLnootnoP CRWILRssalC91x6 CAP-6
GNITAVACXE
SLEVOHSREWOP
seniltsioH CRWIGRssalC73x6;CRWIGRroRR52x6 CAP-6
CRWIGRssalC73x6 VRCAP-6;CAP-6
seniLtcarteRdnadworC CRWIGRssalC73x6;CRWIGRroRR52x6 VRCAP-6;CAP-6
seniLmooB CRWIGRssalC73x6;CRWIGRroRR52x6 VRCAP-6;CAP-6seniLpirT CFRRelaeSnotgnirraW33x6;CFRRnotgnirraW91x6 a/n
SROTAVACXEENILGARD
senilgarD CRWIGRssalC91x6 CAP-6
seniLtsioH CRWIGRroRRssalC91x6 VRCAP-6;CAP-6
senilmooB CRWIGRssalC73x6;CRWIGRroRRssalC91x6 VRCAP-6;CAP-6
seniLpmuD CRWIGRroRR52x6 VRCAP-6;CAP-6
SLLEHSMALC
seniLtsioH 7x91;CRWIRRssalC91x6 DD63;91PFS;CAP-ELPIRT;CAP-6
seniLgnisolCdnagnidloH CFroCRWIRRssalC73x6;CRWIGRroRRssalC91x6 VRCAP-6;CAP-6
seniLmooB CRWIVR62x6;CRWIRR52x6 CAP-ELPIRT;VRCAP-6;CAP-6
seniLgaT CFRRelaeSnotgnirraW33x6 a/n
SNOGAWDNASREPARCSLLA-YRRAC
seniLpmuDdnatsioH CRWIGRroRRssalC73x6;CRWIGRroRR52x6 CAP-6
SLEVOHSLLUPDNASREHCTID,SEOHHCNERT
seniLgniggiD CRWIGRssalC91x6 CAP-6
seniLtsioH CRWIRRelaeSnotgnirraW62x6;CRWIRR52x6 CAP-6
seniLgeL-raehSroseniLmooB CRWIRR62x6 CAP-6
SROTAVACXEENILKCALS
seniLkcarT CFGRdnartsdenettalf;CFGRssalC91x6 VRCAP-6;CAP-6
seniLluahnUrodaoL CRWIRRssalC91x6 CAP-6
seniLgnitsujdAkcarTronoisneT CRWIRR52x6 CAP-6
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RR = Right regular layRG = Right Lang layRV = Right reverse layFC = Fiber coreIWRC = Independent wire rope core
BXL, or plastic-infusion, may be added to many standard and specialty wire rope constructions, and is therefore not listed as a recommendationunder Severe Conditions. Refer to Specialty Applications: BXL for further information.
In some instances, WW specifies class and not a specific construction. This is due to multiple diameters used on a particular application, and/ormultiple constructions suitable for the application. For more information, please contact WW's sales or engineering department.
Refer to product data for grades.
NOITACILPPA SNOITIDNOCLARENEG SNOITIDNOCEREVES
SEHCNIWDNASTSIOH
stsioHnoitcurtsnoC CRWIRRssalC73x6;CRWIRRssalC91x6 CAP-6
stsioHriAdnacirtcelE 91PFS;7x91;CFRRssalC73x6;CFRRnotgnirraW91x6 a/n
sehcniW CRWIRRssalC73x6;CRWIRRssalC91x6 CAP-6
GNIGGOL
NRETSAE
seniLhcniW CRWIRRelaeSnotgnirraW62x6 B-repuS
srekohC CRWIRRelaeSnotgnirraW62x6 a/n
NRETSEW
senilhcrA CRWIRRelaeSnotgnirraW62x6 CAP-REPUS,B-repuS
sredaoLmooB CRWIRRelaeSnotgnirraW62x6 CAP-REPUS,B-repuS
srekohC CRWIRRelaeSnotgnirraW62x6 CAP-REPUS,B-repuS
skcabluaH CRWIRRelaeSnotgnirraW62x6;CRWIRRelaeS91x6 CAP-REPUS,B-repuS
srekohCretpocileH ETIRBYKS a/n
senilniaM CRWIRRelaeSnotgnirraW62x6 CAP-REPUS,B-repuS
egairraCllimwaS CRWIRR52x6 CAP-REPUS;B-repuSsenilykS CRWIRRelaeSnotgnirraW62x6;CRWIRRelaeS91x6 CAP-REPUS,B-repuS
senilwartS CRWIRRelaeS91x6 CAP-REPUS;B-repuS
seniLmurDelpirT CRWIRRelaeSnotgnirraW62x6 CAP-REPUS;B-repuS
seniLhcniW CRWIRRelaeSnotgnirraW62x6 CAP-REPUS;B-repuS
ENIRAMDNADLEIFLIO
seniLrohcnA CRWIRRssalC73x6;CRWIRRssalC91x6 sedon-Z,caphteB,dezinavlag
seniLgnibbawS&dnaS,gniroC CF7x6 a/n
slleBgniviD 7x91 DD63
seniLgnirooM dnartsdezinavlag;CRWIGRsessalC73x6dna91x6 sedon-Z,caphteB,epordezinavlag
seniLrenoisneTresiR CRWIRRssalC73x6 caphteB
seniLllirDyratoR CRWIRRelaeSnotgnirraW62x6;CRWIRRelaeS91x6 caphteBseniLwoT CRWIRRssalC73x6 dezinavlag
seniLgnibuT CRWIRRelaeSnotgnirraW62x6 B-repuS
sresahCniahC,eriWkroW CRWIRRssalC73x6;CRWIRRssalC91x6 dezinavlag
LLIMLEETS
sepoRlleB CRWIRR52x6 CAP-6
epoRredrateR,rettopS,relluPraC CFroCRWIRRssalC91x6 CAP-6
senarCeldaL CRWIRRssalC73x6 CAP-ELPIRT;CAP-6
sredaolnUdnasegdirBerO CRWIRRssalC91x6 CAP-6
stsioHpikS CFGRdnartsdenettalf;CFGRroRRssalC91x6 CAP-ELPIRT
senarCtiPgnikaoSdnareppirtS CRWIGRssalC73x6 CAP-ELPIRT;CAP-6
Suggested Wire Rope Constructions
8
galvanized
6x31 swedged, SUPER-PAC
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9
Standard Wire Ropes
This construction is used whereropes are dragged on the ground or
over rollers, and resistance to wearand abrasion are important factors.The wires are quite large and willstand a great deal of wear. In fact,
this construction is sometimescalled coarse laid because of thelarge wires.
The 6x7 is a stiff rope andneeds sheaves and drums of largesize. It will not withstand bend-ing stresses as well as ropes with
smaller wires. Because of the smallnumber of wires, with the resultinghigher percentage of load carriedby each wire, a larger factor of
safety should be considered with6x7 ropes than with ropes havinga larger number of wires.
