MazzellaCatalog13 WireRope LR PDF

Wire Rope
Mazzella Lifting Technologies Progressive Crane Mazzella Crane Service Indusco Wire Rope & Supplies
Phone: 800-362-4601 Phone: 800-83-CRANE Phone: 877-96-CRANE Phone: 410-727-0665
www.mazzellalifting.com www.progressivecrane.com www.mazzellacraneservice.com www.induscowire.com
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MazzellaCatalog13_WireRope.indd 644 7/3/13 10:06 AM

Large Inventory…
Cranes / Jibs
Overhead
maintained for
immediate delivery

Stocking well over 2,000,000 feet of
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wire rope in our various locations.
■ In sizes from 1/4" to 3" diameter and

9 mm to 52 mm diameter
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■ Domestic and Non-Domestic
■ In stock and ready for same or next day
shipment from one of our many
Engineered
service centers
Products
Slings
Hardware
Products
Lifting
Rope
Wire
Cordage
Securement
Load
Contractors
Supply
Protection
J Henry Holland Alabama Sling Center Tennessee Sling Center KCI Crane Service
Phone: 757-460-3300 Phone: 205-744-0230 Phone: 901-345-8918 (Memphis) Phone: 205-345-4701
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www.jhenryholland.com www.alabamaslingcenter.com Phone: 423-634-9005 (Chattanooga) www.kcicraneservice.com

www.tennesseeslingcenter.com
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Wire Rope Index Oilfield Wire Ropes.........................................698
Rotation-Resistant Ropes..............................699 - 700
Product Design Specialized Wire Ropes.................................701 - 703
Wire Rope is a Machine.................................647 BXL—Plastic-Infused Wire Ropes..................704
Wire Rope Parts List......................................648 Oilfield & Natural Gas Drilling Products..........705 - 706
Strands & Strand Construction.......................649 Flex-X® 19 & Flex-X® 6...................................707
Standard 6 x 19 & 6 x 36 PFV® & Tuf-Kote®...........................................708
Classification Ropes................................650 Starlift Plus, Eurolift & Turboplast...................709
Seven Primary Features.................................651 - 652 Overhead Crane Ropes.................................711
Identification & Construction...........................653 Galvanized Steel Strand.................................712
Lang Lay Ropes.............................................654 Structural Strand............................................713 - 714
How to Unreel, Uncoil & Store........................655 Related Products
Winding Wire Rope........................................656 Wire Rope Lubricant.......................................715
Using the Right Drum.....................................657 Wire Rope Pulling / Splicing Grips.................716 - 720
Sheave Design...............................................658 - 659
Warnings
How Sheave Size Affects
Product Warnings...........................................721 - 723
Wire Rope Strength.................................660
How to Determine For the complete catalog index,
Overhauling Weights................................660 refer to the front of the book.
Technical Information.....................................661 - 667
Inspection
Wire Rope Inspection.....................................668 - 671
Guide to Examination.....................................672 - 673
Inspection of Sheaves & Drums.....................674
Troubleshooting Guide...................................675 - 677
Products Safety & Warning
Product Safety................................................678 - 686
Wire Rope Technical
Board Warning.........................................686
Product Detail
General Purpose Wire Ropes
6 x 7 Classification...................................687
Aircraft Cable & Strand...................................688
Standard 6 x 19 & 6 x 36
Classifications..........................................689
Standard & High-Performance
Wire Ropes for Crane Applications..........690
High-Performance Wire Ropes......................691
Dyform® 6/6PI.................................................692
Constructex®...................................................693
Tiger® Blue......................................................693
Dyform® 18/18PI.............................................694
Dyform® 34LR/PI/Max.....................................695
Tower Crane Ropes........................................696
Mobile Crane Ropes.......................................697, 710
646

A Wire Rope Is A Machine
Cranes / Jibs
Overhead
With Many Moving Parts.

From childhood, many of us have been conditioned
to think of a machine as some device with gears, shafts,
belts, cams, and assorted whirring parts. Yet, by the rules
Hoists
of physics, an ordinary pry bar is a simple machine, even
though it has only one part.
A wire rope is, in reality, a very complicated machine. A
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typical 6 x 25 rope has 150 wires in its strands, all of which
move independently and together in a very complicated
pattern around the core as the rope bends. Clearances
between wires and strands are balanced when a rope is
designed so that proper bearing clearances will exist to
Engineered
Products
permit internal movement and adjustment of wires and
strands when the rope has to bend. These clearances will
vary as bending occurs, but are of the same range as the
clearances found in automobile engine bearings.
Understanding and accepting the “machine idea” gives a
Slings
rope user a greater respect for rope, and enables him to
obtain better performance and longer useful life from rope
applications. Anyone who uses a rope can use it more
efficiently and effectively when he fully understands the By this same reasoning, a 1-inch rope wrapped on a
Hardware
machine concept. 30-inch hoist, the drum must compensate internally for a
6-1/4" length differential in each wrap.
How A Wire Rope Machine Works
This change of dimension is achieved by the sliding and
The extent to which wires move in a rope when it bends is adjusting of the strands in relation to one another, and a
Products
Lifting
illustrated by the following example—what actually happens similar sliding and adjusting of the individual wires within
when you wrap a 1-inch rope over a 30-inch sheave. each strand.
Between the point where the rope first touches the sheave
on one side, and where it leaves the sheave on the other By painting stripes around a wire rope as illustrated here,
side, the length of rope in contact with the sheave would be and actually bending the rope, we can see the movement
Rope
of strands as the rope bends. Anytime a rope flexes, this
Wire
3-1/8 inches shorter than the length of the side away from
the sheave—if the rope did not move and adjust internally movement takes place. The sharper the bend, the more
by wires sliding back and forth. the movement.
The mathematics is simple: Just subtract half the Quite obviously, the grade of wire will affect such things as
Cordage
circumference of a 30" circle from half the circumference strength, resistance to wear, fatigue resistance, corrosion
of a 32" circle. resistance and so on. Today, the greatest portion of all wire
rope is made from two grades of wire—Extra Improved,
Circumference = π x Diameter Plow Steel (EIP) and Double Extra Improved Plow Steel
Securement
C= 3.1416 x 32 = 100.5312 (EEIP). Both are tough, strong, wear-resisting carbon steel,
Load
C = 3.1416 x 30 = 94.2490 with EEIP providing about 10% greater tensile strength.
6.2931 / 2 = 3.14 Sometimes wire is plated or galvanized before strands are
formed, where special corrosion or wear characteristics are
Thus, circumference of a 32-inch circle is slightly more than desired. Most wire is “Bright”—that is, without any surface
Contractors
6-1/4" longer than that of a 30-inch circle. Since a rope only coating or treatment.
Supply
touches half of a sheave at any time, the length differential

which a rope must accommodate is 3-1/8".
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647

The Parts List of a
Wire Rope Machine
Wire rope consists of three basic components; while few in
number, these vary in both complexity and configuration so
as to produce ropes for specific purposes or characteristics.
The three basic components of a standard wire rope design
are: 1) wires that form the strand, 2) multi-wire strands laid
helically around a core, and 3) the core.
Wire, for rope, is made in several materials and types:

steel, iron, stainless steel, monel and bronze. By far,
the most widely used material is high-carbon steel. This available ropes always include these abbreviations to
is available in a variety of grades each of which has identify the core type.
properties related to the basic curve for steel rope wire.
Wire rope manufacturers select the wire type that is most The Lay
appropriate for requirements of the finished product.
The word “lay” is used to describe three physical
Grades of wire rope are referred to as extra improved plow characteristics of wire rope. It is both an engineering term
steel (EIP), and double extra improved plow steel (EEIP). and a descriptive term. Lay describes:
(These steel grade names originated at the earliest stages
of wire rope development and have been retained as 1. The DIRECTION strands “lay” in the rope—
references to the strength of a particular size and grade Right or Left. When you look along a rope,
of rope.) The plow steel strength curve forms the basis for strands of a Right Lay make the rope.
calculating the strength of all steel rope wires; the tensile 2. The RELATIONSHIP between the direction
strength (psi) of any steel wire grade is not constant, it strands lay in the rope and the direction wires
varies with the diameter and is highest in the smallest wires. lay in the strands. In a Regular Lay rope,
wires lay opposite the direction of the
The most common finish for steel wire is "bright" or un- strand. In a Lang Lay rope, wires lay in the
coated. Steel wires may also be galvanized, i.e., zinc coated. same direction as strands.
"Drawn galvanized" wire has the same strength as bright 3. The LENGTH along the rope which one
wire, but wire "galvanized at finished size" is usually 10% strand uses to make one complete spiral
lower in strength. In certain applications, "tinned" wire is around the rope core.
used, but it should be noted that tin provides no sacrificial,
i.e., cathodic, protection for the steel as does zinc. A comparison of typical wire rope lays:
A. Right Regular Lay D. Left Lang Lay
Strands are made up of two or more wires, laid in any one B. Left Regular Lay E. Right Alternate Lay
of many specific geometric arrangements, or in a combina- C. Right Lang Lay
tion of steel wires with some other materials such as natural
or synthetic fibers. It is conceivable that a strand can be
made up of any number of wires, or that a rope can have any A
number of strands. The following section, IDENTIFICATION
and CONSTRUCTION, provides a complete description of
wire rope constructions. B
The Core is the foundation of a wire rope; it is made of
materials that will provide proper support for the strands C
under normal bending and loading conditions. Core materials
include fibers (hard vegetable or synthetic) or steel. A steel
core consists either of a strand or an independent wire rope. D
The three most commonly used core designations are: fiber
core (FC), independent wire rope core (IWRC), and wire
strand core (WSC). Catalog descriptions of the various E
648

The Number of Strands Single Layer
Cranes / Jibs
Overhead
What is sometimes called the “Single Layer
& the Strand Construction Principle” is the basis for this strand construction.
Probably the most common example is a single
Determine the wire center with six wires of the same diameter
Classification of a Rope.
around it. It is called simply, a 7-wire (1-6) strand.
Hoists
Filler Wire
Strands are basic building blocks. A strand consists of a This construction has two layers of uniform size
“center” which supports a specified number of wires around wire around a center wire, with the inner layer
it in one or more layers. The strands provide all the tensile having half the number of wires as the outer layer.
strength of a fiber core rope, and 92-1/2% of the strength of Small filler wires, equal in number to the inner
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an IWRC six strand rope. layer, are laid in the valleys of the inner layer.
Example: 25 Filler Wire (1-6-6f-12) strand
Such physical characteristics as fatigue resistance and
resistance to abrasion are directly affected by the design of Seale
strands. In most strands with two or more layers of wires,
Engineered
The Seale Principle features two layers of
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inner layers support outer layers in such a manner that all wires around a center wire, with the same number
wires may slide and adjust freely when the strand flexes. of wires in each layer. All wires in each layer
are the same diameter, and the strand is
designed so that the large outer wires rest in
As a general rule, a strand made up of a small number of
the valleys between the smaller inner wires.
large wires will be more abrasion resistant and less fatigue Example: 19 Seale (1-9-9) strand.
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resistant than a strand of the same size made up of many
smaller wires.
Warrington
The Warrington Principle is a 2-layer construction
Illustrated on the right are the basic strand with uniform-sized wires in the inner layer, and
constructions.
Hardware
two diameters of wire alternating large and small
in the outer layer. The larger outer-layer wires
rest in the valleys, and the smaller ones on the
crowns, of the inner layer. Example: 19 Warrington
Standard Rope Classifications [1-6-(6+6)] strand.
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Lifting
Most common wire rope constructions are grouped into
four standard classifications, based on the number of Combined Patterns
When a strand is formed in a SINGLE OPERA-
strands and wires per strand, as shown in this chart. All
TION using two or more of the above construc-
ropes of the same size and wire grade in each classification tions, it is referred to as a “Combined Pattern.”
have the SAME strength and weight ratings, and usually
Rope
Wire
This example is basically a Seale strand in its first
the same pricing. Ropes within each classification may two layers. The third layer utilizes the Warrington
differ in working characteristics such as abrasion and Principle, and the outer layer is a typical Seale
fatigue resistance. pattern of same-size wires. It is described: 49
Seale Warrington Seale [1-8-8-(8+8)-16] strand.
Cordage
Classification Wires Per Strand
Multiple Operation
6X7 5 through 9 In contrast to all the above strand types which
are formed in a single operation, a Multiple
6 X 19 15 through 26
Securement
Operation construction strand is one in which one

6 x 36 27 through 49 of the above designs is covered with one or more
Load
8 x 19 15 through 26 layers of uniform-sized wires in a different work

operation. The second operation is necessary
because the outer layers must have a different
length of lay or direction of lay. This example is a
Contractors
Warrington strand overlayed with 18 same-size

Supply
wires. It is described: 37 Warrington 2-Operation

[1-6-(6+6)/18] strand.
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649

Standard 6 x 19 & 6 x 36 6 x 19 Classification Ropes—
6 x 19S (Seale)
Classification Ropes In this construction, each strand has nine
outer wires over nine smaller inner wires over
The 6 x 19 classification of wire ropes includes standard one large center wire. A comparison of cross
6 strand, round strand ropes with 16 through 26 wires per sections shows that these outside wires are
strand. The 6 x 36 classification of wire ropes includes larger than those of 6 x 25FW or 6 x 26WS.
Therefore, its resistance to abrasion is
standard 6 strand, round strand ropes with 27 through
increased, but its fatigue resistance is
49 wires per strand. Although their operating characteristics
decreased. This is a rope to withstand
vary, all have the same weight per foot and the same abrasion or crushing on the drum.
minimum breaking force, size for size.
6 x 25FW (Filler Wire)
While the 6 x 19 ropes give primary emphasis to abrasion
To most wire rope users, 6 x 19 means 6 x 25
resistance in varying degrees, the 6 x 36 ropes are filler wire. It was the most common rope in the
important for their fatigue resistance. 6 x 19 classification. This rope has a good
balance between both abrasion resistance and
This fatigue resistance is made possible by the greater fatigue resistance in relation to other ropes.
number of small wires per strand.
Although there are exceptions for special applications,

the constructions in 6 x 36 classification are primarily 6 x 26WS (Warrington Seale)
designed to be the most efficient for each rope diameter. This construction has better resistance to
As the rope size increases, for instance, a large number of abrasion than a 6 x 25FW. It also features a
wires can be used to achieve required fatigue resistance, compact construction with solid support for the
and still those wires will be large enough to offer adequate wires; hence, it has high resistance to crushing.
Its number and relative size of the inner wires
resistance to abrasion.
add to the stability of the strand and gives a
fatigue resistance comparable to a 6 x 25FW.
A standard 6 x 26WS construction the best rope
for a wide range of applications. In general,
we recommend the use of a 6 x 26WS in any
application where a 6 x 25FW is used.
6 x 36 Classification Ropes
In most rope sizes, only one 6 x 36 classification
rope is made. These constructions were
selected to provide fatigue resistance without
having wires that are too small. The greater
number of wires in the 6 x 36 classification
makes these ropes more susceptible to
crushing. This can be minimized, however,
by specifying an Independent Wire Rope Core
(IWRC) and by using well-designed sheaves,
grooved drums and proper operating
techniques.
650

Seven Primary Features 1. Strength
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Overhead
Wire rope strength is usually measured in tons of 2000 pounds. In
for Consideration in Wire

published material wire rope strength is shown as minimum breaking
force. Minimum breaking force refers to calculated strength figures
Rope Selection that have been accepted by the wire rope industry.
When placed under tension on a test device a new rope should break
Each Characteristic Affects at a figure equal to, or higher than, the minimum breaking force shown
Hoists
for that rope.
Other Characteristics
To account for variables which might exist when such tests are made
to determine the breaking strength of a new wire rope an “acceptance”
Every wire rope has its own “personality” which is a strength may be used. The acceptance strength is 2-1/2% lower
reflection of its engineered design. Each rope construction than the minimum breaking force and ropes must meet or exceed
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has been established to produce a desired combination this strength.
of operating characteristics which will best meet the The minimum breaking force applies to new, unused rope. A rope should
performance requirements of the work, or application, never operate at, or near, the minimum breaking force. During its
for which that design is intended…and each rope useful life, a rope loses strength gradually due to natural causes, such
construction is, therefore, a design compromise. as surface wear and metal fatigue.
Engineered
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2. Reserve Strength
The best illustration of a design compromise–or best The Reserve Strength of a standard rope is a relationship between the
combination of desired characteristics—is the strength represented by all the wires in the outer strands and the wires
remaining in the outer strands with the outer layer of wires removed.
interrelationship between resistance to abrasion
Reserve Strength is calculated using actual metallic areas of the
and fatigue resistance. individual wires. Since there is a direct relationship between metallic
Slings
area and strength, Reserve Strength is usually expressed as a
Fatigue resistance (a rope’s capability to bend repeatedly percentage of the rope’s minimum breaking force. Reserve Strength
under stress) is accomplished by using many wires in is used as a relative comparison between the internal wire load bearing
capabilities of different rope constructions.
the strands. Resistance to metal loss through abrasion is
achieved primarily with a rope design which uses fewer Reserve Strength is an important consideration in selection, inspection
Hardware
and, therefore, larger wires in the outer layer to reduce and evaluation of a rope for applications where the consequences
of a rope failure are great. The use of Reserve Strength is premised on
the effects of surface wear. the theory that the outer wires of the strands are the first to be subjected
to damage or wear. Therefore, the Reserve Strength figures are less
Therefore, from a design standpoint, when anything is significant when the rope is subjected to internal wear, damage, abuse,
done to alter either abrasion resistance or fatigue resistance, corrosion or distortion.
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Lifting
both of these features will be affected. The more wires there are in the outer layer of a strand construction, the
greater will be the rope’s Reserve Strength. Geometrically, as more
wires are required in the outer layer of a strand, they must be smaller
Abrasion Resistance in diameter. This results in greater metallic area remaining to be filled
by the inner wires. Separate columns are shown for standard Fiber Core
and IWRC ropes. For Fiber Core ropes, the Reserve Strength is the
Rope
Wire
approximate percentage of the rope’s metallic area made up by the
inner wires of the outer strands.
An IWRC in a rope is considered to contribute 7-1/2% to the rope’s

total strength. By definition, the core is not included in the Reserve
Strength calculation so a 7-1/2% reduction has been made for ropes
Cordage
with an IWRC.
Rotation Resistant ropes, due to their construction, can experience

different modes of wear and failure than standard ropes. Therefore,
Fatigue Resistance their Reserve Strength is calculated differently. For Rotation
Securement
Resistant ropes, the Reserve Strength is based on the percentage

Load
of the metallic area represented by the core strand plus the inner
wires of the strands of both the outer and inner layers.
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Protection
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651

Seven Primary Features

In a general sense, IWRC ropes
are more crush resistant than
for Consideration in Wire

fiber core ropes. Lang Lay ropes
are less crush resistant than
Rope Selection (Continued)

Regular Lay ropes…and 6-strand
ropes have greater crush
resistance than 8-strand ropes.
Reserve Strength of Standard Ropes
Percent of Minimum Breaking Force Represented 5. Fatigue Resistance
Rope
by Inner Wires of Outer Strands Fatigue resistance involves
Construction
Fiber Core IWRC metal fatigue of the wires that
6x7 17 — make up a rope. To have high
6 x 19 S 32 30 fatigue resistance, wires must
6 x 19 OP 40 37 be capable of bending
6 x 19 W 42 39 repeatedly under stress—
6 x 21 FW 36 33 as when a rope passes over
6 x 25 FW 43 40 a sheave.
6 x 26 WS 36 33
6 x 30 Style G 26 24 Increased fatigue resistance is achieved in a rope design by using
6 x 31 WS 43 40 a large number of wires. It involves both the basic metallurgy and
6 x 33 OP 44 41
the diameters of wires.
6 x 36 WS 48 44
6 x 36 2 OP 56 52
In general, a rope made of many wires will have greater fatigue
6 x 41 SFW 53 49
resistance than a same-size rope made of fewer larger wires,
Reserve Strength of Rotation Resistant Ropes
because smaller wires have greater ability to bend as the rope
Percent of Minimum Breaking Force Represented
Rope passes over sheaves or around drums. To overcome the effects of
by Core Strand and Inner Wires of Strands
Construction fatigue, ropes must never bend over sheaves or drums with
of Inner and Outer Layers
diameter so small as to kink wires or bend them excessively.
8 x 25 Resistwist 38
19 x 7 23
There are precise recommendations for sheave and drum sizes to
properly accommodate all sizes and types of ropes.
3. Resistance to Metal Loss and Deformation Every rope is subject to metal fatigue from bending stress while in
Metal loss refers to the actual
operation, and therefore, the rope’s strength gradually diminishes as
wearing away of metal from the
the rope is used.
outer wires of a rope, and metal
deformation is the changing
of the shape of outer wires of 6. Bend-ability
a rope. Bend-ability relates to the ability of a rope to bend easily if an arc.
Four primary factors affect this capability:
In general, resistance to metal loss 1. Diameter of wires that make the rope.
by abrasion (usually called 2. Rope and Strand Construction.
“abrasion resistance”) refers to a 3. Metal Composition of wires and finish, such as galvanizing.
rope’s ability to withstand metal 4. Type of rope core—fiber or IWRC.
being worn away along its exterior.
This reduces strength of a rope. Some rope constructions are by nature more bend-able than
others. Small ropes are more bend-able than big ones. Fiber core
The most common form of metal deformation is generally called ropes bend more easily than comparable IWRC ropes. As a
“peening”—since outside wires of a peened rope appear to have general rule, ropes made of many wires are more bend-able than
been “hammered” along their exposed surface. Peening usually same-size ropes made with fewer larger wires.
occurs on drums, caused by rope-to-rope contact during take-up
of the rope on the drum. It may also occur on sheaves. 7. Stability
The word “stability” is most often used to describe handling and
Peening causes metal fatigue, which in turn may cause wire failure. working characteristics of a rope. It is not a precise term, since
The “hammering”, which causes metal of the wire to flow into a new the idea expressed is to some degree a matter of opinion, and is
shape, realigns the grain structure of the metal, thereby affecting more nearly a “personality” trait than any other rope feature.
its fatigue resistance. The out-of-round shape also impairs wire
movement when the rope bends. For example, a rope is called stable when it spools smoothly on
and off a drum…or doesn’t tend to tangle when a multi-part reeving
4. Crushing Resistance system is relaxed.
Crushing is the effect of external pressure on a rope, which damages
it by distorting the cross section shape of the rope, its strands or core— Strand and rope construction contribute most to stability. Preformed
or all three. rope is usually more stable than nonpreformed, and Lang Lay rope
tends to be less stable than Regular Lay. A rope made of simple
Crushing resistance therefore is ability to withstand or resist 7-wire strands will usually be more stable than a more complicated
external forces, and is a term generally used to express comparison construction with many wires per strand.
between ropes.
There is no specific measurement of ropes have stability.
When a rope is damaged by crushing, the wires, strands and
core are prevented from moving and adjusting normally in operation.

652

Identification &
Cranes / Jibs
Overhead
Construction
Wire rope is identified not only by its component parts, but also by its construction, i.e., by the way the wires have been
laid to form strands, and by the way the strands have been laid around the core.
Hoists
In Figure 1, "A" and "C" show strands as normally laid into the rope to the right in a fashion similar to the threading in a
right-hand bolt. Conversely, the "left lay" rope strands (illustrations "B" and "D") are laid in the opposite direction.
Again in Figure 1, the first two ("A" and "B") show regular lay ropes. Following these are the types known as lang lay ropes
("C" and "D"). Note that the wires in regular lay ropes appear to line up with the axis of the rope; in lang lay rope the wires
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form an angle with the axis of the rope. This difference in appearance is a result of variations in manufacturing techniques:
regular lay ropes are made so that the direction of the wire lay in the strand is opposite to the direction of the strand lay in
the rope; lang lay ropes are made with both strand lay and rope lay in the same direction. Finally, "E," called alternate lay,
consists of alternating regular and lang lay strands.
Engineered
Products
Figure 1: A comparison of typical wire rope lays
A. Right Regular Lay
Slings
Hardware
B. Left Regular Lay
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Lifting
C. Right Lang Lay
Rope
Wire
Cordage
D. Left Lang Lay Securement
Load
Contractors
E. Right Alternate Lay

Supply
Protection
Fall

653

Lang Lay Ropes sheaves at or near the critical
tread diameter, not withstanding
the somewhat greater inherent
Lang Lay Ropes, when properly recommended, installed flexibility of the Lang Lay for
and used, have several advantages over Regular Lay normal service.
Ropes, but are more subject to abuse. For the same size
and construction, ropes having the same wire sizes and lays, Swivels should not be used
Lang Lay Ropes are somewhat more flexible than Regular with Lang Lay Ropes except
Lay and have several times the wearing surface per wire to
under certain conditions as
resist abrasion, as seen in the photo below and in figure on
individually recommended for
the right (top). Both ropes shown in the photos have been
any particular equipment.
ground to the same reduction of rope diameter so as to show
this comparison of the abraded areas of the wires. The Lang Failure to comply with these
Lay Ropes as usually made are about 15% more flexible
foregoing precautions will lead
than the same construction Regular Lay, but this value will
to very uneconomical rope
vary depending upon the relation of the strand lay to the
service.
rope lay.
While the total area of surface wear on the rope as a
Partially Worn Regular Lay
whole is the same for the two types of same construction
ropes for a given depth of wear, the wear on the equipment
and largely the rope service rendered would favor the
Lang Lay construction.
It is therefore not the total area of worn surface of the rope

as a whole, but the nature of such wear that causes longer
Partially Worn Lang Lay
life to the equipment and to the rope where Lang Lay Ropes
can be economically used. To explain this “nature” of wear,
we show both on the photo to the left—lines “a-b,” the line of
contact of a moving rope with the sheave; “a-b” is parallel to
the direction of rope travel, that is, to the longitudinal axis of
the rope.
Because of the greater wearing surface per wire in the
It will be noted that in the Regular Lay, the line of contact
Lang Lay Ropes, there is less wear on the sheave
is axial with one wire; in the Lang Lay (for the 6 x 19 Seale
and drum equipment.
construction used in this comparison), the line of contact is
diagonally across three worn wires.
On the other hand, very small tread diametered sheaves
or pinching grooves in sheaves are both detrimental to
The shorter exposed length of the worn wires in the
Lang Lay Ropes, the latter frequently causing “bird-caging”
Regular Lay Rope causes these wires to spring up, arching
of the rope.
radially away from the axis of the rope as in figure below.
That causes heavier individual pressure of the wires on the
Also, Lang Lay Ropes will crush out of shape more readily
sheave and an earlier fatigue failure of these wires at the
than Regular ropes when winding onto small drums under
“neck” of wear due to local reverse bending when the
heavy winding tension.
contact pressure with the sheave depresses this wire.
The stiffer the wire (that is, the higher the strength or grade
The wires of the Regular Lay Ropes are subjected to
of wire), the more pronounced this arching of the wires at
higher unit pressure when the rope is passed over sheaves
the thinnest worn section or “neck.”
or drum, causing a somewhat heavier transverse pressure
within the rope structure. Thus the “bending” stresses are
somewhat higher in the Regular Lay Rope and it is
termed “stiffer.”
The mobility of, and capacity of shifting among, the wires

is greater in the Lang Lay; it is this very feature, combined
with the longer exposed length of wires, that causes a
misplacement of the wires in the Lang Lay when bent over
654

How to Unreel, Uncoil
Cranes / Jibs
Overhead
& Store Wire Rope
The Right Way to Unreel and
Uncoil a Wire Rope
Hoists
There is always a danger of kinking a wire rope if you improperly unreel or uncoil it. You should mount a reel on jacks or
a turntable so that it will revolve as you pull the rope off. Apply sufficient tension by means of a board acting as a brake
against the reel flange to keep slack from accumulating. With a coil, stand it on edge and roll it in a straight line away from
the free end. You may also place a coil on a revolving stand and pull the rope as you would from a reel on a turntable.
Services
Engineered
Products
Slings
Hardware
Products
Lifting
Reel Reel
Rope
Wire
Drum Drum
A–Correct B–Wrong
How to Store Wire Rope Properly Cordage
We recommend you store your wire rope under a roof or a weatherproof covering so that moisture cannot reach it.
Securement
Similarly, you must avoid acid fumes or any other corrosive atmosphere – including ocean spray – in order to protect the
Load
rope from rust. If you’re storing a reel for a lengthy period, you may want to order your rope with a protective wrap.
If not, at least coat the outer layers of rope with a good rope lubricant.
If you ever take a rope out of service and want to store it for future use, you should place it on a reel after you’ve thoroughly
Contractors
cleaned and relubricated it. Give the same storage considerations to your used rope as you would your new rope.
Supply
Be sure to keep your wire rope in storage away from steam or hot water pipes, heated air ducts or any other source of
heat that can thin out lubricant and cause it to drain out of your rope.
Protection
Fall

655

Winding Wire Rope attached to the drum using the attachment provided. A
tension should be induced into the line by providing some
means of braking the shipping reel. A tight winding is
Invariably in winding wire rope onto a shipping reel or a
imperative, particularly if multiple layer winding is required.
coiling drum, the rope is wound over the top of the reel or
drum. The fact that the rope comes from under the stock
When winding a rope onto a grooved drum, the groove will
reel to wind reversely on top of the shipping reel has no
properly guide the rope. If the rope is to be rewound on a
effect on the physical condition of the rope, provided the
smooth drum, then a helper should guide the rope, making
stock reel is set at least 20 feet, or preferably more,
sure each turn is winding tightly against the adjacent turn.
from the rewinding machine.
A lead or brass hammer is useful in tapping the line over as
The rope should be wound “thread lay,” with close, even
it is being wound. Do not use a steel head hammer or pinch
winding throughout the length of the rope. If wound unevenly,
bars. These can readily cause damage to the lines.
the turns of rope bunch-up, cross wind and are liable to form
doglegs, particularly on the more flexible ropes.
Calculating Drum Capacity
Never fill the reel full to the rim or edge of the flanges.
If possible, leave a clearance equivalent to at least two The length of rope that can be wound on a drum or reel may
layers of rope. This will save injury to the rope when be calculated as follows. L = the length of the rope in feet.
the reel is rolled over obstructions on the ground. All other dimensions are in inches.
The manner in which wire rope is installed or wound on a

drum will, to a large measure, determine the service life of
that rope. Improperly wound ropes will cause undue crushing
of the rope, doglegs, kinks, excessive abrasion and cutting
of the individual wires. Bad spooling also causes uneven
application of force and motion. This results in fast fatiguing
of the line from the end attachment to the drum.
There are five precautionary steps that should be

taken before starting the actual winding of the rope
off the coil or shipping reel. L = (A + D) x A x B x K
K = Constant obtained by dividing .2618 by the
1. A check should be made of the drum to determine the square of the actual rope diameter.
condition, size and shape of the grooves. If the drum is A = H - D Desired clearance in inches.
a smooth type, then the surface should be checked for 2
straightness and smoothness. B = Traverse in inches.
2. Flanges should be checked to determine the extent of D = Barrel in inches.
undercutting at the base. H = Flange diameter in inches.
3. Dirt, grit, filled grease or any other type of debris should L = Rope length in feet.
be cleaned off.
4. Bearings should be checked.
Values of K
5. Cracks or breaks in segments of the drum should
be reported. Rope Rope
K K
Diameter Diameter
Whenever any of these five conditions are observed, 1/4" 3.29 1-1/8" .191
the equipment should be removed from service 5/16" 2.21 1-1/4" .152
and properly cleaned, repaired or replaced. 7/16" 1.19 1-1/2" .107
This recommendation is made not just to improve 1/2" .925 1-5/8" .0886
or maintain good rope life, but to eliminate a 9/16" .741 1-3/4" .0770
potential hazard. 5/8" .607 1-7/8" .0675
3/4" .428 2" .0597
After establishing the satisfactory condition of the drum, 7/8" .308 2-1/8" .0532
the shipping reel is mounted on suitable jacks. The end is 1" .239 2-1/4" .0476
656

Using the Right Drum and not be removed from the drum during normal use.
Cranes / Jibs
Overhead
On grooved drums, the grooves control the rope spooling
Reduces Wear on Ropes. on the first layer, making all the rope usable in the system.
However, various codes do require a minimum of two to
Drums should be large enough to properly wind the rope six dead wraps, depending on the application.
using the smallest number of layers. Drums having a
diameter 24 times the rope diameter should be considered After spooling the first layer, the rope rides up on the
Hoists
as a minimum for proper spooling. last turn and starts winding back across the face of the
drum, but falls into the depression of the successive
Multiple layers on a plain (smooth) faced drum crush the turns of rope on the first layer.
first layer of rope much more than on a grooved drum.
Services
The grooved drum is also recommended to provide Advancing across the drum on the second layer, the rope,
better spooling. following the depressions of the first layer, actually
winds back a turn in each revolution of the drum. It
The correct lay for each winding direction. The direction must then cross over two depressions of the first layer
of winding on a drum (overwind or underwind) is determined to have a net advance of one turn per revolution.
Engineered
Products
by standing behind it and looking toward the direction of
rope travel. This cross over is unavoidable on the second and
succeeding layers. Severe punishment of the rope results
When winding only one layer on a smooth drum, due to abrasion of the adjacent turns against each other
attaching right and left lay ropes as shown in the drawings and the crushing from the next layer above at these
below will give the best service. points. Parallel and counter-balanced, grooved-controlled,
Slings
crossover drums minimize this condition.
Multiple Layer Winding
If scrubbing (adjacent wrap contact) is a major problem,
When a rope winds in the first layer across the face of it can be reduced by applying the “winding direction rules”
Hardware
a drum, it usually forms a uniform helix. When spooling to the heaviest worked layer instead of the first layer as
on a smooth drum, the first layer helix serves as the shown. To accomplish this, the first layer may or may
drum lagging for succeeding layers. For continuous not be spooled according to the rule as well.
smooth spooling, the first layer should act as a dead layer
Products
Lifting
Rope
Wire
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

657

Sheave Design is Critical Table 1: Suggested Sheave and
Drum Ratios
to Wire Rope Service Life.
These D/d ratios are based on sheave and drum
Bending Wire Rope over Sheaves diameters being approximately 400 times the outer wire
and Drums diameter of the rope. For rope constructions not listed,
consult your Lifting Specialist.
Sheaves, drums and rollers must be of a correct design if
optimum service is to be obtained from both the equipment Suggested
Construction
and the wire rope. Because there are many different types D/d Ratio*
of equipment and many different operating conditions, it is 6x7 42
difficult to identify the one specific size of sheave or drum 19 x 7 or 18 x 7 Rotation Resistant
most appropriate for every application. The guideline to 34
6 x 19 S
follow is this: the most practical design is the one that most 6 x 25 B Flattened Strand
closely accommodates the limiting factors imposed by the 6 x 27 H Flattened Strand
equipment, the operating conditions and the wire rope. 6 x 30 G Flattened Strand
30
6 x 31 V Flattened Strand
All wire ropes operating over sheaves and drums are 6 x 21 FW
6 x 26 WS
subjected to cyclic bending stresses, thus the rope wires
8 x 19 S
will eventually fatigue. The magnitude of these stresses 7 x 21 FW
depends—all other factors being constant—upon the ratio 6 x 25 FW 26
of the diameter of the sheave or drum to the diameter 6 x 31 WS
of the rope. Frequently, fatigue from cyclic, high-magnitude 6 x 37 FWS
bending stress is a principal reason for shortened rope 7 x 25 FW
service. In order for a rope to bend around a sheave, the 6 x 36 WS
23
rope's strands and wires must move relative to one another. 6 x 43 FWS
7 x 31 WS
This movement compensates for the difference in diameter
6 x 41 WS
between the underside and the top side of the rope, the 6 x 41 SFW
distance being greater along the top side than it is on the 6 x 49 SWS
underside next to the groove. Proper rope movement (and 7 x 36 WS 20
service) is adversely affected if the wires cannot adjust to 8 x 25 FW
compensate for this length differential. Also, there can 19 x 19 Rotation Resistant
be additional limitations to wire movement because of 35 x 7 Rotation Resistant
excessive pressure caused by a sheave groove diameter 6 x 46 SFW
6 x 46 WS 18
which is too small, or by lack of rope lubrication. Avoid
8 x 36 WS
changing the bending direction from one sheave to another
as this reverse bending further accelerates wire fatigue.
*D = Pitch diameter of sheave
d = nominal diameter of rope
The relationship between sheave diameter and rope
diameter is a critical factor that is used to estimate the To find any pitch diameter from this table, the diameter for the rope
rope's fatigue resistance or relative service life. It is construction to be used is multiplied by its nominal diameter (d).
expressed in the D/d ratio mentioned earlier in which For example, the minimum sheave pitch diameter for a 1/2" (nominal
D is the pitch diameter of the sheave and d is the diameter diameter) x 30 (minimum ratio) or 15".
of the rope. Table 1 lists suggested minimum D/d values
for various rope constructions. Smaller values can affect
rope life. Table 2 (on next page) shows the effect of
rope construction and D/d on service life.
658

