WIRE ROPE SLING USERS MANUAL Second Edition WIRE ROPE TECHNICAL BOARDForeword This publication is a cooperative effort of THE WIRE ROPE TECHNICAL BOARD and the companies which make up the wire rope manufacturing industry in the United States. THE WIRE ROPE TECHNICAL BOARD (WRT) is an association of engineers representing companies that account for more than 90 percent of the ‘wire rope produced in the United States; it has the following objectives: + To promote development of engineering and scientific knowledge relating to wire ropes + To assist in establishing technological standards for military, governmental and industrial use; + To promote development, acceptance and implementation of safety standards; + Tohelp extend the uses of wire rope by disseminating technical and engineering information to equipment manufacturers; and + Toconduet and/or underwrite research for the benefit of both industry and user. ‘The information contained in this manual represents current thinking in the use and preparation of wire rope slings. It must be noted that wire rope slings can fail if they are damaged, misused, overloaded or over used. Wire rope slings should be inspect- ‘ed prior to each use. They should be used only by trained personnel under proper working conditions. Use, inspection and retirement criteria can be found in OSHA regulations and the ASME B30.9 standard which are partially reproduced in this ‘manual. Data, specifications, architectural/engineering information and drawings presented in this publication have been delineated in accordance with recognized professional principles and practices, and are for general information only. Suggested procedures and products should not, therefore, be used without first securing competent advice with respect to their suitability or any given application. ‘The Publication of the material contained herein is not intended as a warranty on the part of the WIRE ROPE TECHNICAL BOARD - or that of any person named herein - that these data are suitable for general or particular use, or of freedom from infringement of any patent or patents. Any use of these data or suggested practices can only be made with the understanding that THE WIRE ROPE TECHNICAL BOARD makes no warranty of any kind respecting such use and the user assumes all liability arising therefrom. WIRE ROPE TECHNICAL BOARD E-Mail: [email protected] For Information on WRTB Publications ~ Tel. 888-BUY-WRTB, First Edition Published and © 1990 Second Edition © 1997, The Wire Rope Technical Board All rights reserved. Printed in US.A. Permision to reproduce or quot any portion ofthis Book as editorial reference is hereby granted. When making such reproductions or quotations, the courtesy of crediting this publication and the Wire Rope Technical Board wll be appreciated.° Table of Contents PAGE General Discussion... cece ceeeeeee see eee ees 5-26 Rated Capacity Tables* 27-149 Section 1 1-Part Slings, Hand Tucked Splice 2.0.0.0. .00000.27 Mechanical Splice ......... 33 Stainless Steel Mechanical Splice 44 Poured Sockets . ao Section 2. Cable Laid Slings Section 3 Multi-Part Slings 3-Part Slings . 4-Part Slings .... 6-Part Slings ... 8-Part Slings ... 9-Part Slings Section 4 Grommet Slings Strand Laid/Hand Tucked ... Cable Laid/ Hand Tucked ... Strand Laid/Mechanical Spl... Cable Laid/Mechanical Spl. Useful Guidelines Useful Guidelines for the Rigger .. Load Turning. Rigger’s Checklist. . , ‘Wedge Socket Installation... Slings Inspection Criteria How to Inspect a Sling . ene USA Standard Crane Hand Signals ...... 157-158 Proper Storage for Wire Rope Slings ........0..0005 Wire Rope Strength and Weight Tables 6-Strand Ropes ~ Fiber Core... ‘6-Strand Ropes -IWRC ..... +. ‘Small Cord Ropes... 200 Glossary of Wire Rope Terms "All Rated Capacities are for 6x19 and 6x36 classification wire rope unless ‘otherwise stated on the table, and all capacities are stated in Tons of 2,000 Ibs.