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4/1 5.6 490.0 46.2
61/5 0.8 51.0 01.4
8/3 5.9 12.0 68.5
61/7 0.11 92.0 39.7
2/1 0.31 83.0 3.01
61/9 5.41 84.0 0.31
8/5 0.61 95.0 9.51
4/3 0.91 48.0 7.22
8/7 0.22 51.1 7.03
1 0.62 05.1 7.93
8/1-1 0.92 09.1 8.94
4/1-1 0.23 43.2 0.16
8/3-1 0.53 48.2 1.37
2/1-1 0.83 83.3 2.68
*Acceptance strength is not less than 2-1/2% below thenominal strengths listed. Tons of 2,000lbs.
**Galvanizing: For Class A galvanized wire rope, deduct10% from the nominal strength shown.
6x7 Class Wire Rope
Strands: 6Wires per strand: 7Core: Fiber coreStandard grade(s): PurpleLay: Regular or LangFinish: Bright or galvanized
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10
Standard Wire Ropes
6x19 Class Wire Rope
Strands: 6Wires per strand: 19 to 26
Core: IWRC or fiber coreStandard Grade: Purple PlusLay: Regular or LangFinish: Bright or galvanized
The 6x19 Classification of wirerope is the most widely used. Withits good combination of flexibility
and wear resistance, rope in thisclass can be suited to the specificneeds of diverse kinds of machinery
and equipment.The 6x19 Seale construction,with its large outer wires, providesgreat ruggedness and resistance
to abrasion and crushing. How-ever, its resistance to fatigue issomewhat less than that offeredby a 6x25 construction. The 6x25
possesses the best combinationof flexibility and wear resistancein the 6x19 Class due to the filler
wires providing support and im-
parting stability to the strand. The6x26 Warrington Seale constructionhas a high resistance to crushing.
This construction is a good choicewhere the end user needs the wearresistance of a 6x19 Class Rope andthe flexibility midway between a
6x19 Class and 6x37 Class rope.
6x19 Warrington with fiber core
6x19 Seale with IWRC
6x26 Warrington Seale with IWRC
6x31 Warrington Seale with IWRC
6x49 Filler Wire Seale with IWRC6x25 Filler Wire with IWRC 6x36 Warrington Seale IWRC
6x37 Class Wire Rope
Strands: 6Wires per strand: 27 to 49
Core: IWRC or fiber coreStandard Grade: Purple PlusLay: Regular or LangFinish: Bright or galvanized
The 6x37 Class of wire ropeis characterized by the relativelylarge number of wires used ineach strand. Ropes of this class
are among the most flexible avail-able due to the greater number of
wires per strand, however theirresistance to abrasion is less than
ropes in the 6x19 Class.The designation 6x37 is only
nominal, as in the case with the6x19 Class. None of the ropes
actually has 37 wires per strand.Improvements in wire rope design,as well as changing machine de-
signs, have resulted in the use ofstrands with widely varying num-bers of wires and a smaller number
of available constructions. Typical6x37 Class constructions include6x33 for diameters under 1/2",6x36 Warrington Seale (the mostcommon 6x37 Class construction)
offered in diameters 1/2" through1-5/8", and 6x49 Filler Wire Sealeover 1-3/4" diameter.
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12
Alternate LayWire Rope
Alternate Lay, sometimes
referred to as reverse lay, is a
stranded rope where the type oflay of the outer strands is alter-
nately regular lay followed by lang
lay such that three of the outer
strands are regular lay and three
are lang lay.
Alternate lay wire rope has
the extra flexibility of lang lay in
combination with the structural
stability of regular lay. It unites
the best features of both types of
wire rope.Alternate lay is made with
relatively large outer wires to pro-
vide increase of abrasion resistance
to scrubbing against sheaves and
drums. Finer inside wires and flex-
ibility enable alternate lay ropes to
absorb severe bending stresses. It is
well suited to winding applications
where abrasion and crushing can
occur.
Alternate lay wire rope ap-plications include boom hoists
and numerous types of excavating
equipment like clamshells, shovels,
cranes, winches and scrapers.
Nominal
Strength
Rope Diameter Approx. tonsWeight
(lb./ft.)
Purple Plus
inches mm.
1/2 13.0 0.46 13.3
9/16 14.5 0.59 16.8
5/8 16.0 0.72 20.6
3/4 19.0 1.04 29.4
7/8 22.0 1.42 39.8
1 26.0 1.85 51.7
1-1/8 29.0 2.34 65.0
1-1/4 32.0 2.89 79.9
*Acceptance strength is not less than 2-1/2% below the
nominal strengths listed. Tons of 2,000 lbs.
Standard Wire Ropes
Strands: 6Wires per strand: 26Core: IWRCStandard Grade: Purple Plus
Lay: CombinationFinish: Bright
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13
Rotation-Resistant Ropes
In certain instances the use of
rotation-resistant wire rope is neces-sary to provide rotational stability tothe lifted load. In general, the use of
these wire ropes is limited to thosesituations where it is impractical to:
1. Use a tag line.
2. Relocate rope dead end.3. Increase sheave sizes.4. Eliminate odd-part
reeving.5. Significantly reduce rope
loading and rope fall length.
Rotation-resistant wire ropes haveless of a tendency to unlay when loadedthan do conventional wire ropes. This
results in improved rotational stability
to the lifted load. Rotation-resistantwire ropes are designed in such a waythat the rotational force of the outer
strands is partially counteracted by therotational force of the inner strands or
core when the rope is subjected to aload.
The chart compares the rotational
properties of rotation-resistant ropeswith a standard 6x25 wire rope. The
rotation-resistant ropes far surpass the
rotational stability of a conventional
6x25 IWRC wire rope on both short andlong falls.
Safety Design FactorsASME B30.5 specifies that rota-
tion-resistant ropes have a safetydesign factor of five or greater. The
required strength design factor ofrotation-resistant rope becomes very
important from the standpoint ofmaintaining the inherent low rota-tion of the rope and eliminating any
tendency to overload the inner core,thereby causing a reduction in rope
strength.
Handling & Installation
Precautions should be followedwhen using rotation-resistant wire
rope. The rope ends must be properlyseized and secured (refer to Handling
and Installation: Seizing Wire Rope)and cut with a saw or impact hammer
to prevent unlaying of the strands.Attachment of end fittings must
be done with care to prevent kinking
or unlaying of rope, which harms therotational balance of the rope.
Operation of rotation-resistant
wire ropes with a swivel is notrecommended by WW. The use of aswivel allows the inner core to twist
tighter, resulting in a significantreduction in rope strength, possiblyleading to premature rope failure.
A swivel may be used as a tempo-rary device only during the initial
installation period to help eliminateany installation-induced twisting or
cabling.The swivel must be removed
from the reeving after rope instal-lation is completed and before thecrane begins operation.
Due to the opposite lay directionof the inner core and outer strand
layers in rotation-resistant ropes, careshould be taken to avoid shockloading.