Sheave Design is Critical without any possible obstructions as it makes its way
Cranes / Jibs
Overhead
through the system. If no problems appear in running the
to Wire Rope Service Life. rope, the next step should include several repetitions
(Continued) of the normal operational cycle under increasing loads and

speeds. This procedure allows the component parts of
the new rope to make a gradual adjustment to the actual
Table 2: Relative Bending Life Factors operating conditions. Taking the time and effort to perform
Hoists
these breaking-in procedures should result in obtaining
Rope Construction Factor the optimum service life from the wire rope.
6 x 7 or 7 x 7 Aircraft .60
19 x 7 or 18 x 7 R.R. .70 Bending-Life Factor
Services
6 x 19 S .80
6 x 19 W
Bending-Life Factors (shown in the Relative Service Curve)
6 x 21 FW
provide a comparison of the service life of different
6 x 26 WS
6 x 25 B FS .90 constructions under repeated bending stresses.
Engineered
6 x 27 H FS
Products
6 x 30G FS
6 x 31 V FS
7 x 21F W
6 x 25 FW
1.00
6 x 31 WS
8 x 19 S
Slings
8 x 21 FW 1.10
7 x 25 FW
6 x 29 FW
6 x 36 WS
1.15
6 x 36 SFW
Hardware
6 x 43 FWS
7 x 31 WS
8 x 25 FW
6 x 41 WS
6 x 41 SFW 1.25
Products
6 x 49 SWS
Lifting
7 x 36 FW
6 x 46 SFW
6 x 46 WS
8 x 36 WS 1.35
6 x 61 FWS
Rope
6 x 57 SFWS
Wire
Note: This table, with some modifications, is based on outer wire
This service life curve only takes into account bending
diameter relationships. For rope constructions not listed, consult your
Lifting Specialist. and tensile stresses. This curve can be utilized to predict
comparative service life of a specific wire rope with varying
Cordage
D/d ratios. That resultant comparison is illustrated by the
Breaking In a New Wire Rope following example: A rope working with a D/d ratio of 26 has
a relative service life of 17. If the same rope works over a
A new wire rope requires careful installation and following all sheave that increases its D/d ratio to 35, the relative service
Securement
the appropriate guidelines previously noted. After the rope life increases to 32. In short, if this rope is used on the
is installed and the ends secured in the correct manner, the
Load
larger sheave, one could estimate an increase in its bending

equipment should be started carefully and then permitted to service life from 17 to 32 or an 88% increase.
run through a cycle of operation at very slow speed. During
this trial operation, closely watch all working parts—sheaves,
Contractors
drums, rollers—to make certain that the rope runs freely, and
Supply
Protection
Fall

659

How Sheave Size Affects How to Determine
Wire Rope Strength Overhauling Weights
The radius of bend has an effect on the strength of wire To determine the weight of the block or overhaul ball
rope. In order to take this fact into account in selecting the that is required to free fall the block, the following information
size sheave to be used with a given diameter wire rope, the is needed:
following table can be used as a guide:
■ Size of wire rope
Ratio “A” = Strength Efficiency ■ Number of line parts
Sheave Dia. Compared to Catalog ■ Type of sheave bearing
Rope Dia. Strength in % ■ Length of crane boom
40 95 ■ Drum Friction
30 93 (nominally, 100 pounds)
20 91
15 89 Formula to Determine
10 86 Block Weight:
8 83 Required Block Weight = Multiply Boom Length by
6 79 Rope Weight Factor “A” and add Drum Friction then
4 75 Multiply by Overhaul Factor “B”.
2 65
1 50
Factor “A” Wire Rope Weight
For Example: Using a 1/2" dia. wire rope with a 10" dia. sheave, Rope Diameter Lbs. Per Foot
Ratio “A” = 10 ÷ 1/2" = 20 and the strength efficiency = 91% as com- 3/8" .26
pared to the catalog strength of wire rope. 7/16" .35
1/2" .46
9/16" .59
The repeated bending and straightening of the wire rope 5/8" .72
causes a cyclic change of stress known as “fatiguing.” The 3/4" 1.04
radius of bend has considerable effect on the fatigue life of 7/8" 1.42
wire rope and the following can be used as comparison of 1" 1.85
relative fatigue life as influenced by sheave diameter: 1-1/8" 2.34
1-1/4" 2.89
Ratio “B” = Relative Fatigue

Sheave Dia. Factor “B” Overhaul Factors
Bending Life
Rope Dia.
Roller Bronze
30 10.0 No.
25 6.6
Bearing Bushed
20 3.8 1 1.03 1.05
18 2.9 2 2.07 2.14
16 2.1 3 3.15 3.28
14 1.5 4 4.25 4.28
12 1.1 5 5.38 5.72
6 6.54 7.03
7 7.73 8.39
For Example: Using a 12" dia. sheave with a 3/4" dia. wire rope,
8 8.94 9.80
Ratio “B” = 12 ÷ 3/4" = 16 and the units of fatigue life = 2.1. However, a
9 10.20 11.30
22.5" dia. sheave using a 3/4” wire rope has a Ratio “B”= 225 ÷ 3/4" = 30
10 11.50 12.80
and the units of fatigue life = 10. So, the expected extension of fatigue
life when using a 22.5" dia. instead of a 12" diameter sheave would be
10 ÷ 2.1 or 4.7 times greater. For Example: Using 5 parts of 7/8" Wire Rope, 50 ft. Boom and
Roller Bearing Sheaves, Required Weight = [(50 x 1.42) + 100]
x 5.38 = 920 lbs.
660

Technical Information By using the values given, it is possible to make a reasonable estimate
Cranes / Jibs
Overhead
of elastic extension, but if greater accuracy is required, it is advisable to
carry out a modulus test on an actual sample of the rope. As rope users
Properties of Extension of Steel will find it difficult to calculate the actual metallic steel area, the values
Wire Ropes can be found in the Wire Rope Users Manual or obtained from Bridon
Engineering.
Any assembly of steel wires spun into a helical formation,
Hoists
Elastic Extension = WL ÷ EA (inches)
either as a strand or wire rope (when subjected to a tensile
W = load applied (pounds)
load) can extend in three separate phases, depending L = rope length (inches)
on the magnitude of the applied load. E = elastic modulus (pounds/in2)
A = rope area (in2)
There are also other factors which produce rope extension,
Services
which are very small and can normally be ignored. Phase 3—Permanent Extension
The permanent, non-elastic extension of the steel caused by tensile
Phase 1—Initial or Permanent loads exceeding the yield point of the material. If the load exceeds
Constructional Extension the Limit of Proportionality, the rate of extension will accelerate as the
Engineered
load is increased until a loading is reached at which continuous
Products
At the commencement of loading a new rope, extension is created
by the bedding down of the assembled wires with a corresponding extension will commence, causing the wire rope to fracture without
reduction in overall diameter. This reduction in diameter is any further increase of load.
accommodated by a lengthening of the helical lay. When sufficiently
large bearing areas have been generated on adjacent wires to Thermal Expansion and Contraction
withstand the circumferential compressive loads, this mechanically The coefficient of linear expansion (∝) of steel wire rope is (6.94 x 10-6
per °F) and therefore the change in length of 1 foot of rope produced by
Slings
created extension ceases and the extension in Phase 2 commences.
The Initial Extension of any rope cannot be accurately determined a temperature change of t (°F) would be:
by calculation and has no elastic properties.
Change in length ∆L = ∆L t where
The practical value of this characteristic depends upon many factors, ∝ = coefficient of linear expansion
Hardware
the most important being the type and construction of rope, the range of L = original length of rope (in)
loads and the number and frequency of the cycles of operation. It is t = temperature change (°F)
not possible to quote exact values for the various constructions of rope
in use, but the following approximate values may be employed to give The change will be an increase in length if the temperature rises and a
reasonably accurate results. decrease in length if the temperature falls.
Products
Lifting
Extension Due to Rotation
% of Rope Length The elongation caused by a free rope end being allowed to rotate.
Fiber Core Steel Core
Extension Due to Wear
Lightly Loaded
0.25 0.125 The elongation due to inter-wire wear which reduces the cross-sectional
Factor of Safety about 8:1
area of steel and produces extra constructional extension.
Rope
Wire
Normally Loaded
0.50 0.25
Factor of Safety about 5:1
Example: What will be the total elongation of a 200 ft. length of 1-1/8"
Heavily Loaded diameter Blue Strand 6 x 41 IWRC wire rope at a tension of 20,000 Ibs.
0.75 0.50
Factor of Safety about 3:1 and with an increase in temperature of 20°F?
Heavily Loaded with many
Cordage
Up to 2.00 Up to 1.00 Permanent Constructional Extension =
bends and/or deflections
0.25% of rope length = .5 = 6"
Phase 2—Elastic Extension
Elastic Extension =
Following Phase 1, the rope extends in a manner which complies
WL ÷ EA = 20,000 x 200 x 12 ÷ 13,500,000 x .62 = 5.73"
Securement
approximately with Hookes Law (stress is proportional to strain) until the

Load
limit of proportionality or elastic limit is reached.

Thermal Expansion =
∆L = ∝L0 t = 6.94 x 106 x 200 x 20 = .33"
It is important to note that wire ropes do not possess a well defined
Young’s Modulus of Elasticity, but an ‘apparent’ Modulus of Elasticity can
Therefore, Total Extension =
be determined between two fixed loads.
Contractors
6" + 5.73" + .33" = 12.06"

Supply
The Modulus of Elasticity also varies with different rope constructions,

This page reprinted with permission from Bridon American.
but generally increases as the cross-sectional area of steel increases.
Protection
Fall

661

Technical Information The pressure of the rope against the sheave also causes
distortion and flattening of the rope structure. This can be
(Continued) controlled by using sheaves with the correct groove profile,
which, for general purposes, suggests a recommended
Pressures between Ropes and groove diameter of nominal rope diameter +6%. The profile
Sheaves or Drums at the bottom of the groove should be circular over an angle
of approximately 120° and the angle of flare between the
In addition to bending stresses experienced by wire ropes sides of the sheave should be approximately 52°.
operating over sheaves or pulleys, ropes are also subjected
to radial pressure as they make contact with the sheave.
This pressure sets up shearing stresses in the wires, Hardness of Rope Wire
distorts the rope’s structure and affects the rate of wear of
the sheave grooves. When a rope passes over a sheave, the Rope Grade Approximate Hardness
load on the sheave bearing results from the tension in the Minimum Tensile
rope and the angle of rope contact. It is independent of the Brinell Rockwell 'C'
Strength
diameter of the sheave. EEIP 444/486 46-50
EIP 415/461 44-48
Load on bearing = 2T sin 0 ÷ 2
T = rope tension (pounds) IPS 388/444 42-46
0 = angle of rope contact
Recommended pulley hardness: 250-300 Brinell for Mn steel
Assuming that the rope is supported in a well fitting or equivalent alloy steel.
groove, then the pressure between the rope and the groove
is dependent upon the rope tension and diameter, but is
independent of the arc of contact.
Design Factor
Pressure, P = 2T ÷ Dd (Minimum Rope Breaking Strength /
P = pressure (psi) Maximum Load on Rope)
T = rope tension (pounds)
D = diameter of sheave or drum (in) Industry standards provide minimum design factors allowed
d = diameter of rope (in) for certain rope applications. Some typical minimum design
factors follow:
It must be realized that this method of estimation of pressure
assumes that the area of contact of the rope in the groove is Hoist
3.5
on the full rope diameter, whereas in fact only the crowns Rope
of the outer wires are actually in contact with the groove. It Hoist Rope
is estimated that the local pressures at these contact points Mobile Crane (Rotation 5
may be as high as five times those calculated. If the pres- Resistant)
sure is high, the compressive strength of the material in the Boom Hoist
3.5
groove may be insufficient to prevent excessive wear and Rope
indentation, and this in turn will damage the outer wires of Wire Rope Slings 5
the rope and effect its working life. As with bending stresses,
Tower Cranes 5
stresses due to radial pressure increase as the diameter
of the sheave decreases. Although high bending stresses Offshore Pedestal Cranes 5
generally call for the use of flexible rope constructions having Drill Lines 3
relatively small diameter outer wires, these have less ability
Overhead Cranes 5
to withstand heavy pressures than do the larger wires in the
less flexible constructions. If the calculated pressures are
too high for the particular material chosen for the sheaves or
drums or indentations are being experienced, consideration
should be given to an increase in sheave or drum diameter.
Such a modification would not only reduce the groove
pressure, but would also improve the fatigue life of the rope.
662

Technical Information If designers or operators of equipment are seeking
Cranes / Jibs
Overhead
optimum rope performance or regard bending fatigue life
(Continued) as a key factor in the operation of equipment, such
information can be provided by BRIDON for guidance
Bend Fatigue purposes.
Bend fatigue testing of ropes usually consists of cycling
a length of rope over a sheave while the rope is under a Service Life Curve for Various D:d Ratios
Hoists
constant tension. As part of their ongoing development
program, BRIDON has tested literally thousands of ropes
in this manner over the years on their own in-house
design bend testing equipment.
Services
Through this work, BRIDON has been able to compare the
effects of rope construction, tensile strength, lay direction,
sheave size, groove profile and tensile loading on bend
fatigue performance under ideal operating conditions. At
Engineered
Products
the same time it has been possible to compare rope life to
discard criteria (e.g. as laid down in ISO 4309) with that to
complete failure of the rope, i.e. to the point where the
rope has been unable to sustain the load any longer. As
part of the exercise, it has also been possible to establish Oversize Tolerance
the residual breaking strength of the rope at discard level Wire ropes are manufactured slightly larger than the
Slings
of deterioration. nominal diameter. The maximum allowable oversize
tolerances provided by industry standards are shown in
Effects of D:d Ratio and Loading on the following table:
Fatigue Life—Typical Example Dyform 6
Hardware
Nominal Rope Tolerance
Diameter Under Over
Up to 1/8" -0 +8%
Over 1/8" to 3/16" -0 +7%
Products
Lifting
Over 3/16" to 1/4" -0 +6%
Over 1/4" -0 +5%
Bending Ratios D:d

Typical minimum bending ratios (sheave or drum dia.: rope
Rope
dia.) provided by some industry standards are as follows:
Wire
Drum Sheave
What needs to be recognized, however, is that very few Load hoist 18 18
Cordage
ropes operate under these controlled operating conditions, Mobile Crane Boom hoist 15 15
making it very difficult to use this base information when Load block – 16
attempting to predict rope life under other conditions. Hoist 18 18
Other influencing factors, such as dynamic loading, Tower Cranes
Load block – 16
differential loads in the cycle, fleet angle, reeving
Securement
arrangement, type of spooling on the drum, change in Rotary Drilling Drill line 20 20
Load
rope direction, sheave alignment, sheave size and groove Offshore Pedestal Hoist 18 18
profile, can have an equally dramatic effect on rope Cranes
performance. Hoist 24 24
Surface Mining
Contractors
Drag 22 22
Supply
However, the benefit of such testing can be particularly

helpful to the rope manufacturer when developing new or
improving existing products.
Protection
Fall

663

Technical Information system to prevent rotation in certain operating conditions.
However, this should be done only when employee safety is
(Continued) the issue.
These rope constructions, when used in a reeving system

The Use of Swivels with Wire Rope with one end free to rotate, will have a high level of rotation.
Under certain circumstances it may be necessary to use This will cause the rope to unlay and, to some degree,
a swivel in a lifting system to prevent rotation of the load. distortion of the rope will occur.
This is typically done for employee safety considerations.
■ Blue Strand 6 x 19 and 6 x 36—Class Regular Lay
It is possible however, that the use of a swivel will have an
■ Endurance Dyform 6 and 8 Regular Lay
adverse affect on rope performance and may, in some
cases, damage the wire rope. Group 3a and 3b
There are many types of accessories available The ropes in this Group are designed with an inner rope
that incorporate different types and degrees of rotation- that is laid in the opposite direction to the outer strands to
preventing swivels. The swivel may be either an provide a medium resistance to rotation. Ropes with
independent accessory or an integral part of a lifting device, medium rotation characteristics are used with a swivel in
such as a crane block with a swivel hook. A typical single part reeving applications. However, a swivel is not
independent accessory is a ball bearing anti-friction swivel. recommended for multiple part hoisting applications or in
There are also headache balls with swivel hooks. any application where the swivel is not necessary for safety
The type of swivel that causes the most concern from the reasons. If it is necessary to use a swivel, the rope must be
standpoint of the wire rope is the independent anti-friction operating at a design factor of 5 or greater, must not be
swivel that attaches directly to the rope. The purpose of shock loaded and must be inspected daily by a qualified
using a swivel in a lifting system is to prevent rotation of the person for distortion.
load. This then allows the wire rope to rotate. Excessive It should be noted that if a swivel is used on conjunction
rope rotation can damage a wire rope. with Group 3a ropes, rope service life might be reduced
To assist in determining whether or not a swivel should be due to increased internal wear between the outer strands
used in the lifting system, the following recommendations and the inner rope.
should be considered. It must also be recognized that the ■ Group 3a—Endurance 8RR Rotation Resistant
rotation characteristics of different types and constructions • Group 3a—Endurance l9 Rotation Resistant
of wire rope vary considerably. The following types and ■ Group 3b—Endurance Dyform 18 Rotation Resistant
constructions of wire rope are grouped according to their
rotation characteristics. Group 4
Group 1 Wire ropes having low rotation characteristics used in either
single or multiple part reeving may be used with a swivel.
Wire rope constructions having very high rotation The reason for this is that the ropes will exhibit very little, if
characteristics should not be used with a swivel under any, rotation when used at the proper design factor.
any circumstances. Application parameters, such as a fleet angle, may induce
These rope constructions will rotate excessively with one turn into a wire rope that can be relieved by the use of a
end free to rotate, and the rope will unlay and distort and swivel. However, if the application does not induce any turn
be easily damaged with a loss of rope breaking force. into the rope, or if a swivel is not beneficial to the
performance of the rope, the swivel may not be necessary.
■ Blue Strand 6 x 19 and 6 x 36 Class Lang Lay
■ All constructions of Triangular (Flattened) ■ Endurance 35 LS
Strand Lang Lay ■ Endurance Dyform 34LR/PI/MAX
■ Endurance Dyform 8 Lang Lay Note: When using a swivel with any wire rope, frequent
■ Constructex inspection of the rope is necessary. The rope should not be
shock loaded or overloaded.
Group 2
Wire rope constructions having high rotation characteristics This page reprinted with permission from Bridon American.
when used in single part reeving may require a swivel in the
664

Technical Information At the Sheave
Cranes / Jibs
Overhead
Where a fleet angle exists as the rope enters a sheave, it initially makes
(Continued) contact with the sheave flange. As the rope continues to pass through
the sheave it moves down the flange until it sits in the bottom of the
groove. In doing so, even when under tension, the rope will actually roll,
Fleet Angle as well as slide. As a result of the rolling action, the rope is twisted,
i.e. turn is induced into or out of the rope, either shortening or length-
Of all the factors which have some influence on the
Hoists
ening the lay length of the outer layer of strands. As the fleet angle
winding of a rope on a smooth drum, the fleet angle,
increases, so does the amount of twist.
arguably, has the greatest effect.
To reduce the amount of twist to an acceptable level, the fleet angle
Fleet angle is usually defined as the included angle should be limited to 2.5° for grooved drums and 1.5° for plain drums and
between two lines: one which extends from a fixed sheave when using Rotation Resistant, ropes the fleet angle should be limited
Services
to the flange of a drum, and the other which extends from to 1.5°.
the same fixed sheave to the drum in a line perpendicular
However, for some crane and hoist applications, it is recognized that for
to the axis of the drum (see illustration).
practical reasons. It is not always possible to comply with these general
Illustration of Fleet Angle recommendations, in which case, the rope life could be affected.
Engineered
Products
Rope Torque
The problem of torsional instability in crane hoist ropes would not exist
if the ropes could be perfectly torque balanced under load. The torque
generated in a wire rope under load is usually directly related to the
applied load by a constant ‘torque factor’. For a given rope construction,
Slings
the torque factor can be expressed as a proportion of the rope diameter
and this has been done below.
If the drum incorporates helical grooving, the helix angle of the groove Variation with rope construction is relatively small and hence the scope
needs to be added or subtracted from the fleet angle as described above for dramatically changing the stability of a hoisting system is limited.
to determine the actual fleet angle experienced by the rope.
Hardware
Nevertheless, the choice of the correct rope can have a deciding influ-
ence, especially in systems which are operating close to the critical limit.
At the Drum
It should be noted that the rope torque referred to here is purely that due
When spooling rope onto a drum, it is generally recommended that the
to tensile loading. No account is taken of the possible residual torque
fleet angle is limited to between 0.5° and 2.5°. If the fleet angle is too
due, for example, to rope manufacture or installation procedures.
small, i.e. less than 0.5°, the rope will tend to pile up at the drum flange
Products
and fail to return across the drum. In this situation, the problem may be Torsional Stability
Lifting
alleviated by introducing a ‘kicker’ device or by increasing the fleet angle Torsional Stability and the Cabling Graph are two methods which can
through the introduction of a sheave or spooling mechanism. be used to determine torsional stability or the tendency of the rope
to cable. The torque factors quoted are approximate maximum values
If the rope is allowed to pile up, it will eventually roll away from the
for the particular constructions. To calculate the torque value for a
flange, creating a shock load in both the rope and the structure of the
particular rope size, multiply by the nominal rope diameter.
mechanism, an undesirable and unsafe operating condition.
Rope
Wire
Example: for 20mm dia. Dyform 34LR at 20% of minimum
Excessively high fleet angles will return the rope across the drum
breaking force:
prematurely, creating gaps between wraps of rope close to the
flanges, as well as increasing the pressure on the rope at the Torque value = torque factor x rope dia.
cross-over positions. = 0.76% x 20mm
Cordage
= 0.152mm
Even where helical grooving is provided, large fleet angles will
inevitably result in localized areas of mechanical damage as the wires To calculate the torque generated in a particular rope when
‘pluck’ against each other. This is often referred to as ‘interference’, subjected to a tensile load, multiply the load by the torque value
but the amount can be reduced by selecting a Langs lay rope if the and combine the units.
Securement
reeving allows. The “interference” effect can also be reduced by

Load
employing a Dyform rope, which offers a much smoother exterior Example: for 20mm dia. Dyform 34LR at 6000 kg f load
surface than conventional rope constructions.
Torque generated = torque value x load
Floating sheaves or specially designed fleet angle compensating devices = 0.152 . 6000
may also be employed to reduce the fleet angle effect. = 912 kgf.mm
Contractors
Supply

Protection
Fall

665

Technical Information Angular Displacement of Block
To predict the amount of angular displacement by which a
(Continued) sheave block may turn under the influence of rope torque:
sin 0 = (4 000 L. Tv) (for even number of falls)

The torsional characteristics of wire rope will have the effect of causing S2
angular displacement of a sheave block when used in multi-fall reeving
arrangements. The formula below gives a good approximation under The equations assume that rope is torque-free in the noload
such arrangements. condition, therefore, induced torque during or immediately after
installation will adversely influence the calculated effect.
S2 = 4000L. Tv
sin 0 The above data assumes a constant torque value which is a
valid assumption for a new rope. Wear and usage can have
Where S is the rope spacing in mm a significant effect on the torque value, but practical work
L is the length of each part in the reeving shows that under such circumstances, the torque value will
Tv is the torque value of the rope diminish, thus improving the stability of the arrangement.
0 is the angular displacement of the sheave block Some arrangements may be of such complexity that the
evaluation demands a computer study.
When the angular displacement of the sheave block exceeds 90°
(sin 0 = 1) torsional instability results and ‘cabling’ of the reeving will Examples:
occur. Therefore, the test for stability of any particular reeving can be Assuming a pedestal crane working on two falls is roped
expressed as: with 20mm diameter DYFORM 34LR and the bottom block
carries a sheave of 360mm diameter with the falls parallel:
S>√4000 L. Tv
Torque value = 0.76% x 20 = 0.152mm
Where S is the rope spacing in mm
L is length of each part in meters If the rope is new (worst condition) and no account is taken of block
Tv is torque value in mm weight and friction then angular displacement for a height of lift of
30 meters is given by:
The preceding equations are all relative to a simple two part reeving. For
more complex systems, a similar approach may be used if account is sin 0 = (4 000 . 30 . 0.152) = 0.141 i.e. 8° 10ꞌ
taken of the different spacings of the ropes. 3602
Even Number of Falls The reeving would be expected to ‘cable’ at a height of lift
Effective calculated as:
Rope Plan Rope Spacing
L = S2
4 000 . Tv
= 3602
4 000 . 0.152
= 213 metres
From the crane designer’s viewpoint, a safety factor against ‘cabling’

should be recognized (angular displacement limited at 30°), hence the
practical height of lift is approximately 106.5 meters.
Note: For hoisting arrangements in which the rope falls are not
parallel an average rope spacing should be used.
Uneven Number of Falls

(Rope Termination at Bottom Block) Rope Plan
Effective Rope Spacing and modified

formula for stable condition
Effective Rope Spacing S

Stable condition if:
S>√6000 . L.
Tv
666

Technical Information S is determined as follows
Cranes / Jibs
Overhead
S = Spacing (Ft)
(Continued)
Cabling Graph
2 Part
Field research jointly conducted by the Wire Rope Technical
Hoists
Board and the Power Crane and Shovel Association has
shown that cabling of the rope parts in a multiple part reeved
hoisting arrangement is controlled by several factors. The 3 Part
following calculations and graphs can be used to determine 2/3 of 2 Part
Services
when and if cabling will occur on multiple part reeved
hoisting arrangements.
The graph illustrates two dimensional ratios. They are:

1. L/S = Length of fall per unit rope spacing
Engineered
Products
2. D/d = Average pitch diameter of traveling and crown 4 Part
block sheave per unit rope diameter.
Various constructions of rope shown on the graph indicate

the limited conditions for torsional stability with the angular 5 Part
Slings
displacement of the hoist block to a maximum of 90 degrees.
4/5 of 4 Part
When the operating conditions for a particular installation
give a resultant above the appropriate band, then cabling of
the falls will most likely occur. If the operating conditions
give a resultant below any particular band, the cabling of the
Hardware
falls will most likely not occur. If the operating conditions
for any particular installation fall within the band, cabling 6 Part
is unpredictable.
Products
Lifting
7 Part
6/7 of 6 Part
Rope
Wire
Cordage

Securement
Load
Contractors
Supply
Protection
Fall

667

Wire Rope Inspection
The following is a fairly comprehensive listing of critical ■ Internal or external corrosion

inspection factors. It is not, however, presented as ■ Loosening or tightening of rope lay
a substitute for an experienced inspector. It is rather a ■ Inner wire breakage
user’s guide to the accepted standards by which ropes ■ Rope stretch
must be judged. ■ Ironing or milking of strands
1. Abrasion In the past, whether or not a rope was allowed to remain

Rope abrades when it moves through an abrasive medium in service depended to a great extent on the rope’s
or over drums and sheaves. Most standards require diameter at the time of inspection. Currently, this practice
that rope is to be removed if the outer wire wear exceeds has undergone significant modification.
1/3 of the original outer wire diameter. This is not easy to
determine, and discovery relies upon the experience Previously, a decrease in the rope’s diameter was
gained by the inspector in measuring wire diameters of compared with published standards of minimum diameters.
discarded ropes. The amount of change in diameter is, of course, useful in
assessing a rope’s condition. But, comparing this figure
2. Rope Stretch with a fixed set of values can be misleading. These long-
All ropes will stretch when loads are initially applied. As accepted minimums are not, in themselves, of any serious
a rope degrades from wear, fatigue, etc. (excluding significance since they do not take into account such factors
accidental damage), continued application of a load of as: (1) variations in compressibility between IWRC and Fiber
constant magnitude will produce incorrect varying Core; (2) differences in the amount of reduction in diameter
amounts of rope stretch. from abrasive wear, or from core compression, or a
combination of both; and (3) the actual original diameter
Phase 1: Initial stretch, during the early (beginning) period of the rope rather than its nominal value
of rope service, caused by the rope adjustments to operating
conditions (constructional stretch). As a matter of fact, all ropes will show a significant reduction
Phase 2: Following break-in, there is a long period—the in diameter when a load is applied. Therefore, a rope
greatest part of the rope’s service life—during which a slight manufactured close to its nominal size may, when it is
increase in stretch takes place over an extended time. This subjected to loading, be reduced to a smaller diameter than
results from normal wear, fatigue, etc. that stipulated in the minimum diameter table. Yet under
Phase 3: Thereafter, the stretch occurs at a quicker rate. these circumstances, the rope would be declared unsafe
This means that the rope has reached the point of rapid although it may, in actuality, be safe.
degradation; a result of prolonged subjection to abrasive
wear, fatigue, etc. This second upturn of the curve is a As an example of the possible error at the other extreme,
warning indicating that the rope should soon be removed. we can take the case of a rope manufactured near the
upper limits of allowable size. If the diameter has reached
3. Reduction in Rope Diameter a reduction to nominal or slightly below that, the tables
Any marked reduction in rope diameter indicates would show this rope to be safe. But it should, perhaps,
degradation. Such reduction may be attributed to: be removed.
■ Excessive external abrasion
668

Wire Rope Inspection 5. Kinks
Cranes / Jibs
Overhead
Are tightened loops with permanent strand distortion that
(Continued) result from improper handling when a rope is being installed
or while in service. A kink happens when a loop is permitted
Today, evaluations of the rope diameter are first predicated to form and then is pulled down tight, causing permanent
on a comparison of the original diameter—when new and distortion of the strands. The damage is irreparable and the
subjected to a known load—with the current reading under sling must be taken out of service.
Hoists
like circumstances. Periodically, throughout the life of the
rope, the actual diameter should be recorded when the 6. Doglegs
rope is under equivalent loading and in the same operating Are permanent bends caused by improper use or
section. This procedure, if followed carefully, reveals a handling. If the dogleg is severe, the sling must be removed
Services
common rope characteristic: after an initial reduction, the from service. If the dogleg is minor, exhibiting no strand
diameter soon stabilizes. Later, there will be a continuous, distortion and cannot be observed when the sling is under
albeit small, decrease in diameter throughout its life. tension, the area of the minor dogleg should be marked for
observation and the sling can remain in service.
Core deterioration, when it occurs, is revealed by a more
Engineered
Products
rapid reduction in diameter and, when observed, it is time 7. “Bird Caging”
for removal. Bird caging results from torsional imbalance that comes
about because of mistreatments, such as sudden stops, the
Deciding whether or not a rope is safe is not always a simple rope being pulled through tight sheaves or wound on too
matter. A number of different but interrelated conditions small a drum. This is cause for rope replacement unless
must be evaluated. It would be dangerously unwise for an the affected section can be removed.
Slings
inspector to declare a rope safe for continued service simply
because its diameter had not reached the minimum 8. Localized Conditions
arbitrarily established in a table if, at the same time, other Particular attention must be paid to wear at the equalizing
observations lead to an opposite conclusion. sheaves. During normal operations, this wear is not visible.
Hardware
Excessive vibration or whip can cause abrasion and/or
Because criteria for removal are varied, and because fatigue. Drum cross-over and flange point areas must be
diameter, in itself, is a vague criterion, the table of minimum carefully evaluated. All end fittings, including splices, should
diameters has been deliberately omitted from this manual. be examined for worn or broken wires, loose or damaged
strands, cracked fittings, worn or distorted thimbles and
4. Corrosion
Products
tucks of strands.
Lifting
Corrosion, while difficult to evaluate, is a more serious cause
of degradation than abrasion. Usually, it signifies a lack of 9. Heat Damage
lubrication. Corrosion will often occur internally before there After a fire or the presence of elevated temperatures, there
is any visible external evidence on the rope surface. Pitting may be metal discoloration or an apparent loss of internal
of wires is a cause for immediate rope removal. Not only lubrication; fiber core ropes are particularly vulnerable; under
Rope
Wire
does it attack the metal wires, but it also prevents the rope’s these circumstances the rope should be replaced.
component parts from moving smoothly as it is flexed.
Usually, a slight discoloration because of rusting merely 10. Protruding Core
indicates a need for lubrication. If, for any cause, the rope core protrudes from an opening
Cordage
between the strands, the rope is unfit for service and should
Severe rusting, on the other hand, leads to premature be removed.
fatigue failures in the wires necessitating the rope’s
immediate removal from service. When a rope shows more 11. Damaged End Attachments
than one wire failure adjacent to a terminal fitting, it should Cracked, bent or broken end fittings must be eliminated.
Securement
be removed immediately. To retard corrosive deterioration, The cause should be sought out and corrected. In the case
Load
the rope should be kept well lubricated with a clear wire of bent hooks, the throat openings—measured at the
rope lube that can penetrate between strands. In situations narrowest point—should not exceed 5%, not to exceed
where extreme corrosive action can occur, it may be 1/4" opening and any visibly apparent bend or twist from
necessary to use galvanized wire rope. the plane of the unbent hook over normal nor should
Contractors
twisting be greater than 10°.