| e Acknowledgements i ‘Tabular data and accompanying reference drawings for wire rope thimbles were provided by The Crosby Group. All other illustrations used throughout were furnished by member companies of The Wire Rope Technical Board. Drawings ‘were prepared especially for this publication and are based wholly or in part on ‘graphic material that originally appeared in literature issued separately by various ‘member companies. ‘Numerical and factual data, not otherwise credited, were obtained from published and unpublished sources supplied by The Wire Rope Technical Board and the companies which sponsor it. Bridon American Corporation Broderick & Bascom Leschen Wire Rope Macwhyte Company Paulsen Wire Rope ‘The Rochester Corporation Union Wire Rope WilinsportWierope Works, In. @ Wireco Wire Rope ‘The WIRE ROPE TECHNICAL BOARD invites interested parties to make suggestions and recommendations for improving this manual, for inclusion in future editions. All such correspondence should be addressed to the Publications ‘Committee of the WIRE ROPE TECHNICAL BOARD. "General Discussion igure 1 ‘9 SLING ANGLES Figure 2A. How do you cary wo pace of er? Te above re tons typify the esses imposed on slings when te legs ae attached to the Toad at various angles ‘The purpose of this manual is to define wire rope slings in keeping with good practice and sound engineering design. Many areas of design apply to all types of slings. Specific design criteria will be covered in the appropriate sections. Rated Capacities shown in this manual are for wire rope slings fabricated from new wire rope, DESIGN FACTOR is a number which is divided into the nominal strength of asling to arrive at arated capacity. A design factor is necessary to allow for condi- tions such as wear, abrasion, damage and variations in load which are not readily apparent. Design factors have been established which allow the sling to give the ‘most efficient service to the user. Rated capacity tables contained in this manual are based on a design factor of five (5). Other design factors may be applied for engineered lifts; however, the sling manufacturer should always be consulted. Sling Rated Capacity is based upon the minimum breaking force, formerly called nominal (catalog) strength, of the wire rope used in the sling and other factors Which affect the overall strength of the sling, These other factors include splicing efficiency, number of parts of rope in the sling, type of hitch (e.g. straight pull, choker hitch, basket hitch, etc), diameter around which the body of the sling is bent (Did) and the diameter of pin used in the eye of the sting (Figure 1). ‘SLING ANGLE is the angle measured between a horizontal plane and the sling leg or body. This angle is very important and can have a dramatic effect on the rated capacity of the sling (2A). As illustrated (Figure 2B), when this angle decreases, the load on each leg increases. This principle applies whether one sling is used to pull at an angle, in a basket hitch or for multilegged bridle stings. Sling angles of less than 30 degrees shall not be used. g a g g 4 & ‘os ¥ HX sofia.’ Ss, Figure 2B SLING ANGLES in this manual are measured from the horizontal plane. If the horizontal angle is used you must use the trigonometric sine of the horizontal ange. ‘When the vertical angle is used you must use the trigonometric cosine of the vertical angle (Figure 2C).—_ eee Figure 3. Choker hitch ated capacity adjustment, for wire rope sings in choker hitch when angle is LESS than 13Sdegrees. Choke angles greater ‘han 13Sdepres are unstable and should not Be used, igure 4. When D js 25 times the body diameter (d), the Dd Ratio is expressed as 25/1, CHOKER HITCH configurations affect the rated capacity of a sling. This is because the sling leg or body is passed around the load, through one end attachment ‘or eye and is suspended by the other end attachment or eye. The contact of the sling body with the end attachment or eye causes reduction of sling efficiency at this Point. Ifa load is hanging free, the normal choke angle is approximately 135 degrees. When the choke angle i less than 135 degrees, an adjustment in the choker rated capacity must be made (Figure 3), Extreme care should be taken to determine the choke angle as accurately as possible. As indicated in Table 1, the decrease in rated capacity is dramatic. TABLE 1 CHOKER HITCH - RATED CAPACITY ADJUSTMENT CHOKE ANGLE IWRC AND FIBER CORE ROPE, (DEGREES) —_ PERCENT OF CHOKER RATED CAPACITY 121-135 100 90-120 87 60-89 14 30-59 