Shockloading will result in distortionof the rope structure, causing birdcag-ing, core protrusion, etc. Due to the
potential for complete rope failure,shockloaded wire ropes must be im-
mediately removed from service.
Rotational Property Comparison
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Rotation Resistant Ropes
14
The rated strengths of the 8x19 Class and 19x7 wire ropes are less than wire ropes in the 6x19
and 6x37 Classes. Larger sheaves are required in order to achieve comparable fatigue life.Refer toTechnical Information: Effect of Sheave Size for further information on proper sheave sizes.
The 8x19 Classification rotation-
resistant ropes are recommended
for hoisting unguided loads with
a single-part or multipart line.
The eight outer strands are
manufactured in right lay, with the
inner strands being left lay.
These ropes are slightly stron-
ger and significantly more rugged
than the 19x7 construction. How-
ever, the rotation-resistant proper-ties of the 8x19 rotation-resistant
ropes are much less than those of
the 19x7 construction.
These ropes are manufactured
in right regular lay in the 8x19
Seale and 8x25 Filler Wire construc-
tions.
19x7 is recommended for
hoisting unguided loads with a
single-part line.
The rotation-resistant proper-
ties of this rope are secured by
two layers of strands. The inner
strands are left lay, while the 12
outer strands are right lay, which
enables one layer to counteract
the other layer's rotation.
The rotation-resistant charac-teristics of the 19x7 wire ropes are
superior to those of the 8x19 Class
wire ropes.
Strands: 19Wires per strand: 7Core: WSCStandard grade(s): Purple PlusLay: RegularFinish: Bright
Strands: 8Wires per strand: 19 to 25Core: IWRCStandard grade(s): Purple PlusLay: Right RegularFinish: Bright
8x19 Seale
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8/5 0.61 37.0 1.81
4/3 0.91 60.1 9.52
8/7 0.22 44.1 0.53
1 0.62 88.1 5.54
8/1-1 0.92 93.2 3.75
4/1-1 0.23 49.2 5.07
8/3-1 0.53 65.3 9.48
2/1-1 0.83 42.4 0.001
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2/1 0.31 054.0 08.01
61/9 5.41 085.0 06.31
8/5 0.61 017.0 08.61
4/3 0.91 020.1 00.42
8/7 0.22 093.1 05.23
1 0.62 028.1 02.24
8/1-1 0.92 003.2 01.35
4/1-1 0.23 048.2 01.56
8/3-1 0.53 034.3 04.87
2/1-1 0.83 080.4 08.29
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8x19 Classification Rotation-Resistant
19x7 Rotation-Resistant
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15
SFP 19 is recommended forboth multipart load and single-part fast line applications whererotational stability of the liftedload is needed, such as for useas a long fall on offshore pedes-tal cranes, rough and all terraincranes, and crawler cranes.
SFP 19 provides: Fatigue Resistance. Improvedfatigue properties are derived
through the combination of theflexible 19x19 construction and die
drawn strands. The drawn strandsurfaces minimize the interstrand
and interlayer nicking that takeplace in round rotation-resistantropes.
Abrasion Resistance. Diedrawn ropes provide improvedabrasion resistance as comparedwith round wire ropes because of
the greater wire and strand bearingsurfaces contacting sheaves anddrums.
Resistance to Drum Crushing.SFP 19 wire ropes are resistant tothe effects of drum crushing due tothe compacted strands and smooth-
ness of the rope surface. Flexibility. With 19 strandsof 19 wires in all diameters, SFP19 remains extremely flexible and
easy to handle during both theinstallation process and under theextremely harsh conditions from
fast line speeds during spooling.
Strands: 19Wires per strand: 7/19
Core: WSCStandard grade(s): Royal PurpleLay: Right RegularFinish: Bright
Rotation-Resistant Ropes
SFP 19 Rotation-Resistant
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8/5 0.61 38.0 7.22
4/3 0.91 91.1 4.23
8/7 0.22 26.1 8.341 0.62 21.2 9.65
8/1-1 0.92 86.2 5.17
4/1-1 0.23 13.3 9.78
8/3-1 0.53 10.4 0.601
2/1-1 0.83 77.4 0.521
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Specialized Wire Rope
17
6-PAC RV is recommended in se-vere boom hoist applications where
heavy duty cycles occur, the rope issubjected to premature abrasion andcrushing, and increased strengthand/or service life over flattenedstrand and standard 6x26 alternatelay ropes is desired.
6-PAC RV provides the samefatigue resistance as 6-PAC. Otherfeatures of 6-PAC RV include:
Superior Performance. In mul-tiple field trials, 6-PAC RV provided
a service life 100% higher than theprevious flattened strand and 6x26
alternate lay wire ropes. Abrasion Resistance. 6-PAC RVscompacted strand design provides
improved abrasion resistance as com-pared with standard 6x26 alternate lay
ropes because of the increased wire andstrand surfaces contacting sheaves and
drums. Superior Flexibility. 6-PAC RVis 27% more flexible than flattenedstrand, making it easier to install andhandle in the field. 6-PAC RV also of-
fers better spooling at high line speedsand longer rope service life.
Increased Strength. 6-PAC RVoffers a nominal breaking strength 3%
higher than flattened strand. Resistance To Multilayer DrumCrushing. 6-PAC RV offers increasedresistance to the crushing effects ofmultilayer drum winding than con-
ventional 6x26 alternate lay ropes.
6-PAC is recommended foruse where the rope is subjected to
heavy use or where conditions areextremely abusive, such as offshorepedestal, crawler and lattice boomequipped truck crane boom hoistapplications. 6-PAC is also recom-mended for winch lines, overheadcranes, multipart hoist lines whererotation-resistant ropes are notrequired, and other applicationswhere flexibility, high strength andresistance to crushing are impor-tant, and a cost-effective 6-strand
rope is desired.6-PAC provides: Fatigue Resistance. Improvedfatigue properties are derived from
the combination of 6-PACs flexibleconstructions and the compactedstrands. The compacted strand sur-
face minimizes the interstrand andinterlayer nicking that take place in
standard 6-strand ropes. Abrasion Resistance. 6-PACscompacted strand design provides im-proved abrasion resistance as compared
to standard 6-strand ropes because ofthe increased wire and strand surfacescontacting sheaves and drums.
Flexibility. 6-PACs design pro-vides increased flexibility, making it
easy to install, and 6-PAC also offersbetter spooling at high line speeds.
Resistance To Multilayer DrumCrushing. 6-PAC dramatically in-creases the amount of wire contact
with the drums and sheaves, reducingthe wire rope, sheave and drum wear
normally associated with standard wire
rope . Damage at the crossover pointsis also reduced.