Supply
Protection
Fall

669

Wire Rope Inspection On occasion, a single wire will break shortly after installation.
However, if no other wires break at that time, there is
(Continued) no need for concern. On the other hand, should more wires
break, the cause should be carefully investigated.
12. Peening
Continuous pounding is one of the causes of peening. The On any application, valley breaks—i.e., where the wire
rope strikes against an object, such as some structural part fractures between strands—should be given serious
of the machine, or it beats against a roller or it hits itself. attention. When two or more such fractures are found, the
Often, this can be avoided by placing protectors between rope should be replaced immediately. (Note, however, that
the rope and the object it is striking. Another common cause no valley breaks are permitted in elevator ropes.)
of peening is continuous working-under high loads—over a
It is well to remember that once broken wires appear—in a
sheave or drum. Where peening action cannot be controlled,
rope operating under normal conditions—a good many more
it is necessary to have more frequent inspections and to be
will show up within a relatively short period. Attempting to
ready for earlier rope replacement.
squeeze the last measure of service from a rope beyond
13. Scrubbing the allowable number of broken wires (refer to table on the
Scrubbing refers to the displacement of wires and strands next page) will create an intolerably hazardous situation.
as a result of rubbing against itself or another object. This,
A diagnostic guide to some of the most prevalent rope
in turn, causes wear and displacement of wires and strands
abuses are given on the following pages—these abuses are
along one side of the rope. Corrective measures should be
illustrated and described.
taken as soon as this condition is observed.
14. Fatigue Fracture

Below are plain views and cross-sections
Wires that break with square ends and show little surface
show effects of abrasion and peening on wire
wear have usually failed as a result of fatigue. Such
rope. Note that a crack has formed as a
fractures can occur on the crown of the strands or in the
result of heavy peening.
valleys between the strands where adjacent strand
contact exists. In almost all cases, these failures are
related to bending stresses or vibration.
Abrasion Peening
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 will 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.
15. Broken Wires

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

Rope that has either been in contact with a live power line
or been used as “ground” in an electric welding circuit,
will have wires that are fused, discolored and/or annealed
and must be removed.
670

Wire Rope Inspection
Cranes / Jibs
Overhead
(Continued)
When to Replace Wire Rope—Based on Number of Broken Wires
Hoists
Operating Ropes Standing Ropes
ASME Number Broken Wires * Number Broken Wires
Equipment
Standard In One In One In One At End
Rope Lay Strand Rope Lay Connection
Services
ASME B30.2 Overhead & Ganrty Cranes 12 4 Not Specified Not Specified
ASME B30.4 Portal, Tower & Pillar Cranes 6 3 3 2
ASME B30.5 Crawler, Locomotive & Truck Cranes 6 3 3 2
ASME B30.6 Derricks 6 3 3 2
Engineered
Products
ASME B30.7 Base Mounted Drum Hoists 6 3 3 2
ASME B30.8 Floating Cranes & Derricks 6 3 3 2
ASME B30.16 Overhead Hoists 12 4 Not Specified Not Specified
ANSI A10.4 Personnel Hoists 6 3 2 2
Slings
ANSI A10.5 Materials Hoists 6 Not Specified Not Specified Not Specified
American National Standards Institute (ANSI)

American Society of Mechanical Engineers (ASME)
Hardware
* All ropes in the above applications—one outer wire broken at the point of contact with the core that has worked its way out of the
rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required.
Products
Replacement Criteria for
Lifting
Rotation Resistant Ropes
Recommended retirement criteria for all Rotation

Resistant Ropes are 2 broken wires in 6 rope
Rope
Wire
diameters or 4 broken wires in 30 rope diameters
(i.e. 6 rope diameters for a 1" diameter rope = 6").
Distortion of Rotation Resistant Ropes, as shown to

the right, can be caused by shock load / sudden load
Cordage
release and/or induced torque, and is the reason
for immediate removal from service.
Securement
Load
Contractors
Supply
Protection
Fall

671

Guide to Examination
Typical Examples of Wire Rope Deterioration
Mechanical damage
Typical wire
due to rope movement
1 9 fractures as a result
over sharp edge projection
of bend fatigue.
while under load.
Wire fractures
Localized wear due to
at the strand or core
2 abrasion on supporting 10 interface as distinct
structure.
from ‘crown’ fractures.
Narrow path of wear,

resulting in fatigue fractures Break up of IWRC,
3 caused by working in a 11 resulting from high
grossly oversize groove or stress application.
over small support rollers.
Two parallel paths of broken Looped wires

wires indicative of bending as a result of torsional
4 12
through an undersize groove imbalance and/or
in the sheave. shock loading.
Typical example of
Severe wear associated
5 13 localized wear and
with high tread pressure.
deformation.
Severe wear Multi strand rope

6 in Langs Lay caused 14 ‘bird caged’ due to
by abrasion. torsional imbalance.
Protrusion of rope
7 Severe corrosion. 15 center, resulting from
build up of turn.
Internal corrosion while Substantial wear

8 external surface shows little 16 and severe internal
evidence of deterioration. corrosion.
672

Guide to Examination Some of the More Common Types of Wire
Cranes / Jibs
Fractures Can Include:
Overhead
(Continued)
The continued safe operation of lifting equipment, lifting
accessories (e.g. slings) and other systems employing A. Severed by Wear
wire rope depends to a large extent on the operation of
Pictures courtesy of S.M.R.E. Crown Copyright 1966
Hoists
well programmed periodic rope examinations, and the
assessment by the competent person of the fitness B. Tension
of the rope for further service.
Examination and discard of ropes by the competent person
Services
should be in accordance with the instructions given in the C. Fatigue
original equipment manufacturer’s handbook. In addition,
account should be taken of any local or application-specific
regulations.
D. Corrosion Fatigue
Engineered
The competent person should also be familiar, as
Products
appropriate, with the latest versions of related ASME B30,
International, European or National standards.
E. Plastic Wear
Particular attention must be paid to those sections
of rope which experience has shown to be liable to
deterioration. Excessive wear, broken wires, F. Martensite
Slings
distortions and corrosion are the more common
visible signs of deterioration (see below).
Note: This publication has been prepared as an aid G. Sheared End

for rope examination and should not be regarded as a
Hardware
substitute for the competent person.
Wear is a normal feature of rope service, and the use Factors Affecting Rope Performance
of the correct rope construction ensures that it remains
a secondary aspect of deterioration. Lubrication may Multi-layers of the rope on the drum can result in severe
distortion in the underlying layers.
Products
help to reduce wear.
Lifting
Broken wires are a normal feature of rope service towards Bad spooling (due to excessive fleet angles or slack
the end of the rope’s life, resulting from bending fatigue winding) can result in mechanical damage, shown as severe
and wear. The local break up of wires may indicate some crushing, and may cause shock loading during operation.
mechanical fault in the equipment. Correct lubrication Small diameter sheaves can result in permanent set of the
in service will increase fatigue performance.
Rope
Wire
rope and will certainly lead to early wire breaks.
Distortions are usually a result of mechanical damage, Oversize grooves offer insufficient support to the rope
and if severe, can considerably affect rope strength. leading to increased localized pressure, flattening of the
Visible rusting indicates a lack of suitable lubrication rope and premature wire fractures. Grooves are deemed to
resulting in corrosion. Pitting of external wire surfaces
Cordage
be oversize when the groove diameter exceeds the nominal
becomes evident in some circumstances. Broken wires rope diameter by more than 15%.
ultimately result.
Undersize grooves in sheaves will crush and deform the
Internal corrosion occurs in some environments when rope, often leading to two clear patterns of wear and
lubrication is inadequate or of an unsuitable type.
Securement
associated wire breaks.

Reduction in rope diameter will frequently guide the
Load
observer to this condition. Confirmation can only be made Excessive angle of fleet can result in severe wear of the
by opening the rope with clamps or the correct use of spike rope due to scrubbing against adjacent laps on the drum.
and needle to facilitate internal inspection. Rope deterioration at the Termination may be exhibited in
the form of broken wires. An excessive angle of fleet can
Contractors
Note: Non-destructive testing (NDT) using electromagnetic also induce rotation causing torsional imbalance.
Supply
means may also be used to detect broken wires and/or loss

in metallic area. This method complements the visual
examination, but does not replace it. This page reprinted with permission from Bridon American.
Protection
Fall

673

Inspection of Figure 1: Cross-sections illustrating three sheave groove
conditions: A is correct, B is too tight and C is too loose.
Sheaves & Drums
Under normal conditions, machines receive periodic
inspections and their overall condition is recorded. Such
inspections usually include the drum, sheaves and
any other parts that may come into contact with the
wire rope and subject it to wear. As an additional
precaution, rope-related working parts, particularly in
the areas described below, should be re-inspected A
prior to the installation of a new wire rope.
The very first item to be checked when examining sheaves

and drums is the condition of the grooves (Figs. 1, 2
and 3). To check the size, contour and amount of wear,
a groove gauge is used. As shown in Figure 1, the gauge
should contact the groove for about 150° of arc.
B C
Two types of groove gauges are in general use and it is
important to note which of these is being used. The two differ Figure 2: These sheave groove cross-sections represent
by their respective percentage over nominal rope diameter. three wire rope seating conditions: A is a new rope in a new
groove, B is a new rope in a worn groove and C is a worn
For new or re-machined grooves, the groove gauge is rope in a worn groove. (See also Figs. 1 and 3)
nominal plus the full oversize percentage. The gauge carried
by most wire rope representatives today is used for worn
grooves and is made nominal plus 1/2 the oversize
percentage.
This latter gauge is intended to act as a sort of “no-go”

gauge. Any sheave with a groove smaller than this must A
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 “recommended minimum new
groove” given. Please refer to the Wire Rope Users Manual B C
or contact your local Lifting Specialist for the table that lists
requirements for new or re-machined grooves. The chart
gives the groove gauge diameter in terms of the nominal Figure 3: Illustrating the various dimensions of a sheave
wire rope diameter plus a percentage thereof. Similarly, the and the use of a sheave gauge.
size of the “no-go” gauge is given, against which worn
grooves are judged. Experience has clearly demonstrated
that the service life of the wire rope will be materially
increased by strict adherence to these standards.
674

Troubleshooting Guide
Cranes / Jibs
Overhead
The following is a simplified guide to common wire rope problems. In the event of no other standard being applicable,
Bridon recommends that ropes are inspected / examined in accordance with ASME B30.5.
Problem Cause / Action
Hoists
Mechanical damage caused by the rope ■ Generally results from operational conditions.
contacting the structure of the crane on which it is ■ Check sheave guards and support / guide sheaves to
operating or an external structure—usually of a ensure that the rope has not “jumped out” of the intended
localized nature. reeving system.
■ Review operating conditions.
Services
Opening of strands in Rotation Resistant ropes— ■ Check sheave and drum groove radii using sheave gauge to
in extreme circumstances the rope may develop a ensure that they are no smaller than nominal rope radius
“birdcage distortion” or protrusion of inner strands. +2.5%—Bridon recommends that the sheave and drum groove
radii are checked prior to any rope installation.
Engineered
Note—Rotation Resistant ropes are designed ■ Repair or replace drum / sheaves if necessary.
Products
with a specific strand gap which may be apparent ■ Check fleet angles in the reeving system—a fleet angle in
on delivery in an off tension condition. These excess of 1.5 degrees may cause distortion.
gaps will close under load and will have no effect ■ Check installation method—turn induced during
on the operational performance of the rope. installation can cause excessive rope rotation resulting
in distortion.
■ Check if the rope has been cut “on site “ prior to installation
Slings
or cut to remove a damaged portion from the end of the rope.
If so, was the correct cutting procedure used? Incorrect
cutting of Rotation Resistant, low rotation and parallel closed
ropes can cause distortion in operation.
■
Hardware
Rope may have experienced a shock load.
Broken wires or crushed or flattened rope on ■ Check tension on underlying layers. Bridon recommends an
lower layers at crossover points in multi-layer installation tension of between 2% and 10% of the minimum
coiling situations. breaking force of the wire rope. Care should be taken to
ensure that tension is retained in service. Insufficient tension
Wire breaks usually resulting from crushing will result in these lower layers being more prone to
Products
Lifting
or abrasion. crushing damage.
■ Review wire rope construction. Dyform wire ropes are more
resistant to crushing on underlying layers than conventional
rope constructions.
■ Do not use more rope than necessary.
■ Check drum diameter. Insufficient bending ratio increases
Rope
Wire
tread pressure.
Wires looping from strands. ■ Insufficient service dressing.
■ Consider alternative rope construction.
■ If wires are looping out of the rope underneath a crossover
Cordage
point, there may be insufficient tension on the lower wraps on
the drum.
■ Check for areas of rope crushing or distortion.
■ Possible fleet angle problems causing rope rotation.
Securement
“Pigtail” or severe spiralling in rope. ■ Check that the sheave and drum diameter is large enough—
Bridon recommends a minimum ratio of the drum / sheave to
Load
nominal rope diameter of 18:1.

■ Indicates that the rope has run over a small radius or
sharp edge.
■ Check to see if the rope has “jumped off” a sheave and has
Contractors
run over a shaft.

Supply

Protection
Fall

675

Troubleshooting Guide (Continued)
Two single axial lines of broken wires running along ■ Check sheave and drum groove radii using sheave gauge
the length of the rope approximately 120 degrees to ensure that they are no smaller than nominal rope
apart indicating that the rope is being “nipped” in a radius + 2.5%—Bridon would recommend that the
tight sheave. sheave / drum groove radii are checked prior to any
rope installation.
■ Repair or replace drum / sheaves if necessary.
One line of broken wires running along the length ■ Check to see if the groove diameter is no greater than
of the rope indicating insufficient support for the rope, 15% greater than the nominal rope diameter.
generally caused by oversize sheave or drum ■ Repair or replace drum / sheaves if necessary.
grooving. ■ Check for contact damage.
Short rope life resulting from evenly / randomly ■ Bending fatigue is accelerated as the load increases and as
distributed bend fatigue wire breaks caused by the bending radius decreases. Consider whether either factor
bending through the reeving system. can be improved.
■ Check wire rope construction—Dyform ropes are capable
Fatigue induced wire breaks are characterized ends of doubling the bending fatigue life of a conventional
by flat on the broken wires. steel wire rope.
Short rope life resulting from localized bend fatigue ■ Bending fatigue is accelerated as the load increases and as
wire breaks. the bending radius decreases. Consider whether either factor
can be improved.
Fatigue induced wire breaks are characterized ends ■ Check wire rope construction—Dyform ropes are capable
by flat on the broken wires. of doubling the bending fatigue life of a conventional
steel wire rope.
■ Localized fatigue breaks indicate continuous repetitive bends
over a short length. Consider whether it is economic to
periodically shorten the rope in order to move the rope through
the system and progressively expose fresh rope to the severe
bending zone. In order to facilitate this procedure it may be
necessary to begin operating with a slightly longer length
of rope.
Broken rope—ropes are likely to break when ■ Review operating conditions.
subjected to substantial overload or misuse
particularly when a rope has already been subjected
to mechanical damage.
Corrosion of the rope both internally and/or externally

can also result in a significant loss in metallic area.
The rope strength is reduced to a level where it is
unable to sustain the normal working load.
Wave or corkscrew deformations normally associated ■ Check sheave and drum groove radii using sheave gauge
with multi-strand ropes. to ensure that they are no smaller than nominal rope
radius +2.5%—Bridon recommends that the sheave / drum
groove radii are checked prior to any rope installation.
■ Repair or replace drum / sheaves if necessary.
■ Check fleet angles in the reeving system—a fleet angle in
excess of 1.5 degrees may cause distortion.
■ Check that rope end has been secured in accordance with
manufacturers instructions.
■ Check operating conditions for induced turn.
676

Troubleshooting Guide (Continued)
Cranes / Jibs
Overhead
Rotation of the load in a single fall system. ■ Review rope selection.
■ Consider use of Rotation Resistant rope.
Hoists
Rotation of the load in a multi-fall system resulting ■ Review rope selection.
in “cabling” of the rope falls. ■ Consider use of Rotation Resistant rope.
■ Review installation procedure or operating procedures.
Possibly due to induced turn during installation
or operation.
Services
Core protrusion or broken core in single layer six or ■ Caused by repetitive shock loading—
eight strand rope. review operating conditions.
Rope accumulating or “stacking” at drum flange— ■ Review drum design with original equipment
due to insufficient fleet angle. manufacturer—consider adding rope kicker,
Engineered
fleeting sheave, etc.
Products
Sunken wraps of rope on the drum normally ■ Check correct rope diameter.
associated with insufficient support from lower ■ If grooved drum check groove pitch.
layers of rope or grooving. ■ Check tension on underlying layers—Bridon recommends
an installation tension of between 2% and 10% of the
minimum breaking force of the wire rope—Care should
Slings
be taken to ensure that tension is retained in service.
Insufficient tension will result in these lower layers being
more prone to crushing damage.
■ Make sure that the correct rope length is being used.
Too much rope (which may not be necessary) may aggravate
Hardware
the problem.
Short rope life induced by excessive wear ■ Check fleet angle to drum.
and abrasion. ■ Check general alignment of sheaves in the reeving system.
■ Check that all sheaves are free to rotate.
■ Review rope selection. The smooth surface of Dyform
Products
Lifting
wire ropes gives better contact with drum and sheaves and
offers improved resistance to “interference” between
adjacent laps of rope.
External corrosion. ■ Consider selection of galvanized rope.
■ Review level and type of service dressing.
Rope
Wire
Internal corrosion. ■ Consider selection of galvanized rope.
■ Review frequency amount and type of service dressing.
■ Consider selection of plastic impregnated (PI) wire rope.
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

677

Product Safety: Internally—being loaded or bent.
Instructions & Warnings on

Abrasion weakens the rope by removing metal from
both the inner and outer wires. Therefore, a rope with
the Use of Steel Wire Rope large outer wires should normally be selected.
1.4 Vibration
The following Instructions and Warnings combine to Vibration in wire rope will cause deterioration. This
provide guidance on Product Safety and are intended for may become apparent in the form of wire fractures
use by those already having a working knowledge of where the vibration is absorbed.
wire ropes, as well as the new user. They should be read,
followed and passed on to others. These fractures may be internal only and will not be
visually identified.
Failure to read, understand and follow these instructions
could result in harmful and damaging consequences. 1.5 Distortion
Wire rope can be distorted due to high pressure
1. Rope Selection Criteria against a sheave, improperly sized grooves or as a
result of multi-layer spooling on a drum.
Ensure that the correct type of wire rope is selected for
the equipment by referring to the OEM’s instruction Rope with a steel core is more resistant to crushing
manual or other relevant documents. If in doubt, contact and distortion.
Bridon for guidance.
1.6 Corrosion
1.1 Rope Strength Rope with a large number of small wires is more
If necessary, refer to the appropriate Regulations susceptible to corrosion than rope with a small number
and/or application standards and calculate the of large wires. Therefore, if corrosion is expected to
maximum force to which the rope will be subjected. have a significant effect on rope performance. The rope
may have to be lubricated frequently in service or a
The calculation may take into account the mass to be
galvanized rope may be selected.
lifted or moved, any shock loading, effects of high
speed, acceleration, any sudden starts or stops, 1.7 Cabling
frequency of operation and sheave bearing friction. ‘Cabling’ of rope reeving due to block rotation can
occur if the rope is incorrectly selected. Applications
By applying the relevant design factor and, where
involving high lifts are particularly vulnerable to this
applicable, the efficiency of the rope termination, the
condition, therefore, ropes specifically designed to
required minimum breaking load or force of the rope
resist rotation need to be selected.
will be determined, the values of which are available
from the relevant National or International standards 1.8 Fixing of Rope Ends
or from specific Product Data literature. If in doubt, Ropes which have high rotation characteristics must
ask for advice from Bridon. not be selected unless both ends of the rope are fixed
or the load is guided and unable to rotate.
1.2 Bending Fatigue
The size and number of sheaves in the system will 1.9 Connecting Ropes
influence the performance of the rope. In the event that it is necessary to connect one rope to
another (in series), it is essential that they have the
Wire rope which bends around sheaves, rollers or
required strength, are of the same type and both have
drums will deteriorate through ‘bending fatigue’.
the same lay direction (i.e. connect ‘right’ lay to
Reverse bending and high speed will accelerate the
‘right’ lay).
process. Therefore, under such conditions select
a rope with high bending fatigue resistance. Failure to heed this warning could result in
Refer to Product Data Information, and if in doubt, catastrophic failure particularly at a termination,
ask for advice. which is capable of being pulled apart (i.e. splice)
due to unlaying.
1.3 Abrasion
Wire rope which is subject to abrasion will become 1.10 Rope Length
progressively weaker as a result of: Rope length and/or difference in length between two
or more ropes used in a set may be a critical factor
Externally—dragging it through overburden, sand or
and must be considered along with rope selection.
other abrasive materials and passing around a sheave,
roller or drum.
678

Product Safety: with the details on the Certificates and/or other
Cranes / Jibs
relevant documents.
Overhead
Instructions & Warnings on Check the rope diameter and examine any rope
the Use of Steel Wire Rope

terminations to ensure that they are compatible with
the equipment or machinery to which they are to
(Continued) be fitted.
Hoists
2.2 Select a clean, well ventilated, dry, undercover
Wire rope will elongate under load. Other factors,
location. Cover with waterproof material if the delivery
such as temperature, rope rotation and internal
site conditions preclude inside storage.
wear, will also have an effect. These factors should
also be considered during rope selection.
Rotate the reel periodically during long periods of
Services
1.11 Preformed and Non-preformed Ropes storage, particularly in warm environments, to prevent
Single layer round strand rope is normally supplied migration of the lubricant from the rope.
preformed. However, if a non-preformed rope is
Never store wire rope in areas subject to elevated
selected then personnel responsible for its installation
temperatures as this may seriously affect its
and/or maintenance need to take particular care
Engineered
Products
future performance. In extreme cases, its original
when handling such rope, especially when cutting.
as-manufactured strength may be severely reduced
For the purposes of this instruction, Rotation Resistant rendering it unfit for safe use.
ropes should be regarded as non-preformed ropes.
Ensure that the rope does not make any direct
1.12 Operating Temperatures contact with the floor and that there is a flow of air
Slings
Wire rope with a steel core should be selected if there under the reel.
is any evidence to suggest that a fiber core will not
Failure to do so may result in the rope becoming
provide adequate support to the outer strands and/or
contaminated with foreign matter and start
if the temperature of the working environment may
the onset of corrosion before the rope is even put
be expected to exceed 180°F.
Hardware
to work.
For operating temperatures above 200°F, de-rating of
Support the reel on a simple A-frame or cradle located
the minimum breaking force of the rope is necessary
on ground, which is capable of supporting the total mass
(e.g. between 200°F and 400°F reduce by 10%;
of rope and reel. Ensure that the rope is stored where it
between 400°F and 600°F reduce by 25%; between
is not likely to be affected by chemical fumes, steam or
600°F and 800°F reduce by 35%).
Products
other corrosive agents.
Lifting
Do not use ropes with high carbon wires above 800°F.
Failure to do so may seriously affect its condition
Failure to observe this general guidance could rendering it unfit for safe use.
result in failure of the ropes to support the load.
2.3 Examine ropes in storage periodically and,
when necessary, apply a suitable dressing which is
Rope
Wire
For temperatures over 800°F, other materials, such as
stainless steel or other special alloys, should be compatible with the manufacturing lubricant.
considered. Contact the rope supplier, Bridon or original equipment
manufacturer’s (OEM) manual for guidance on types
Rope lubricants and any synthetic filling and/or of dressings available, methods of application and
Cordage
covering materials may become ineffective at equipment for the various types of ropes and
certain low or high operating temperature levels. applications.
Certain types of rope end terminations also have Re-wrap the rope unless it is obvious that this will be
limiting operating temperatures and the manufacturer or detrimental to rope preservation.
Securement
Bridon should be consulted where there is any doubt.

Ropes with aluminium ferrules must not be used at Failure to apply the correct dressing may render
Load
temperatures in excess of 300°F. the original manufacturing lubricant ineffective and

rope performance may be significantly affected.
2. Storage
Contractors
2.1 Unwrap the rope and examine the rope

Supply
immediately after delivery to check its identification

and condition and verify that it is in accordance
Protection
Fall

679

Product Safety:

to the body from wire and rope ends; bruising of the
body and damage to limbs due to rope recoil,

backlash and any sudden deviation from the line of
path of rope.
the Use of Steel Wire Rope 4.3 Ensure that the correct rope has been supplied
(Continued) by checking to see that the description on the
Certificate is in accordance with that specified in the
Ensure that the rope is stored and protected in such a purchaser’s order.
manner that it will not be exposed to any accidental
4.4 Check by measurement that the nominal diameter
damage either during the storage period or when
of the new rope conforms to the nominal size stated on
placing the rope in or taking it out of storage.
the Certificate.
Failure to carry out or pay attention to any of the
For verification purposes, measure the diameter by
above could result in a loss of strength and/or
using a suitable rope vernier fitted with jaws broad
a reduction in performance. In extreme cases, the
enough to cover not less than two adjacent strands.
rope may be unfit for safe use.
Take two sets of measurements spaced at least
3. Certification and Marking 3′ apart, ensuring that they are taken at the largest
cross-sectional dimension of the rope. At each point,
Make sure that the relevant Certificate has been take measurements at right angles to each other.
obtained before taking the rope into use for a lifting
operation. The average of these four measurements should be
within the tolerances specified in the appropriate
Check to verify that the marking on the rope or its Standard or Specification.
package matches the relevant Certificate.
For a more general assessment of rope diameter,
Note: The rating of a component part of a machine use a rope calliper.
or lifting accessory is the responsibility of the designer
of the machine or accessory. Any re-rating of a lifting 4.5 Examine the rope visually to ensure that no
accessory must be approved by a competent person. damage or obvious signs of deterioration have taken
place during storage or transportation to the
Retain the Certificate in a safe place for identification installation site.
of the rope when carrying out subsequent periodic
statutory examinations in service. 4.6 Check the working area around the equipment
for any potential hazards which may affect the safe
4. Handling and Installation installation of the rope.
4.1 Handling and installation of the rope should be 4.7 Check the condition of the rope-related equipment
carried out in accordance with a detailed plan and in accordance with the OEM’s instructions. Include the
should be supervised by a competent person. following—
Incorrectly supervised handling and installation Drum

procedures may result in serious injury to persons in Check the general condition of the drum.
the vicinity of the operation, as well as those persons
directly involved in the handling and installation. If the drum is grooved, check the radius and pitch and
ensure that the grooves will satisfactorily accommodate
4.2 Wear suitable protective clothing, such as overalls, the size of the new rope.
industrial gloves, helmet, eye protectors and safety
footwear (and respirator, particularly where the Check the condition and position of the kicker plates
emission of fumes due to heat is likely). or wear plates, if fitted, to ensure that the new rope
will spool correctly on the drum.
Failure to wear suitable protective clothing and
equipment may result in skin problems from over Sheaves
exposure to certain types of rope lubricants and Ensure that the grooving is of the correct shape and
dressings; burns from sparks, rope ends, molten size for the new rope
lubricants and metals when cutting ropes or
preparing sockets for re-use; respiratory or other Check that all sheaves are free to rotate and in
internal problems from the inhalation of fumes when good condition.
cutting ropes or preparing sockets for re-use; eye
injuries from sparks when cutting ropes; lacerations This page reprinted with permission from Bridon American.
680

Product Safety: Reels
Cranes / Jibs
Pass a shaft through the reel and place the reel in a
Overhead

suitable stand, which allows it to rotate and be braked
to avoid overrun during installation. Where multi-layer
the Use of Steel Wire Rope coiling is involved, it may be necessary for the reel
to be placed in equipment which has the capability of
(Continued) providing a back tension in the rope as it is being
Hoists
transferred from reel to drum. This is to ensure that
Rope Guards the underlying (and subsequent) laps are wound tightly
Check that any rope guards are correctly fitted and on the drum.
are in good condition.
Position the reel and stand such that the fleet angle
Check the condition of any wear plates or rollers during installation is limited to 1.5 degrees.
Services
which are protecting structural members.
If a loop forms in the rope, ensure that it does not
Failure to carry out any of the above could result tighten to form a kink.
in unsatisfactory and unsafe rope performance.
A kink can severely affect the strength of a
Engineered
Products
Note: Grooves must have clearance for the rope and six strand rope and can result in distortion of
provide adequate circumferential support to allow for a Rotation Resistant rope leading to its
free movement of the strands and facilitate bending. immediate discard.
When grooves become worn and the rope is pinched at
the sides, strand and wire movement is restricted and Ensure that the reel stand is mounted so as not to
the ability of the rope to bend is reduced. create a reverse bend during reeving (i.e. for a winch
Slings
drum with an overlap rope, take the rope off the top
4.8 When a new rope is fitted, a variation in size of the reel).
compared with the old worn rope will be apparent. The
new rope may not fit correctly into the previously worn 4.9 Ensure that any equipment or machinery to be
groove profile and unnecessary wear and rope distortion roped is correctly and safely positioned and isolated
Hardware
is likely to occur. This may be remedied by machining from normal usage before installation commences.
out the grooves before the new rope is installed. Before Refer to the OEM’s instruction manual and the relevant
carrying out such action, the sheaves or drum should ‘Code of Practice’.
be examined to ensure that there will be sufficient
4.10 When releasing the outboard end of the rope
strength remaining in the underlying material to safely
from a reel or coil, ensure that this is done in a
support the rope.
Products
controlled manner. On release of the bindings and
Lifting
The competent person should be familiar with the servings used for packaging, the rope will want to
requirements of the appropriate application / machinery straighten itself from its previously bent position.
standard. Unless controlled, this could be a violent action.
Stand clear.
Note: General guidance to users is given in the
Rope
Failure to control could result in injury.
Wire
Wire Rope Users Manual.
Transfer the wire rope carefully from the storage area Ensure that the as-manufactured condition of the rope
to the installation site. is maintained during installation.
If installing the new rope with the aid of an old one,
Cordage
Coils
Place the coil on the ground and roll it out straight one method is to fit a wire rope sock (or stocking) to
ensuring that it does not become contaminated with each of the rope ends. Always ensure that the open
dust, grit, moisture or any other harmful material. end of the sock (or stocking) is securely attached to
the rope by a serving or alternatively by a clip. Connect
Securement
If the coil is too large to physically handle it may be the two ends via a length of fiber rope of adequate
placed on a ‘swift’ turntable and the outside end of strength in order to avoid turn being transmitted from
Load
the rope pulled out allowing the coil to rotate. the old rope into the new rope. Alternatively, a length of
fiber or steel rope of adequate strength may be reeved
Never pull a rope away from a stationary coil as this into the system for use as a pilot / messenger line.
will induce turn into the rope and kinks will form. Do not use a swivel during the installation of the rope.
Contractors
These will adversely affect rope performance.

Supply

Protection
Fall

681

Product Safety:
Figure 1
The products used in the manufacture
of steel wire ropes for lubrication and

protection present minimal hazard to
the user in the form shipped. The user
the Use of Steel Wire Rope must however, take reasonable care to
minimize skin and eye contact and also
(Continued) avoid breathing their vapor and mist.
4.11 Monitor the rope carefully as it is being pulled 4.13 Ensure that any fittings, such
into the system and make sure that it is not obstructed as clamps or fixtures, are clean and
by any part of the structure or mechanism which may undamaged before securing rope ends.
cause the rope to come free.
Make sure that all fittings are secure in
Failure to monitor during this operation could accordance with the OEM’s instruction
result in injury. manual or manufacturer’s instructions
and take particular note of any specific
This entire operation should be carried out carefully safety requirements e.g. torque values
and slowly under the supervision of a competent (and frequency of any re-application
person. of torque).
4.12 Take particular care and note the manufacturer’s When terminating a rope end with a
instructions when the rope is required to be cut. wedge socket, ensure that the rope tail
Apply secure servings on both sides of the cut mark. cannot withdraw through the socket
by securing a clamp to the tail or by
Ensure that the length of serving is at least equal following the manufacturer’s instructions.
to two rope diameters. (Note: Special servings are The tail length should be a minimum of
required for spiral ropes, i.e. spiral strand and 20 rope diameters for all Rotation
locked coil.) Resistant wire rope and a minimum
of 6 rope diameters for 6 and 8 strand
One serving either side of the cut is normally sufficient ropes.
for preformed ropes. For non-preformed ropes, (i.e.
Rotation Resistant ropes) a minimum of two servings (See Fig. 1 for two recommended methods of securing
each side of the cut will be necessary. the rope tail of a wedge socket termination).
Arrange and position the rope in such a manner that The loop back method uses a rope grip and the loop
at the completion of the cutting operation the rope ends should be lashed to the live part of rope by a soft wire
will remain in position, thus avoiding any backlash or serving or tape to prevent flexing of the rope in service.
any other undesirable movement.
The method of looping back should not be used if
Cut the rope with a high speed abrasive disc cutter. there is a possibility of interference of the loop with the
Other suitable mechanical or hydraulic shearing mechanism or structure.
equipment may be used although not recommended
when a rope end is required to be welded or brazed. Failure to secure in accordance with instructions could
lead to loss of the rope and/or injury.
When using a disc cutter be aware of the danger
from sparks, disc fragmentation and fumes. 4.14 When coiling a rope on a plain (or smooth)
barrel drum, ensure that each lap lies tightly against
Ensure adequate ventilation to avoid any build-up of the preceding lap. The application of tension in
fumes from the rope and its constituent parts including the rope greatly assists in the coiling of the rope.
any fiber core (natural or synthetic) any rope lubricant(s)
and any synthetic filling and/or covering material. Any looseness or uneven winding will result in
excessive wear, crushing and distortion of the rope.
Rope produced from carbon steel wires in the
form shipped is not considered a health hazard. With plain barrel drums, it is difficult to achieve
During subsequent processing (e.g. cutting, satisfactory multi-layer coiling beyond three layers.
welding, grinding, cleaning), dust and fumes may
be produced which contain elements which
may affect exposed workers.
682

Product Safety: fittings when assembling end terminations to fixtures.
Cranes / Jibs
Refer to manufacturer’s instructions.
Overhead
Instructions & Warnings on Failure to pay attention to any of the above could result
the Use of Steel Wire Rope in unsafe operation and potential injury.
(Continued)

4.16 Limit switches, if fitted, must be checked and
readjusted, if necessary, after the rope has been
Hoists
installed.
The direction of coiling of the rope on the drum is
important, particularly when using plain barrel drums, 4.17 Record the following details on the Certificate
and should be related to the direction of lay of the after installation has been completed: type of
rope in order to induce close coiling. equipment, location, plant reference number, duty and
Services
date of installation and any re-rating information /
(See Fig. 2 for
Figure 2: signature of competent person. Then safely file the
proper method of
Proper method of locating rope Certificate.
locating rope
anchorage point on a plain drum.
anchorage point on 4.18 ‘Run in’ the new rope by operating the equipment
a plain drum.)
Engineered
slowly, preferably with a low load, for several cycles.
Products
This permits the new rope to adjust itself gradually to
When multi-layer
working conditions.
spooling has to be
used it should be Note: Unless otherwise required by a certifying
realized that after authority, the rope should be in this condition before
the first layer is any proof test of the equipment or machinery is
Slings
wound on a drum, carried out.
the rope has to cross
the underlying rope Check that the new rope is spooling correctly on the
in order to advance drum and that no slack or cross laps develop.
across the drum in
Hardware
the second layer. Apply as much tension as possible (2%-5% of the
The points at which MBF of the rope) to ensure tight and even spooling,
the turns in the especially on the first layer.
upper layer cross
those of the lower Where multi-layer spooling is unavoidable, succeeding
layers should spool evenly on the preceding layers
Products
layer are known
Lifting
Note: Thumb indicates side of of rope.
as the cross-over rope anchorage
points and the rope
Irregular spooling usually results in severe surface
in these areas is
wear and rope malformation, which in turn is likely
susceptible to increased abrasion and crushing. Care
to cause premature rope failure.
should be taken when installing a rope on a drum and
Rope
Wire
when operating a machine to ensure that the rope is 4.19 Ensure that the as-manufactured condition of
spooled and layered correctly. the rope is maintained throughout the whole of the
handling and installation operation.
4.15 Check the state of re-usable rope end
terminations for size, strength, defects and cleanliness 4.20 If samples are required to be taken from the
Cordage
before use. Nondestructive testing may be required rope for subsequent testing and/or evaluation,
depending on the material and circumstances of use. it is essential that the condition of the rope is not
Ensure that the termination is fitted in accordance with disturbed. Refer to the instructions given in 4.12 and,
the OEM’s instruction manual or manufacturer’s depending on the rope type and construction, any
instructions. When re-using a socket and depending other special manufacturer’s instructions.
Securement
on its type and dimensions, the existing cone should be

Load
pressed out. Otherwise, heat may be necessary. 5. Inspection

When melting out sockets which have previously 5.1 Inspect the rope and related equipment at the
been filled with hot metal, the emission of toxic beginning of every work period at least daily in most
fumes is likely. Note that white metal contains a
Contractors
instances and particularly following any incident which

high proportion of lead.
Supply
could have damaged the rope or installation.

Correctly locate and secure any connection pins and
Protection
Fall

683

Product Safety: deterioration becomes excessive.

5.2 Remove broken wires as they occur by bending
backwards and forwards using a pair of pliers until they

break deep in the valley between two outer strands.
Wear protective clothing, such as overalls, industrial
(Continued) gloves, helmet, eye protectors and safety footwear
during this operation.
The entire length of rope should be inspected and
Do not shear off the ends of broken wires with
particular attention paid to those sections that
pliers as this will leave an exposed jagged edge,
experience has proven to be the main areas of
which is likely to damage other wires in the
deterioration. Excessive wear, broken wires, distortion
rope and lead to premature removal of the rope
and corrosion are the usual signs of deterioration.
from service. Failure to wear adequate protective
For a more detailed examination, special tools are
clothing could result in injury.
necessary, which will also facilitate internal inspection.
Note: Broken wires are a normal feature of service,
In the case of ropes working over drums or sheaves,
more so towards the end of the rope’s life, resulting
it is particularly necessary to examine those areas
from bending fatigue and wear. The local break
entering or leaving the grooves when maximum loads
up of wires may indicate some mechanical fault in
(i.e. shock loads) are experienced, or those areas
the equipment.
which remain for long periods in exposed places, such
as over a jib head sheave. Record the number and position in the rope of any
removed broken wires.
On some running ropes, but particularly relevant to
standing ropes (e.g. pendant ropes), the areas adjacent 5.3 Do not operate an appliance if for any reason
to terminations should be given special attention by (e.g. rope diameter, certified breaking force, rope
rope diameter measurements and visual examination construction, length or strength and type of rope
for broken wires and corrosion. termination) the wire rope and its termination is
considered unsuitable for the required duty.
Note: Shortening the rope repositions the areas
of maximum deterioration in the system. Where 5.4 Do not operate an appliance if the wire rope
conditions permit, begin operating with a rope which fitted has become distorted, been damaged or has
has a slightly longer length than necessary in order deteriorated to a level such that discard criteria
to allow for periodic shortening. has been reached or is likely to be reached prior
to normal expected life based on historical
When a non-preformed rope or multi-layer rope is
performance data.
used with a wedge socket and is required to be
shortened, it is essential that the end of the rope is Rope distortion is usually a result of mechanical
secured by welding or brazing before the rope is damage and can significantly reduce rope strength.
pulled through the main body of the socket to
its new position. 5.5 An authorized competent person must examine
the rope in accordance with the appropriate
Slacken the wedge in the socket. Pass the rope Regulations.
through the socket by an amount equivalent to the
crop length or sample required. Note that the 5.6 Do not carry out any inspection, examination,
original bent portion of the rope must not be retained dressing / lubrication, adjustment or any other
within the wedge socket. Replace the wedge and maintenance of the rope while it is suspending a load,
pull up the socket. Prepare and cut in accordance with unless otherwise stated in the OEM’s instruction
section 4.12. Ensure that the rope tail cannot withdraw manual or other relevant documents.
through the socket, see section 4.13.
Do not carry out any inspection or maintenance of the
Failure to observe this instruction will result in rope if the appliance controls are unattended unless the
a significant deterioration in the performance surrounding area has been isolated or sufficient warning
of the rope and could render the rope completely signs have been posted within the immediate vicinity.
unfit for further service. If the appliance controls are attended, the authorized
person must be able to communicate effectively with the
In cases where severe rope wear takes place at one driver or controller of the appliance during the
end of a wire rope, the life of the rope may be inspection process.
extended by changing round the drum end with the
load end, i.e. turning the rope ‘end for end’ before This page reprinted with permission from Bridon American.
684

Product Safety: A ‘dry’ rope unaffected by corrosion, but subject to bend
Cranes / Jibs
fatigue, is likely to achieve only 30% of that normally
Overhead
Instructions & Warnings on attained by a ‘lubricated’ rope.