62 Upto29 49 Slings with the choke angle greater than 135 degrees are not recommended since they are unstable, NOMINAL SPLICE EFFICIENCY is the efficiency of the sling splice, Any time wire rope is disturbed such as in splicing an eye, the strength of the rope is reduced, This reduction must be taken into account when determining the nominal sling strength and in calculating the rated capacity. Each type of splice has a differ- ent efficiency, thus the difference in rated capacities for different types of slings. Nominal splice efficiencies have been established after many hundreds of tests over years of testing. Did RATIO is the ratio of the diameter around which the sling is bent divided by the body diameter ofa single part sling (Figure 4), or the component rope diame- ter in a multi-part sling, This ratio has an effect on the rated capacity ofthe sling ‘only when the sling is used in a basket hitch. Tests have shown that whenever wire rope is bent around a diameter, the strength of the rope is decreased, Figure 5 illustrates the percentage of decrease to be expected. This Did ratio is applied to wire rope slings to assure that the strength in the body of the sling is at least equal to the splice efficiency. When D/d ratios smaller than those listed in the rated capacity tables are necessary the rated capacity of the sling must be decreased, RATED CAPACITY is the maximum static load a sling is designed to lift using. ‘new, unused rope. The tables give rated capacities in tons of 2000 pounds. Rated capacities contained in all the tables were calculated using component rope strength 8s a basis, Due to rounding of numeric values, rated capacity values for 2,3, or 4 leg slings may not be even multiples of single leg values. Rounding also accounts for ‘small differences in values between tables in other publications and the tables in this ‘manual. These small differences should not be construed to be in error.9 Figure 5, Derived from standard test dat, tis curve relates rope strength efficiency wo various Did ‘ation: The cure ts based oa slate Toads only, tisa wightd average of 458 tess over pins and thimbles, on {6x 19 and 6x 36 classification ropes fiber core and IWRC, regular and lang ay Tecicaly, eficieney variations can be expected Tor specific rope constictons and ‘wire manufacturing praties, To ‘bain data forthe wire rope itis recommended that tess be conducted, ‘Note: This graph refers to bend- ing wire rope over pins. Any time 2 wire rope sing is bent around! sharp comers addtional reduc- tions in efficiency will oceur. Sharp ‘corners should always be padded to prevent damage tothe sling, See Page 151. Rated capacity tables in this manual are expressed in the following manner: Rated capacities .99 tons or less are shown to 2 decimal places: rated capacities 1.0 109.9 tons are shown to 1 decimal place; and rated capacities 10 tons and above are shown as whole numbers. All values are rounded in the following way: ifthe ‘number following the last expressed number is 5 or greater the number is increased by 1, and if it is 4 or less the number is not changed. In the sling industry, similar terms are often applied to designate Rated Capacity. The term Rated Load is commonly used to describe Rated Capacity. Another tenm, Working Load Limit (WL) is often used to describe Rated Capacity. This term, WL, however, is used much more commonly in Alloy Chain Slings and is not common when referring to the Rated Capacity of wire rope slings. Due to space limitation, no Metric dimesions or Rated Capacity values have been shown in the tables in this manual, Diameters are stated in inches, Rated Capacities in Tons of 2,000 U.S. pounds. To convert Rated Capacities to Metric, ‘multiply tons by 9.078 to obtain Kilograms (Kg). To convert inches to Millimete (mum), multiply inches by 25.4 REDUCTION IN EFFICIENCY OF WIRE ROPE WHEN BENT OVER PINS OF VARIOUS SIZES. 