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61/9 5.41 62x6 246.0 5.81
8/5 0.61 62x6 597.0 7.22
4/3 0.91 13x6 341.1 4.23
8/7 0.22 13x6 745.1 8.34
1 0.62 13x6 570.2 9.65
8/1-1 0.92 13x6 575.2 5.17
4/1-1 0.23 13x6 961.3 9.78
8/3-1 0.53 63x6 857.3 0.601
2/1-1 0.83 63x6 465.4 0.521
8/5-1 3.14 63x6 653.5 0.641
4/3-1 5.54 63x6 212.6 0.961
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6-PAC 6-PAC RV
Strands: 6Wires per strand: 19 to 36Core: IWRCStandard grade(s): Royal PurpleLay: Right RegularFinish: Bright
Strands: 6Wires per strand: 19 to 36
Core: IWRCStandard grade(s): Royal PurpleLay: Right ReverseFinish: Bright
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19
Specialized Wire Rope
BXL is infused with a spe-
cially-engineered polymer, creat-ing a well-balanced matrix. BXL
is recommended for numerous
hoist, marine and logging rope
applications.
BXL provides:
Fatigue Resistance. Improved
fatigue resistance is derived from
the cushioning and dampening
effect of the polymer on the wires
and strands. BXL also evenly dis-
tributes stresses which may lead tofatigue breaks.
Abrasion Resistance. The
polymer acts as a barrier between
the individual strands, preventing
penetration of any adverse mate-
rial. BXL distributes and reduces
contact stresses between the rope
and sheave, reducing wire rope
wear.
Resistance To Multilayer
Drum Crushing. BXLs smoothprofile evenly distributes crushing
pressures from the overlying layers
of rope in multilayer drum winding
applications.
Extended Sheave And Drum
Service Life. BXL minimizes
corrugation and wear normally
associated with standard rope us-
age by restricting water and dirt
penetration and eliminating pickup
of abrasive materials.
Clean Handling. The exterior
rope surface is free from the grease
normally applied to standard
ropes.
Strands: 6
Wires per strand: 19 to 36Core: IWRCStandard grade(s): Purple PlusLay: Regular or LangFinish: Plastic-infused
BXL
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61/9 5.41 16.0 8.61
8/5 0.61 67.0 6.02
4/3 0.91 90.1 4.92
8/7 0.22 94.1 8.93
1 0.62 49.1 7.15
8/1-1 0.92 64.2 0.56
4/1-1 0.23 30.3 9.97
8/3-1 0.53 76.3 0.69
2/1-1 0.83 73.4 0.411
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20
ASME Rules & GuidelinesSpecialized Wire Rope
SUPER-B
Super-B is a superior swaged
product ideal for applications
in logging such as winch lines,
chokers, skylines and haulbacks,
as well as other applications
where a swaged rope is used.
When compared with a standard
swaged rope, Super-B provides:
Superior Strength. Improved
strength properties are derived
from WWs superior swaging pro-
cess.
Abrasion Resistance. Super-
Bs swaged rope design provides
improved abrasion resistance as
compared to standard swaged
6-strand ropes because of the in-
creased wire and strand surfaces
contacting sheaves and drums.
Resistance to Multilayer
Drum Crushing. Super-B dra-
matically increases the amount of
wire contact with the drums andsheaves, reducing the wire rope,
sheave and drum wear normally
associated with standard wire rope.
Damage at the crossover points is
also reduced.
Increased Service Life. Super-
Bs design provides a significant
increase in service life over stan-
dard swaged ropes due to the ropes
ruggedness.
Also available for
logging applications:
SUPER-PAC is a com-pacted strand and compactedrope design. SUPER-PAC pro-
vides abrasion resistance andresistance to drum crushing farsuperior to that provided by
Super-B. SUPER-PAC also offers abreaking strength significantly
higher than Super-B.
SKYBRITE is a plastic-infused rope designed solelyfor helicopter chokers used inthe Western logging market.
SKYBRITE provides superiorvisibility from the air or ground
on any terrain in both clear andovercast conditions.
Contact WWs customer
service department for furtherinformation on either product.
Approx. Weight Industry StandardRope Diameter (lb./ft.) Strengths (tons)
inches mm. Super-B Super-Pac Super-B Super-Pac
1/2 13.0 0.617 .648 15.5 18
9/16 14.5 0.773 .810 19.6 23
5/8 16.0 0.962 .995 24.2 29
3/4 19.0 1.36 1.430 34.9 40
7/8 22.0 1.84 1.920 47.4 52
1 26.0 2.28 2.420 62.0 68
1-1/8 29.0 2.86 2.960 73.5 85
1-1/4 32.0 3.44 3.510 90.0 100
1-3/8 35.0 4.04 4.310 106.0 120
1-1/2 38.0 4.74 4.880 130.0 140
*Acceptance strength is not less than 2-1/2% below the
nominal strengths listed. Tons of 2,000 lbs.
Strands: 6Wires per strand: 26Core: IWRC
Standard grade(s): Royal PurpleLay: Right RegularFinish: Bright
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Specialized Wire Rope
FLATTENED STRAND
This rope is particularly suit-able where severe conditions of
crushing and abrasion are en-
countered on the drum or where
a higher strength design factor
is required than can be obtained
with a similar round rope.
The triangular strand shape not
only provides better resistance to
crushing, but also offers a greater
exposed surface area for contact
with sheaves, drums or underlyinglayers of spooled rope. This fea-
ture, in connection with the use of
Lang lay construction, distributes
the abrasive wear over a greater
number and length of wires.
The smooth surface of the rope
also helps minimize wear on drums
and sheaves.
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8/1-1 0.92 82.2 93.2 7.36 5.86
4/1-1 0.23 18.2 59.2 1.87 48
8/3-1 0.53 04.3 75.3 1.49 101
2/1-1 0.83 50.4 52.4 111 911
8/5-1 0.24 57.4 99.4 031 041
4/3-1 0.54 15.5 97.5 251 161
8/7-1 0.84 33.6 56.6 171 481
2 0.25 02.7 65.7 491 702
8/1-2 0.45 31.8 45.8 512 332
4/1-2 0.85 01.9 65.9 042 062
.detsilshtgnertslanimonehtwoleb%2/1-2nahtsseltonsihtgnertsecnatpeccA*.sbl000,2fosnoT
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21
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The Wrong Way
The Right Way
22
Handling & Installation
HandlingMeasuring Rope Diameter
Rope diameter is specified by
the user and is generally given in theequipment manufacturers instruction
manual accompanying the machine onwhich the rope is to be used.
Rope diameters are determined by
measuring the circle that just touchesthe extreme outer limits of the strands
that is, the greatest dimension thatcan be measured with a pair of paral-
lel-jawed calipers or machinists calipersquare. A mistake could be made bymeasuring the smaller dimension.