Note: The authorized person carrying out a rope
inspection must be capable of recognizing the potential
(Continued) loss of safe performance of such a rope in comparison
with lubricated rope.
Hoists
5.7 Never clean the wire rope without recognizing
Clean the rope before applying a fresh dressing /
the potential hazards associated with working on
lubricant if it is heavily loaded with foreign matter e.g.
a moving rope.
sand, dust.
Failure to pay attention or take adequate precaution
Services
5.10 The authorized person responsible for carrying
could result in injury.
out wire rope maintenance must ensure that the ends of
If cleaning by cloth / waste, the material can be snagged the rope are secure. At the drum end, this will involve
on damaged surfaces and/or broken wires. checking the integrity of the anchorage and ensuring
that there are at least three dead wraps tightly spooled.
Engineered
Products
If cleaning by brush, eye protectors must be worn. If At the outboard end, the integrity of the termination
using fluids, it should be recognized that some products must be checked to ensure that it is in accordance with
are highly inflammable. A respirator should be worn if the OEM’s manual or other documents approved by
cleaning by a pressurized spray system. the owner of the appliance.
Failure to take adequate precaution could result in Adjust the lengths of ropes in multi-rope systems in
Slings
injury or damage to health. order that equal forces (within approved limits) are
evident.
Only use compatible cleaning fluids which will not
impair the original rope lubricant nor affect the rope 5.11 Damage to, or removal of, component parts
associated equipment. (mechanical or structural) caused by abnormal
Hardware
contact with wire rope can be hazardous to the
The use of cleaning fluids (particularly solvent based) safety of the appliance and/or the performance of
is likely to ‘cut back’ the existing rope lubricant leading the rope (e.g. damage to the drum grooving such
to a greater quantity of lubricant accumulating on that spooling is erratic and/or the rope is ‘pulled
the surface of the rope. This may create a hazard in down’ into underlying layers, which might cause a
appliances and machinery which rely on friction dangerous condition or, alternatively, cause
Products
between the rope and the drive sheave (e.g. elevators,
Lifting
localized rope damage at ‘cross-over’ positions,
friction winders and ski lifts). which might then radically affect performance;
loss / removal of wear plates protecting the
5.8 Lubricants selected for in-service dressing must structure leading to major structural damage by
be compatible with the rope manufacturing lubricant and cutting and/or failure of the wire rope due to
should be referenced in the OEM’s instruction manual mechanical severance).
Rope
Wire
or other documents approved by the owner of the
appliance. If in doubt, contact Bridon. 5.12 Following any periodic examination or
routine or special inspection where any corrective
5.9 Take particular care when applying any in-service action is taken the Certificate should be updated
lubricant / dressing. Application systems which involve and a record made of the defects found, the extent
Cordage
pressure should only be operated by trained and of the changes and the condition of the rope.
authorized persons and the operation carried out strictly
in accordance with the manufacturer’s instructions. 5.13 Apply the following procedures for the selection
and preparation of samples, from new and used
Most wire ropes should be lubricated at regular intervals lengths of rope, for the purpose of examination and
Securement
(including cleaning) in order to extend safe performance. testing to destruction.

Load
Ensure that any in-service lubricant dressing penetrates Check that the rope end, from which the sample will
into the core of the rope. be taken, is secured by welding or brazing. If not,
select the sample length further away from the rope
Ensure that the in-service lubricant dressing is not
end and prepare new servings.
Contractors
applied excessively so that the amount of lubricant on

Supply
the rope will hinder rope examination.

Protection
Fall

685

Product Safety:

covering rope discard may also be applicable. In the
case of synthetic sheaves (or synthetic linings), refer

to the OEM’s instruction manual or contact the sheave
(or lining) manufacturer for specific discard criteria.
the Use of Steel Wire Rope 6.2 If a wire rope is removed from service at a level of
(Continued) performance substantially different to historically
established performance data and without any obvious
Handle the rope in accordance with the instructions reason(s), contact Bridon for further guidance.
given in Section 4. Serve the rope using the buried
6.3 Only qualified and experienced personnel, taking
wire technique and apply a rope clamp or grip as
the appropriate safety precautions and wearing the
close to the cut mark as practically possible. Do not
appropriate protective clothing, should be responsible
use solder to secure the servings.
for removing the wire rope.
Ensure that the sample is kept straight throughout the
Take particular care when removing ropes with
whole procedure and ensure that the minimum sample
mechanical damage as they may fail abruptly during
length is 10′ unless otherwise specified.
the change-out procedure.
The rope should be cut with a high speed abrasive
Take the utmost care when removing ‘exhausted / failed’
disc cutter or an oxyacetylene torch. Weld the rope
ropes from drums and sheaves as they may be grossly
ends of the sample as described in section 4.12, after
distorted, lively and tightly coiled.
which the clamp or grip can be removed.
Failure to take adequate precautions could
The identification of the rope must be established and
result in injury.
the sample suitably marked and packed. It is
recommended that the 10′ sample is retained straight 6.4 Store discarded rope in a safe and secure location
and secured to a wood pallet for transportation. or compound and ensure that it is suitably marked to
identify it as rope which has been removed from service
Failure to comply with these procedures will result in
and not to be used again.
measured breaking force values which are not truly
representative of the actual strength of the rope. Discarded rope can be a danger (e.g. protruding broken
wires, excessive grease / lubricant and rope mass) to
6. Wire Rope Discard personnel and equipment if not handled correctly and
safely during disposal.
6.1 Discard the wire rope in accordance with current
Regulations and in accordance with the OEM’s 6.5 Record the date and reason for discard on the
instruction manual. Certificate before filing for future reference.
Note: The authorized competent person should also 6.6 Pay attention to any Regulations affecting the safe
be familiar with the latest versions of ANSI, ASME or disposal of steel wire rope.
ISO Standards. Other standards and instructions
Wire Rope Technical

Board Warning WARNING
Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged,
improperly maintained or abused.
Wire Rope failure may cause serious injury or death!
Protect yourself and others:
■ ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE
BEFORE USE.
■ NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED.
■ NEVER OVERLOAD a wire rope.
■ INFORM YOURSELF: Read and understand manufacturer's
literature or "Wire Rope and Wire Rope Sling Safety Bulletin".*
■ REFER TO APPLICABLE CODES, STANDARDS and
REGULATIONS for INSPECTION REQUIREMENTS and
REMOVAL CRITERIA.*
* For additional information or the BULLETIN, ask your employer
or wire rope supplier.
© 1993, Wire Rope Technical Board Form No. 193
686

General Purpose WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Wire Ropes
6 x 7 Classification
6 x 7 Classification Wire Ropes give long service in
Hoists
operating conditions where ropes are dragged along the
ground or over rollers. Larger sheaves and drums (than
those used for more flexible constructions) are required to
avoid breakage from fatigue. 6 x 7 Classification Ropes
Services
contain 6 strands with 3 through 14 wires, no more than
9 of which are outside wires.
In a 6 x 7 rope, the wires are larger than those of other Characteristics 6 x 7 Rope
constructions of the same diameter. Wires of a 6 x 7 are
Engineered
Excellent abrasion resistance;
Products
approximately twice the diameter of outer wires of a less bending fatigue resistance.
6 x 25 FW rope. The large size of the outer wire gives
the class excellent abrasion resistance—at great sacrifice Typical Applications
of bendability and resistance to fatigue. The standard Dragging and haulage in mines,
6 x 7 rope construction is made with fiber core and right inclined planes and tramways,
Slings
regular lay. sand lines.
Bright / Fiber Core Galvanized / Fiber Core

Diameter Minimum Minimum Diameter
Hardware
Approx. Approx.
(in.) Breaking Force Breaking Force (in.)
Wt. / Ft. Wt. / Ft.
(Tons of (Tons of
(lbs.) (lbs.)
2,000 lbs.) 2,000 lbs.)
3/16 0.056 1.5 – – 3/16
1/4 0.094 2.64 0.094 2.38 1/4
Products
5/16 0.15 4.1 0.15 3.69 5/16
Lifting
3/8 0.21 5.86 0.21 5.27 3/8
7/16 0.29 7.93 0.29 7.14 7/16
1/2 0.38 10.3 0.38 9.27 1/2
9/16 0.48 13 0.48 11.7 9/16
5/8 0.59 15.9 0.59 14.3 5/8
Rope
Wire
3/4 0.84 22.7 0.84 20.4 3/4
Warranty
Cordage
Any warranty, as to quality or performance of fitness for use of wire rope products, is always premised on the condition that
the published strengths apply only to new, unused rope, that the mechanical equipment on which such products are used
is properly designed and maintained, that such products are properly stored, handled, used and maintained, and properly
inspected on a regular basis during the period of use.
Securement
Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including
Load
but not 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 other product.
Contractors
Supply
Protection
Fall

687

Aircraft Cable & Strand WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
7x7 7x7 Galvanized Stainless Steel

Diameter Approx. Weight Min. Breaking Min. Breaking
(in.) 1000 ft. / lbs. Force (lbs.) Force (lbs.)
1/16 7.5 480 480
3/32 16 920 920
1/8 28.5 1700 1700
5/32 43 2600 2400
3/16 62 3700 3700
1/4 106 6100 6100
5/16 167 9200 9000
3/8 236 13,000 12,000
7 x 19 7 x 19 Galvanized Stainless Steel
3/32 17 1000 920
1/8 29 2000 1760
5/32 45 2800 2400
3/16 65 4200 3700
7/32 86 5600 5000
1/4 110 7000 6400
9/32 139 8000 7800
5/16 173 9800 9000
Most Common Construction 3/8 243 14,400 12,000
1 x 19 1 x 19 Galvanized Stainless Steel
1/16 8.5 500 500
3/32 20 1200 1200
1/8 35 2100 2100
5/32 55 3300 3300
3/16 77 4700 4700
1/4 135 8200 8200
5/16 210 12,500 12,500
3/8 300 17,500 17,500
7x7 Vinyl Coated Galvanized Aircraft Cable

Approx. Min.
Diameter Coated to Construction Weight Breaking
(in.) inches 1000 ft. / lbs. Force (lbs.)
3/32 3/16 7x7 28 920
1/8 3/16 7x7 39 1700
1/8 3/16 7 x 19 39 2000
3/16 1/4 7 x 19 78 4200
1/4 5/16 7 x 19 125 7000
3/8 7/16 7 x 19 272 14,400
Galvanized Extra High Strength Strand
Nominal Number of Approx. Minimum Breaking
Diameter Wires in Weight Force of Strand (lbs.)
Strand (in.) Strand 1000 ft. / lbs.
1/8 1x7 32 1830
7 x 19 5/32 1x7 51 2940
3/16 1x7 73 3990
7/32 1x7 98 5400
1/4 1x7 121 6650
9/32 1x7 164 8950
5/16 1x7 205 11,200
3/8 1x7 273 15,400
7/16 1x7 399 20,800
1/2 1x7 517 26,900
1/2 1 x 19 504 26,700
9/16 1x7 671 35,000
9/16 1 x 19 637 33,700
5/8 1x7 813 42,400
5/8 1 x 19 796 40,200
3/4 1 x 19 1155 58,300
Preformed, made in accordance with commercial specifications. Military and Federal Specification rope available.
688

Standard 6 x 19 & 6 x 36 WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Classification Ropes
Minimum Breaking Forces and Weights
for Standard 6 x 19 and 6 x 36 Classification Ropes
Hoists
6 x 19 Class 6 x 36 Class
6 x 19 Seale, 6 x 25 Filler Wire and 6 x 36 Warrington Seale, 6 x 36 Warrington Seale,
6 x 26 Warrington Seale 6 x 41 Warrington Seale and 6 x 49 Warrington Seale
Services
Engineered
Products
Slings
Fiber Core IWRC
Diameter Minimum Minimum
Breaking Force Breaking Force
Hardware
Approx. Approx.
Wt. / Ft. (Tons of Wt. / Ft. (Tons of
in. mm (lbs.) 2,000 lbs.) (lbs.) 2,000 lbs.)
EIP EIP EEIP
1/4 – .11 3.02 .12 3.40 –
Products
5/16 – .16 4.69 .18 5.27 –
Lifting
3/8 10 .24 6.72 .26 7.55 –
7/16 11 .32 9.09 .35 10.2 11.2
1/2 13 .42 11.8 .46 13.3 14.6
9/16 14 .53 14.9 .58 16.8 18.5
5/8 16 .66 18.3 .72 20.6 22.7
Rope
Wire
3/4 19 .95 26.2 1.04 29.4 32.4
7/8 22 1.29 35.4 1.41 39.8 43.8
1 25 1.68 46 1.85 51.7 56.9
1-1/8 29 2.13 57.9 2.34 65 71.5
1-1/4 32 2.63 71 2.89 79.9 87.9
Cordage
1-3/8 35 3.18 85.4 3.49 96 106
1-1/2 38 3.78 101 4.16 114 125
1-5/8 – 4.44 118 4.88 132 146
1-3/4 – 5.15 136 5.66 153 169
Securement
1-7/8 – 5.91 155 6.49 174 192

Load
2 – 6.73 176 7.39 198 217

2-1/8 – 7.60 197 8.34 221 243
2-1/4 – 8.52 220 9.35 247 272
2-3/8 – – – 10.42 274 301
Contractors
Supply
Ask your Lifting Specialist about stainless steel wire rope.

Protection
Fall

689

Standard & High- 6x
■
36 Classification
High quality six strand rope
Performance Wire Ropes ■ High strength—confirmed by Bridon’s “Powercheck”
for Crane Applications

testing of a sample
■ Consistent bending fatigue performance
■ Fully lubricated
Standard Wire Rope ■ Steel Core, Fiber Core
6x 19 Classification 6x 26 Alternate Lay Rope

■ High quality six strand rope ■ High quality six strand rope
■ High strength—confirmed by Bridon’s “Powercheck” ■ High strength—confirmed by Bridon’s “Powercheck”
testing of a sample testing of a sample
■ Excellent resistance to wear ■ Fully lubricated
■ Fully lubricated ■ Good resistance to drum crushing
■ Steel Core, Fiber Core
Standard Wire Ropes High-Performance Wire Ropes

6 x 26 Endurance
6 x 19 6 x 36 Endurance Endurance Endurance Endurance Endurance Endurance
Alternate Dyform Constructex
Class Class 35LS Dyform 18 Dyform 6 Dyform 6PI Dyform 8 Dyform 8PI
Lay 34LR
Telescopic Mobile Crane
Main Hoist Rope ■ ■ ■ ■ ■
Auxiliary Rope ■ ■ ■ ■ ■
Tower Crane
Derricking Rope ■ ■ ■
Trolley Rope ■ ■ ■
Container Crane
Boom Hoist Rope ■ ■ ■ ■
Trolley Rope ■ ■
Mobile Lattice Boom Crane
Main Hoist Rope ■ ■ ■ ■ ■ ■
Boom Hoist Rope ■ ■ ■
Auxiliary Rope ■ ■ ■ ■ ■
Dockside Crane
Main Hoist Rope ■ ■
Boom Hoist Rope ■ ■ ■ ■
Overhead Crane
Steel Mill Ladle Crane
Offshore Pedestal Crane
Main Hoist Rope ■ ■ ■
Whipline Rope ■ ■ ■
Boom Hoist Rope ■ ■ ■
Unloader Ropes
Boom Hoist Rope ■ ■ ■ ■ ■
Closing Rope ■ ■ ■ ■ ■
Racking Rope ■ ■ ■
Pilling Ropes
Main Hoist Rope ■
Pipe Handling Rope ■
690

High-Performance
Cranes / Jibs
Overhead
Wire Ropes
Endurance Dyform 34LR/PI
Endurance Dyform 6/6PI
■ Strongest of all ropes in the rotation resistant product—
Hoists
confirmed by Bridon’s “Powerchecked” testing of a ■ Strongest of all ropes in the six strand product range—
sample from each production length. confirmed by Bridon’s “Powerchecked” testing of a
■ Greatest resistance to rotation of all ropes in the rotation sample from each production length.
resistant product range—confirmed by Bridon’s unique ■ Superior bending fatigue life when compared with
conventional six strand ropes—confirmed by
Services
“Twistcheck” type testing program.
■ Superior bending fatigue life when compared with laboratory testing and extensive field experience.
conventional rotational resistant ropes—confirmed by ■ Excellent resistance to crushing and abrasion resulting
laboratory testing and extensive field experience. from the overall compactness and robustness of the
■ Excellent resistance to crushing and abrasion resulting rope and the Dyform strands—recommended when
Engineered
Products
from the overall compactness and robustness of the multi-layer spooling is involved.
rope and the Dyform strands—recommended multi-layer ■ Reduced elongation results from increased steel content
spooling is involved. and the Dyform process.
■ Reduced elongation results from increased steel content ■ Optional plastic coating (PI) of IWRC to further extend
and the Dyform process. fatigue life, improved structural stability and resistance
■ Optional plastic coating (PI) of IWRC to further extend to corrosion.
Slings
fatigue life, improve structural stability and resistance
to corrosion. Endurance Dyform 8/8PI
Endurance 35LS ■ High breaking force—confirmed by Bridon’s
Hardware
“Powerchecked” testing of a sample from each
■ Greatest resistance to rotation of all ropes in the rotation production length.
resistant product range—confirmed by Bridon’s unique ■ Superior bending fatigue life when compared with
“Twistcheck” type testing program. conventional eight strand ropes—confirmed by
■ Most flexible construction in the rotation resistant laboratory testing and extensive field experience.
Products
product range. ■ Excellent resistance to crushing and abrasion resulting
Lifting
from the overall compactness and robustness of the
Endurance Dyform 18/18PI rope and the Dyform strands—recommended when
multi-layer spooling is involved.
■ High strength rotation resistant rope incorporating ■ Reduced elongation results from increased steel content
Dyform strands—confirmed by Bridon’s “Powercheck” and the Dyform process.
Rope
Wire
testing of a sample from each production length. ■ Optional plastic coating (PI) of IWRC to further extend
■ Good resistant to rotation—confirmed by Bridon's fatigue life, improved structural stability and resistance
unique “twistchecked” type testing program. to corrosion.
■ Superior bending fatigue life when compared with
conventional multi strand ropes—confirmed by Constructex
Cordage
laboratory testing and extensive field experience.
■ Excellent resistance to crushing and abrasion resulting ■ Nine strand rope made up of three different strand
from the overall compactness and robustness of the construction. Each outside strand manufactured
rope and the Dyform strands recommended when with a soft plastic center.
Securement
multi-layer spooling is involved. ■ High strength—confirmed by Bridon’s “Powerchecked”

Load
■ Optional plastic coating (PI) of IWRC to further extend testing of a sample.

fatigue life, improved structural stability and resistance ■ Excellent resistance to crushing and wear resulting
to corrosion. from the overall compactness and robustness of
the rope.
Contractors
■ Flexible construction with good fatigue life in

Supply
most applications.
Protection
Fall

691

Endurance Dyform® WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
6/6PI
Strongest of all ropes in the six strand product
range—confirmed by Bridon’s “Powercheck” testing
of a sample from each production length.
Superior bending fatigue life when compared with

conventional six strand ropes—confirmed by laboratory
testing and extensive field experience.
Excellent resistance to crushing and abrasion

resulting from the overall compactness and robustness
of the rope and the Dyform strands—recommended
when multi-layer spooling is involved.
Reduced elongation results from increased steel

content and the Dyform process.
Optional plastic coating of IWRC to further

extend fatigue life, improve structural stability Minimum
Diameter Weight
and resistance to corrosion. Breaking Force
(in.) (lbs. / ft.)
(tons)
3/8 .28 8.8
7/16 .38 11.9
1/2 .50 15.3
9/16 .63 19.3
5/8 .78 22.7
3/4 1.13 32.4
7/8 1.53 43.8
1 2.00 57.5
1-1/8 2.54 71.5
1-1/4 3.13 87.9
1-3/8 3.79 106
1-1/2 4.50 125
Dyform is a registered trademark of Bridon American.
692

Constructex® WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Nine Strand rope made up of three different strand
constructions. Each outside strand manufactured
with a soft plastic center.
Hoists
High strength—confirmed by Bridon’s “Powercheck”
testing of a sample.
Excellent resistance to crushing and wear

Services
of the rope.
Flexible construction with good fatigue life in

most applications.
Engineered
Products
Minimum
Diameter Weight
Slings
Breaking Force
(in.) (lbs. / ft.)
(tons)
5/8 0.9 25.5
3/4 1.1 36.5
Hardware
7/8 1.5 48.5
1 2 62.5
Ask about
1-1/8 2.6 79.5
1-1/4 3.2 97.6
Bridon’s Tiger Blue— 1-3/8

1-1/2
3.8
4.6
119
139
Products
Plastic Filled Rope
Lifting
1-5/8 5.3 162
1-3/4 6.2 185
Tiger® Blue Hoist Ropes

Constructex is a registered trademark of Bridon American.
■ 6 x 36 and 6 x 41
■ Fully plastic filled rope
Rope
Wire
for demanding
applications requiring
excellent resistance
to wear and bending
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

693

ON PAGES 721 - 723.
18/18PI
High strength Rotation Resistant rope incorporating
Dyform strands—confirmed by Bridon’s “Powercheck”
testing of a sample from each production length.
Good resistance to rotation—confirmed by

Bridon’s unique “Twistcheck” type testing program.
Superior bending fatigue life when compared

with conventional multi-strand ropes—confirmed by
laboratory testing and extensive field experience.

of the rope and the Dyform strands—recommended
Minimum
Reduced elongation results from increased steel Diameter Weight
Breaking Force
content and the Dyform process. (in.) (lbs. / ft.)
(tons)
3/8 .031 8.3
Optional plastic coating of IWRC to further
7/16 .420 11.2
extend fatigue life, improve structural stability
1/2 .550 14.6
and resistance to corrosion.
9/16 .700 19.2
5/8 .860 22.7
3/4 1.24 34.2
7/8 1.69 43.8
1 2.21 57.5
1-1/8 2.79 71.5
1-1/4 3.45 87.9
1-3/8 4.17 106
1-1/2 4.97 125
Dyform is a registered trademark of Bridon American.
694

ON PAGES 721 - 723.
Cranes / Jibs
Overhead
34LR/PI/Max
Strongest of all ropes in the Rotation Resistant product
range—confirmed by Bridon’s “Powercheck” testing of a
sample from each production length.
Hoists
Greatest resistance to rotation of all ropes in the
Rotation Resistant product range—confirmed by Bridon’s
unique “Twistcheck” type testing program.
Services
Superior bending fatigue life when compared with
conventional Rotation Resistant ropes—confirmed
by laboratory testing and extensive field experience.
Engineered
Endurance Dyform® 34LR
Products
resulting from the overall compactness and robustness Minimum
Diameter Weight Breaking Force
of the rope and the Dyform strands—recommended (lbs. / ft.) (tons)
in. mm 1960 2160
– 14 .65 20.1 21.5
Reduced elongation results from increased steel
Slings
9/16 – .68 20.8 22.7
content and the Dyform process. 5/8 16 .84 26.1 28.2
– 18 1.07 33.5 35.9
Optional plastic coating of IWRC to further extend 3/4 19 1.21 37 40
fatigue life, improve structural stability and resistance – 20 1.32 41.6 44.6
Hardware
to corrosion. – 21 1.51 45 48.6
– 22 1.61 49.7 54.2
7/8 – 1.65 50.4 54.8
– 23 1.75 54 56.9
– 24 1.92 59.3 64
1 – 2.15 62.4 70
Products
Lifting
– 26 2.28 69.5 74
– 28 2.63 76 82.6
1-1/8 – 2.73 79.5 83.6
– 30 3.07 92.5 94
1-1/4 32 3.37 98.2 110.2
Rope
Wire
Endurance Dyform® 34 XL
Diameter Minimum
Weight Breaking Force
(lbs. / ft.)
in. mm (tons)
Cordage
5/8 16 .84 30.6
3/4 19 1.21 42.9
1 – 2.15 71.7
– 26 2.28 74
Securement
– 28 2.63 84.4
1-1/8 – 2.73 86.9
Load
– 29 2.94 86.9
1-1/4 32 3.37 110.2
Endurance Dyform® 34 MAX
Contractors
1 – 2.26 76.9
Supply
– 26 2.39 79.3
– 28 2.76 91.6
Dyform is a registered trademark of Bridon American. 1-1/4 32 3.74 122
Protection
Fall

695

Tower Crane Ropes
Endurance® 35LS
(Main Hoist Rope)
■ Rotation Resistant
■ Flexible construction
■ Excellent spooling
Endurance Dyform® 34LR

(Main Hoist Rope)
■ Reduced downtime
■ Longer life
■ Recommended for multi-layer applications
■ Reduced sheave wear
Endurance Dyform® 6
(Derricking Rope & Trolley Rope)
■ Long service life

■ Crush resistant
■ Lower downtime
■ Lower lifetime cost
■ Robust construction
6 x 19 Class and 6 x 36 Class

(Derricking Rope & Trolley Rope)
■ Single Layer Ropes

■ Consistent performance with lower initial cost
696

Mobile Lattice Boom
Cranes / Jibs
Overhead
Crane Ropes
Endurance 8RR
(Main Hoist Rope)
Hoists
■ Suitable for single-part and multi-part reeving
Constructex®
Services
(Boom Hoist Rope)
■ Exceptional service life in the most

demanding applications
Engineered
■ High breaking force
Products
■ Excellent Crush Resistance
(Main Hoist Rope & Whipline Hoist Rope)
■ Rotation Resistant Dyform Hoist Rope
Slings
■ Crush Resistant
■ Recommended for multi-layer spooling
Hardware
Endurance 19
(Main Hoist Rope & Whipline Hoist Rope)
Products
Lifting
■ Suitable for single-part reeving
(Boom Hoist Rope & Main Hoist Rope)
Rope
Wire
■ Tough six strand wire rope
■ Crush resistant
■ Recommended for multi-layer spooling
Cordage
■ Suitable as a hoist rope where height of lift is
low and rotation is not critical
Endurance Dyform® 34LR 6 x 19 Class & 6 x 36 Class

Securement
(Main Hoist Rope & Whipline Rope) (Main Hoist Rope & Boom Hoist Rope)
Load
■ Rotation Resistant Dyform Hoist Rope ■ Single Layer Ropes

■ Long service life ■ Consistent performance with lower initial cost
■ Crush resistant ■ Recommended for main hoist rope where
height of lift is not critical
Contractors
■ Recommended for multi-layer coiling

Supply
■ Recommended for high lifts

Protection
Fall

697

Oilfield Wire Ropes WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Sand Line
■ Large outer wires for
resistance to wear
■ Exceptional spooling
characteristics Rotary Drill Line
■ Resistance to kinking ■ Combination of strength,
■ Easy to splice flexibility and resistance
to peening
Approx. Min. Breaking ■ Good resistance to wear
Diameter
Weight Force and fatigue
in. lb. / ft. tons ■ Long service life when
3/8 .21 5.9 sheaves and drums are
7/16 .29 7.9 of moderate size
1/2 .38 10.3
9/16 .48 13
Approx. Min. Breaking Min. Breaking
5/8 .59 15.9 Diameter
Weight Force—EIP Force—EEIP
3/4 .84 22.7
in. lb. / ft. tons tons
Note: Typical Construction 6 x 7 Fiber Core 1 1.85 51.7 56.9
1-1/8 2.34 65 71.5
1-1/4 2.89 79.9 87.9
Swaged Tubing Line 1-3/8 3.49 96 106
■ Excellent resistance 1-1/2 4.16 114 125
to crushing 1-5/8 4.88 132 146
1-3/4 5.66 153 169
■ Good resistance Note: Typical Construction 6x19 (S) & 6x26 (WS)
to abrasion
Diameter
Approx. Min. Breaking Constructex
Weight Force ■ Swaged to increase
in. lb. / ft. tons wearing surface and
7/8 1.7 47.4 density
1 2.22 62 ■ Long service life due
1-1/8 2.8 73.5 to resistance to
Note: Typical Construction 6 x 31 Swaged scrubbing and crushing
■ Flexible construction
Tubing Line
■ Combination of flexibility Approx. Min. Breaking
and resistance to crushing Diameter
Weight Force
■ Outstanding resistance in. lb. / ft. tons
to wear and fatigue 5/8 .90 25.5
3/4 1.1 36.5
Approx. Min. Breaking 7/8 1.5 4.85
Diameter
Weight Force 1 2 62.5
in. lb. / ft. tons 1-1/8 2.6 79.5
3/4 1.04 29.4 1-1/4 3.2 97.6
7/8 1.41 39.8 1-3/8 3.8 119
1 1.85 51.7 1-1/2 4.6 139
1-1/8 2.34 65 1-5/8 5.3 162
Note: Typical Construction 6 x 26 IWRC
698

Rotation-Resistant Ropes: WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
8 x 19 Classification
■ Strands: 8
■ Wires per strand: 19 to 25
■ Core: IWRC
Hoists
■ Standard grade(s): Purple Plus
■ Lay: Right Regular
■ Finish: Bright
The 8 x 19 Classification Rotation-Resistant Ropes:
Services
rotation-resistant ropes are recommended for hoisting
unguided loads with a single-part or multipart line. 19 x 7 Classification
The eight outer strands are manufactured in right lay, ■ Strands: 19
Engineered
with the inner strands being left lay. ■ Wires per strand: 7
Products
■ Core: WSC
These ropes are slightly stronger and significantly ■ Standard grade(s): Purple Plus
more rugged than the 19 x 7 construction. However, the ■ Lay: Regular
rotation-resistant properties of the 8 x 19 rotation-resistant ■ Finish: Bright
ropes are much less than those of the 19 x 7 construction.
Slings
These ropes are manufactured in right regular lay in the 19 x 7 is recommended for
8 x 19 Seale and 8 x 25 Filler Wire constructions. hoisting unguided loads with a single-part line.
The rotation-resistant properties of this rope are secured

Nominal
Rope Approx. by two layers of strands. The inner strands are left lay, while
Hardware
Strength
Diameter Weight the 12 outer strands are right lay, which enables one layer
(tons)
(lb./ft.) to counteract the other layer’s rotation.
in. mm Purple Plus
7/16 11 .36 9 The rotation-resistant characteristics of the 19 x 7 wire
1/2 13 0.47 11.6 ropes are superior to those of the 8 x 19 Class wire ropes.
Products
Lifting
9/16 14.5 0.6 14.7
5/8 16 .73 18.1
Nominal
3/4 19 1.06 25.9 Rope Approx. Strength
7/8 22 1.44 35 Diameter Weight
1 26 1.88 45.5
(tons)
(lb./ft.)
1-1/8 29 2.39 57.3 in. mm Purple Plus
Rope
Wire
1-1/4 32 2.94 70.5 7/16 11 .35 8.33
1-1/2 38 4.24 100 1/2 13 .45 10.8
9/16 14.5 .58 13.6
5/8 16 .71 16.8
Cordage
3/4 19 1.02 24
7/8 22 1.39 32.5
1 26 1.82 42.2
1-1/8 29 2.3 53.1
1-1/4 32 2.84 65.1
Securement
1-3/8 35 3.43 78.4

Load
1-1/2 38 4.08 92.8

Contractors
Supply
Protection
Fall

699

Rotation-Resistant Ropes: WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Super Flex PAC 19

■ Strands: 19
■ Wires per strand: 7/19
■ Core: WSC
■ Standard grade(s): Royal Purple
■ Finish: Bright
SFP 19 is recommended for both multi-part load and Rotation-Resistant Ropes:

single-part fast line applications where rotational
stability of the lifted load is needed, such as for use Super Flex PAC 35
as a long fall on offshore pedestal cranes, rough
and all terrain cranes, and crawler cranes. ■ Strands: 35
■ Wires per strand: 7
SFP 19 provides: ■ Core: WSC
■ Standard grade(s): 2160 N/mm2
Fatigue Resistance. Improved fatigue properties are derived ■ Lay: Right Regular
through the combination of the flexible 19 x 19 construction
and die drawn strands. The drawn strand surfaces minimize the
■ Finish: Bright
interstrand and interlayer nicking that take place in round
rotation-resistant ropes. SFP 35 is a rotation-resistant rope of high strength
that can resist block twist in long falls.
Abrasion Resistance. Die drawn ropes provide improved
abrasion resistance as compared with round wire ropes because SFP 35 provides:
of the greater wire and strand bearing surfaces contacting
sheaves and drums. Superior Rotation Resistance—the SFP 35 rope is the most
rotation-resistant rope manufactured by WW. Due to its rotation-resistant
Resistance to Drum Crushing. SFP 19 wire ropes are resistant properties, SFP 35 may be used with a swivel in both single-part and
to the effects of drum crushing due to the compacted strands and multipart reeving.
smoothness of the rope surface.
High Strength. WW’s compaction process provides a high-strength rope
which exceeds EEIP nominal breaking strength.
Nominal
Rope Approx. Strength Application. SFP 35 excels in crawler and truck-type crane load lines,
Diameter Weight (tons) and tower crane hoist ropes.
(lb./ft.)
in. mm Purple Plus
Flexibility. SFP 35’s multiple strand construction provides increased
1/2 13 .54 14.6 flexibility which improves service life and high speed spooling. The
9/16 14.5 .69 18.5 compacted multiple strand construction also reduces sheave and drum
5/8 16 .83 22.7 abrasion and provides excellent resistance to drum crushing.
3/4 19 1.19 32.4
7/8 22 1.62 43.8 Rope Approx. Nominal
1 26 2.12 56.9 Diameter Weight Strength
1-1/8 29 2.68 71.5 in. mm (kg/m) (lb/ft) (kN) * (tons) *
1-1/4 32 3.31 87.9 – 19 1.79 – 344 –
1-3/8 35 4.01 106 3/4 – – 1.21 – 38.7
1-1/2 38 4.77 125 – 22 2.40 – 466 –
7/8 – – 1.65 – 53
Note: 5/8 and below 19 x 7 construction; 1 – – 2.15 – 70
3/4 and larger 19 x 19 construction
– 26 3.36 – 660 –
– 28 3.90 – 758 –
1-1/8 – – 2.73 – 86.9
* Acceptance strength is not less than 2-1/2% below

the nominal strengths listed. Tons of 2,000 lbs.
700

Specialized Wire Ropes: WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
6-PAC
■ Strands: 6
■ Core: IWRC
Hoists
■ Standard grade(s): Royal Purple
■ Finish: Bright
6-PAC is recommended for use where the rope is
Services
Nominal
subjected to heavy use or where conditions Rope
Approx. Strength
are extremely abusive, such as offshore pedestal, Diameter Standard
Weight (tons)
crawler and lattice boom equipped truck crane Constructions
(lb./ft.) Purple
boom hoist applications. 6‑PAC is also recommended in. mm
Plus
Engineered
for winch lines, overhead cranes, multipart hoist
Products
3/8 9.5 6 x 19 Seale .285 8.3
lines where rotation-resistant ropes are not required, 7/16 11 6 x 19 Seale .388 11.2
and other applications where flexibility, high strength 1/2 13 6 x 26 .503 14.6
and resistance to crushing are important, and a 9/16 14.5 6 x 26 .642 18.5
cost‑effective 6‑strand rope is desired. 5/8 16 6 x 26 .795 22.7
3/4 19 6 x 31 1.143 32.4
Slings
6‑PAC provides: 7/8 22 6 x 31 1.547 43.8
1 26 6 x 31 2.075 56.9
Fatigue Resistance. Improved fatigue properties are derived from
1-1/8 29 6 x 31 2.575 71.5
the combination of 6‑PAC’s flexible constructions and the compacted
strands. The compacted strand surface minimizes the interstrand 1-1/4 32 6 x 31 3.169 87.9
Hardware
and interlayer nicking that take place in standard 6‑strand ropes. 1-3/8 35 6 x 36 3.758 106
1-1/2 38 6 x 36 4.564 125
Abrasion Resistance. 6‑PAC’s compacted strand design provides 1-5/8 41.3 6 x 36 5.356 146
improved abrasion resistance as compared to standard 6‑strand 1-3/4 45.5 6 x 36 6.212 169
ropes because of the increased wire and strand surfaces contacting
sheaves and drums. For Bethpac, or 6-PAC over 1-3/4" diameter, please refer to
Products
Lifting
WW’s Bethlehem Mining Products catalog or contact our
Flexibility. 6‑PAC’s design provides increased flexibility, Customer Service Department.
making it easy to install, and 6‑PAC also offers better spooling at
high line speeds.
Resistance To Multilayer Drum Crushing. 6-PAC dramatically

increases the amount of wire contact with the drums and sheaves,
Rope
Wire
reducing the wire rope, sheave and drum wear normally associated
with standard wire rope. Damage at the crossover points is
also reduced.
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