50 EFFICIENCY (%) gs 3 38 8 a a Did RATIO ‘The rated capacity is calculated as follows Rc = MBFxLx DF (MBF x Lx Sin A) cre = A x CF Where: RC = Rated Capacity (Tons) Sin A = Trigonometric Sine of Smallest CRC = Choker Rated Capacity (Tons)* Horizontal Sling Angle MBF = Minimum Breaking Force DF = Design Factor of the rope (Tons) jominal Splice Efficiency L = Number of Sling Legs * This Choker Rated Capacity (CRC) does not apply to multi-part stings. Please refer to the multi-part sling section for applicable equations,Figure 7. Normally, fr bridle stings with legs of unequal length se the smallest horizontal angle for rated cacy colons. oe tyme loading, an engineering analysis is aig an engin analy Rated Capacity Calculation Examples: Utilizing a 1" 6x19 classifi TWRC sling, various rated capacities are calculated as follows Example 1 ~ Single LegVertical Mechanical (Figure 6) (MBFRLXSINA) gp DF MBF=51.7 TONS Rc = —GLTEIAD _ x 95x1=98T0Ns Example 2~ Vertical Basket Hitch Mechanical rc = MBEXLXSINA) Nop DF RC = SDD x 95x 1=19.6=20TONS Example 3-3 Leg Bridle with Unequal Angles (Figure 7) Rc = MBFXLxSinA) . yop DF 15° (Smallest), A2 = 603 A3 = 60° (51.7.x3 x.707) 5 RC x 95x1=208=21 TONS ion EIPS,TABLE 2 WIRE ROPE THIMBLES HOT DIP GALVANIZED STEEL Dimensions (inches) ayes |[eclol]e For Rope Overall | Max. | Weight Diam. | Overall] Overall |Length | width | Thick- | Pin’ | Per 100 (inches) | Length | width | inside |Inside| ness | Diam. | (Ibs) a | 2%6 [te | 1% |e | se | Sie | 675 fae | ave [iene | i%e [ahe| ve | Pe [11.25 3a | 2% [ive | ie | ive | B72 | tie | 21.00 Tie _| Sie [296 | 2% | 1% | 4 | the | 30.00 | ta | 3% [2% | 2% | 1¥e | ese | a7h6 | 51.00 |_| re | wae ae oa [He | Be | Tae | B09 : Se | aie [3%e | 3¥4 [194 [7 ‘he | 75.00 3s _ [aie | 3% [2 [1% | 176 | 447.00 Figure 8 Te | si2 |4ta [ava [aim [1% | 2¥e | 175.00 1 eva [4tne | ave [ave | 196 | 2% | 275.00 Tie-t% | 7 [ste [sve [2% | 1%e | 2% [400.00 PROOF LOAD is a specific load applied to a sling assembly in a nondestructive test to verify the workmanship of the sling. ASME B30.9 requires that all swaged socket and poured socket assemblies used within its scope be proof tested. The proof load is generally two (2) times the vertical rated capacity for mechanical splice slings. ‘The maximum proof load for hand tucked slings is 1.25 times the vertical rated capacity. Care should be taken to assure that sling eyes are not damaged during the proof load. Thimbles or padding should be used to prevent such damage. EYE DIMENSIONS are generally eight (8) sling body diameters wide by six- teen (16) body diameters long. Whenever possible thimbles (Figure 8) are recom- ‘mended to protect the rope in the sling eye. Table 2 contains dimensions for thimbles used in standard single part slings. The rated capacities inthis manual are based on these natural eye sizes. If small eye sizes without thimbles are used, a reduction in rated capacity may occur, Splicing efficiencies for other eye sizes should be confirmed. Other specialized thimbles are available, Consult your sling manufacturer for details. PIN DIAMETER should not be any greater than the natural width of the slifig eye. For any sized eye and type of sling body, the maximum allowable pin diameter ‘may be calculated as follows ‘Maximum pin diameter = (2L +W) x 0.2 Where: L= length of eye W= width of eye ‘The minimum pin diameter should never be smaller than the sling body diameter. 93} ( J 10 GRADE & CONSTRUCTION of wire rope for stings is normally bright Improved Plow Steel, Extra Improved Plow Steel or Extra Extra Improved Plow Steel grade, 6x19 or 6X36 classification, right regular lay. IWRC rope has a higher rated capacity than fiber core rope for mechanically spliced slings, but the same rated capacity for hand tucked slings. Ths is because when making a hand tucked splice, the core (IWRC) of the rope is cut in the splice area and doesn’t add to the overall stength of the sling. Rated capacities of slings using galvanized rope may be less than the same grade bright rope sling. The sling manufacturer should be consulted regarding rated capacities for these types of slings. MINIMUM SLING BODY LENGTH is the minimum distance between splices, sleeves or fittings. Generally the minimum body length for single par slings is equal to ten (10) times the sling body diameter. Ths allows approximately one and one half (11) rope lays between splices. For multipart slings the minimum body length ‘between splices is equal to forty (40) times the component rope diameter. LENGTH TOLERANCE is generally plus