Unreeling & Uncoiling
The Right Way To Unreel. Tounreel wire rope from a heavy reel,place a shaft through the center and
jack up the reel far enough to clear thefloor and revolve easily. One person
holds the end of the rope and walks astraight line away from the reel, taking
the wire rope off the top of the reel.A second person regulates the speedof the turning reel by holding a wood
block against the flange as a brake,taking care to keep slack from develop-
ing on the reel, as this can easily causea kink in the rope. Lightweight
reels can be properly unreeled using a
vertical shaft; the same care should betaken to keep the rope taut. The Wrong Way To Unreel. If areel of wire rope is laid on its flangewith its axis vertical to the floor and
the rope unreeled by throwing off theturns, spirals will occur and kinks are
likely to form in the rope. Wire ropealways should be handled in a way thatneither twists nor unlays it. If handled
in a careless manner, reverse bends andkinks can easily occur.
The Right Way To Uncoil. Thereis only one correct way to uncoil wire
rope. One person must hold the end ofthe rope while a second person rollsthe coil along the floor, backing away.
The rope is allowed to uncoil natu-rally with the lay, without spiraling
or twisting. Always uncoil wire ropeas shown.
The Wrong Way To Uncoil. If a
coil of wire rope is laid flat on the floorand uncoiled by pulling it straight off,spirals will occur and kinking is likely.Torsions are put into the rope by every
loop that is pulled off, and the ropebecomes twisted and unmanageable.
Also, wire rope cannot be uncoiled likehemp rope. Pulling one end through
the middle of the coil will only resultin kinking.
Kinks
Great stress has been placedon the care that should be taken toavoid kinks in wire rope. Kinks are
places where the rope has been unin-tentionally bent to a permanent set.This happens where loops are pulled
through by tension on the rope untilthe diameter of the loop is only a few
inches. They are also caused by bend-ing a rope around a sheave having too
severe a radius. Wires in the strands atthe kink are permanently damaged
and will not give normal service, evenafter apparent restraightening.
Drum Winding
When wire rope is wound onto
a sheave or drum, it should bend inthe manner in which it was originally
wound. This will avoid causing a re-verse bend in the rope. Always windwire rope from the top of the one reelonto the top of the other. Also ac-ceptable, but less so, is re-reeling from
the bottom of one reel to the bottom of
another. Re-reeling may also be donewith reels having their shafts vertical,but extreme care must be taken toensure that the rope always remains
taut. It should never be allowed to dropbelow the lower flange of the reel. A
reel resting on the floor with its axishorizontal may also be rolled along the
floor to unreel the rope.
Correct
Correct
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23
Handling & Installation
Wire rope should be attached at the cor-rect location on a flat or smooth-faced
drum, so that the rope will spoolevenly, with the turns lying snuglyagainst each other in even layers. If
wire rope is wound on a smooth-facedrum in the wrong direction, the turns
in the first layer of rope will tend tospread apart on the drum. This results
in the second layer of rope wedgingbetween the open coils, crushing and
flattening the rope as successive layersare spooled.
A simple method of determining
how a wire rope should be started ona drum is shown above. The observer
stands behind the drum, with the ropecoming towards him. Using the righthand for right-lay wire rope, and the
left hand for left lay wire rope, theclenched fist denotes the drum, the
extended index finger the oncomingrope.
Wire Rope ClipsClips are usually spaced about
six wire rope diameters apart to giveadequate holding power. They should
be tightened before the rope is placedunder tension. After the load is placed
on the rope, tighten the clips againto take care of any lessening in rope
diameter caused by tension of theload. A wire rope thimble should beused in the eye of the loop to prevent
kinking.
The correct number of clips forsafe operation and the spacing dis-
tances are shown in the table. U-bolt Clips. There is only onecorrect method for attaching U-bolt
clips to wire rope ends, as shown in The
Right Way. The base of the clip bears
on the live end of the rope; the U ofthe bolt bears on the dead end.
Compare this with the incorrect
methods. Five of the six clips shownare incorrectly attachedonly thecenter clip in the top view is correct.
When the U of the clip bears on thelive end of the rope, there is a possibil-
ity of the ropes being cut or kinked,with subsequent failure.
Twin-base Clips. Twin-base clipsare installed as shown below. Due totheir special design, they cannot be
installed incorrectly.
The Right Way
The Wrong Way
Number of clips and spacing for safe application (center to center)
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By holding the right hand or left hand with the index finger extended, palm up or palm down,the proper procedure for applying left and right lay rope can easily be determined.
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24
ASME Rules & GuidelinesHandling & Installation
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Suggested Seizing Wire Diameters
Seizing Wire RopeProper seizing and cutting opera-
tions are not difficult to perform, and
they ensure that the wire rope willmeet the users performance expecta-
tions. Proper seizings must be appliedon both sides of the place where the
cut is to be made. In a wire rope, care-lessly or inadequately seized ends maybecome distorted and flattened, and
the strands may loosen. Subsequently,when the rope is operated, there may
be an uneven distribution of loadsto the strands; a condition that will
significantly shorten the life of therope.
Either of the following seizing
methods is acceptable. Method No. 1is usually used on wire ropes over one
inch in diameter. Method No. 2 appliesto ropes one inch and under.
Method No. 1: Place one end ofthe seizing wire in the valley betweentwo strands. Then turn its long end at
right angles to the rope and closely andtightly wind the wire back over itself
and the rope until the proper lengthof seizing has been applied. Twist the
two ends of the wire together, and byalternately pulling and twisting, draw
the seizing tight. Method No. 2: Twist the two endsof the seizing wire together, alter-
nately twisting and pulling until theproper tightness is achieved.
The Seizing Wire. The seizingwire should be soft or annealed wire
Installation
The majority of wire rope prob-lems occurring during operation
actually begin during installation,
when the rope is at its greatest risk ofbeing damaged. Proper installation
procedures are vital in the protec-tion and performance of wire rope
products.
Provide Proper Storage
Until the rope is installed it shouldbe stored on a rack, pallet or reel
stand in a dry, well-ventilated stor-age shed or building. Tightly sealedand unheated structures should be
avoided as condensation between ropestrands may occur and cause corrosion
problems. If site conditions demandoutside storage, cover the rope with
waterproof material and place the reelor coil on a support platform to keepit from coming directly in contact with
the ground.While lubrication is applied during
the manufacturing process, the wirerope must still be protected by addi-
tional lubrication once it is installed.Lubricants will dry out over a period of
time and corrosion from the elementswill occur unless measures are takento prevent this from happening. When
the machine becomes idle for a periodof time, apply a protective coating of
lubricant to the wire rope. Moisture(dew, rain, and snow) trapped between
Suggested End Preparations
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Method No. 1
Method No. 2
or strand. Seizing wire diameter and
the length of the seize will dependon the diameter of the wire rope. The
length of the seizing should never beless than the diameter of the rope
being seized. Proper end seizing while cut-ting and installing, particularly onrotation-resistant ropes, is critical.Failure to adhere to simple precaution-
ary measures may cause core slippageand loose strands, resulting in serious
rope damage. Refer to the table forestablished guidelines. If core protru-sion occurs beyond the outer strands,
or core retraction within the outerstrands, cut the rope flush to allow
for proper seizing of both the core and
outer strands.In the absence of proper seizing
wire or tools, the use of sufficiently-sized hose clamps is acceptable.