701

ON PAGES 721 - 723.
Super-PAC
■ Strands: 6
■ Wires per strand: 26/31
■ Core: IWRC
■ Standard grade(s):
Royal Purple Plus
■ Finish: Bright
SUPER-PAC is a double compacted product ideal for

Specialized Wire Ropes:
applications where abrasion and drum crushing are an 8-PAC
issue. When compared with standard ropes,
■ Strands: 8
SUPER-PAC provides: ■ Wires per strand: 19 to 36
■ Core: Plastic filled (BXL)
Better Resistance to Multi-layer Drum Crushing. SUPER-PAC
dramatically reduces the damage at cross over points on smooth face ■ Standard grade(s): Royal Purple
drums, such as those found on many boom hoist systems on mobile ■ Lay: Right
cranes. This is achieved by compaction of the strands and the rope, ■ Finish: Bright
making a tough but flexible product.
8-PAC is recommended for hoist ropes for steel mill
Abrasion Resistance. The compaction process also increases the
contact between the rope and the drum and sheaves, reducing sheave
ladle cranes and hoist and trolley ropes for container
and drum wear. cranes, or other hoisting applications with heavy-duty
cycles or where severe bending occurs.
Super Strength. The double compaction process also increases the
minimum breaking strength of standard EIP rope more than 20%. Other features of 8-PAC include:
Superior Fatigue Resistance. SUPER-PAC is engineered for overall Superior Performance. 8-PAC has higher breaking strength and gives
performance, its wire tensile strength being the key to its superior fatigue superior performance in difficult hoisting applications compared to
resistant properties. In addition to contribution to SUPER-PAC’s EEEIP standard 6-strand and 6-strand compacted ropes.
breaking strength, the wire used in the manufacture of SUPER-PAC
remains ductile, minimizing the occurrences of external and internal wire Abrasion Resistance. 8‑PAC compacted strand design provides
breaks caused by operating stresses. improved abrasion resistance as compared to standard 6 and 8 strand
ropes because of the increased wire and strand surfaces contacting
Application. SUPER-PAC is ideal for all types of boom hoist and
the sheaves and drums.
lowering ropes.
Superior Flexibility. 8‑PAC is significantly more flexible than
Nominal standard 6 and compacted 6 strand ropes with better spooling and
Rope Approx. longer service life.
Strength
Diameter Weight (tons)
(lb./ft.) Resistance To Multi-layer Drum Crushing. 8-PAC’s plastic-filled (BXL)
in. mm Purple Plus core offers increased resistance to crushing through better support of
5/8 16 .995 29 the outer strands.
3/4 19 1.43 40
7/8 22 1.92 52 Nominal
Rope Approx.
1 26 2.42 68 Standard Strength
Diameter Weight
1-1/8 29 2.96 85 Constructions (tons)
1-1/4 32 3.51 102
(lb./ft.)
in. Purple Plus
5/8 8 x 26 WS .8 25
3/4 8 x 26 WS 1.17 36
7/8 8 x 26 WS 1.6 48.3
1 8 x 26 WS 2.1 62.8
1-1/8 8 x 26 WS 2.63 79
1-1/4 8 x 31 WS 3.26 98
Note: Other sizes available

702

ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Triple-PAC
■ Strands: 6
■ Wires per strand: 26/31 or 36
■ Core: IWRC
Hoists
Royal Purple Plus
TRIPLE-PAC was developed for the most demanding Specialized Wire Ropes:
Services
hoist applications. TRIPLE-PAC offers the extra
high strength and crushing resistance needed for Flattened Strand
applications such as boom hoist ropes, boom
pendants and multipart load lines. ■ Strand: 6
Engineered
■ Wires per strand: 27
Products
TRIPLE-PAC provides superior abrasion and fatigue ■ Core: IWRC or fiber core
resistance as compared with most compacted ropes due ■ Standard Grade(s): Purple Plus
to WW’s unique design of compacting the IWRC, individual ■ Lay: Lang
strands and the rope itself. ■ Finish: Bright
Slings
Other benefits include: This rope is particularly suitable where severe
conditions of crushing and abrasion are encountered
High Strength. TRIPLE-PAC is designed to provide a nominal
on the drum or where a higher strength design
strength of 35% above EIP. WW achieves this strength
through selected grades of steel and TRIPLE-PAC’s unique factor is required than can be obtained with a similar
round rope.
Hardware
design and manufacturing processes.
Superior Resistance to Multi-layer Drum Crushing. The triangular strand shape not only provides better
TRIPLE-PAC provides superior resistance to crushing through resistance to crushing, but also offers a greater exposed
its design. Its triple compaction provides a denser cross section,
enabling the rope to withstand the rigors of multilayer spooling.
surface area for contact with sheaves, drums or underlying
layers of spooled rope. This feature, in connection with
Products
Damage at the cross over points is also significantly reduced.
Lifting
In addition, TRIPLE-PAC’s design increases the amount of wire the use of Lang lay construction, distributes the abrasive
contact with sheaves and drums, reducing wire rope, drum wear over a greater number and length of wires.
and sheave wear.
The smooth surface of the rope also helps minimize
Nominal wear on drums and sheaves.
Rope Standard Approx. Strength
Rope
Wire
Diameter Construc- Weight (tons)
tions (lb./ft.) Nominal
in. mm Purple Plus Rope Approx. Strength
7/16 11 6 x 26 .412 13.8 Diameter Weight (tons)
1/2 13 6 x 26 .543 18
Purple Plus
Cordage
9/16 14.5 6 x 26 .681 22.7
Fiber Fiber
5/8 16 6 x 26 .858 27.8 in. mm IWRC IWRC
Core Core
3/4 19 6 x 31 or 36 1.3 39.7
1-1/8 29 2.28 2.39 63.7 68.5
7/8 22 6 x 31 or 36 1.72 53.7
1-1/4 32 2.81 2.95 78.1 84
Securement
1 26 6 x 31 or 36 2.3 69.8
1-3/8 35 3.4 3.57 64.1 101
Load
1-1/8 29 6 x 31 or 36 2.89 87.8

1-1/2 38 4.05 4.25 111 119
1-1/4 32 6 x 31 or 36 3.54 107.9
1-5/8 42 4.75 4.99 130 140
1-3/8 35 6 x 31 or 36 4.04 129.6
1-3/4 45 5.51 5.79 152 161
1-1/2 38 6 x 31 or 36 4.99 153.6
1-7/8 48 6.33 6.65 171 184
Contractors
2 52 7.2 7.56 194 207

Supply
2-1/8 54 8.13 8.54 215 233

2-1/4 58 9.1 9.56 240 260
Protection
Fall

703

BXL—Plastic-Infused WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Wire Ropes
■ Strands: 6
■ Core: IWRC
Purple Plus
■ Lay: Regular or Lang
■ Finish: Plastic-infused
BXL is infused with a specially-engineered polymer,

creating a well-balanced matrix. BXL is recommended
for numerous hoist, marine and logging rope
applications.
BXL provides:
Fatigue Resistance. Improved fatigue resistance is derived

from the cushioning and dampening effect of the polymer on the
wires and strands. BXL also evenly distributes stresses,
which may lead to fatigue breaks.
Abrasion Resistance. The polymer acts as a barrier between

the individual strands, preventing penetration of any adverse material.
BXL distributes and reduces contact stresses between the rope and
sheave, reducing wire rope wear.
Resistance to Multi-layer Drum Crushing. BXL’s smooth profile

evenly distributes crushing pressures from the overlying layers
of rope in multilayer drum winding applications.
Extended Sheave and Drum Service Life. BXL minimizes

Approx. Nominal
corrugation and wear normally associated with standard rope Rope
Weight Strength
usage by restricting water and dirt penetration and Diameter
eliminating pickup of abrasive materials. (lb./ft.) (tons) *
6-Pac 6-Pac
in. mm BXL BXL
Clean Handling. The exterior rope surface is free from the BXL BXL
grease normally applied to standard ropes. 3/8 9.5 0.27 – 7.5 –
7/16 11 0.37 – 10.2 –
1/2 13 0.49 0.513 13.3 15.5
9/16 14.5 0.61 – 16.8 –
5/8 16 0.76 0.826 20.6 22.7
3/4 19 1.09 1.224 29.4 32.3
7/8 22 1.49 1.608 39.8 43.8
1 26 1.94 2.154 51.7 56.9
1-1/8 29 2.46 2.672 65 71.5
1-1/4 32 3.03 3.214 79.9 87.9
1-3/8 35 3.67 3.905 96 106
1-1/2 38 4.37 4.529 114 125
1-5/8 41.3 5.12 – 132 –
1-3/4 45.5 5.94 – 153 –
1-7/8 48 6.82 – 174 –
2 52 7.76 – 198 –
2-1/8 54 8.77 – 221 –
2-1/4 58 9.83 – 247 –
2-3/8 60 10.9 – 274 –
2-1/2 64 12.2 – 302 –
* Acceptance strength is not less than 2-1/2% below the

nominal strengths listed. Tons of 2,000 lbs.
704

Oilfield & Natural Gas WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Drilling Products
6 x 19 Rotary Drill Line
Features:
Hoists
Excellent balance between
fatigue and wear resistance
Services
Steel Core
Standard EIP EEIP
Diameter Approx. Minimum Minimum
Construc-
(in.) Weight Breaking Breaking
tion
(lb/ft) Strength Strength
Engineered
Products
(net tons) (net tons)
1 6 x 19 S 1.85 51.7 56.9
1-1/8 6 x 19 S 2.34 65 71.5
1-1/4 6 x 19 S 2.89 79.9 87.9
1-3/8 6 x 19 S 3.5 96 106
1-1/2 6 x 19 S 4.16 114 125
Slings
6 x 19 S /
1-5/8 4.88 132 146
6 x 26 WS
6 x 19 S /
1-3/4 5.67 153 169
6 x 26 WS
1-7/8 6 x 26 WS 6.5 174 192
Hardware
2 6 x 26 WS 7.39 198 217
All drill lines have asphaltic lube, post lube, and are RRL.
6 x 7 Sand Lines &
Products
6 x 21 Cable Tool Line
Lifting
Swabbing Lines
Features:
Increased resistance to bending Features:
fatigue on Cable Tool Rigs High abrasion resistance
Rope
Wire
Fiber Core
Cordage
Fiber Core
Standard Minimum Standard Minimum
Diameter Approx. Diameter Approx.
Construc- Breaking Construc- Breaking
(in.) Weight (in) Weight
tion Strength tion Strength
(lb/ft) (lb/ft)
Securement
5/8 6 x 19 S 1.85 51.7 3/8 6x7 .21 5.86

Load
3/4 6 x 19 S 2.34 65 7/16 6x7 .29 7.93

7/8 6 x 19 S 2.89 79.9 1/2 6x7 .38 10.3
1 6 x 19 S 3.5 96 9/16 6x7 .48 13
9/16 6 x 7 Galv. .47 13
Contractors
All cable lines have petroleum lube, are LRL and FC. 5/8 6x7 .59 15.9
Supply
All cable lines have petroleum lube, and are RRL.

Protection
Fall

705

Oilfield & Natural Gas WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Drilling Products (Cont.)

Riser Tensioner Ropes
Features:
Special construction and
multiple wire tensile increasing
fatigue resistance
Steel Core
Diameter Standard Minimum
Construc- Approx.
Breaking
tion Weight
Strength
(lb/ft)
in. mm (net tons)
1-3/4 45 6 x 49 1.42 39.8
1-7/8 48 6 x 49 1.85 51.7
2 52 6 x 49 2.34 65
2-1/8 54 6 x 49 2.35 66
2-1/4 58 6 x 49 2.36 67
2-3/8 60 6 x 49 2.37 68
2-1/2 64 6 x 49 2.38 69
2-5/8 67 6 x 57 2.39 70
2-3/4 70 6 x 57 2.40 71
All tensioners have asphaltic lube, and are RLL or LLL.
6 x 26 Tubing Line Swaged Tubing Line

Features: Features:
Excellent balance between Compacted rope
fatigue and wear resistance
Steel Core Steel Core

Standard Minimum Standard Minimum
Diameter Approx. Diameter Approx.
Construc- Breaking Construc- Breaking
(in.) Weight (in.) Weight
tion Strength tion Strength
(lb/ft) (lb/ft)
7/8 6 x 19 WS 1.42 39.8 7/8 6 x 26 WS 1.80 47
1 6 x 19 WS 1.85 51.7 7/8 6 x 26 WS 1.82 47
1-1/8 6 x 19 WS 2.34 65 1 6 x 26 WS 2.35 62
1 6 x 26 WS 2.26 62
All tubing lines have petroleum lube, and are RRL.
All swaged tubing lines have petroleum lube, and are RRL or LRL.
706

Flex-X® 19 & Flex-X® 6 WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Flex-X® 19 Wire Ropes
Flex-X delivers extra value when you need high strength in a
rotation-resistant wire rope. Its rotation-resistant construction
provides a smooth, extremely compact wire rope with
Hoists
more steel in the cross-section than conventional ropes.
Flex-X 19 is made from 19-wire Seale strands. Six strands
are laid around a core strand in one direction, then 12
strands are laid around this first operation in the opposite
Services
direction.
Because of its tightly compacted, smooth design,
Flex-X 19 offers several advantages:
Engineered
Products
■ More crush resistance than a standard 19 x 7 rope
while providing the same rotation resistance.
■ Higher strength-to-diameter due to compacted wires Flex-X® 19 Flex-X® 6
in the strands. With increased metallic area, it provides
rope strengths equal to 6 strand XXIP IWRC ropes
Wire Ropes Wire Ropes
of the same diameter.
Slings
Flex-X 19 Flex-X 6
■ Resistance to bending fatigue due to the uniformity of
the wires within each strand. The strand’s outer surface Minimum Minimum
is smooth, reducing contact pressures between the Diameter Breaking Breaking
Approx. Approx.
rope’s strands and radial pressures as it operates (in.) Force Force
Wt. / Ft. Wt. / Ft.
Hardware
over sheaves and drums. (Tons of (Tons
(lbs.) (lbs.)
■ Exceptional stability due to the higher density strands 2,000 of 2,000
coupled with the smooth outer surface. lbs.*) lbs.)
■ Improved handling, operating and spooling 3/8 – – 0.32 8.8
characteristics. 7/16 0.43 11.2 0.41 11.9
Products
1/2 0.49 14.6 0.55 15.3
■ Reduced wear to sheaves and drums.
Lifting
9/16 0.69 18.5 0.70 19.3
Flex-X has also demonstrated greater fatigue resistance to 5/8 0.78 22.7 0.86 22.7
substantially reduce rope expense and extend rope service 3/4 1.16 32.4 1.25 32.4
life. It’s ideal for single-part or multi-part hoist lines wherever 7/8 1.58 43.8 1.67 43.8
you encounter spooling problems, drum crushing, block 1 2.05 56.9 2.18 56.9
1-1/8 2.57 71.5 2.71 71.5
Rope
Wire
twisting or have fast line speeds.
1-1/4 – – 3.43 87.9
1-3/8 – – 4.25 106
1-1/2 – – 5.01 125
Flex-X® 6 Wire Ropes

Cordage
* These strengths apply only when a test is conducted with both
ends fixed. When in use, the strengths of these ropes may be
■ Superior performance 6-strand rope significantly reduced if one end is free to rotate.
■ Increased service life
■ Less sheave and drum wear
Securement
Less sheave and drum wear Flex-X 6 users receive Flex-X® vs. standard rope of similar construction:
Load
superior performance and increased service life in many Flex-X designs reduce drum scrubbing between the lead
applications compared to the ropes they had previously line and the previous wrap. The smooth contact creates
employed. When compared to conventional six strand ropes, less interference, less metal loss and wire deformation.
Flex-X 6 ropes provide greater surface area and more The increased surface area of Flex-X can be seen in
Contractors
steel per given diameter. This increases rope stability and the comparison of the contact points of a standard
Supply
strength. This results in a longer service life and less 6 x 26WS and Flex-X as shown.
sheave and drum wear.
Protection
Fall

707

PFV® & Tuf-Kote® WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
General-purpose wire rope that delivers

extra-long service life.
The key to PFV and Tuf-Kote wire rope’s benefits lie in
its exclusive patented fabrication. Standard, lubricated
Macwhyte® and Union® Wire Rope is used in the extrusion
process where the “gaps” (or valleys) between the individual
rope strands are impregnated with a sealing thermoplastic
material. Each strand “valley” in the finished rope is filled
with plastic. The finished rope may have a thin “skin coat-
ing” of plastic but this has no significant effect on the outside
diameter of the PFV and Tuf-Kote rope or its serviceability.
Result: PFV and Tuf-Kote wire rope is a balanced

sealed-lubricated wire rope that delivers exceptional
performance and service life on applications that produce
severe operating conditions, such as: haulback lines in
high lead logging systems, saw mill carriage lines,
draglines, towing hawser and drilling lines. And there
is less sheave and drum wear.
Rope PREmium GRADE Rope 19 X 7

6 X 19 IWRC
Diameter 6 x 36 IWRC 7-Flex IWRC Diameter
(in.) (in.) M.B.F. WT.
M.B.F. WT. M.B.F. WT. M.B.F. WT.
3/8 7.55 .27 7.55 .27 7.55 .27 5/16 4.3 .177
7/16 10.2 .37 10.2 .37 10.2 .37 3/8 6.15 .25
1/2 13.3 .49 13.3 .49 13.3 .49 7/16 8.33 .35
9/16 16.8 .61 16.8 .61 16.8 .61 1/2 10.8 .45
5/8 20.6 .76 20.6 .76 20.6 .76 9/16 13.6 .58
3/4 29.4 1.09 29.4 1.09 29.4 1.09 5/8 16.8 .71
7/8 39.8 1.49 39.8 1.49 39.83 1.49 3/4 24 1.02
1 51.7 1.94 51.7 1.94 51.7 1.94 7/8 32.5 1.39
1-1/8 65 2.46 65 2.46 65 2.46 1 42.2 1.82
1-1/4 79.9 3.03 79.9 3.03 79.9 3.03 1-1/8 53.1 2.3
1-3/8 96 3.67 96 3.67 96 3.67 1-1/4 65.1 2.83
1-1/2 114 4.37 114 4.37 114 4.31 1-3/8 78.4 3.43
1-5/8 132 5.12 132 5.12 132 5.12 1-1/2 92.8 4.08
1-3/4 153 5.94 153 5.94 153 5.94
1-7/8 174 6.82 174 6.82 174 6.83
2 198 7.76 198 7.76 198 7.77
2-1/8 221 8.77 221 8.77 221 8.27
2-1/4 247 9.83 247 9.83 247 9.88
2-3/8 274 10.9 274 10.9 – –
M.B.F. = Minimum Breaking Forces are listed in Tons of 2,000 pounds. Note: Minimum breaking forces apply only to new, unused PFV wire
WT. = Approximate weight in pounds per foot. rope. Any performance specifications are conditional on proper rope size,
construction, and grade; on proper design and maintenance of
mechanical equipment on which wire rope products are used; and
on proper storage, handling, use, maintenance and periodic inspection
of such products during the period of use.
708

Starlift Plus, Eurolift WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
& Turboplast
Please contact a Lifting Specialist for details of
Casar’s entire product line. Below is a sample of their
most popular ropes.
Hoists
Starlift Plus
■ Available in langs lay or regular lay.
■ Is a rotation resistant, flexible hoist rope
Services
with a compacted steel core.
■ Is fully lubricated.
■ Has a high breaking load.
■ Has a core in a special design, avoiding crossovers
between the strands of the core and reducing the
Engineered
Products
danger of internal rope destruction.
■ Is known worldwide for its excellent service life.
■ Is especially suited for multi-layer spooling.
■ Available in sizes from: 3/8" to 2" and 10 mm
to 50 mm
■ Minimum breaking loads from 18,400 lbs.
Slings
to 524,460 lbs.
Eurolift
Hardware
■ Is a rotation resistant, flexible hoist rope made out of
compacted steel core.
■ Has an extremely high breaking load and a very good
resistance against drum crushing.
Products
Lifting
■ Has a core in a special design, avoiding crossovers
between the strands of the core and preventing internal
rope destruction.
■ Is especially suited for multi-layer spooling.
■ Available in sizes from: 7/16" to 2" and 10 mm to 50 mm
■ Available in 1770, 1960 and 2160 grades.
Rope
Wire
■ Minimum breaking loads from 18,364 lbs. to 581,234 lbs.
Turboplast
Cordage
■ Is an 8 strand rope made out of compacted
outer strands.
■ Has a plastic layer between the steel core and the
Securement
outer strands, giving the rope a high structural stability,

avoiding internal rope destruction and protecting the
Load
core against corrosive environment.

■ Has a very high breaking load and a good resistance
against crushing.
■ Note: this rope may not be used with a swivel.
Contractors
Ask our Lifting Specialists for more details and

Supply
■ Available in sizes from: 5/16" to 2" and 8 mm to 50 mm

■ Available in 1770 and 1960 grades. a complete diameter and breaking load chart for
■ Minimum breaking loads from 11,243 lbs. to 510,437 lbs. these and other Casar ropes.
Protection
Fall

709

Mobile Crane Ropes WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
SureLift 35
■ Highly rotation resistant
■ Specially designed for
high performance cranes
with long drops
■ High strength-to-weight ratio
ensures high breaking loads
■ Long life, high flexibility,
and excellent spooling properties
■ Smooth surface area for decreased wear on sheaves
and drums
■ Can be used with a swivel
■ Available in diameters from 10 mm to 44 mm;
with minimum breaking loads from 11 to 191 tons
Cushion-Pac 8
■ Excellent choice for
production-oriented cranes
■ Exceptionally long service life
for minimized downtime = Main Hoist Rope = Boom Hoist Rope
■ High lifting capacity and resistance
to crushing
■ Reduced drum and sheave wear
and good spooling properties
■ Advanced cushioned core for superior rope life DyPac 6
■ Reverse-lay core version is available
■ Available in diameters from 1/2" (13 mm) to 1-1/2" (38 mm); ■ Proven 6-strand construction
with minimum breaking loads from 16 to 138 tons (EEIP) with special high tensile wires
and 14 to 125 tons (EIP) ■ Exceptional durability ensures
high productivity
■ DyPac design for high breaking
loads and smooth outer surface
Cushion-Pac 18 ■ High crush resistance and
enhanced drum spooling
■ Rotation resistant rope ■ Available in diameters from 3/8" (10 mm) to 1-1/2" (38 mm);
for hoisting applications with minimum breaking loads from 8 to 125 tons
■ Suitable for both single-fall
and multi-reeve applications
■ Multi-strand construction with
specially selected wire tensiles Power-Pac 9
■ DyPac design for increased
lifting capacity and crushing resistance ■ Proven 6-strand construction
■ Smooth outer strand for efficiency on high speed hoisting lines with special high tensile wires
■ Advanced cushion core for superior service life ■ Exceptional durability ensures
■ Excellent spooling properties high productivity
■ Available in diameters from 3/8" (10 mm) to 1-1/2" (38 mm); ■ DyPac design for high breaking
with minimum breaking loads from 8 to 133 tons loads and smooth outer surface
■ High crush resistance and
■ Available in diameters from 5/8" (16 mm) to 1-1/8" (29 mm);
710

Overhead Crane Ropes WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Cushion-Pac 8
■ Excellent choice for
production-oriented cranes
■ Exceptionally long service life
Hoists
for minimized downtime
■ High lifting capacity and resistance
to crushing
■ Reduced drum and sheave wear
and good spooling properties
Services
■ Advanced cushioned core for superior rope life
■ Reverse-lay core version is available
with minimum breaking loads from 16 to 138 tons (EEIP)
Engineered
and 14 to 125 tons (EIP)
Products
Cushion-Pac 18
Slings
■ Rotation resistant rope
for hoisting applications
■ Suitable for both single-fall
and multi-reeve applications
■ Multi-strand construction with
Hardware
specially selected wire tensiles
■ DyPac design for increased
lifting capacity and crushing resistance
■ Smooth outer strand for efficiency on high speed hoisting lines = Main Hoist Rope
■ Advanced cushion core for superior service life
■ Excellent spooling properties
Products
Lifting
■ Available in diameters from 3/8” (10 mm) to 1-1/2” (38 mm);
DyPac 6
Rope
Wire
■ Proven 6-strand construction
with special high tensile wires
■ Exceptional durability ensures
Cordage
high productivity
■ DyPac design for high breaking
loads and smooth outer surface
■ High crush resistance and
Securement

Load

Contractors
Supply
Protection
Fall

711

Galvanized Steel Strand WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
1x7 1 x 19
Nominal Nominal Minimum Breaking Force of Strand (lb.)

Number Approx.
Diameter Diameter of High Extra-High
of Wt. of Strand Utilities
of Strand Coated Wires Strength Strength
Wires (lbs. / 1000 ft.) Grade
(in.) (in.) Grade Grade
3/16 7 .062 73 – 2,850 3,990
7/32 7 .072 98 – 3,850 5,400
1/4 7 .080 121 – 4,750 6,650
9/32 7 .093 164 – 6,400 8,950
5/16 7 .104 205 – 8,000 * 11,200 *
3/8 7 .120 273 11,500 * 10,800 * 15,400 *
7/16 7 .145 399 18,000 14,500 * 20,800 *
1/2 7 .165 517 25,000 18,800 * 26,900 *
1/2 19 .100 504 – 19,100 26,700
9/16 7 .188 671 – 24,500 35,000
9/16 19 .113 637 – 24,100 33,700
5/8 7 .207 813 – 29,600 42,400
5/8 19 .125 796 – 28,100 40,200
3/4 19 .150 1,155 – 40,800 58,300
7/8 19 .177 1,581 – 55,800 79,700
1 19 .200 2,073 – 73,200 104,500
* ASTM A 363 (Weldless) is also available in these sizes and grades upon request.
712

Structural Wire Products WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Galvanized Structural Strand
to ASTM A-586
■ Usually supplied pre-stressed.
Hoists
■ Cut-to-length and paint striped.
■ Parallel contact core construction
with amorphous polypropylene
lubricant available.
■ Class A zinc-coated wire.
Services
Recommended for:
■ Main cables of suspension bridges.
Engineered
Products
■ Boom supports.
■ Guys for towers.
■ Load-carrying members in building structures.
Slings
Galvanized Structural Bridge Rope
to ASTM A-603
Hardware
■ Good modulus of elasticity.
■ Pre-stressed when required
with a modulus of elasticity =
20,000,000 psi.
■ Class A zinc-coated wire.
Products
Lifting
Recommended for:
7x7 6 x 25 IWRC
■ Main support cables on
short-span suspension bridges.
Rope
Wire
■ Suspension cables on large
suspension bridges.
■ Roof supports for large buildings.
Cordage
Securement
6 x 7 IWRC 6 x 41 IWRC
Load
Contractors
Supply
Protection
Fall

713

Structural Wire Products WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
(Continued)
Galvanized Structural Strand and Bridge Rope
Strand Rope
Rope or
Class 'A' Approx. Approx. Approx. Approx.
Strand Class 'A'
Coating Metallic Area Wt. / Ft. Metallic Area Wt. / Ft.
Diameter Coating
Throughout
in. MBF Tons in. sq. lbs. MBF Tons in. sq. lbs.
1/2 15 .15 .52 11.15 .119 .42
9/16 19 .19 .66 – – –
5/8 24 .23 .82 18 .182 .68
11/16 29 .28 .99 – – –
3/4 34 .34 1.18 26 .268 .95
13/16 40 .40 1.39 – – –
7/8 46 .46 1.61 35 .361 1.28
15/16 54 .53 1.85 – – –
1 61 .60 2.1 45.7 .471 1.67
1-1/16 69 .68 2.37 – – –
1-1/8 78 .76 2.66 57.8 .596 2.11
1-3/16 86 .85 2.96 – – –
1-1/4 96 .94 3.28 72.2 .745 2.64
1-5/16 106 1.03 3.62 – – –
1-3/8 116 1.13 3.97 87.8 .906 3.21
1-7/16 126 1.24 4.34 – – –
1-1/2 138 1.35 4.73 104 1.08 7.82
1-9/16 150 1.47 5.13 – – –
1-5/8 162 1.59 5.55 123 1.27 4.51
1-11/16 176 1.71 5.98 – – –
1-3/4 188 1.84 6.43 143 1.47 5.24
1-13/16 202 1.97 6.9 – – –
1-7/8 216 2.11 7.39 164 1.69 6.03
1-15/16 230 2.25 7.89 – – –
2 245 2.40 8.4 186 1.92 6.85
2-1/16 261 2.55 8.94 – – –
2-1/8 277 2.71 9.49 210 2.17 7.73
2-3/16 293 2.87 10.05 – – –
2-1/4 310 3.04 10.64 235 2.42 8.66
2-5/16 327 3.21 11.24 – – –
2-3/8 344 3.38 11.85 261 2.69 9.61
2-7/16 360 3.57 12.48 – – –
2-1/2 376 3.75 13.13 288 2.97 10.6
2-9/16 392 3.94 13.8 – – –
2-5/8 471 4.13 14.47 317 3.27 11.62
2-11/16 432 4.33 15.16 – – –
2-3/4 452 4.54 15.88 347 3.58 12.74
2-7/8 494 4.96 17.36 379 3.91 13.9
3 538 5.40 18.9 412 4.25 15.11
3-1/8 584 5.86 20.51 – – –
3-1/4 625 6.34 22.18 475 5.04 18
3-3/8 673 6.83 23.92 – – –
3-1/2 724 7.35 25.73 555 5.83 21
3-5/8 768 7.88 27.6 – – –
3-3/4 822 8.44 29.53 640 6.67 24
3-7/8 878 9.01 31.53 – – –
4 925 9.60 33.6 730 7.59 27
714

Wire Rope Lubricant
Cranes / Jibs
Overhead
Wire ropes contain numerous
moving parts which require
lubrication. Each time the rope
bends or flexes, the internal
Hoists
strands rub together. Whitmore’s
Wire Rope Lubricant coats
these strands to prevent friction
and wear. This results in longer
wire rope life, less downtime
Services
for rope changes and more
production.
Whitmore’s Wire Rope Lubricant
quickly penetrates to the core.
Engineered
Products
This ensures that the rope is
lubricated throughout while
providing a non-drying, non-tacky
film on the outside of the rope.
This protects outer strands from corrosion, as well as
lubricating the wire rope drums and sheaves.
Slings
Applications:
Vitalife® products are the preferred wire rope lubricants
Whitmore’s Wire Rope Lubricant is easily pumpable at
in the industry because of their ability to penetrate into
temperatures down to -25°F (-35°C). Its nondrying
Hardware
wire rope and displace water and contaminants, thus
film remains flexible in the most extreme weather conditions,
reducing wear and corrosion throughout the rope.
which eliminates flaking and peeling.
■ Available in a variety of container sizes.
Whitmore’s Wire Rope Lubricant can be used to lubricate
■ Provides inner strand preservation and lubricity.
all sizes of wire rope, as well as chains, leaf springs and
■ Allows for easy visual inspection of the ropes.
Products
other applications where penetrating oil is needed. It may be
Lifting
■ Reduces the friction between the strands of the wire
applied by hand or automatic lube system.
rope, thus extending rope life.
Benefits: ■ Adheres to surface of strands, forming an outer film
which provides excellent corrosive protection.
■ Prolongs wire rope life—readily penetrates to the ■ Non-tacky (will not attract dust)
Rope
Wire
core and lubricates internal strands. ■ Vitalife® in aerosol form is a regulated dangerous good.
■ Non-tacky—eliminates dirt pick-up and lubricant See MSDS sheet for shipping instructions.
sling-off. ■ Vitalife® Bio-Lube has been developed especially for
■ Guards against rust and corrosion—displaces water environmentally friendly applications.
as it penetrates.
Cordage
■ Vitalife® 500 has been developed exclusively for
■ Extreme load carrying ability—extends wire rope ski lifts and tramways.
life and minimizes downtime. ■ Vitalife® 600 has been developed exclusively for
■ Aerosol propellant is non-flammable—safe to use. elevator applications.
Recommended Application Rate:
Securement
Load
■ Drip system: first week—3 drops per minute,

per inch diameter rope.
■ Second week and thereafter—1 drop per minute,
Contractors
per inch diameter rope.

Supply
■ Spray system: every 15 minutes for 30 seconds

(on payout only).
Protection
Fall

715

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

swivels for attachment to pulling lines; they have great
strength for trouble free pulling jobs.
Shoulder protectors contain the cable inside the grip and

smooth the passage of the grip over line stringing blocks
or conduit bends; they protect the leading edge of the grip
from abrasion.
The galvanized steel mesh grip provides strength for

secure pulling jobs and a slim profile with little build-up;
it has flexibility to follow cable path.
The multi-weave styles available add strength for big pulling

jobs and provide positive gripping power.
Endless weave allows easy installation onto cable. It has

a snag-free low profile; designed to be reusable tool.
716

Kellems® Wire CAUTION SEE CAUTION INFORMATION
ON PAGES 721 - 723.
Cranes / Jibs
Overhead
Management Products
(Continued)
Hoists
Splicing Grips
Wire Rope Splicing Grips
Triple, Double, Single Weave, Galvanized Steel
Wire Rope Splicing
Services
Kellems Wire Rope Grips are made of high strength galvanized steel
strand in a construction of triple, double and single weave for superior
gripping ability. They are available with or without a rotating barrel,
which will help eliminate twist in the old rope from being transferred
to the new rope.
Engineered
Products
Regular Wire Rope Grips
Application
Approx. Approx.
Wire Rope Grips are used for changing wire rope on oil derricks, large Cable Dia.
Breaking Length Catalog
cranes, overhead cranes and drag lines. They provide a quick, safe, Range
Strength of Grip Number
inexpensive temporary splice. By installing the used wire rope in one (in.)
(lbs.) (ft.)
Slings
end and the new rope in the other, the new wire rope can be pulled
9/16" to 5/8" 7,500 5.75 03316001
in as the old one is pulled out.
3/4" to 7/8" 12,500 6.75 03316002
Benefits 1" to 1-1/8" 16,000 7.00 03316003
1-1/4" to 1-3/8" 20,000 8.00 03316004
Hardware
■ High strength for secure pulling. 1-3/8" to 1-1/2" 20,000 8.00 03316006
■ Easy installation.
■ Flexible to pass through sheaves and blocks.
Note:
1. During installation, each end of the grip should be banded and taped
down securely over the rope to insure smooth passage through
Products
Lifting
sheaves and to guard against accidental release.
2. The rotating barrel is not a swivel and will not turn while under
tension. It can turn to relieve pulling torque when tension is relaxed.
Rotating Wire Rope Grips
Approx. Approx. Barrel
Cable Dia.
Cable Splicing Range
Breaking Length Dimensions Catalog
Rope
Strength of Grip Length x O.D. Number
Wire
Splicing Grips are made of galvanized steel in double or single weave (in.)
(lbs.) (ft.) (in.)
mesh construction. They are available in various lengths and sizes to suit
most applications. 7/16" to 1/2" 5,000 5.33 3.00" x .87" 03317001
9/16" to 5/8" 7,500 5.83 4.25" x 1.00" 03317002
Application 3/4" to 7/8" 12,500 6.50 4.25" x 1.00" 03317003
Cordage
1" to 1-1/8" 16,000 8.67 5.50" x 1.37" 03317004
Splicing Grips are used as a temporary splice for rope, cable or wire rope. 1-1/4" to 1-3/8" 20,000 9.00 5.50" x 1.37" 03317005
They can also be used as cable reinforcement, and can act as a shield to 1-1/2" to 1-3/4" 20,000 11.00 5.50" x 1.37" 03317006
protect cables and hoses from abrasion.
Securement
Benefits
Load
■ Easily installed or removed.