or minus two (2) body diameters, or plus or minus 0.5% of the sling length, whichever is greater. The legs of bridle slings, ‘or matched slings are normally held to within one (1) body diameter. Tolerances should always be specified to the sling manufacturer before the order is placed. HAND TUCKED SPLICE (See Rated Capacity Tables Section) AHAND TUCKED splice is made by passing the wire rope around a thimble ‘or forming an eye and splicing the dead end (short end) into the live end (long end) of the rope. Normally, each dead end strand is given one forming tuck and three full tucks around the same strand in the body of the rope. One additional fll tuck is ‘made when splicing more pliable wire ropes such as 6x36 classification. ‘A “forming tuck” is made by prying two adjacent strands apart, inserting a dead ‘end strand into the opening and passing the strand under one, two, or three adjacent strands in the body of the rope. The dead end is set or locked tightly. ‘A “full tuck” is made by inserting a dead end strand under and rotating it one full 360 degrees turn around a strand in the body of the wire rope. The tucked strand is set or locked tightly. Each subsequent full tum of the dead end strand around the live end strand constitutes an additional full tuck. “Setting” or “locking” of a dead end strand is accomplished by pulling the strand end in under considerable force. A marlin spike is inserted in the same open- ing in the body of the rope ahead of the tucked strand and is rotated about the axis of the rope back to the start of the splice or toward the previous tuck. This helps set the tuck. Certain applications may require special splices such as the Navy Admiralty Splice of logging splice. Splices made by these special methods may also attain the efficiencies used in calculating the rated capacity tables where the rope quality and number of tucks are equivalent to that outlined above, Development of these efficiencies should be confirmed. Serving or wrapping of wire rope sling splices does not affect the splicing efficiencies nor rated capacities. Such servings are optional, although unserved splices are often preferred because they permit visual inspection of the spliced area.NOMINAL SPLICE EFFICIENCY is the ratio determined by dividing the actual breaking strength of the spliced termination by the actual Minimum Breaking Force (formerly called nominal or catalog strength) ofthe rope. This efficiency will change from splice to splice because of the many variable factors involved in pro- ducing the splice. Splice efficiencies given in Table 3 were established so that these normal variations are accommodated. The design factor used in establishing the rated capacities further assures thatthe sling will lift the load even in those rare instances when the splice efficiency falls slightly below the values given in the tables. Rated capacities shown in this manual have met with the most exacting test, that of the fest of time and use over years of actual field experience. TABLE 3 NOMINAL SPLICE EFFICIENCIES HAND TUCKED SPLICE IPS, EIPS AND EEIPS# 6X19 & 6X36 CLASS ROPES ++ NOTE: Because EEIPS ropes are Rope Nominal Rope Nominal BiG bea ni Cia Diameter (in) Bflcieney Factor Di a i Eiclency Factor bok are for IWRC rope on 56 89 1% 80 3/8 38 ih 80 m6 87 15h 80 i) 86 13a 80 96 85 1h 80 38 84 a 80 34 82 28 80 78 80 2M 80 1 80 23%8 80 1s 30 2h 80 Rated capacities for choker hitch hand tucked slings are calculated as follows: Re = MBFXLXSINA) oy cre = x CF Where: RC = Rated Capacity (Tons) ¢ CRC = Choker Rated Capacity (Tons)* ‘MBF = Minimum Breaking Force of the rope (Tons) L=Number of Sling Legs Sin A = Trigonomettic Sine of Smallest Horizontal Sling Angle 4 DF = Design Factor 9 NSE = Nominal Splice Efficiency (CF = Choke Factor =.70 * This Choker Rated Capacity (CRC) does not apply to multi-part slings. Please refer to the multi-part sling section for applicable equations.12 Figure 10, Mechanical splice (Flemish eye) Notice that the splice efficiency factor plays no role in the calculation of the ‘choker hitch rated capacity. This is because as the body of the sling passes through the eye of the sling in a choke, the weakest part ofthe sling isin the body at the ‘choke