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25
Handling & Installation
Rope Kinked During Installation
Poor Spooling
strands and wires will create corrosionif the rope is unprotected. Also apply
lubricant to each layer of wire ropeon a drum because moisture trappedbetween layers will increase the likeli-
hood of corrosion.
Check The Rope Diameter Prior
To Installation
Always use the nominal diameteras specified by the equipment manu-
facturer. Using a smaller diameter ropewill cause increased stresses on the
rope and the probability of a criticalfailure is increased if the rated break-ing strength does not match that of
the specified diameter. Using a largerdiameter rope leads to shorter service
life as the rope is pinched in thesheave and drum grooves which wereoriginally designed for a smaller di-
ameter rope. Just as using a differentdiameter rope can create performance
problems, so can the use of an exces-sively undersized or oversized rope.
Measure the wire rope using a
parallel-jawed caliper as discussed inMeasuring Rope Diameter. If the rope
is the wrong size or outside the rec-ommended tolerance, return the rope
to the wire rope supplier. It is neverrecommended nor permitted by federal
standards to operate cranes with theincorrect rope diameter. Doing so willaffect the safety factor or reduce ser-
vice life and damage the sheaves anddrum. Note that in a grooved drum
application, the pitch of the groove
may be designed for the ropes nominal
diameter and not the actual diameteras permitted by federal standards.
Use Proper Unreeling
ProceduresWire rope can be permanently
damaged by improper unreeling or
uncoiling practices. The majority ofwire rope performance problemsstart here. Improper unreeling prac-tices lead to premature rope replace-ment, hoisting problems and rope
failure.Place the payout reel as far away
from the boom tip as is practical,moving away from the crane chassis.Never place the payout reel closer to
the crane chassis than the boom pointsheave. Doing so may introduce a
reverse bend into the rope and causespooling problems. Follow the guide-
lines highlighted under Unreeling &Uncoiling and Drum Winding. Takecare to determine whether the wire
rope will wind over or under the drumbefore proceeding. If the wire rope
supplier secured the end of the ropeto the reel by driving a nail through
the strands, ask that in the future aU-bolt or other nondestructive tie-down method be used; nails used in
this manner damage the rope.Take extra precaution when in-
stalling Lang lay, rotation-resistant,flattened strand or compacted ropes.
Loss of twist must be avoided to pre-vent the strands from becoming loos-ened, causing looped wire problems.
Keep Wraps Tight
The end of the rope must besecurely and evenly attached to the
drum anchorage point by the methodrecommended by the equipment manu-facturer. Depending on the cranes
regulatory requirements, at least twoto three wraps must remain on the
drum as dead wraps when the rope isunwound during normal operations.
Locate the dead end rope anchoragepoint on the drum in relation to thedirection of the lay of the rope as
shown inDrum Winding. Do not usean anchorage point that does not cor-
respond with the rope lay. Mismatch-ing rope lay and anchorage point will
cause the wraps to spread apart fromeach other and allow the rope to crossover on the drum. Very gappy winding
will occur resulting in crushing damagein multilayer applications.
Back tension must be continu-ally applied to the payout reel and
the crewman installing the rope mustproceed at a slow and steady pace
whether the drum is smooth orgrooved. Regardless of the benefitsof a grooved drum, tension must be
applied to ensure proper spooling. Animproperly installed rope on a grooved
drum will wear just as quickly as animproperly installed rope on a smooth
drum. If a wire rope is poorly woundand as a result jumps the grooves, itwill be crushed and cut under operat-
ing load conditions where it crossesthe grooves.
Every wrap on the first or foun-dation layer must be installed verytightly and be without gaps. Careless
winding results in poor spooling andwill eventually lead to short service
life. The following layers of rope mustlay in the grooves formed between
adjacent turns of the preceding layerof rope. If any type of overwind orcrosswinding occurs at this stage of
installation and is not corrected im-mediately, poor spooling and crushing
damage will occur.
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26
ASME Rules & GuidelinesHandling & Installation
On a multilayer spooling drumbe sure that the last layer remains at
least two rope diameters below thedrum flange top. Do not use a longer
length than is required because the
excess wire rope will cause unnec-essary crushing and may jump theflange. Loose wraps that occur at anytime must be corrected immediately to
prevent catastrophic rope failure.The use of a mallet is acceptable
to ensure tight wraps, however a steel-faced mallet should be covered with
plastic or rubber to prevent damageto the rope wires and strands.
Treat Rotation-Resistant Ropes
With Extra Care
Rotation-resistant ropes of allconstructions require extra care in
handling to prevent rope damageduring installation. The lay length ofa rotation-resistant rope must not be
disturbed during the various stagesof installation. By introducing twist
or torque into the rope, core slippagemay occurthe outer strands become
shorter in length, the core slips andprotrudes from the rope. In this con-dition the outer strands become over-
loaded because the core is no longer
taking its designed share of the load.Conversely, when torque is removedfrom a rotation-resistant rope core
slippage can also occur. The outerstrands become longer and the innerlayers or core become overloaded,
reducing service life and causing ropefailure.
Secure The Ends BeforeCutting
The plain end of a wire rope must
be properly secured. If the entirecross section of the rope is not firmly
secured, core slippage may occur,causing the core to pull inside theropes end and allowing it to protrude
elsewhere, either through the outerstrands (popped core) or out the other
end of the line. The outer layer ofthe outside strands may also become
overloaded as there is no completecore-to-strand support.
Secure the ends of the rope witheither seizing or welding methods as
recommended under Seizing. It is im-perative that the ends be held together
tightly and uniformly throughout the
entire installation procedure, includ-ing attaching the end through thewedge socket and the drum dead endwedge.
Use a Cable Snake
When installing a new line, con-nect the old line to the new line by
using a swivel-equipped cable snake orChinese finger securely attached to therope ends. The connection between the
ropes during change-out must be verystrong and prevent torque from the
old rope being transferred into thenew rope. Welding ropes together orusing a cable snake without the benefitof a swivel increases the likelihood ofintroducing torque into the new rope.
A swivel-equipped cable snake is notas easy as welding the ropes, but this
procedure can be mastered with a littlepatience and practice.
Standard Operating
Practices
Perform A Break-in Procedure
Perform a break-in procedure toachieve maximum service life. Runthe new rope through its operating
cycle several times under a light loadat a reduced line speed. A light load is
normally considered to be 10% of theworking load limit. This allows the rope
to adjust gradually to working condi-tions, enables the strands to becomesettled, and allows for slight stretching
and diameter reduction to occur.
Maintain Equipment
Wire rope performance depends
upon the condition of the equip-ment on which it operates. Poorlymaintained equipment may result in
reduced service life.