■ Galvanized steel construction for strength.
■ Flexible to follow cable path.
Note:
Contractors
Supply
1. During installation, each end of the splicing grip should be banded

and taped down securely to the cable to insure smooth passage
with the cable and guard against accidental release.
Protection
Fall

717

Kellems® Wire CAUTION SEE CAUTION INFORMATION
ON PAGES 721 - 723.
Management Products
(Continued)
Tools and Bands
Punch-Lok Bands
Punch-Lok® Bands
Grip Band
Band
Punch-Lok Bands are applied over the tail of a grip to prevent the mesh Banding Inside Catalog
from being tripped or pulled loose. Also, they assure full gripping action Width Model
Range Diameter Number
by locking the mesh of the tail in tight contact with the cable or rope. (in.)
(in.) (in.)
When the tail of a grip is the leading end, the bands are particularly 1/4" to 1-1/8" 3/8" 1-3/8" 0-311 20320050
important to prevent accidental release caused by tripping on 1-1/8" to 1-5/8" 3/8" 2" 0-316 20320051
obstructions. A conductor-to-conductor (double-socking) pulling operation 1-5/8" to 2-1/4" 5/8" 2-1/2" 0-10 20320052
is a good example: where two grips connect two conductors to form 2-1/4" to 3-1/2" 5/8" 4" 0-16 20320053
a temporary splice. Bands should be applied to the ends of the grips as 3-1/2" to 5" 5/8" 6" 0-24 20320054
illustrated herein. It is also common practice to tape over the banded
tail area to assure smooth passage through the sheaves. The conductor
Accessories
should be installed in the grip up to the elbows of the aluminum
shoulders in order to assure full and complete gripping action. Punch-Lok Tools Catalog
Description Number
P-1000 for use with 5/8" width Banding Tool. 20320048
Swivels P-38 for use with 3/8" and 5/8" width Banding tool
20320047
Swivels are essential to the efficiency and safety of any high tension for tight spaces
application. They are particularly important where continuous pulls
Note: In all cases two Punch-Lok Bands should be double wrapped
develop higher and higher torque levels. Torque is intensified by the
approximately 1" to 2" from the grip’s tail. Banding is required to ensure
pull resistance of the cable itself and the resistance of the high tension
maximum reliability and guard against accidental release.
controlling equipment regulating line sag.
Ball bearing swivels release torque and prevent it from reaching

dangerous levels that can damage the cable and obstruct the lines
as it passes through sheaves, wheels or blocks.
718

Klein Tools Pulling Grips
Cranes / Jibs
Overhead
Forged-Steel Grips Introduction
Klein grips offer total wire and cable-pulling capability for the
power utility, telecommunication and many other industries.
Hoists
Klein “Chicago”® and "Haven"® Grips are widely used in the power,
Inside-Jaw Contours
communications and general construction fields to pull wire and cable,
Klein "Chicago" Grips are offered with three types of jaw contour:
and to maintain temporary tension until it can be permanently
Single V, Double V, and Round. Each grip comes with the proper
terminated. These grips are to be used for pulling up lines to tension
inside-jaw contour for the type of wire or cable to be worked.
only and are not to be used as anchors.
Services
Single V. Simple three-point contact jaws designed for use
Klein has designed and built standard and custom grips of outstanding
on small-diameter bare wire and cable (solid and stranded).
quality since 1885. They are proven dependable. The complete line
includes a type and size for every application. Doubts V. Four-point contact provides greater gripping pressure
and assures proper alignment of wire and cable within the jaws.
There is a Klein grip for virtually every type of wire and cable, including:
Designed for high-strength steel guy wire and messenger wire,
Engineered
Products
■ Extra-high-strength cables, messenger, guy strand and conductors
and extra high-strength cables and conductors.
■ Bare wire
■ Large-diameter conductors Round. Round jaws provide maximum contact and gripping
■ Bare A.C.S.R., aluminum and stranded-copper cables power to minimize conductor damage. This jaw design is
■ PVC-covered conductors recommended for use on bare aluminum, A.C.S.R., and copper
■ Weatherproof wire conductors.
Slings
■ Telephone cable
Repair or replace?
Klein "Chicago" Grips have locking loop handles, standard on most grips Never repair any grip. Grip laws can sometimes be replaced if the grip
and available on hot-line grips by ordering with spring. The locking fea- is returned to Klein, but structural wow or damage cannot be safely
ture allows the jaws to be held in an open position for easier placement corrected. Grips that are bent, misaligned or otherwise distorted should
Hardware
on wire or cable. Saves substantial time, makes grip positioning easier be discarded and replaced.
than with wedge or boil-on designs. To lock, open jaws and fold loop
handle toward the side plates. Before each use, check all grips for jaw condition, proper alignment of
jaws and all parts, and possible distortion caused by exceeding safe-load
Klein "Chicago"® Grips specifications. Grips should operate smoothly. Spring-loaded grips
should lock open with loop handle in "Down" position and should dose
How to select the
Products
automatically with loop handle "Up".
Lifting
proper grip.
Care should be taken in The Klein parallel jaw grip maybe tested by opening and closing the jaws
choosing grips to assure correct by hand, exercising proper caution. All parts and rivets which may be
handling of wire and cable. distorted due to exceeding safe load should be checked.
Three basic factors determine
Recommended Care and Maintenance
Rope
Wire
the selection of the proper grip
The following guidelines have been established in order to maintain all
for each specific application:
grips in good condition:
1. Type of wire or cable.
1. Clean the grip jaws. Use emery cloth or a clean wire brush to
2. Outside diameter of wire or cable.
periodically clean the surfaces of grip jaws.
3. Maximum safe load required.
Note: Aluminum-strand conductors may have a die-grease
Cordage
All three of these factors are included in the description of each Klein coating which can de¬posit on grip jaws. Now aluminum
grip along with the type of inside jaw contour available. Correct selection conductors should be wiped clean before grip application.
of gripping jaws is essential to avoid damage to wire or cable. In pulling Grip jaws should be wiped clean of all grease before use.
stranded wire, the jaws should be long enough to take a full lay of cable Be sure to clean grip jaws before and after each use on wire or
cable which has been galvanized or otherwise coated.
Securement
to avoid damage to the conductor.

Load
The tables in this grip section are supplied to assist you in determining 2. Clean aft working parts. Use Klein's Cinch Cleaner / Degreaser
outside diameters and breaking points of the various types and sizes of Cat. No. 51101 to clean all joints and moving parts, then apply
wire and cable in general use. Cinch Yellow No. 51045.
For our recommendations of the proper grip to meet your needs, 3. Check all parts. Look carefully for distortion or misalignment.
Contractors
send exact cable description and pulling requirements.

Supply
4. Never repair any grip. If there is ever any question about the
Please order grips by description and specifications only. safe condition of any grip, please consult us directly.
Actual product may vary from photo. Please remember this rule.
Protection
Fall

719

Klein Tools Pulling Grips WARNING SEE WARNING INFORMATION
ON PAGES 721 - 723.
(Continued)
When pulling EHS (extra-high-strength) galvanized
steel cable, the galvanizing has a tendency to coat the
Inside Jaw
jaws of any grip, causing the cable to slip. To reduce Contour
the possibility of slippage and damage to the cable, the
jaws of this grip are milled on a curve with a
double “V” contour.
Minimum Maximum Maximum Approx.

Catalog Jaw Length
Cable Size Cable Size Safe Load Weight Each
Number in. (cm)
in. (mm) in. (mm) lbs. (kg) lbs. (kg)
1684-74 .218 (5.54) .55 (13.97) 8,000 (3,629) 6.25 (2.83) 5 (12.7)
Designed for use when light, compact grip is desired and

where conductor damage is not a factor. Gripping pressure
of the knurled jaw is applied to 1/4" (6.35 mm) cable area.
1604-20L and 1625 series have a swing latch to help
hold cable in the jaw. 1625-20 can be furnished to fit 7/8"
(22.2 mm) or 1" (25.4 mm) cable on special order.
Minimum Maximum Maximum Approx.

Catalog
Cable Size Cable Size Safe Load Weight Each
Number
in. (mm) in. (mm) lbs. (kg) lbs. (kg)
1604-10 14 B&S .06 (1.52) 2 B&S .25 (6.35) 2,500 (1,136) 1 (.45)
1604-20 8 B&S .125 (3.18) Steel Strand .50 (12.70) 5,000 (2,272) 2.5 (1.14)
1604-20L 8 B&S .125 (3.18) Steel Strand .50 (12.70) 5,000 (2,272) 2.5 (1.14)
1625-20 1 B&S .28 (7.11) Wire Rope .75 (19.05) 8,000 (3,636) 3.5 (1.59)
1625-20, 7/8 .38 (9.65) Wire Rope .88 (22.35) 8,000 (3,636) 3.5 (1.59)
1625-20, 1 .50 (12.70) Wire Rope 1.00 (25.40) 8,000 (3,636) 3.5 (1.59)
Caution: Grip-Cleaning Brush Set

Proper maintenance and field inspection of all grips is necessary Set of four wire-bristle brushes
before each use. Check to be sure there is no accumulation of foreign
designed for cleaning Klein
material in the jaws which might cause slippage. Check mechanical
condition of entire grip. Check grip to be sure it is correct size and type wire- and cable-pulling grips.
for the application. Clean and lubricate. Do not lubricate gripping
surfaces of jaws. Check all parts for distortion or misalignment.
Brushes have stiff wire bristles.
Available in round and square
OSHA requires that all hand tools and equipment be maintained in shapes and two lengths for
good working order and that they be free from damage caused efficient cleaning of different jaw
by wear or abuse (OSHA Part 1910, Subpart P, Section 1910.242).
configurations. Semi-flexible
In addition, OSHA Part 1926 Subpart V, Section 1926.955 steel shafts set into comfortable
paragraph 7 (ii) and 8 specifically state that: “That manufacturer’s wooden handles provide the
load rating shall not be exceeded for stringing lines, pulling lines, necessary reach into grip jaws.
sock connections and all load bearing hardware and accessories.” Illustrated general grip care and
“Conductor grips shall not be used on wire rope unless designed
maintenance instructions
for this application.” are included.
Contains:
Round-bristle 3/8" x 3" (10 x 76 mm), 12" (305 mm) long;
Square-bristle 3/8" x 3" (10 x 76 mm), 12" (305 mm) long;
Round-bristle 1-9/16" x 5" (40 x 127 mm), 14" (356 mm) long;
Square-bristle 1-9/16" x 5" (40 x 127 mm), 14" (356 mm) long.
720

Wire Rope
Product Warnings
& Cautions
721

Wire Rope Technical
Board Warning
WARNING
Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused.

■ ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.
■ INFORM YOURSELF: Read and understand manufacturer's literature or
"Wire Rope and Wire Rope Sling Safety Bulletin".*
■ REFER TO APPLICABLE CODES, STANDARDS and REGULATIONS for
INSPECTION REQUIREMENTS and REMOVAL CRITERIA.*
* For additional information or the BULLETIN, ask your employer or wire rope supplier.
For complete warning and application information,

see Wire Rope Technical Board at www.wireropetechnicalboard.org

see Bridon American at www.bridonamerican.com

see Bethlehem / Wire Rope Works, Inc. at www.wwwrope.com

see WireCo / Union Wire Rope at www.unionrope.com

see Wire Rope Industries at www.wirerope.com

see Casar at www.casar.de/en
722

Kellems® Wire Management Products
Pulling / Splicing Grips Cautions & Warnings
Safety and Working Load Factors CAUTION

For Wire Mesh Grips
It is very important to comply with all of the following
The broad application of Kellems grips on a wide variety of precautions. Failure to do so may result in property damage,
objects requires that adequate safety factors be used to personal injury or death.
establish working loads. The approximate breaking strength
of a Kellems grip represents an average calculation based 1. Pulling grips are to be installed by a qualified individual in
on data established from actual direct tension testing done accordance with all applicable national and local safety,
in our engineering laboratories. electrical and rigging codes.
2. Ensure that the correct grip is selected for your
It is impossible to catalog or guarantee a safety factor suitable specific needs.
for all applications as operating conditions are never the same. 3. Do not use a pulling grip for any application other than
The tension, diameter, movement, number of objects gripped, pulling cable.
gripping surface, and the attachments used are just some of the 4. Thoroughly examine the grip for damage. Do not use a
factors which vary with each application. These factors, damaged grip.
together with the effects of abrasion, corrosion, prior use or 5. Ensure that the recommended work load of the grip
abuse and any other variables of a specific application, is suitable for the application. Never use grips at their
must be considered by the user and the grip replaced as approximated rated breaking strength. A safety
appropriate. Where the conditions of the application factor of 5 is recommended for pulling grips.
are not well defined or known, or where risk of injury to 6. Do not alter grips in any way. For example, do not modify
persons or property is involved, a greater safety factor pulling eyes, shoulders, fittings or lugs.
should be utilized. 7. Do not attach any type of pulling hardware to any point
on the grip other than the pulling eye. The pulling eye is the
Under normal conditions, Kellems’ recommended factor of
only acceptable means of attachment to external hardware.
safety is five for catalog listed pulling grips, and ten for
8. Always apply 2 bands at 1" and 2" respectively, from the
catalog listed support grips. Any warranty as to quality,
tail end of the mesh to guard against accidental release of
performance or fitness for use of grips is always premised
the grip. Accidental release can occur if an object contracts
on the condition that the published breaking strengths
and pushes against the tail end of the mesh, thereby
apply only to new, unused grips, and that such products
expanding and releasing it’s hold.
are properly stored, handled, used, maintained and inspected
by the user at a frequency appropriate for the use and
condition of the grip. For complete warning and application
information, see Hubbell Incorporated
at www.hubbell.com
Klein Tools Pulling Grips WARNING
Warnings ■ Before each use, clean jaw area and inspect grip for
proper operation to avoid slippage.
■ When used on/near energized lines, ground, insulate,
or isolate grip before pulling.
■ Do not exceed rated capacity.
■ Always match proper size and type of grip to application.
■ Grips are to be used for temporary installation, not
for permanent anchorage.
For complete warning and application

information, see Klein Tools, Inc.
at www.kleintools.com
723

Wire Rope Assemblies
& End Fittings Index
Steel Swage Buttons......................................726
Wedge Ferrules Buttons.................................727
Terminal Efficiencies.......................................728
Boom Pendant Inspection..............................729
Boom Pendant Thimbles................................730
Boom Pendants..............................................731, 733
Spelter Socket Assemblies.............................731
Open & Closed Spelter Sockets.....................732
Swaged Socket Assemblies...........................733
Open & Closed Swage Sockets.....................734
Forged Wire Rope Clips.................................735
Fist Grip® Wire Rope Clips.............................736
Wedge Socket................................................737
Super Terminator® Wedge Socket..................738
Threaded Sleeve............................................739
Threaded Stud................................................740
Wire Rope Terminals......................................741 - 743
Copper Oval & Copper Stop Sleeves.............744
Nickel Plated Copper Oval Sleeves...............745
Stainless Steel Oval Sleeves.........................745
Aluminum Oval Sleeves.................................746
Cutter Tools....................................................747 - 750
Wire Rope Cutters..........................................751
Precision Cable Cutters..................................752
Movable Bridge Cable Assemblies.................753
Security, Barrier and Guardrail
Cable Assemblies & Fittings....................754
Warnings
Product Warnings...........................................755 - 757
For the complete catalog index,

refer to the front of the book.
724
MazzellaCatalog13_WireRopeAssemblies.indd 724 7/3/13 10:11 AM

Every Order Made to
Cranes / Jibs
Overhead
Purchaser’s Specifications
How to order:
We can produce any assembly to fit your specifications
Hoists
precisely. When ordering, please consider the following:
■ Diameter of the wire rope.

■ Wire rope classification or construction.
Services
■ Rope material (stainless, galvanized, bright, etc.).
■ Rated capacity required.
■ Length as described by reference points
(see diagram below).
■ Fitting material required.
Engineered
Products
■ For threaded fittings, specify the type,
length and hand of thread.
■ For terminals, such as forks and eyes,
please specify how they should be positioned
relative to each other—same plane or
Slings
opposite planes.
■ The number of completed assemblies required.
Hardware
How to measure reference points
for specifying your assemblies.
Here are several examples of various assemblies.
The dotted vertical lines indicate the reference points.
Products
Lifting
Please specify these reference points when you
order. If you need a customized assembly not
shown here, please call us and we’ll supply you
what you need.
Rope
Wire
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

725

Steel Swage Buttons WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Wire Rope After Swaging

Size Diameter Long
(in.) (in.) (in.)
1/8 3/8 5/8
5/32 7/16 3/4
3/16 1/2 7/8
7/32 9/16 1
1/4 9/16 1-3/16
9/32 11/16 1-1/4
5/16 3/4 1-3/8
3/8 3/4 1-3/4
7/16 1 2
1/2 1-1/8 2-3/16
9/16 1-1/4 2-7/16
5/8 1-3/8 2-7/8
3/4 1-1/2 3-1/4
7/8 1-3/4 3-7/8
1 2 4-3/8
1-1/8 2-1/4 4-13/16
1-1/4 2-1/2 5-7/16
1-3/8 2-3/4 6
1-1/2 3 6-1/2
726

Wedge Type Ferrules
Cranes / Jibs
Overhead
ESCO ferrules are made of high strength alloy steel
and feature a two-piece wedge that is rifled to provide
more gripping surface on the wire rope strands and
greater holding power.
Hoists
ESCO machined wedge-type ferrules permit the make up
or repair of chokers and winch lines in minutes—no molten
socket metal or swaging equipment is required. Wedge type
ferrules may be applied with ESCO Socketfast.
Services
Wedge-type ferrules are intended only for use with
new 6 x 19 class or 6 x 37 class, right regular lay, EIP,
IWRC rope made to U.S. specifications.
Engineered
Products
Slings
Hardware
Products
Lifting
Rope
Wire
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

727

Terminal Efficiencies (Approximate)
Efficiencies are based on nominal strengths.
Efficiency
Type of Termination
Rope with IWRC * Rope with FC ** Profile
Wire Rope Socket (Spelter or Resin) 100% 100%
Swaged Socket (Regular Lay Ropes Only)
(Regular Lay Ropes Only) 100% (Not established)
Mechanical Spliced Sleeve

1" dia. and smaller 95% 92-1/2 %
Greater than 1" dia. through 2" 92-1/2% 90%
Greater than 2" dia. through 3-1/2" 90% (Not established)
Loop or Thimble Splice-Hand Spliced (Tucked) (Carbon Steel Rope)
1/4" 90% 90%
5/16" 89% 89%
3/8" 88% 88%
7/16" 87% 87%
1/2" 86% 86%
5/8" 84% 84%
3/4" 82% 82%
7/8" thru 2-1/2" 80% 80%
Loop or Thimble Splice-Hand Spliced (Tucked) (Stainless Steel Rope)
1/4" 80% –
5/16" 79% –
3/8" 78% –
7/16" 77% –
1/2" 76% –
5/8" 74% –
3/4" 72% –
7/8" 70% –
Wedge Sockets ***
(Depending on Design) 75% to 80% 75% to 80%
Clips ***
(Number of clips varies with size of rope) 80% 80%
* IWRC = Independent Wire Rope Core

** FC = Fiber Core. For terminal efficiencies on Premium High Performance Ropes,
*** Typical values when applied properly. Refer to fittings contact local customer service representative.
manufacturers for exact values and method.
728

Boom Pendant Inspection
Cranes / Jibs
Overhead
Boom pendant inspection is vital for
proper use.
General guide to boom pendant inspection:
Hoists
1. Measure the diameter of the rope at several points
along the pendant, especially near the end fittings.
Measurements below the rope's nominal diameter may
mean that the core is deteriorating, even if the outside This assembly
Services
wires and strands appear to be in good condition. must be replaced.
2. Inspect the outside wires and strands for damaging
rust or abrasive wear caused by loss of lubrication,
Engineered
Products
or by the rope’s contact with the boom or other
structures on the crane.
3. Inspect the rope for broken wires—especially near

the end fittings. Even one broken wire near an Watch for broken
end fitting may be a sign that the rope is deteriorating wires in this area
Slings
and may be near failure. Any “valley breaks,”
that is, wires that have broken in the valley between
two strands may also be a sign that there is serious
vibration fatigue in the core.
Hardware
4. Inspect the fitting attachments. 5. Inspect the end fittings: inspect the fittings for any
signs of cracking or distortion. Pay particular attention
Hand spliced: look for slippage in the splice or any to the area around the pin holes and along the ears
tucks that may have pulled out. of open sockets.
Products
Lifting
Poured zinc or thermo-set resin sockets: look at the Inspect the pin holes for any signs of elongation or
base of the sockets for any signs that the wires may excessive wear.
be pulling out of the zinc or thermo-set resin. Look at
the top of the cone for any sign that the zinc or Inspect the socket pins for any signs of bending or
thermo-set resin is cracked or is chipping or flaking off. excessive wear.
Rope
Wire
Returned loop swaged: look for any sign that the
Note: If any of the above conditions exists, the pendant should
sleeve may be cracked, crushed or peeling back.
be removed from service and inspected or tested further.
Look for any sign that the rope may be pulling out
of sleeve.
Cordage
This is intended to be a general guide only. Contact
Flemish eye swaged: look for any sign that the the manufacturer of the equipment, the pendants and/or
sleeve may be cracked, crushed or peeling back. the end fittings to get specific retirement criteria. Securement
Swaged sockets: look for any signs of a cracked Reference to ASME Standard B30.9.
Load
or bent shank. Look for any sign that the rope may be
pulling out of the socket.
Contractors
Supply
Protection
Fall

729

Boom Pendant Thimbles
Illustrated below is a NEWCO Boom Pendant fabricated
with a flemish eye splice and swaged steel sleeves which
fit around a pendant fitting that is either open or closed.
Available In sizes from 9/16" to 2-3/8". Pendants are not
to be used for any other purpose other than Boom Pendant
application. NEWCO Pendant Thimbles are interchangeable
with standard sockets. Weight on open pendant includes
pin (D) and cotter.
Wire Rope Est.

Closed Dimensions & Data (in.)
Diameter Weight
(in.) A B C D E F G (lbs.)
9/16 to 5/8 4-3/2 3-1/8 1-1/4 1-1/16 1-1/16 11/16 2-1/8 1.7
3/4 4-27/32 3-5/8 1-7/16 1-5/16 1-3/16 13/16 2-1/2 2.6
7/8 5-5/16 4-1/8 1-11/16 1-1/2 1-3/8 15/16 2-3/4 3.5
1 5-31/32 4-9/16 2-1/16 1-3/4 1-5/8 1-1/8 3 4.6
1-1/8 6-3/8 5-1/16 2-5/16 2 1-3/4 1-1/4 3-1/4 5.6
1-1/4 to 1-3/8 7-3/8 6-1/8 2-9/16 2-1/4 2-1/8 1-1/2 4 9.6
1-1/2 8-3/16 6-3/4 2-13/16 2-1/2 2-3/8 1-5/8 4-1/2 14
1-5/8 10-7/16 8 3-1/16 2-5/8 2-1/2 1-3/4 5-1/2 29
1-3/4 to 1-7/8 12-5/16 9-3/4 3-9/16 3-1/8 3 2 7 41
2 to 2-1/8 13 10-1/2 3-13/16 3-7/16 3-1/4 2-1/4 7-1/2 57
2-1/4 to 2-3/8 17-5/16 11-3/4 4-3/8 3-7/8 3-5/8 2-1/2 8-1/2 76
Wire Rope Open Dimensions & Data (in.) Est.

Diameter Weight
(in.) A B C D E F G H J L P R (lbs.)
9/16 to 5/8 8-3/64 2-3/8 1-1/4 1-3/16 15/32 11/16 2-1/8 3-1/8 2-17/32 4-1/4 2-9/32 9/16 5.3
3/4 9-3/32 2-13/16 1-1/2 1-3/8 17/32 13/16 2-1/2 3-5/8 3-1/32 4-3/4 2-3/4 21/32 7.5
7/8 10-5/16 3-1/4 1-3/4 1-5/8 5/8 15/16 2-3/4 4-1/8 3-1/4 5-1/4 3-1/4 3/4 12.5
1 11-11/16 3-3/4 2 2 3/4 1-1/18 3 4-9/16 3-11/16 5-7/8 3-7/8 7/8 19
1-1/8 12-25/32 4-1/4 2-1/4 2-1/4 7/8 1-1/4 3-1/4 5-1/16 3-27/32 6-17/32 4-7/16 1 26
1-1/4 to 1-3/8 15-1/32 4-3/4 2-1/2 2-1/2 15/16 1-1/2 4 6-1/8 4-5/16 8 4-15/16 1-1/8 39
1-1/2 17-1/8 5-3/8 3 2-3/4 1-1/16 1-5/8 4-1/2 6-3/4 4-13/16 9-1/8 5-5/8 1-3/16 56
1-5/8 20-1/2 5-5/8 3 3 1-3/16 1-3/4 5-1/2 8 6-7/16 10-5/8 6-1/8 1-5/16 78
1-3/4 to 1-7/8 24-1/16 6-5/8 3-1/2 3-1/2 1-5/16 2 7 9-3/4 7-7/16 12-3/4 6-7/8 1-9/16 125
2 to 2-1/8 27 7-5/8 4 3-3/4 1-11/16 2-1/4 8 10-3/4 9-3/4 13-1/4 7-1/8 1-13/16 166
730

Spelter Socket Assemblies WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Cranes / Jibs
Overhead
(Boom Pendants)
Molten zinc is standard as the bonding medium surrounding wires inside
the socket, but epoxy compound may be specified.
Hoists
Both mediums have same capacity ratings. Steel forgings are used for
rope sizes 1/2" through 4", and cast steel fittings for larger sizes. Larger than
4" available on special order. Assembly length is measured from centerline
of pin for open sockets and bearing point for closed sockets.
Wire rope assemblies with fittings permanently attached at ends are custom
Services
fabricated for use as boom pendants, guylines, raising lines, backstays,
lifting bridles, etc. These are offered in both poured or spelter sockets and
mechanically swaged sockets.
Wire Rope Closed Spelter Socket Dimensions & Data (in.)
Engineered
Products
Diameter
(in.) A B C D F G H J K L
1/4 4.50 .50 1.50 .88 .38 .69 1.56 2.25 .50 1.75
5/16 to 3/8 4.88 .62 1.69 .97 .50 .81 1.69 2.25 .69 2
7/16 to 1/2 5.44 .69 2 1.16 .56 .94 1.88 2.50 .88 2.25
9/16 to 5/8 6.31 .81 2.63 1.41 .69 1.12 2.38 3 1.00 2.50
3/4 7.56 1.06 3 1.66 .81 1.25 2.75 3.56 1.25 3
Slings
7/8 8.75 1.25 3.63 1.88 .94 1.50 3.25 4 1.50 3.50
1 9.88 1.38 4.13 2.30 1.13 1.75 3.75 4.44 1.75 4
1-1/8 11 1.50 4.50 2.56 1.25 2.00 4.13 5 2.00 4.50
1-1/4 to 1-3/8 12.12 1.63 5.30 2.81 1.50 2.25 4.75 5.50 2.25 5
1-1/2 13.94 1.94 5.33 3.19 1.63 2.75 5.25 6 2.50 6
Hardware
1-5/8 15.13 2.13 5.75 3.25 1.75 3.00 5.50 6.50 2.75 6.50
1-3/4 to 1-7/8 17.25 2.19 6.75 3.75 2 3.13 6.38 7.50 3 7.56
2 to 2-1/8 19.50 2.44 7.63 4.38 2.25 3.75 7.38 8.50 3.25 8.56
2-1/4 to 2-3/8 21.13 2.63 8.50 5 2.50 4 8.25 9 3.63 9.50 Rated Capacity—Tons
2-1/2 to 2-5/8 23.50 3.12 9.50 5.50 2.88 4.50 9.25 9.75 4 10.62
2-3/4 to 2-7/8 25.38 3.12 10.75 6.25 3.12 4.88 10.19 11 4.88 11.25 Wire Rope 6 x 19 & 6 x 36
Products
3 to 3-1/8 27 3.25 11.50 6.75 3.38 5.25 11.50 12 5.25 11.75 Diameter IWRC
Lifting
3-1/4 to 3-3/8 29.25 4 12.25 7.25 3.62 5.75 12.25 13 5.75 12.25 (in.) EIP EEIP
3-1/2 to 3-5/8 31 4 13 7.75 3.88 6.50 13 14 6.25 13
3-3/4 to 4 33.25 4.25 14.25 8.50 4.25 7.25 14.25 15 7 14 1/2 2.7 2.9
9/16 3.4 3.7
5/8 4.1 4.5
Wire Rope Open Spelter Socket Dimensions & Data (in.) 3/4 5.9 6.5
Diameter 7/8 8 8.8
Rope
Wire
(in.) A C D F G H J L M N 1 10 11
1/4 4.56 .91 .69 .38 .69 1.56 2.25 1.56 1.31 .36 1-1/8 13 14
5/16 to 3/8 4.84 .81 .81 .50 .81 1.69 2.25 1.75 1.50 .44 1-1/4 16 18
7/16 to 1/2 5.56 1 1 .56 .94 1.88 2.50 2.00 1.88 .50 1-3/8 19 21
9/16 to 5/8 6.75 1.25 1.19 .69 1.13 2.25 3 2.50 2.25 .56 1-1/2 23 25
Cordage
3/4 7.94 1.50 1.38 .81 1.25 2.62 3.50 3 2.62 .62 1-5/8 26 29
7/8 9.25 1.75 1.63 .94 1.50 3.25 4 3.50 3.13 .80 1-3/4 31 34
1 10.56 2 2 1.13 1.75 3.75 4.50 4 3.75 .88 1-7/8 35 38
1-1/8 11.81 2.25 2.25 1.25 2 4.12 5 4.62 4.12 1 2 40 43
1-1/4 to 1-3/8 13.19 2.50 2.50 1.50 2.25 4.75 5.50 5 4.75 1.13 2-1/8 44 49
2-1/4 49 54
Securement
1-1/2 15.12 3 2.75 1.63 2.75 5.25 6 6 5.38 1.19

1-5/8 16.25 3 3 1.75 3 5.50 6.50 6.50 5.75 1.31 2-3/8 55 60
Load
1-3/4 to 1-7/8 18.25 3.50 3.50 2 3.13 6.38 7.50 7 6.50 1.56 2-1/2 60 66
2 to 2-1/8 21.50 4 3.75 2.25 3.75 7.38 8.50 9 7.00 1.81 2-5/8 66 73
2-1/4 to 2-3/8 23.50 4.50 4.25 2.50 4 8.25 9 10 7.75 2.13 2-3/4 72 79
2-1/2 to 2-5/8 25.50 5 4.75 2.88 4.50 9.25 9.75 10.75 8.50 2.38 2-7/8 78 86
2-3/4 to 2-7/8 27.25 5.25 5 3.12 4.88 10.50 11 11 9 2.88 3 85 94
Contractors
3 to 3-1/8 29 5.75 5.25 3.38 5.25 11.12 12 11.25 9.50 3.00 3-1/8 92 101
Supply
3-1/4 to 3-3/8 30.88 6.25 5.50 3.62 5.75 11.88 13 11.75 10 3.12 3-1/4 98 109
3-1/2 to 3-5/8 33.25 6.75 6 3.88 6.50 12.38 14 12.50 10.75 3.25 3-3/8 106 116
3-3/4 to 4 36.25 7.50 7 4.25 7.25 13.62 15 13.50 12.50 3.50 3-1/2 113 124
Protection
Fall

731

Open & Closed
Spelter Sockets
Wire Rope Open Spelter Socket Dimensions & Data (in.)

Diameter
(in.) A C D F G H J L M N
1/4 4.56 .91 .69 .38 .69 1.56 2.25 1.56 1.31 .36
5/16 to 3/8 4.84 .81 .81 .50 .81 1.69 2.25 1.75 1.50 .44
7/16 to 1/2 5.56 1 1 .56 .94 1.88 2.50 2.00 1.88 .50
9/16 to 5/8 6.75 1.25 1.19 .69 1.13 2.25 3 2.50 2.25 .56
3/4 7.94 1.50 1.38 .81 1.25 2.62 3.50 3 2.62 .62
7/8 9.25 1.75 1.63 .94 1.50 3.25 4 3.50 3.13 .80
1 10.56 2 2 1.13 1.75 3.75 4.50 4 3.75 .88
1-1/8 11.81 2.25 2.25 1.25 2 4.12 5 4.62 4.12 1
1-1/4 to 1-3/8 13.19 2.50 2.50 1.50 2.25 4.75 5.50 5 4.75 1.13
1-1/2 15.12 3 2.75 1.63 2.75 5.25 6 6 5.38 1.19
1-5/8 16.25 3 3 1.75 3 5.50 6.50 6.50 5.75 1.31
1-3/4 to 1-7/8 18.25 3.50 3.50 2 3.13 6.38 7.50 7 6.50 1.56
2 to 2-1/8 21.50 4 3.75 2.25 3.75 7.38 8.50 9 7.00 1.81
2-1/4 to 2-3/8 23.50 4.50 4.25 2.50 4 8.25 9 10 7.75 2.13
2-1/2 to 2-5/8 25.50 5 4.75 2.88 4.50 9.25 9.75 10.75 8.50 2.38
2-3/4 to 2-7/8 27.25 5.25 5 3.12 4.88 10.50 11 11 9 2.88
3 to 3-1/8 29 5.75 5.25 3.38 5.25 11.12 12 11.25 9.50 3.00
3-1/4 to 3-3/8 30.88 6.25 5.50 3.62 5.75 11.88 13 11.75 10 3.12
3-1/2 to 3-5/8 33.25 6.75 6 3.88 6.50 12.38 14 12.50 10.75 3.25
3-3/4 to 4 36.25 7.50 7 4.25 7.25 13.62 15 13.50 12.50 3.50 Note: Above drawing illustrates one
groove used on sockets 1/4" thru 3/4".
Sizes 7/8" thru 1-1/2" use 2 grooves.
Sizes 1-5/8" and larger use 3 grooves.
Wire Rope Closed Spelter Socket Dimensions & Data (in.)

Diameter
(in.) A B C D F G H J K L
1/4 4.50 .50 1.50 .88 .38 .69 1.56 2.25 .50 1.75
5/16 to 3/8 4.88 .62 1.69 .97 .50 .81 1.69 2.25 .69 2
7/16 to 1/2 5.44 .69 2 1.16 .56 .94 1.88 2.50 .88 2.25
9/16 to 5/8 6.31 .81 2.63 1.41 .69 1.12 2.38 3 1.00 2.50
3/4 7.56 1.06 3 1.66 .81 1.25 2.75 3.56 1.25 3
7/8 8.75 1.25 3.63 1.88 .94 1.50 3.25 4 1.50 3.50
1 9.88 1.38 4.13 2.30 1.13 1.75 3.75 4.44 1.75 4
1-1/8 11 1.50 4.50 2.56 1.25 2.00 4.13 5 2.00 4.50
1-1/4 to 1-3/8 12.12 1.63 5.30 2.81 1.50 2.25 4.75 5.50 2.25 5
1-1/2 13.94 1.94 5.33 3.19 1.63 2.75 5.25 6 2.50 6
1-5/8 15.13 2.13 5.75 3.25 1.75 3.00 5.50 6.50 2.75 6.50
1-3/4 to 1-7/8 17.25 2.19 6.75 3.75 2 3.13 6.38 7.50 3 7.56
2 to 2-1/8 19.50 2.44 7.63 4.38 2.25 3.75 7.38 8.50 3.25 8.56
2-1/4 to 2-3/8 21.13 2.63 8.50 5 2.50 4 8.25 9 3.63 9.50
2-1/2 to 2-5/8 23.50 3.12 9.50 5.50 2.88 4.50 9.25 9.75 4 10.62
2-3/4 to 2-7/8 25.38 3.12 10.75 6.25 3.12 4.88 10.19 11 4.88 11.25
3 to 3-1/8 27 3.25 11.50 6.75 3.38 5.25 11.50 12 5.25 11.75
3-1/4 to 3-3/8 29.25 4 12.25 7.25 3.62 5.75 12.25 13 5.75 12.25
3-1/2 to 3-5/8 31 4 13 7.75 3.88 6.50 13 14 6.25 13
3-3/4 to 4 33.25 4.25 14.25 8.50 4.25 7.25 14.25 15 7 14
Note: Above drawing illustrates one
Notice: All cast steel spelter sockets 1-5/8" and larger are magnetic particle groove used on sockets 1/4" thru 3/4".
inspected and ultrasonic inspected. Proof testing available on special order. Sizes 7/8" thru 1-1/2" use 2 grooves.
Sizes 1-5/8" and larger use 3 grooves.
732

Swaged Socket Assemblies WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Cranes / Jibs
Overhead
(Boom Pendants) OS-OS CS-CS OS-CS
In mechanically swaged fittings, high pressure swagers and precision

dies cause metal of the socket to flow around wires and strands to
offer the ultimate in compactness and strength with minimum weight.
Hoists
Normally, only regular lay rope is used. Swaged assemblies are
interchangeable with poured sockets up through 2" rope diameters.
Assembly length is measured from centerline of pins for both
Services
open and closed sockets.
Indicate choice of end fittings on purchase orders by the suffixes

“OS” or “CS” after the stock number, for open or closed type fittings.
Pins and cotters are supplied as standard on open fittings, but
Engineered
Products
assemblies may be specified without pins. Fittings will be assembled
Pins Pins Pins Pins Pins Pins
in the same plane unless specified otherwise on the order. Same Opposite Same Opposite Same Opposite
Plane Plane Plane Plane Plane Plane
Wire Rope Open Swage Socket Dimensions & Data (in.)

Diameter
Slings
(in.) A B C D E F H L M N
1/4 4.81 .50 1.38 .69 .27 2.13 .69 4.00 .38 1.50
5/16 6.25 .77 1.62 .81 .34 3.19 .81 5.31 .47 1.75
3/8 6.25 .77 1.62 .81 .41 3.19 .81 5.31 .47 1.75
7/16 7.81 .98 2.00 1.00 .48 4.25 1.00 6.69 .56 2.00
Hardware
1/2 7.81 .98 2.00 1.00 .55 4.25 1.00 6.69 .56 2.00
9/16 9.50 1.25 2.38 1.19 .61 5.31 1.25 8.13 .68 2.25
5/8 9.50 1.25 2.38 1.19 .67 5.31 1.25 8.13 .68 2.25
3/4 11.56 1.55 2.75 1.38 .80 6.38 1.50 10.00 .78 2.75
7/8 13.41 1.70 3.13 1.62 .94 7.44 1.75 11.63 .94 3.25
1 15.47 1.98 3.69 2.00 1.06 8.50 2.00 13.38 1.06 3.75
1-1/8 17.31 2.25 4.06 2.25 1.19 9.56 2.25 15.00 1.19 4.25
Products
Lifting
1-1/4 19.06 2.53 4.50 2.50 1.33 10.63 2.50 16.50 1.22 4.75
1-3/8 20.94 2.80 5.00 2.50 1.45 11.69 2.50 18.13 1.38 5.25
1-1/2 22.88 3.08 5.50 2.75 1.58 12.75 3.00 19.75 1.69 5.75
1-3/4 26.63 3.39 6.69 3.50 1.86 14.88 3.50 23.00 2.11 6.75
2 31.44 3.94 8.00 3.75 2.11 17.00 4.00 26.88 2.37 8.00
Rope
Wire
Wire Rope Closed Swage Socket Dimensions & Data (in.) Rated Capacity—Tons
Diameter
A B C D E F H L Wire Rope 6 x 19 & 6 x 36
(in.)
Diameter IWRC
1/4 4.31 .50 1.38. .75 .27 2.12 .50 3.50
5/16 5.44 .77 1.62 .88 .34 3.19 .67 4.50 (in.) EIP EEIP
Cordage
3/8 5.44 .77 1.62 .88 .41 3.19 .67 4.50 1/4 .68 .74
7/16 6.91 .98 2.00 1.06 .48 4.25 .86 5.75 5/16 1.1 1.2
1/2 6.91 .98 2.00 1.06 .55 4.25 .86 5.75 3/8 1.5 1.7
9/16 8.66 1.25 2.38 1.25 .61 5.31 1.13 7.25 7/16 2 2.2
5/8 8.66 1.25 2.38 1.25 .67 5.31 1.13 7.25 1/2 2.7 2.9
3/4 10.28 1.55 2.88 1.44 .80 6.38 1.31 8.63
Securement
9/16 3.4 3.7

7/8 11.94 1.70 3.12 1.69 .94 7.44 1.50 10.13 5/8 4.1 4.5
Load
1 13.56 1.98 3.63 2.06 1.06 8.50 1.75 11.50 3/4 5.9 6.5
1-1/8 15.03 2.25 4.00 2.31 1.19 9.56 2.00 12.75 7/8 8 8.8
1-1/4 16.94 2.53 4.50 2.56 1.33 10.63 2.25 14.38 1 10 11
1-3/8 18.63 2.80 5.00 2.56 1.45 11.69 2.25 15.75 1-1/8 13 14
1-1/2 20.12 3.08 5.50 2.81 1.58 12.75 2.50 17.00 1-1/4 16 18
Contractors
1-3/4 23.56 3.69 6.25 3.56 1.86 14.88 3.00 20.00 1-3/8 19 21
Supply
2 27.62 3.94 7.25 3.81 2.11 17.00 3.25 23.00 1-1/2 23 25

1-3/4 31 34
2 40 43
Protection
Fall

733

Open & Closed
Swage Sockets
■ Forged from special bar quality carbon steel, suitable
for cold forming.
■ Hardness controlled by spheroidize annealing. Before using any National Swage fitting with any other
■ Swage Socket terminations have an efficiency rating type lay, construction or grade of wire rope, it is
of 100% based on the catalog strength of wire rope. recommended that the termination be destructive tested
■ Stamp for identification after swaging without concern and documented to prove the adequacy of the assembly
for fractures (as per directions in National to be manufactured.
Swaging Brochure).
In accordance with ASME B30.9, all slings terminated
Note: S-502 Swage Sockets are recommended for use with swage sockets shall be proof loaded.
with 6 x 19 or 6 x 36, IPS or XIP (EIP), XXIP (EEIP), RRL,
FC or IWRC wire rope.
S-501 Open Swage Socket Specifications

Wire Weight Before Swage Dimensions (in.)
Rope Dia. Each
(in.) (lbs.) A B C D E F H L M N
1/4 .52 4.81 .50 1.38 .69 .27 2.13 .69 4.00 .38 1.50
5/16 1.12 6.25 .77 1.62 .81 .34 3.19 .81 5.31 .47 1.75
3/8 1.30 6.25 .77 1.62 .81 .41 3.19 .81 5.31 .47 1.75
7/16 2.08 7.81 .98 2.00 1.00 .48 4.25 1.00 6.69 .56 2.00
1/2 2.08 7.81 .98 2.00 1.00 .55 4.25 1.00 6.69 .56 2.00
9/16 4.67 9.50 1.25 2.38 1.19 .61 5.31 1.25 8.13 .68 2.25
5/8 4.51 9.50 1.25 2.38 1.19 .67 5.31 1.25 8.13 .68 2.25
3/4 7.97 11.56 1.55 2.75 1.38 .80 6.38 1.50 10.00 .78 2.75
7/8 11.52 13.41 1.70 3.13 1.62 .94 7.44 1.75 11.63 .94 3.25
1 17.80 15.47 1.98 3.69 2.00 1.06 8.50 2.00 13.38 1.06 3.75
1-1/8 25.25 17.31 2.25 4.06 2.25 1.19 9.56 2.25 15.00 1.19 4.25
1-1/4 35.56 19.06 2.53 4.50 2.50 1.33 10.63 2.50 16.50 1.22 4.75
1-3/8 43.75 20.94 2.80 5.00 2.50 1.45 11.69 2.50 18.13 1.38 5.25
1-1/2 58.50 22.88 3.08 5.50 2.75 1.58 12.75 3.00 19.75 1.69 5.75
1-3/4 88.75 26.63 3.39 6.69 3.50 1.86 14.88 3.50 23.00 2.11 6.75
2 146.25 31.44 3.94 8.00 3.75 2.11 17.00 4.00 26.88 2.37 8.00
S-502 Closed Swage Socket Specifications

Wire Weight Before Swage Dimensions (in.)
Rope Dia. Each
(in.) (lbs.) A B C D E F H L
1/4 .33 4.31 .50 1.38 .75 .27 2.12 .50 3.50
5/16 .75 5.44 .77 1.62 .88 .34 3.19 .67 4.50
3/8 .72 5.44 .77 1.62 .88 .41 3.19 .67 4.50
7/16 1.42 6.91 .98 2.00 1.06 .48 4.25 .86 5.75
1/2 1.42 6.91 .98 2.00 1.06 .55 4.25 .86 5.75
9/16 2.92 8.66 1.25 2.38 1.25 .61 5.31 1.13 7.25
5/8 2.85 8.66 1.25 2.38 1.25 .67 5.31 1.13 7.25
3/4 5.00 10.28 1.55 2.88 1.44 .80 6.38 1.31 8.63
7/8 6.80 11.94 1.70 3.12 1.69 .94 7.44 1.50 10.13
1 10.40 13.56 1.98 3.63 2.06 1.06 8.50 1.75 11.50
1-1/8 14.82 15.03 2.25 4.00 2.31 1.19 9.56 2.00 12.75
1-1/4 21.57 16.94 2.53 4.50 2.56 1.33 10.63 2.25 14.38
1-3/8 28.54 18.63 2.80 5.00 2.56 1.45 11.69 2.25 15.75
1-1/2 38.06 20.12 3.08 5.50 2.81 1.58 12.75 2.50 17.00
1-3/4 51.00 23.56 3.39 6.25 3.56 1.86 14.88 3.00 20.00
2 89.25 27.62 3.94 7.25 3.81 2.11 17.00 3.25 23.00
734

Forged Wire Rope Clips WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Cranes / Jibs
Overhead
G-450 Crosby® Clips
■ Each base has a Product Identification Code (PIC) for material
traceability, the name CROSBY or CG, and a size forged into it.
■ Based on the catalog breaking strength of wire rope, Crosby wire
SS-450 Stainless Steel Wire Rope Clips
Hoists
rope clips have an efficiency rating of 80% for 1/8" - 7/8" sizes,
and 90% for sizes 1" through 3-1/2". ■ Each base has a Product Identification Code (PIC) for
■ Entire Clip-Galvanized to resist corrosive and rusting action.
material traceability, the name CROSBY or “CG”, and a size
■ Sizes 1/8" through 2-1/2" and 3" have forged bases.
forged into it.
■ All Clips are individually bagged or tagged with proper application ■
Services
Entire clip is made from 316 Stainless Steel to resist corrosive
instructions and warning information.
and rusting action.
■ Clip sizes up through 1-1/2" have rolled threads. ■ All components are Electro-Polished.
■ Meets or exceeds all requirements of ASME B30.26 including ■ All Clips are individually bagged or tagged with proper
identification, ductility, design factor, proof load and temperature
application instructions and warning information.
requirements. Importantly, these wire rope clips meet other
Engineered
Products
critical performance requirements, including fatigue life, impact
properties and material traceability, not addressed by Crosby Clips, all sizes 1/4" and larger, meet the performance requirements
of Federal Specification FF-C-450 TYPE 1 CLASS 1, except for those provisions
ASME B30.26.
required of the contractor.
■ Look for the Red-U-Bolt®, your assurance of Genuine Crosby Clips.
* Electro-plated
G-450 Crosby® Clips U-Bolt and Nuts.
Slings
Rope Size G-450 Std. Weight Dimensions (in.) ** 2-3/4" and 3-1/2"
Stock Package Per 100
in. mm No. Qty. (lbs.) A B C D E F G H base is made of
cast steel.
1/8 * 3-4 * 1010015 100 6 .22 .72 .44 .47 .37 .38 .81 .99
3/16 * 5* 1010033 100 10 .25 .97 .56 .59 .50 .44 .94 1.18
Hardware
1/4 6-7 1010051 100 19 .31 1.03 .50 .75 .66 .56 1.19 1.43
5/16 8 1010079 100 28 .38 1.38 .75 .88 .73 .69 1.31 1.66 G-450
3/8 9-10 1010097 100 48 .44 1.50 .75 1.00 .91 .75 1.63 1.94
7/16 11 1010113 50 78 .50 1.88 1.00 1.19 1.13 .88 1.91 2.28
1/2 12-13 1010131 50 80 .50 1.88 1.00 1.19 1.13 .88 1.91 2.28
9/16 14-15 1010159 50 109 .56 2.25 1.25 1.31 1.34 .94 2.06 2.50
Products
5/8 16 1010177 50 110 .56 2.25 1.25 1.31 1.34 .94 2.06 2.50
Lifting
3/4 18-20 1010195 25 142 .62 2.75 1.44 1.50 1.39 1.06 2.25 2.84
7/8 22 1010211 25 212 .75 3.12 1.62 1.75 1.58 1.25 2.44 3.16
1 24-26 1010239 10 252 .75 3.50 1.81 1.88 1.77 1.25 2.63 3.47
1-1/8 28-30 1010257 10 283 .75 3.88 2.00 2.00 1.91 1.25 2.81 3.59
1-1/4 32-34 1010275 10 438 .88 4.44 2.22 2.34 2.17 1.44 3.13 4.13
1-3/8 36 1010293 10 442 .88 4.44 2.22 2.34 2.31 1.44 3.13 4.19
Rope
Wire
1-1/2 38 1010319 10 544 .88 4.94 2.38 2.59 2.44 1.44 3.41 4.44
1-5/8 41-42 1010337 Bulk 704 1.00 5.31 2.62 2.75 2.66 1.63 3.63 4.75
1-3/4 44-46 1010355 Bulk 934 1.13 5.75 2.75 3.06 2.92 1.81 3.81 5.24
2 48-52 1010373 Bulk 1300 1.25 6.44 3.00 3.38 3.03 2.00 4.44 5.88
2-1/4 56-58 1010391 Bulk 1600 1.25 7.13 3.19 3.88 3.19 2.00 4.56 6.38
2-1/2 62-65 1010417 Bulk 1900 1.25 7.69 3.44 4.13 3.69 2.00 4.69 6.63
Cordage
** 2-3/4 ** 68-72 1010435 Bulk 2300 1.25 8.31 3.56 4.38 4.88 2.00 5.00 6.88
3 75-78 1010453 Bulk 3100 1.50 9.19 3.88 4.75 4.44 2.38 5.31 7.61
** 3-1/2 ** 85-90 1010426 Bulk 4000 1.50 10.75 4.50 5.50 6.00 2.38 6.19 8.38
SS-450 Stainless Steel Wire Rope Clips

Securement
Load
Rope Size SS-450 Std. Weight Dimensions (in.)

Stock Package Per 100 SS-450
(in.) (mm) No. Qty. (lbs.) A B C D E F G H
1/8 3-4 1011250 Bulk 6 .22 .72 .44 .47 .41 .38 .81 .99
3/16 5 1011261 Bulk 10 .25 .97 .56 .59 .50 .44 .94 1.16
Contractors
1/4 6-7 1011272 Bulk 20 .31 1.03 .50 .75 .66 .56 1.19 1.44
Supply
3/8 9-10 1011283 Bulk 47 .44 1.50 .75 1.00 .91 .745 1.63 1.94
1/2 12-13 1011305 Bulk 77 .50 1.88 1.00 1.19 1.13 .88 1.91 2.28
5/8 16 1011327 Bulk 106 .56 2.38 1.25 1.31 1.34 .94 2.06 2.50
Protection
Fall

735

Fist Grip® WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Wire Rope Clips

■ Entire clip is Galvanized to resist corrosive and rusting action.
■ Based on the catalog breaking strength of wire rope,
Crosby wire rope clips have an efficiency rating of 80% for 3/16"—
7/8" sizes, and 90% for sizes 1" through 1-1/2". NEW STYLE
■ Bolts are an integral part of the saddle. Nuts can be installed FIST GRIP® CLIPS FIST GRIP® CLIPS
in such a way as to enable the operator to swing the wrench in a
3/16" - 5/8" 3/4" - 1-1/2"
full arc for fast installation.
■ All sizes have forged steel saddles.
■ All Clips are individually bagged or tagged with proper application
instructions and warning information.
■ Meets or exceeds all requirements of ASME B30.26 including
requirements. Importantly, these wire rope clips meet other
critical performance requirements, including fatigue life, impact
properties and material traceability, not addressed by
ASME B30.26.
■ Assembled with standard heavy hex nuts.
Fist Grip® wire clips meet or exceed the performance requirements of

Federal Specification FF-C-450 Type III, Class 1, except for those
provisions required of the contractor.
G-429 Fist Grip® Clips

Rope Size Std. Weight Dimensions (in.)
G-429 Package Per 100
in. mm Stock No. C D E G N
Qty. (lbs.)
3/16 - 1/4 5-7 1010471 100 23 .40 .94 .38 1.41 1.44
5/16 8 1010499 100 28 .47 1.06 .38 1350 1.54
3/8 10 1010514 50 40 .51 1.06 .44 1.84 1.78
7/16 - 1/2 11 - 13 1010532 50 62 .59 1.25 .50 2.21 2.15
9/16 - 5/8 14 - 16 1010550 50 103 .72 1.50 .63 2.72 2.57
3/4 18 - 20 1010578 25 175 .86 1.81 .75 2.94 2.67
7/8 22 1010596 25 225 .97 2.12 .75 3.31 2.86
1 24 - 26 1010612 10 300 1.13 2.25 .75 3.72 3.06
1-1/8 28 - 30 1010630 10 400 1.28 2.38 .88 4.22 3.44
1-1/4 32 - 34 1010658 10 400 1.34 2.50 .88 4.25 3.56
1-3/8 to 1-1/2 36 - 40 1010676 Bulk 700 1.56 3.00 1.00 5.56 4.12
* Sizes through 5/8" incorporate New Style Design.
736

S-421T Wedge Socket WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Cranes / Jibs
Overhead
■ Wedge socket terminations have an efficiency rating of 80% based
on the catalog strength of XXIP wire rope.
requirements. Importantly, these sockets meet other critical
Hoists
performance requirements, including fatigue life, impact properties
and material traceability, not addressed by ASME B30.26.
■ Type Approval and certification in accordance with ABS 2006
Steel Vessel Rules.1-1-17.7, and ABS Guide for Certification
of Cranes.
Services
■ Basket is cast steel and individually magnetic particle inspected.
■ Pin diameter and jaw opening allows wedge and socket to be
used in conjunction with closed swage and spelter sockets.
■ Secures the tail or “dead end” of the wire rope to the wedge,
thus eliminates loss or “Punch out” of the wedge.
Engineered
Products
■ Eliminates the need for an extra piece of rope, and is
easily installed.
■ The TERMINATOR™ wedge eliminates the potential breaking Wedge sockets meet the performance requirements of Federal Specification
off of the tail due to fatigue. RR-S-550D, Type C, except those provisions required of the contractor.
■ The tail, which is secured by the base of the clip and the wedge,
is left undeformed and available for reuse. ■ Utilizes standard Crosby Red-U-Bolt® wire rope clip.
Slings
■ Incorporates Crosby’s patented QUIC-CHECK® “Go” and ■ The 3/8" thru 1-1/8" standard S-421 wedge socket can be
“No-Go” feature cast into the wedge. The proper size rope is retrofitted with the new style TERMINATOR™ wedge.
determined when the following criteria are met: ■ Available with Bolt, Nut and Cotter Pin.
1. The wire rope should pass thru the “Go” hole in the wedge. ■ U.S. patent 5,553,360, Canada patent 2,217,004 and
2. The wire rope should NOT pass thru the “No-Go” hole in foreign equivalents.
Hardware
the wedge. ■ Meets the performance requirements of EN 13411-6: 2003.
■ Assembly includes Socket, Wedge, Pin and Wire Rope Clip
Wire Rope Wedge Only Optional G-4082

S-421T Weight S-421TW Bolt, Nut & Cotter
Diameter Weight
Stock Each Stock No.
Products
Each
Lifting
No. (lbs.) Wedge Only G-4082 Stock Weight Each
(in.) (mm) (lbs.) No. (lbs.)
3/8 9-10 1035000 3.18 1035555 .50 1092227 .38
1/2 11-13 1035009 6.15 1035564 1.05 1092236 .69
5/8 14-16 1035018 9.70 1035573 1.79 1092254 1.15
3/4 18-19 1035027 14.50 1035582 2.60 1092281 1.91
Rope
7/8 20-22 1035036 21.50 1035591 4.00 1092307 3.23
Wire
1 24-26 1035045 30.75 1035600 5.37 1092325 5.40
1-1/8 28 1035054 45.30 1035609 7.30 1092343 7.50
1-1/4 30-32 1035063 64.90 1035618 10.60 1092372 10.34
Wire Rope Dimensions
Cordage
Diameter S-421T (inches)
Stock No.
(in.) (mm) A B C D G H J* K* L P R S T U V
3/8 9-10 1035000 5.69 2.72 .81 .81 1.38 3.06 7.80 1.88 .88 1.56 .44 2.13 .44 1.25 1.38
1/2 11-13 1035009 6.88 3.47 1.00 1.00 1.62 3.76 8.91 1.26 1.06 1.94 .50 2.56 .53 1.75 1.88
Securement
5/8 14-16 1035018 8.25 4.30 1.25 1.19 2.12 4.47 10.75 1.99 1.22 2.25 .56 3.25 .69 2.00 2.19
3/4 18-19 1035027 9.88 5.12 1.50 1.38 2.44 5.28 12.36 2.41 1.40 2.63 .66 3.63 .78 2.34 2.56
Load
7/8 20-22 1035036 11.25 5.85 1.75 1.63 2.69 6.16 14.37 2.48 1.67 3.13 .75 4.31 .88 2.69 2.94
1 24-26 1035045 12.81 6.32 2.00 2.00 2.94 6.96 16.29 3.04 2.00 3.75 .88 4.70 1.03 2.88 3.28
1-1/8 28 1035054 14.38 6.92 2.25 2.25 3.31 7.62 18.34 2.26 2.25 4.25 1.00 5.44 1.10 3.25 3.56
1-1/4 30-32 1035063 16.34 8.73 2.62 2.50 3.56 9.39 20.48 2.94 2.34 4.50 1.06 6.13 1.19 4.62 4.94
Contractors
* Nominal Note: For intermediate wire rope sizes, use next larger size socket.
Supply
The S-423T Super TERMINATORTM wedge is designed to be assembled only into the Crosby S-421T TERMINATORTM socket body.
IMPORTANT: The S-423TW for sizes 5/8" through 1-1/8" (14mm through 28mm) will fit respective size standard Crosby S-421T basket.
The 1-1/4" (30-32mm) S-423TW will only fit the Crosby S-421T 1-1/4" basket marked with “ TERMINATORTM ”.
Protection
Fall

737

S-423T Super TerminatorTM WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Wedge Socket
■ Wedge socket terminations have a minimum efficiency rating
on most high performance, high strength, compacted strand,
rotation resistant wire ropes of 80% based on the catalog breaking
strength of the various ropes. **
■ Patent Pending design eliminates the difficulty of installing high
performance wire rope into a wedge socket termination.
■ Proper application of the Super TERMINATOR™ eliminates the
“first load” requirement of conventional wedge socket terminations.
■ S-423TW Wedge Kit can be retrofitted onto existing Crosby S-421T
TERMINATOR™ wedge sockets.
■ Wedge and accessories provided with a zinc finish.
■ Meets the performance requirements of EN13411-6:2003.
requirements. Importantly, these sockets meet other critical
performance requirements, including fatigue life, impact properties Wedge sockets meet the performance requirements of Federal Specification
RR-S-550D, Type C, except those provisions required of the contractor.
and material traceability, not addressed by ASME B30.26. Meets the performance requirements of EN13411-6:2003.
■ Basket is cast steel and individually magnetic particle inspected.
■ Pin diameter and jaw opening allows wedge and socket to ■ Available with Bolt, Nut and Cotter Pin.
be used in conjunction with closed swage and spelter sockets. ■ Assembly includes Socket, Wedge, Pin, Wire Rope Clip,
■ Secures the tail or “dead end” of the wire rope to the wedge, Tensioner, Bolts and Secondary Retention Wire.
thus eliminates loss or “punch out” of the wedge.
■ Eliminates the need for an extra piece of rope, and is ** NOTICE: Due to the unique construction of various ropes,
easily installed. Crosby cannot make a broad general statement that all current and
■ The TERMINATOR™ wedge eliminates the potential breaking future design of ropes, when properly assembled with the Super
off of the tail due to fatigue. TERMINATORTM, will achieve a minimum 80% termination
■ The tail, which is secured by the base of the clip and the efficiency. Contact wire rope manufacturer or Crosby Engineering
tension device, is left undeformed and available for reuse. (918-834-4611) to determine efficiency rating for a specific rope.
Wire Rope S-423T Assembly with S-423TB Assembly with Bolt, S-423TW **
Diameter Round Pin and Cotter Pin Nut and Cotter Pin Wedge Kit
S-423T S-423T Weight Each S-423TB S-423TB Weight Each S-423TW S423TW Weight Each
(in) (mm)
Stock No. lbs. kg Stock No. lbs. kg Stock No. lbs. kg
5/8 14-16 1035123 12.7 5.8 1035218 13.1 5.9 1034018 5.2 2.4
3/4 18-19 1035132 19.4 8.8 1035227 19.1 8.7 1034027 7.2 3.3
7/8 20-22 1035141 28.8 13.1 1035236 27.8 12.6 1034036 10.3 4.7
1 24-26 1035150 39.2 17.8 1035245 37.3 16.9 1034045 11.9 5.4
1-1/8 28 1035169 57.1 25.9 1035254 57.9 25.9 1034054 19.9 9.0
1-1/4 30-32 1035178 88.6 40.2 1035272 88.1 39.9 1034063 33.8 15.3
** Kit contains Wedge, Wire Rope Clip and Bolts, Tensioner, Tensioner Bolt and Secondary Retention Wire.
Wire Rope S-421T Dimensions

Diameter Stock (inches)
(in) (mm) No. A B C D G F G H J* L P R S T U V
5/8 14-16 1035123 8.25 4.50 1.25 1.19 3.00 4.06 2.13 4.61 12.31 1.22 2.25 .56 3.25 .75 6.88 2.60
3/4 18-19 1035132 9.88 5.20 1.50 1.38 3.25 4.81 2.44 5.37 14.69 1.40 2.62 .66 3.63 .88 7.65 3.02
7/8 20-22 1035141 11.25 5.88 1.75 1.63 3.81 5.73 2.69 6.16 16.98 1.67 3.13 .75 4.31 1.00 9.47 3.47
1 24-26 1035150 12.81 6.56 2.00 2.00 3.81 5.73 2.94 7.05 18.54 2.01 3.75 .88 4.70 1.13 10.41 3.82
1-1/8 28 1035169 14.38 6.94 2.25 2.25 4.00 6.85 3.38 7.81 21.23 2.26 4.25 1.00 5.44 1.25 11.83 4.22
1-1/4 30-32 1035178 16.34 8.63 2.62 2.50 4.50 7.76 3.57 9.38 24.10 2.34 4.50 1.06 6.62 1.38 13.87 5.82
* Nominal Note: For intermediate wire rope sizes, use next larger size socket.
The S-423T Super TERMINATORTM wedge is designed to be assembled only into the Crosby S-421T TERMINATORTM socket body.
IMPORTANT: The S-423TW for sizes 5/8" through 1-1/8" (14mm through 28mm) will fit respective size standard Crosby S-421T basket.
The 1-1/4" (30-32mm) S-423TW will only fit the Crosby S-421T 1-1/4" basket marked with “ TERMINATORTM ”.
738

Threaded Sleeve
Cranes / Jibs
Overhead
When you want to maximize the length adjustment of
your assembly at the point where a wire rope is attached,
the threaded sleeve is ideal.
The sleeve is made to meet your requirements.
Hoists
The standard sleeve material is carbon steel, but stainless
steels and higher strength steels are also available
on request.
Services
We furnish the sleeves without wrench flats unless
specified on the order.
You should also measure the length of the assembly,

using the maximum dimensions (from the outside
Engineered
Products
end of the sleeve).
To determine the thread length (TL), use the minimum

dimensions needed. This allows us to use existing
qualified designs. The standard thread used is Right
Hand National Course Class 2A, but other threads
Slings
are available on request.
You may order custom designs with different fitting

lengths if you want, but that may reduce the assembly’s
Hardware
overall rated capacity. Call our Customer Service
Department to evaluate all the possibilities.
Products
Wire Rope Thread Wrench Flat After Swage Length
Lifting
Diameter Length (TL) Thread Thread (Optional) (AS) Diameter B
UNC UNC
in. in. in. in. in.
3/32 * .75 1/4" - 20 1/4" - 20 7/32" x 1/4" .25 1.25
1/8* .75 1/4" - 20 1/4" - 20 7/32" x 1/4" .25 1.25
Rope
5/32 * 1 5/16" - 18 5/16" - 24 9/32" x 1/4" .3125 1.5
Wire
3/16 * 1.25 3/8" - 16 3/8" - 24 11/32" x 1/4" .375 1.75
7/32 * 1.75 7/16" - 14 7/16" - 20 3/8" x 3/8" .4375 2.38
1/4 * 1.75 1/2" - 13 1/2" - 20 7/16" x 3/8" .5 2.38
9/32 1.75 9/16" - 12 9/16" - 18 1/2" x 3/8" .5625 2.50
Cordage
5/16 2.50 5/8" - 11 5/8" - 18 9/16" x 1/2" .625 3.25
3/8 3 3/4" - 10 3/4" - 16 11/16" x 1/2" .75 3.75
7/16 3.25 7/8" - 9 7/8" - 14 13/16" x 1/2" .875 4
1/2 3.75 1" - 8 1" x 14 7/8" x 1/2" 1 4.5
9/16 4 1-1/8" - 7 1-1/8" - 12 1" x 3/4" 1.125 5
Securement
5/8 5 1-1/4" - 7 1-1/4" - 12 1-1/8" x 3/4" 1.25 6

Load
3/4 5.75 1-1/2" - 6 1-1/2" - 12 1-3/8" x 1" 1.5 7

7/8 6.75 1-3/4" - 5 1-3/4" - 12 1-5/8" x 1" 1.75 8
1 7.75 2" - 4.5 2" - 12 1-7/8" x 1-1/4" 2 9.25
Contractors
* Galvanized Aircraft Cable

Supply
Protection
Fall

739

Threaded Stud
When your application requires a simple threaded assembly,
the threaded stud is the most economical choice. You can
depend on the tolerances with this assembly.
Materials available:
■ Carbon Steel (standard)

■ Stainless Steel
■ Higher Strength Steels
■ Zinc Plating, also available
We furnish the studs without wrench flats unless

specified on the order.
When measuring the thread length, use the minimum

dimensions to make use of existing qualified designs.
Thread length may be increased if desired. The standard

thread used is Right Hand National Course Class 2A, but
other threads are available on request.
The B and A fitting dimensions are needed, along

with the maximum length of the assembly measured
using the outside end of the stud.
Custom designs with different fitting lengths and

thread diameters are available, but that may reduce
the assembly’s ultimate rated capacity. Please
check with our Customer Service Department.
Wire Rope Thread Wrench Flat After Swage Length

Diameter Length C Thread (Optional) A B
in. in. in. in. in.
3/32 * 3 1/4" - 20 3/16" x 3/16" .22 4.25
1/8* 3 1/4" - 20 3/16" x 3/16" .22 4.25
5/32 * 6 5/16" - 18 7/32" x 1/4" .25 7.63
3/16 * 6 3/8" - 16 9/32" x 1/4" .31 7.88
7/32 * 6 7/16" - 14 11/32" x 3/8" .38 8.75
1/4* 6 1/2" - 13 3/8" x 1/2" .44 9
9/32 6 9/16" - 12 7/16" x 1/2" .5 9.5
5/16 6 5/8" - 11 1/2" x 1/2" .56 9.75
3/8 6 3/4" - 10 9/16" x 1/2" .63 10.25
7/16 6 7/8" - 9 11/16" x 1/2" .75 11
1/2 6 1" - 8 3/4" x 1/2" .875 11.5
9/16 6 1-1/8" - 7 7/8" x 1/2" 1 12.25
5/8 6 1-1/4" - 7 1" x 1/2" 1.13 12.75
3/4 6 1-1/2" - 6 1-1/8" x 3/4" 1.25 14.25
7/8 7 1-3/4" - 5 1-3/8" x 3/4" 1.5 16.5
1 8 2" - 4.5 1-5/8" x 1" 1.75 19
1-1/8 9 2-1/4" - 4.5 1-7/8" x 1" 2 21.5
1-1/4 10 2-1/2" - 4 2-1/8" x 1" 2.25 24
* Galvanized Aircraft Cable
740

Wire Rope Terminals
Cranes / Jibs
Overhead
Plain Ball BA3—Corrosion Resistant Specifications
Sphere Min
Cable Lbs.
Part A B C D E Dia. Breaking
Dia. Per
Number F Strength
Piece
Hoists
in. in. in. in. in. in. in. Lbs.
.211 .035 .141 .026 .083 .1905
BA3-1 1/32 60 .002
.208 .038 .137 .016 .073 .1875
.211 .076 .141 .026 .083 .1905
BA3-2 1/16 385 .0017
.208 .073 .137 .016 .073 .1875
Services
.288 .106 .174 .041 .099 .253
BA3-3 3/32 735 .004
.284 .102 .170 .031 .089 .250
.355 .143 .190 .041 .142 .317
BA3-4 1/8 1,200 .006
.351 .139 .184 .031 .132 .312
.429 .175 .227 .041 .170 .380
BA3-5 5/32 1,680 .009
Engineered
.425 .171 .220 .031 .160 .375
Products
.498 .207 .264 .041 .197 .442
BA3-6 3/16 2,520 .01
.493 .203 .259 .031 .187 .437
Double Shank Ball MS 20663—Corrosion ResistantSpecifications
Slings
Bs RS
Cable A As B L Ls N Lbs.
Part Sphere D Max
Dia. Dia. Dia. Dia. ± .0075 Ref Dia. Per
Number Dia. Rad
Piece
in. in. in. in. in. in. in. in. in. in.
MS20663C2 1/16 .127 .112 .207 .190 .114 .362 .390 .073 .014 .0016
Hardware
MS20663C3 3/32 .163 .143 .277 .253 .152 .525 .578 .104 .019 .0032
MS20663C4 1/8 .218 .190 .345 .315 .1895 .688 .765 .139 .023 .0094
MS20663C5 5/32 .254 .222 .419 .379 .227 .850 .953 .169 .028 .0125
MS20663C6 3/16 .293 .255 .487 .442 .264 1.012 1.140 .201 .033 .025
MS20663C7 7/32 .347 .302 .555 .505 .3025 1.175 1.328 .233 .038 .032
MS20663C8 1/4 .401 .348 .624 .567 .3395 1.337 1.515 .264 .042 .040
Products
Lifting
MS20663C9 9/32 .439 .382 .694 .632 .3775 1.497 1.7119 .297 .046 .042
MS20663C10 5/16 .475 .413 .763 .694 .4145 1.664 1.875 .328 .046 .043
Single Shank Ball MS 20664—Corrosion Resistant Specifications
Rope
Bs E MS
Wire
Cable A As B N Lbs.
Part Sphere Cs D Rad L Max
Dia. Dia. Dia. Dia. Dia. Per
Number Dia. Ref Rad
Piece
in. in. in. in. in. in. in. in. in. in. in.
MS20663C2 1/16 .132 .112 .212 .190 .156 .114 .0825 .2685 .073 .014 .0019
Cordage
MS20664C3 3/32 .168 .143 .282 .253 .234 .152 .110 .384 .104 .019 .005
MS20663C4 1/8 .223 .190 .350 .315 .313 .1895 .137 .500 .139 .023 .0075
MS20664C5 5/32 .259 .222 .424 .379 .391 .227 .165 .616 .169 .028 .01
MS20664C6 3/16 .298 .255 .492 .442 .469 .264 .192 .730 .201 .033 .015
MS20664C7 7/32 .352 .302 .560 .505 .547 .3025 .220 .846 .233 .038 .025
Securement
MS20664C8 1/4 .406 .348 .629 .567 .625 .3395 .247 .962 .264 .042 .03
Load
MS20664C9 9/32 .444 .382 .699 .632 .750 .3775 .275 1.078 .297 .046 .05
MS20664C10 5/16 .480 .413 .768 .694 .813 .4145 .302 1.193 .328 .046 .066
Contractors
Supply
Protection
Fall