Avoid Slack In The Rope
In any hoisting operation, there
should be no slack in the wire ropewhen the load is applied. Otherwise
the resulting stress will be excessive.
As discussed previously, shockload- ingis destructive and results in irreparabledamage to the rope.
Slowly Lift Or ReleaseThe Load
Overstressing the rope is a result of
too-rapid acceleration or deceleration.Wire rope will withstand considerable
stress if the load is applied slowly.
Use a Wire Rope Only On TheJob For Which It Was
IntendedSometimes an idle rope from one
operation is installed on another to
keep the rope in continuous service.This extremely poor practice is an
expensive economy. Because wirerope tends to set to the conditions of
its particular job, the differing bends,abrasions and stresses of a new opera-tion may produce premature failure.
Therefore, for maximum life and effi-ciency, a rope should be used only on
a job for which it has been specified.
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27
Wire Rope Inspection
The most widely used wire ropereplacement, inspection and main-
tenance standard for mobile-typecranes is ASME B30.5, section 5-2.4.
The following is an excerpt from thatstandard.
All running ropes in service should
be visually inspected once each workingday. A visual inspection shall consist
of observation of all rope which canreasonably be expected to be in use dur-ing the days operations. These visual
observations should be concerned withdiscovering gross damage, such as listed
below, which may be an immediatehazard:
[A] Distortion of the rope such askinking, crushing, unstranding, bird-
caging, main strand displacement, orcore protrusion. Loss of rope diameter
in a short rope length or unevenness ofouter strands should provide evidence
that the rope must be replaced.[B] General corrosion
[C] Broken or cut strands[D] Number, distribution, and
type of visible broken wires
[E] Core failure in rotationresistant ropes: when such damage
is discovered, the rope shall be eitherremoved from service or given an inspection (further detail per S-2.4.2).
The frequency of detailed and
thorough inspections should be deter-mined by a qualified person, who takesinto account the following factors:
Expected rope life as deter-
mined by [a] maintenancerecords, and [b] experience
on the particular installationor similar installations
Severity of environment
Percentage of capacity lifts Frequency rates of operation,
and exposure to shock loads
Inspect the entire length of the
rope. Some areas of the wire rope suchas around the core are more difficult toinspect. To inspect the core, examine
the rope as it passes over the sheaves.The strands have a tendency to open
up slightly which will afford the in-spector a better view of the core. Also
regularly inspect for any reduction indiameter and lengthening of rope lay
as both conditions indicate core dam-age.
Basic Guidelines
Abrasion
Abrasion damage may occur when
the rope contacts an abrasive mediumor simply when it passes over the drum
and sheaves. Therefore it is vital thatall components be in proper working
order and of the appropriate diameterfor the rope. A badly corrugated or
worn sheave or drum will seriouslydamage a new rope, resulting in pre-mature rope replacement.
Corrosion
Corrosion is very difficult toevaluate but is a more serious causeof degradation than abrasion. Usually
signifying a lack of lubrication, corro-sion will often occur internally before
there is any visible external evidenceon the ropes surface. A slight dis-
coloration caused by rusting usually
indicates a need for lubrication whichshould be tended to immediately. Ifthis condition persists, it will lead
to severe corrosion which promotespremature fatigue failures in the wires
and strands, necessitating the ropesimmediate removal from service.
Wire Breaks
The table above shows the num-ber of allowable wire breaks per cranetype. The inspector must know the
ASME standard for the equipment be-ing inspected. The number of broken
wires on the outside of the wire rope isan indication of its general conditionand whether or not it must be consid-
ered for replacement. The inspectormay use a type of spike to gently probe
the strands for any wire breaks that donot protrude. Check as the rope runs
at a slow speed over the sheaves, where
crown (surface) wire breaks may beeasier to see. Also examine the rope
near the end connections. Keeping adetailed inspection record of the wire
breaks and other types of damagewill help the inspector determine the
elapsed time between breaks. Note thearea of the breaks and carefully inspectthese areas in the future. Replace the
rope when the wire breaks reach thetotal number allowable by ASME or
other applicable specifications.
Allowable Wire Breaks
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28
ASME Rules & GuidelinesWire Rope Inspection
Valley breaks, or breaks in between
strands, must be taken very seriouslyat all times! When two or more valley
breaks are found in one lay-length,immediately replace the rope. Valleybreaks are difficult to see; however, if
you see one you can be assured thatthere are a few more hidden in the
same area. Crown breaks are signs ofnormal deterioration, but valley breaks
indicate an abnormal condition suchas fatigue or breakage of other wiressuch as those in the core.
Once crown and valley breaks ap-pear, their number will steadily and
quickly increase as time goes on. The
broken wires should be removed assoon as possible by bending the bro-ken ends back and forth with a pair
of pliers. In this way the wire is morelikely to break inside the rope wherethe ends will be tucked away. If the
broken wires are not removed they maycause further damage.
The inspector must obey the bro-ken wire standard; pushing the rope
for more life will create a dangeroussituation.
Diameter ReductionDiameter reduction is a critical
deterioration factor and can be causedby:
Excessive abrasion of theoutside wires
Loss of core diameter/support Internal or external corrosion
damage Inner wire failure
A lengthening of rope lay
It is important to check and
record a new ropes actual diameterwhen under normal load conditions.
During the life of the rope the inspec-tor should periodically measure theactual diameter of the rope at the
same location under equivalent loadingconditions. This procedure if followed
carefully reveals a common rope char-acteristicafter an initial reduction,
the overall diameter will stabilize andslowly decrease in diameter during thecourse of the ropes life. This condi-
tion is normal. However, if diameterreduction is isolated to one area or
happens quickly, the inspector must
immediately determine (and correct,if necessary) the cause of the diameterloss, and schedule the rope for replace-ment.
Crushing
Crushing or flattening of thestrands can be caused by a number
of different factors. These problemsusually occur on multilayer spoolingconditions but can occur by simply
using the wrong wire rope construc-tion. Most premature crushing and/or
flattening conditions occur because ofimproper installation of the wire rope.
In many cases failure to obtain a verytight first layer (the foundation) will
cause loose or gappy conditionsin the wire rope which will causerapid deterioration. Failure to prop-
erly break-in the new rope, or worse,to have no break-in procedure at all,
will cause similar poor spooling condi-tions. Therefore, it is imperative that
the inspector knows how to inspect the
wire rope as well as how that rope was
installed.
Shockloading
Shockloading (birdcaging) of the
rope is another reason for replacementof the rope. Shockloading is caused bythe sudden release of tension on the
wire rope and its resultant reboundfrom being overloaded. The damage
that occurs can never be corrected andthe rope must be replaced.