741

Wire Rope Terminals (Continued)
Terminal—Cylindrical ST 24 Specifications
Cable Die
Part A B C D C=As Lbs. Per
Dia. Size
Number Piece
in. in. in. in. in. in. in.
.224 .221 .190 .076
ST24-2 1/16 .190 3/32 .0019
.214 .217 .185 .073
.333 .252 .219 .107
ST24-3 3/32 .219 1/8 .005
.323 .248 .214 .104
.416 .298 .250 .146 Also known as “Stop Buttons”,
ST24-4 1/8 .250 5/32 .0075
.406 .294 .245 .141 “Sleeves”, “Boeing Buttons”, these
.510 .377 .313 .177 Stainless Steel Terminals have had
ST24-5 5/32 .313 3/16 .01 a multitude of uses. When properly
.500 .373 .303 .172
.635 .439 .315 .208 applied, they will hold the breaking
ST24-6 3/16 .375 7/32 .114 strength of the wire rope.
.625 .435 .370 .203
Fork End MS 20667—Corrosion Resistant Specifications

F L
Cable A As D G ± Ls N U Z Lbs.
Part +.010 H +.020
Dia. Dia. Dia. Dia. .003 Ref Dia. Dia. Min Per
Number -.005 -.000
Piece
in. in. in. in. in. in. in. in. in. in. in. in.
MS20667-2 1/16 .160 .138 .190 .218 .093 .500 1.572 1.75 .078 .344 .600 .01
MS20667-3 3/32 .218 .190 .190 .254 .108 .670 1.945 2.06 .109 .438 .757 .02
MS20667-4 1/8 .250 .219 .190 .383 .195 .735 2.352 2.61 .141 .547 .914 .0325
MS20667-5 5/32 .297 .250 .250 .406 .202 .800 2.665 3.00 .172 .688 .967 .05
MS20667-6 3/16 .359 .313 .313 .543 .260 .880 3.071 3.24 .203 .781 1.133 .09
MS20667-7 7/32 .427 .375 .313 .625 .296 .970 3.440 3.74 .234 .906 1.252 .15
MS20667-8 1/4 .494 .438 .375 .688 .313 1.070 3.806 4.10 .265 .969 1.368 .20
MS20667-9 9/32 .563 .500 .438 .719 .327 1.170 4.120 4.48 .297 1.156 1.432 .30
MS20667-10 5/16 .635 .563 .438 .765 .348 1.268 4.438 4.86 .328 1.265 1.5 .3812
MS20667-12 3/8 .703 .625 .500 .830 .380 1.525 5.033 5.74 .390 1.5 1.895 .575
MS20667-14 7/16 .781 .688 .562 .830 .380 1.776 6.402 6.57 .468 1.75 2.164 .775
MS20667-16 1/2 .844 .750 .625 1.035 .473 1.903 6.938 7.50 .531 1.875 2.313 1.625
Strap Fork Ends—Corrosion Resistant—MIL Spec. NAS 1435-K Specifications

Cable Lbs.
Part NAS A B C D E F
Dia. Per
Number Number
in. in. in. in. in. in. in. Piece
SP 2-2 NAS 1435K-2 1/16 1-1/16 .454 .188 .042 3/8 .093 .006
SP 2-3 NAS 1435K-3 3/32 1-1/2 .616 .188 .049 7/16 .108 .013
SP 2-4 NAS 1435K-4 1/8 1-5/8 .638 .188 .093 1/2 .195 .303
SP 2-5 NAS 1435K-5 5/32 1-31/32 .699 .25 .096 9/16 .202 .042
SP 2-6 NAS 1435K-6 3/16 2-3/16 .75 .313 .125 11/16 .260 .083
Strap Eyes—Corrosion Resistant—MIL Spec. NAS 1435-E Specifications

Cable
Part NAS A B C D E Lbs. Per
Dia.
Number Number Piece
in. in. in. in. in. in.
SP 2-2 NAS 1435K-2 1/16 1-1/16 .454 .188 .042 3/8 .006
SP 2-3 NAS 1435K-3 3/32 1-1/2 .616 .188 .049 7/16 .013
SP 2-4 NAS 1435K-4 1/8 1-5/8 .638 .188 .093 1/2 .303
SP 2-5 NAS 1435K-5 5/32 1-31/32 .699 .25 .096 9/16 .042
SP 2-6 NAS 1435K-6 3/16 2-3/16 .75 .313 .125 11/16 .083
742

Wire Rope Terminals (Continued)
Cranes / Jibs
Overhead
Eye End MS 20668—Corrosion Resistant Specifications
U
C L
Cable A As D Ls N +.025 Z Lbs.
Part ±. J +.020 P Y
Dia. Dia. Dia. Dia. Ref Dia. -.010 Min Per
Number 020 -.000
Hoists
Dia. Piece
in. in. in. in. in. in. in. in. in. in. in. in. in.
MS20668-2 1/16 .160 .138* .523 .190 .088 1.631 1.809 .078 1.042 .359 .072 .662 .009
MS20668-3 3/32 .218 .190* .707 .190 .103 2.043 2.160 .109 1.261 .438 .092 .856 .018
MS20668-4 1/8 .250 .219* .738 .190 .190 2.337 2.593 .141 1.511 .500 .103 .900 .035
MS20668-5 5/32 .297 .250* .831 .250 .197 2.684 3.029 .172 1.761 .640 .131 .997 .050
Services
MS20668-6 3/16 .359 .313* .903 .313 .255 3.019 3.187 .203 2.011 .781 .155 1.082 .090
MS20668-7 7/32 .427 .375** 1.007 .313 .291 3.382 3.678 .234 2.261 .813 .187 1.195 .135
MS20668-8 1/4 .494 .438** 1.133 .375 .307 3.763 4.062 .265 2.511 .968 .221 1.326 .200
MS20668-9 9/32 .563 .500*** 1.257 .438 .322 4.153 4.512 .297 2.761 1.109 .251 1.465 .250
MS20668-10 5/16 .635 .563*** 1.373 .438 .343 4.546 4.969 .328 3.011 1.218 .281 1.609 .400
MS20668-12 3/8 .703 .625*** 1.688 .500 .375 5.562 5.968 .390 3.511 1.50 .320 2.124 .575
Engineered
* +.000 / -.005 *** +.000 / -.008
Products
MS20668-14 7/16 .781 .688*** 1.968 .562 .375 6.398 6.867 .468 4.011 1.75 .350 2.460 .790 ** +.000 / -.007 **** +.000 / -.009
MS20668-16 1/2 .844 .750**** 2.115 .625 .468 7.323 7.886 .531 4.698 1.875 .406 2.698 1.050
Clevis Pins PI 1—Corrosion Resistant Specifications

Cable Lbs.
Part Fits MS No. A B C D E L F
Slings
Dia. Per
Number Indicated
in. in. in. in. in. in. in. in. Piece
P11-2 MS-20667-2 1/16 3/16 1/4 3/64 3/64 .076 25/64 9/32 .004
P11-3 MS-20667-3 3/32 3/16 1/4 3/64 3/64 .076 25/64 9/32 .004
P11-4 MS-20667-4 1/8 3/16 5/16 3/64 3/64 .076 17/32 13/32 .005
Hardware
P11-5 MS-20667-5 5/32 1/4 3/8 1/16 1/16 .076 17/32 13/32 .009
P11-6 MS-20667-6 3/16 5/16 7/16 1/16 5/64 .106 23/32 9/16 .017
P11-7 MS-20667-7 7/32 5/16 7/16 1/16 5/64 .106 7/8 11/16 .020
P11-8 MS-20667-8 1/4 3/8 1/2 3/32 5/64 .106 31/32 13/16 .033
P11-9 MS-20667-9 9/32 7/16 9/16 1/8 3/32 .106 1-3/32 7/8 .040
P11-10 MS-20667-10 5/16 7/16 9/16 1/8 3/32 .106 1-3/32 7/8 .040
P11-12 MS-20667-12 3/8 1/2 5/8 5/32 7/64 .140 1-1/4 1 .050
Products
Lifting
Cotter Pin Specifications
Part Number A (in.) B (in.) C (in.)
PI 5-1 .062 .75 1/8
PI 5-2 .093 1.00 3/16
Rope
Wire
Marine Eye EY1—Corrosion Resistant Steel Specifications
After
After
C D E F J U Swage
Cable Swage
Cordage
Lbs.
Part +.460 +.010 +.000 +.006 ± L P +.041 ES
Dia. LS Per
Number -.065 -.010 -.005 -.000 1/32 -.078 +.042
Ref Piece
-.079
in. in. in. in. in. in. in. in. in. in. in.
EY1-2 1/16 .500 .264 .160 .078 .218 1.50 1.063 .594 .138 1.809 .015
Securement
EY1-3 3/32 .500 .264 .218 .109 .218 1.758 1.188 .594 .190 2.070 .028
EY1-4 1/8 .500 .264 .250 .141 .218 2.088 1.50 .594 .219 2.401 .033
Load
EY1-5 5/32 .580 .327 .297 .172 .281 2.355 1.688 .75 .25 2.709 .055
EY1-6 3/16 .710 .389 .359 .201 .359 2.750 2 .875 .313 3.147 .090
EY1-7 7/32 .800 .452 .427 .228 .406 3.220 2.313 1 .375 3.787 .015
EY1-8 1/4 .900 .514 .494 .265 .468 3.625 2.5 1.125 .438 4.282 .025
EY1-9 9/32 .990 .514 .563 .295 .468 3.795 2.688 1.125 .500 4.514 .330
Contractors
EY1-10 5/16 1.080 .640 .635 .325 .593 4.495 3.25 1.375 .563 5.274 .50
Supply
EY1-12 3/8 1.150 .640 .703 .390 .593 4.930 3.5 1.375 .625 5.659 .670
EY1-14 7/16 1.240 .765 .781 .468 .719 6.375 4.125 1.625 .688 6.750 1
EY1-16 1/2 1.290 .890 .844 .531 .844 7.375 4.750 1.875 .750 7.187 1.25
Protection
Fall

743

Copper Oval &
Copper Stop Sleeves
Nicopress Finished Nicopress Finished

Oval Sleeve Eye Splice Stop Sleeve Stop
Copper Oval Sleeves

Nicopress Oval Approx. Sleeve Sleeve
Sleeve Stock No. Nicopress
Cable Weight Per Length Before Length After
Hand Tool
Size Plain Zinc-Plated 1000 Sleeves Compressed Compressed
Stock No.
Copper Copper (lbs.) Approx. Approx.
1/32" 17-1-B 27-1-B 17-BA * 0.6 1/4" 5/16"
3/64" 18-11-B4 28-11-B4 51-B4-887 2 3/8" 7/16"
1/16" 18-2-C 28-1-C 51-C-887 3 3/8" 7/16"
3/32" 18-2-G 28-2-G 51-G-887 5 3/8" 7/16"
1/8" 18-3-M 28-3-M 51-M-850 17 9/16" 3/4"
5/32" 18-4-P 28-4-P 51-P-850 23 5/8" 7/8"
3/16" 18-6-X 28-6-X 51-X-850 49 15/16" 1-3/16"
7/32" 18-8-F2 28-8-F2 51-F2-850 56 7/8" 1-1/16"
1/4" 18-10-F6 28-10-F6 3-F6-950 80 1-1/8" 1-1/2"
5/16" 18-13-G9 28-13-G9 3-G9-950 114 1-1/16" 1-3/8"
No. 635 Hydraulic Tool Dies
3/8" 18-23-H5 18-23-H5 Oval H5 153 1-1/4" 1-5/84"
7/16" 18-24-J8 18-24-J8 J8H6 302 1-3/4" 2-5/16"
1/2" 18-25-K8 18-25-K8 Oval K8 410 1-7/8" 2-1/2"
9/16" 18-27-M1 18-27-M1 Oval M1 551 2" 2-5/8"
5/8" 18-28-N5 18-28-N5 Oval N5 802 2-3/8" 3-1/8"
Copper Stop Sleeves
Approx. Sleeve Typical Holding
Nicopress Nicopress Outside
Cable Weight Per Length Before Strength of
Stop Sleeve Hand Tool Diameter
Size 1000 Sleeves Compressed Stop Sleeve
Stock No. Stock No. of Sleeve
(lbs.) Approx. (lbs.) **
1/32" 871-32-B 17-BA * 1/8" 3/4 1/4" 120
3/64" 871-12-B4 51-B4-887 11/64" 1-1/2 7/32" 240
1/16" 871-1-C 51-C-887 13/64" 2 7/32" 430
1/16" 871-1-Q *** 51-q929 1/4" 2 5/32" 425
3/32" 871-17-J (Yellow) 51-MJ 21/64" 8 5/16" 600
3/32" 871-3-Q *** 51-Q-929 1/4" 2 5/32" 55
1/8" 871-18-J (Red) 51-MJ 21/64" 8 5/16" 900
5/32" 871-19-M 51-MJ 27/64" 13 5/16" 1200
3/16" 871-20-M (Black) 51-MJ 27/64" 12 5/16" 1600
7/32" 871-22-M 51-MJ 7/16" 20 5/8" 2500
1/4" 871-23-F6 3-F6-950 21/32" 60 11/16" 3500
5/16" 871-26-F6 3-F6-950 21/32" 60 11/16" 4000
* Formerly 17-1 Tool

** Holding strengths shown are based on use of galvanized aircraft cable.
*** Electro Galvanized Steel Sleeves
744

Nickel Plated
Cranes / Jibs
Overhead
Copper Oval Sleeves
Nicopress Tools Sleeve Sleeve
Weight
Nicopress Single Multi- Length Length
(lbs.)
Hoists
Cable Oval Sleeve Groove Groove Number 635 Before After
Per 1000
Size Stock Hand Tool Hand Tool Hydraulic Compres- Compres-
Sleeves
Number Stock Stock Tool Die sion sion
Approx.
Number Number Approx. Approx.
3/64" 428-1.5-VB4 51-B4-887 33V-CGB4 Oval B4 2 3/8" 7/16"
Services
33V-CGB4 or
1/16" 428-25-VC 51-C-887 Oval C 3 3/8" 7/16"
64-CGMP
33V-CGB4 or
3/32" 428-3-VG 51-G-887 Oval G9 6 3/8" 7/16"
64-CGMP
33V-CGB4 or
Engineered
1/8" 428-4-VM 51-M-850 Oval M 17 9/16" 3/4"
Products
64-XPM
33V-CGB4 or
5/32" 428-5-VP 51-P-850 Oval P 23 5/8" 7/8"
64-XPM
3/16" 428-6-VX 51-X-850 63-XPM Oval X 49 15/16" 1-3/16"
7/32" 428-7-VF2 51-F2-850 – Oval F2 59 7/8" 1-1/16"
1/4" 428-8-VF6 3-F6-950 – Oval F6 81 1" 1-3/8"
Slings
5/16" 428-105-VG9 3-G9-950 – Oval G9 120 1-1/16" 1-3/8"
3/8" 428-12-VH5 – – Oval H5 155 1-3/16" 1-1/2"
7/16" 428-14-VJ8 – – Oval J8 310 1-3/4" 2-5/16"
1/2" 428-16-VK8 – – Oval K8 420 1-7/8" 2-9/16"
Hardware
9/16" 428-18-VM1 – – Oval M1 565 2" 2-13/16"
5/8" 428-20-VN5 – – Oval N5 822 2-3/8" 3-1/4"
The 428 Series oval sleeves are made from special materials and are specifically designed for use with stainless
steel aircraft cable. The nickel plating gives this Nicopress sleeve a distinctive appearance.
Products
Lifting
Stainless Steel
Oval Sleeves
Rope
Wire
Nicopress Oval Sleeves Nicopress Tool Selection
Cable Sleeve Length
Weight (lbs.) Number 35
Size Sleeve Stock Before
Per 1000 Sleeves Hand Tool Hydraulic Tool
Number Compression
Approx. Die
Cordage
Approx.
1/32" 168-1-VB 1/2 1/4" 31-B –
3/64" 168-1.5-VB4 1-1/2 3/8" 31-B4-887 Oval B4
1/16" 168-2-VB4 1-1/2 3/8" 31-B-887 Oval B4
3/32" 1683-VC 2-1/4 3/8" 31-C-887 Oval C
Securement
1/8" 168-4-VG 3-3/4 3/8" 31-G-887 Oval BG

Load
5/32" 168-5-VM 14 23/32" 51-M-850 Oval M

3/16" 168-6-VP 17 3/4" 51-P-850 Oval P
7/32" 168-7-VX 31 7/8" – Oval X
1/4" 168-8-VF2 44 1-1/8" – Oval F2
Contractors
Supply
Conform to military standard (MS-51844).

Protection
Fall

745

Aluminum WARNING SEE WARNING INFORMATION
ON PAGES 755 - 757.
Oval Sleeves
For Steel Cable
Nicopress Oval Sleeves

Nicopress Nicopress Sleeve Length
Size of Approx. Weight Sleeve Length
Oval Sleeves Hand Tools Before
Cable Per 1000 Before
Stock No. Stock No. Compressed
Sleeves (lbs.) Compressed
Approx.
1/16" 118-2-VC 51-C-887 1 3/8" 7/16"
3/32" 188-3-VG 51-G-887 2.8 9/16" 5/8"
1/8" 188-4-VM 51-M-850 6.1 5/8" 13/16"
5/32" 188-5-VP 51-P-850 9 3/4" 1-1/32"
3/16" 188-6-VX 51-X-850 15 7/8" 1-3/16"
1/4" 188-8-VF6 3-F6-950 27 1-1/8" 1-7/16"
Number 635 Hydraulic Tool Dies
5/16" 188-10-VG92 VG92 48 1-3/8" 1-11/16"
3/8" 188-12-VJ8 Oval J8 104 1-7/8" 2-3/8"
7/16" 188-14-VK8 Oval K8 115 1-7/8" 2-3/8"
1/2" 188-16-VM1 Oval M1 169 2-1/8" 2-3/4"
For Fiber Ropes
Nicopress Oval Sleeves

Nicopress Sleeve Length
Size of Nicopress Approx. Weight
Oval Sleeves Before
Rope Hand Tools per 1000
Stock No. Compressed
Stock No. Sleeves (lbs.)
Approx.
1/16" 1700-C 51-C-887 1 3/8"
1/8" 1700-M 51-M-850 7 11/16"
3/16" 1582-P 51-P-850 9 1"
1/4" 1700-X 51-X-850 20 1-1/4"
Number 635 Hydraulic Tool Dies
5/16" 1700-G3 1700-G3 30 1-1/8"
3/8" 1700-H5 1700-H5 63 1-9/16"
1/2" 1700-J8 1700-J8 110 2"
Note: Mechanical hand tools and bench tools are available for compressing sleeves onto cable 1/32" to 5/16".
Larger cable sizes require use of the Nicopress #635 hydraulic tool with pressing dies. Information on power press dies
for high speed production will be furnished upon request.
746

Cutter Tools
Cranes / Jibs
Overhead
Nicopress No. 64-CGMP
Cutter Tool with Cable Cutter
Tool Length: 20"
Hoists
Actual Weight: 5-1/2 pounds
The Nicopress 64-CGMP/Cutter Tool combines

two important functions…cable cutting and oval sleeve
Services
pressing. The 64-CGMP/Cutter Tool eliminates the
handling of two separate tools. Engineered for field
conditions, this tool is made from drop-forged alloy
steel; the working surfaces are heat treated and specially
hardened. Toggle action provides high mechanical
Engineered
force and results in low cutting effort. Cutting blades can
Products
be reversed for long useful life. This versatile field Cuts Cable
and shop tool cuts mechanical cable sizes up
thru 7/32".
The 64-CGMP/Cutter Tool presses Nicopress Oval

Sleeves 1/16" (C), 3/32" (G), 1/8" (M) and 5/32" (P).
Slings
In addition, the 1/16" stop sleeve can be pressed
with the C groove.
This tool cuts mechanical steel cable as large as 7/32",
Hardware
the cutting surfaces surround and support the cable
while it is being cut. There are no frayed cable ends
and cable cuts are clean and round.
Very low cutting effort is required to cut mechanical
Products
steel cable up thru 7/32". Hardened cutter blades
Lifting
surround and support the cable during the cutting action,
which results in round, clean-cut cable ends.
Eye Splices Cable
Rope
Wire
Cordage
Securement
Load
This single tool will cut and eye splice steel cable,
eliminating the need for two separate tools.
The 64-CGMP/Cutter Tool eye splices four cable sizes—
Contractors
Supply
1/16", 3/32", 1/8" and 5/32".

Protection
Fall

747

Cutter Tools (Continued)
No. 32-VC: VG Tool
Tool Length: 11-1/2"

Shipping Weight: 2-1/2 pounds
A small hand tool with two sleeve-pressing grooves

in the head. It is used for splicing with Nicopress Oval
and Stop Sleeves having "C" or "G" letters in their
Stock Numbers.
No. 51 Tools

Each tool has a single sleeve-pressing

groove for the size of cable. Range
accommodated—3/64" through 7/32".
Types No. 63 and No. 64 Tools
Tool Length: 20"

Shipping Weight: 6 pounds
These are multiple sleeve-pressing groove

hand tools. The No. 63V-XPM has three grooves
and is used only with Oval Sleeves.
For cable sizes 1/8", 5/32" and 3/16".
748

Cranes / Jibs
Overhead
NO. 51 Tools for
Stop Sleeves
Hoists
The No. 51-MJ hand tool with two sleeve-

pressing grooves is used for all M and J lettered
Services
Nicopress Stop Sleeves for cable sizes 3/32"
through 7/32". The "M" groove of this tool can
also be used for the No. 18-3-M and No. 28-3-M
Oval Sleeves.
Engineered
The No. 51-Q-929 single-groove tool is used for
Products
galvanized steel Stop Sleeves No. 871-1-Q
and No. 871-3-Q.
Slings
Number 33V-CGB4
Hardware
Nicopress Tool

Products
Lifting
When several small diameter cables are being
used, we recommend this multi-groove tool.
The 33V-CGB4 has three pressing grooves,
which press oval sleeves 3/64" (B-4),
1/16" (C) and 3/32" (G).
Rope
Wire
Cordage
Splices made with these tools typically hold
military specification grade aircraft control
cable in tension until the cable breaks. To ensure
good splices, make the proper number of
presses in each sleeve. Applications that require
Securement
continuous and frequent sleeve pressing call

Load
for the use of our larger toggle action tools,

or power press equipment.
Contractors
Supply
Protection
Fall

749

Model 510 Bench Tool
Tool Length: 21"
Approx. Weight: 6 pounds
Will accommodate the following interchangeable tool heads:

51-B4-887; 51-C-887; 51-G-887; 51-X-850; 51-F2-850;
64-CGIVIP; 51-M-850; 51-P-850; 63V-XPM; 51-MJ.
Designed to speed up bench type cable assembly work by

allowing for one hand operation of bench press thereby
freeing up other hand to position sleeve and cable. Available
in two sizes.
Note: Heads may be removed from No. 51, No. 63 and

No. 64 type hand tools and used in No. 510 Bench Mount.
Model 300 Bench Tool

Tool Length: 35"
Approx. Weight: 19 pounds
Will accommodate the following interchangeable tool heads:

3-C-887; 3-G-887; 3-M-850; 3-P-850; 3-X-850; 3-F2-850;
3-F6-950; 3-G9-950; 3V-CGMP; 3V-F6XM; 3-MJ.
The advantage of using these heads is that fewer presses

are required per splice as compared to the No. 51 tools.
For cable sizes 1/8" through 5/32" only, one press is made
per splice.
Note: Hoods may be removed from No. 3 Type Hand Tools

and used in No. 300 Bench Mount.
Model 3512 Hydraulic Compression Tool

Length: 23"
Weight: 13 pounds
Output: 12 Ton
The 3512 NICOPRESS® Hand Compression Tool is

precision engineered for TROUBLE-FREE application of
Nicopress sleeves: on-site, in-the-field or at the plant.
The Nicopress Model 3512 is match-mated for Nicopress
sleeves to lower your total installation costs.
Features:
■ Range accommodated: 1/32" through 1/2"
diameter cable.
■ Swivel Head pivots 180° for hard to reach splices.
■ Install all but the largest Nicopress Splicing Sleeves—
“in-the-field.”
■ Quick-Change compression dies.
750

Wire Rope Cutters
Cranes / Jibs
Overhead
MO-ST®—Models 1, 1A and 2
The impact type wire rope cutters are the original portable
tools invented by Morse-Starrett to cut wire rope. The cutters
are actuated by striking with a hammer, they are easy to
Hoists
operate and do a superior cutting job with only a few blows
of a hammer. These cutters are precision engineered to
deliver a cut without affecting the original roundness of the
wire rope. The blades and dies are made of the finest tool
Services
steel available, heat treated and ground to close tolerances.
The impact style cutters are available in three sizes and
cutting capacities. The Model 1 has a 3/4" capacity, the
Model 1A a 1-1/16" capacity and the Model 2 has a
1-1/2" capacity. Replacement blades are also available.
Engineered
Products
HYDRASHEAR®—Models W-075,
P-1125 and C-1750
Slings
The self-contained hydraulic cable cutter is a precision-
engineered tool designed to give a clean cut with minimum
effort. Just pump the handle...no outside power is required.
This self-contained portable tool can be easily carried and
is used by contractors, rigging lofts and elevator repairmen.
Hardware
All three models will operate under water. The Pell
HYDRASHEAR® is recommended by wire rope
manufacturers and used by industries throughout the world.
The blades and die sets are made of the finest tool steel
available, heat treated and ground to close tolerances.
Products
Lifting
This means a long life for the blades, as well as superior
performance. The hydraulic cutters are available in three
sizes and capacities. The Model W-075 has a 3/4" capacity,
the Model P-1125 a 1-1/8" capacity and the Model
C-1750 has a 1-3/4" capacity.
Rope
Wire
HYDRASHEAR®—Models POC-1125,
POC 1750 and POC2500
Cordage
The power-operated cutters require an external hydraulic
power source for operation. These models can be
activated by any electric, gasoline, hand, battery or air
operated hydraulic pump capable of developing 10,000
Securement
PSI and having free flow return through the pressure line.
Load
The pumps are hose-connected to the HYDRASHEAR

body. The power-operated cutters are available in three
sizes and cutting capacities. The Model POC1125 has a
1-1/8" capacity, the Model POC1750 a 1-3/4" capacity
Contractors
and the Model POC2500 has a 2-1/2" capacity.

Supply
Protection
Fall

751

Precision Cable Cutters
Swiss Made Felco cutters are recognized around the world
for their precision manufacturing and cutting capabilities.
Lightweight enough for overhead cutting, yet strong enough
for underwater work. Plastic coated handles afford a firm,
comfortable grip. Replacement parts are available from
stock. All cutters are tested before leaving the factory. Type C-108
Type C-7 Length: 22" / Weight: 4.5 Ibs.
Simple construction with all parts
Length: 8" / Weight: 10 oz. protected against rust and salt water.
A cable, when crushed or Designed as an indispensable part
deformed in cutting, is difficult to of boat equipment. Especially suited
use with fittings. These cable for quick, easy cutting of shrouds, stays,
cutters, with unique triangular halyards and other rigging of high-tensile
jaws, never leave a frayed end. wire rope or cable up to 5/16" diameter.
Cutters range from the lightweight Inexpensive insurance for that rare
Type C-7—Capacity: 3/16" time when a mast breaks. The C-108
diameter and smaller. will cut virtually any material, including
steel rods up to 5/16" diameter and
tempered steel spring wires up to
Type CP Cutters— 1/4" diameter.
For Steel Strapping
and Banding
Type C-112
Length: 8" / Weight: 10 oz.
CP cutters are indispensable for Length: 29" / Weight: 8.25 Ibs.
cutting steel strapping and banding. Like the C-108, this cutter also has
They are also especially good for maximum force transmission, which
cutting string, twine, rope, tin and applies the maximum leverage just
many other materials with ease. at the right moment. This, coupled
The red plastic handle is fitted to with Swiss precision blades, make the
the hand to make cutting comfortable. C-112 and the C-108 amazingly
A thumb catch locks the cutter easy to use. The C-112 will handle
when not in use. a maximum capacity of 1/2"
hitensile strands.
Type C-9
Type C-12
Length: 13" / Weight: 1.5 Ibs.
Fills the gap between Length:19" / Weight: 3 Ibs.
C-7 and C-12—cuts 1/4" Capacity: 3/8" diameter and smaller.
steel cable. Ideal for
the tool kit. Type C-16
Length: 23" / Weight: 5 lbs.
Capacity: 5/8" diameter and smaller.
Type C-16E (Electrical)

Length: 23" / Weight: 5 lbs.
Cuts ACSR cable up to 3/4".
752

Moveable Bridge
Cranes / Jibs
Overhead
Cable Assemblies
■ Up-haul, Down-haul, Counterweight Cables and
Special Assemblies.
Hoists
■ Adherences to tight tolerances.
■ As required, meets AASHTO, AREMA and

other related bridge specifications.
Services
■ Your Quality Control People, Engineers and
Government Auditors are welcome to our
state-of-the-art facility during any part of your job.
Engineered
Products
■ Can produce standard and special end fittings.
■ We pre-stretch and proof-test in-house—

our ISO Certified processes ensure quality
and accuracy.
Slings
■ We have in-house engineering.
Hardware
Products
Lifting
Rope
Wire
Cordage
Securement
Load
Contractors
Supply
Protection
Fall

753

Security, Barrier &
Guardrail Cable Assemblies
& Fittings
■ Wire Rope—Turnbuckles
■ Wire Rope Clips—Thimbles
■ Domestic
■ Buy America Act
■ Buy American Act
Highway Guardrail Cable

Assemblies
754

Wire Rope Assemblies
Product Warnings
755

Wire Rope Technical Board Warning:
Spelter & Swage Socket (Boom Pendants)
WARNING
Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused.

■ ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.
■ INFORM YOURSELF: Read and understand manufacturer's literature or
"Wire Rope and Wire Rope Sling Safety Bulletin".*
■ REFER TO APPLICABLE CODES, STANDARDS and REGULATIONS for
INSPECTION REQUIREMENTS and REMOVAL CRITERIA.*
* For additional information or the BULLETIN, ask your employer or wire rope supplier.

see Wire Rope Technical Board at www.wireropetechnicalboard.org
Steel Swage Buttons S-421T Wedge Socket

Warnings Warnings
WARNING WARNING
Button lengths and wall thickness are directly related to rope
capacity. If a shorter button length is required, the shorter button ■ Loads may slip or fall if the Wedge Socket is not
may not achieve the full holding capacity of the rope. Special properly installed.
size buttons—per your specifications are available—ask a Lifting ■ A falling load can seriously injure or kill.
Specialist for more details. ■ Read and understand these instructions before installing
the Wedge Socket.
■ Do not side load the Wedge Socket.
For complete warning and application ■ Apply first load to fully seat the Wedge and Wire Rope in
the socket. This load should be of equal or greater weight
information, see The Crosby Group
than loads expected in use.
at www.thecrosbygroup.com
■ Do not interchange wedges between S-421T and US422T
or between sizes.
■ Do not assemble an old style 1-1/4" S-421W wedge into an
S-421T 1-1/4" TERMINATORTM basket.
■ Do not assemble an old style UWO-422 wedge into a
US-422T TERMINATORTM basket.

756

S-423T Super Terminator® Drop Forge Clips
Wedge Socket Warnings Warnings
WARNING
■ Failure to read, understand, and follow these instructions
WARNING may cause death or serious injury.
■ Read and understand these instructions before using clips.
■ Loads may slip or fall if the Wedge Socket is not
■ Match the same size clip to the same size wire rope.
properly installed.
■ Prepare wire rope end termination only as instructed.
■ A falling load can seriously injure or kill.
■ Do not use with plastic coated wire rope.
■ Read and understand these instructions before installing
■ Apply first load to test the assembly. This load should be of
the Wedge Socket.
equal or greater weight than loads expected in use. Next,
■ Do not side load the Wedge Socket.
check and retighten nuts to recommended torque.
■ Apply recommended torque to tensioner and clip bolts,
and properly install wire to securely lock tensioner bolt to
tensioner.
■ Do not assemble the S-423 Wedge in any brand or model For complete warning and application
socket basket other than the Crosby S-421T TERMINATORTM. information, see The Crosby Group
■ The size is marked on the socket basket and wedge, at www.thecrosbygroup.com
do not interchange wedge between sizes.

information, see The Crosby Group Fist Grip
Clips Warnings
Nicopress® Aluminum
Oval Sleeves Warnings
WARNING
Aluminum sleeves may not develop 100% holding power
(swaging efficiency). Testing is recommended prior to use to
WARNING
determine the holding power for any particular application,
especially when the possibility of personal injury or property ■ Failure to read, understand, and follow these instructions
damage exists. may cause death or serious injury.
■ Read and understand these instructions before using clips.
For complete warning and application ■ Match the same size clip to the same size wire rope.
■ Do not mismatch Crosby clips with other
information, see Nicopress Products
manufacturer's clips.
at www.nicopress.com ■ Prepare wire rope end termination only as instructed.
■ Do not use with plastic coated wire rope.
■ Apply first load to test the assembly. This load should be of
equal or greater weight than loads expected in use. Next,
check and retighten nuts to recommended torque.

757

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Wire Rope

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

■ In sizes from 1/4" to 3" diameter and

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MazzellaCatalog13_WireRope.indd 645 7/3/13 10:07 AM

MazzellaCatalog13_WireRope.indd 646 7/3/13 10:07 AM

A wire rope is, in reality, a very complicated machine. A

Understanding and accepting the “machine idea” gives a

touches half of a sheave at any time, the length differential

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MazzellaCatalog13_WireRope.indd 647 7/3/13 10:07 AM

Wire, for rope, is made in several materials and types:

MazzellaCatalog13_WireRope.indd 648 7/3/13 10:07 AM

Operation construction strand is one in which one

8 x 19 15 through 26 layers of uniform-sized wires in a different work

Warrington strand overlayed with 18 same-size

wires. It is described: 37 Warrington 2-Operation

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MazzellaCatalog13_WireRope.indd 649 7/3/13 10:07 AM

Although there are exceptions for special applications,

MazzellaCatalog13_WireRope.indd 650 7/3/13 10:07 AM

for Consideration in Wire

An IWRC in a rope is considered to contribute 7-1/2% to the rope’s

Rotation Resistant ropes, due to their construction, can experience

Resistant ropes, the Reserve Strength is based on the percentage

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MazzellaCatalog13_WireRope.indd 651 7/3/13 10:07 AM

for Consideration in Wire

Rope Selection (Continued)

MazzellaCatalog13_WireRope.indd 652 7/3/13 10:07 AM

A. Right Regular Lay

E. Right Alternate Lay

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MazzellaCatalog13_WireRope.indd 653 7/3/13 10:07 AM

It is therefore not the total area of worn surface of the rope

The mobility of, and capacity of shifting among, the wires

MazzellaCatalog13_WireRope.indd 654 7/3/13 10:07 AM

How to Store Wire Rope Properly Cordage

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MazzellaCatalog13_WireRope.indd 655 7/3/13 10:07 AM

The manner in which wire rope is installed or wound on a

There are five precautionary steps that should be

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(Continued) of the normal operational cycle under increasing loads and

larger sheave, one could estimate an increase in its bending

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Ratio “B” = Relative Fatigue

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approximately with Hookes Law (stress is proportional to strain) until the

limit of proportionality or elastic limit is reached.

6" + 5.73" + .33" = 12.06"

The Modulus of Elasticity also varies with different rope constructions,

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Bending Ratios D:d

However, the benefit of such testing can be particularly

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