High Stranding
High stranding may occur for a
number of reasons such as failure toproperly seize the rope prior to in-
stallation or maintain seizing during
wedge socket installation. Sometimeswavy rope occurs due to kinks or avery tight grooving problem. Anotherpossibility is simply introducing torque
or twist into a new rope during poorinstallation procedures. This condition
requires the inspector to evaluate thecontinued use of the rope or increase
the frequency of inspection.
Inspection GuidelinesFor Specialty Rope
Plastic-infused Rope
Plastic-infused rope was developedto provide better fatigue, abrasion and
crushing resistance derived from thecushioning and dampening effect of
the plastic. However great the ben-efits, the plastic becomes at the veryleast an inconvenience when trying to
inspect the wire rope. Because of theplastic coating, some operators choose
to forego inspection and run the ropesto failure. Other operators may just
visually inspect the plastic coating.Both practices are wrong and carryequally the potential for disaster.
Abrasion and Crushing. Ininspecting plastic-infused ropes, the
basic inspection guidelines still ap-ply and should be followed. Abrasion
and crushing damage may still occur,so it is imperative to inspect flanges,sheaves, bearings, rollers and fairleads.
Look for unusual wear patterns in theplastica key indicator that damage
to the wire rope is occurring.
Recommended Retirement Criteria Based On Diameter Reduction
)sehcni(retemaiDlanigirO )sehcni(retemaiDfOssoL
rellamsdna"61/5 "46/1 ro "610.
"2/1hguorht"8/3 "23/1 ro "130.
"4/3hguorht"61/9 "46/3 ro "940.
"8/1-1hguorht"8/7 "61/1 ro "360.
"2/1-1hguorht"4/1-1 "23/3 ro "490.
"8/1-2hguorht"4/3-1 "8/1 ro "521.
"8/5-2hguorht"4/1-2 "23/5 ro "651.
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29
Wire Rope Inspection
Wire Breaks. Wire breaks willstill occur in a plastic-infused rope,but are sometimes extremely difficultto detect, though occasionally a bro-
ken wire will protrude through theplastic. Every effort must be made to
determine the overall condition of therope. The plastic covering the crown
(surface) wires is generally applied ina thin coat and tends to wear quicklyin areas which pass over sheaves and
drums. As the rope runs at a slowspeed, inspect the rope in these areas.
As the rope and plastic open up theinspector will be afforded a look at
not only the surface area but also theinterstrand contact points. If a valley
break is detected, immediately pull therope from service. Also inspect areaswhere the plastic has peeled, regard-
less of the location of the window.Remove as much plastic from these
areas as possible to allow for efficientand effective inspection techniques.Remember, due to the nature of plas-
tic-infused ropes, there is no way toclearly determine the number of valley
breaks. Corrosion. Plastic-infused ropesprovide only improved corrosion re-sistance. Regardless of manufacturersclaims, a plastic-infused rope can cor-
rode, and rope failure due to corrosionis still possible. Moisture is sometimes
trapped in the rope and as with allmachines, the lubricant may become
ineffective over time. The inspectormust visually check for any signs of
corrosion damage as evidenced by ropebleeding or rouging. In addition, thediameter must be frequently measured.
If there is any damage to the core,
it will be detected by a reduction indiameter. Also inspect the lay of therope. As the plastic is thinner over the
crown wires, a thorough inspector maybe able to determine a lengthening oflay, also a sign of rope deterioration.
Especially when trying to determine
lengthening of lay, watch for andinspect areas where the plastic pullsaway from the rope. While peeling in
and of itself is not an indication ofrope deterioration and is a factor of
normal wear, peeling in areas whereno abrasion exists may signify a prob-
lem. Maintenance Records. Equallyimportant in inspecting plastic-infused
ropes is maintaining accurate servicerecords. The service records of previ-
ous ropes will provide a guideline as tothe expected life of the rope. However,
they should not be used alone or onlyin conjunction with visual inspections
due to the number of variables whichexist, including installation, spoolingand manufacturing practices. Mainte-
nance records must be used in combi-nation with both visual and physical
inspection techniques to be truly ofvalue in determining the remaininglife of the rope.
Compacted Rope
Die drawn and swaged ropes fallinto the compacted category. Com-
pacting serves several purposes. Byflattening the outer wires, metallicarea increases allowing for a higher
breaking strength as well as improvedcrushing and abrasion resistance. In
addition, the compaction minimizesinterstrand nicking and thereby im-
proves fatigue resistance.In the inspection of compacted
rope designs, again it is imperativeto follow the basic inspection guide-lines and use both visual and actual
measuring techniques to determine
the remaining life of the rope. Infact, actual measuring techniques arevery important when inspecting these
ropes. While corrosion is relativelyeasy to visually determine, diameterreduction may not be due to the com-
pacted ropes appearance. Therefore
the inspector must regularly measurefor diameter reduction and closelyexamine the rope for lay lengthening.
Measurements must be recorded andthe rope monitored for sudden varia-
tions.By and large the most difficult
retirement criteria to determine incompacted ropes is wire breaks. Thesebreaks may not protrude from the rope
due to the compaction and can be eas-ily overlooked. Because of this, the
inspector must slowly and carefullyexamine the rope, especially in those
areas passing over drums and sheavesor in areas where problems existed in
previous ropes.A wire break may appear as noth-
ing more than a crack in the wire,
and again can be easily overlooked.If the inspector notes a flaw in a
wire, it should be carefully checked.The inspector should carry some typeof magnifying device to determine if
a flaw is actually a break. If a breakhas occurred, thoroughly check the
area for additional breaks, both on thecrown and in the valleys. Remember,
valley breaks in round strand ropesare difficult to determine; compac-tion only increases the difficulty. The
inspector must be slow and methodicalin inspecting compacted ropes; a quick
check will reveal nothing.Overall, perhaps the most impor-
tant inspection technique is recogniz-ing the limits of wire rope. While its
true that compacted and plastic-in-fused ropes are more durable, neglectand abuse will still quickly end the
ropes life. There is no substitute
for proper installation, handling andinspection techniques in combinationwith a preventative maintenance pro-
gram.
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ASME Rules & GuidelinesWire Rope Inspection
Representations of three wire ropeseating conditions: [A] new ropein new groove; [B] new rope inworn groove; [C] worn rope in worngroove.
Fleet Angle
Drums & Sheaves
Drums
Inspect the flanges for wear, chips,
cracks and bending. Inspect the Lebusgrooving (if so equipped), visor andkicker plates for wear. Also look for
rope imprinting damage.
Sheaves
Examine the sheave grooves for
wear and proper diameter. To checkthe size, contour and amount of wear,use a sheave gage. The gage should
contact the groove for about 150o ofarc.
Inspect the fleet angle for poorsheave alignment. The fleet angle is
the side, or included, angle betweena line drawn through the middle ofa sheave and a drum, perpendicular
to the axis of each, and a line drawnfrom the intersection of the drum and
its flange to the base of the groove inthe sheave. The intersection of the
drum and its flange represents thefarthest position to which the
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