point. Thus the splice being higher in efficiency, has no effect on the rated capacity, because the efficiency factors are not additive. The rated capacities adjust- ment Table I for choker hitches also applies for mechanical splice slings. Rated capacities for basket hitches are based on a Did ratio of 15. At this Did ratio the efficiency is approximately 90% which is equal to the highest splice eff- ciency forthe hand tucked splice. Remember, D/d ratios only apply to basket hitches. ‘The use of a swivel on single leg lifts and free hanging loads which may rotate is not recommended. A tag line should always be used to prevent rotation of the sling body. When the sling body of a hand tucked splice is allowed to rotate, the splice could unlay, and pull out and drop the load, MECHANICAL SPLICE, (See Rated Capacity Tables Section) MECHANICAL SPLICE slings come in two basic types: the Returned Loop and the Flemish Eye or farmers splice. In either case, the splice is completed by pressing (swaging) one or more metal sleeves over the rope juncture, ‘The retumed loop is fabricated by forming a loop atthe end of the rope, sliding cone or more metal sleeves over the short end of the loop eye and pressing these sleeves to secure the end of the rope tothe sling body. A drawback to this type of sling is that the lifting capacity of the sling depends completely upon the integrity of | the pressed or swaged joint. Should the metal sleeve(s) fail, the entire eye will also fail ‘The Flemish eye splice is fabricated by opening or unlaying the rope body into two parts, one having three strands and the other having the remaining three strands and the core. The rope is unlayed to allow the loop or eye to be formed by looping ‘one part in one direction and the other part in the other direction and laying the rope ‘back together. The strands are rolled back around the rope body. A metal sleeve is then slipped over the ends of the splice and pressed (swaged) to secure the ends to the body of the sling. Nominal splice efficiencies expressed in Table 4 and in the rated capacity tables are based on this splicing method. Splice efficiencies for other splicing methods should be confirmed.TABLE 4 NOMINAL SPLICE EFFICIENCIES MECHANICAL SPLICED SLINGS Diameter (in) WRC FIBER CORES IMPROVED PLOW STEEL: 1/4 through 1 95 925 148 through 2 925 90 2s & larger 90 Not Established EXTRA IMPROVED PLOW STEEL: 14 through 1 95 25 1s through 2 925 90 2s & larger 90 ‘Not Established EXTRA EXTRA IMPROVED PLOW STEEL: 1/4 through 1 95 ‘Not Established STAINLESS STEEL, 302 & 304 GRADE: 1/4 through 1 95 ‘Not Established 1s through 2 925 ‘Not Established 2s & larger 0 Not Established Rated capacities for choker hitch mechanical spliced slings are calculated as follows: ‘The rated capacity is calculated as follows: _ (MBF x Lx Sin A) RC = DE x NSE (MBF xLx Sin) RC = -MBExExSin’) RC De x CF Where: RC = Rated Capacity (Tons) CRC = Choker Rated Capacity (Tons)* MBF = Minimum Breaking Force of the rope (Tons) ‘L=Number of Sling Legs a Sin A = Trigonometric Sine of Smallest Horizontal Sling Angle DF = Design Factor NSE = Nominal Splice Efficiency CF =Choke Factor =.70 “This Choker Rated Capacity (CRC) does not apply to multi-part slings. Please refer to the multi-part sling section for applicable equations.ee 4 Notice that the splice efficiency factor plays no role in the calculation of the (Choker Hitch rated capacity. Ths is because asthe body of the sling passes through the eye of the sling in a choke, the weakest partis atthe choke point. Thus the splice being higher inefficiency, has no effect on the rated capacity, because the efficiency factors are not additive. The rated capacities adjustment Table 1 for choker hitches also applies for mechanical splice slings. Rated capacities for single part, choker and basket hitches are calculated exactly the same as for hand tucked slings except for the nominal splice efficiencies, Minimum Did ratio for basket hitches is 25. This larger D/d ratio is required because ‘he Nominal Splice Efficiency is higher for mechanical splices than hand splices, Care should be taken not to deform or damage the sleeves on mechanically spliced slings. Slings which have sleeves made of a different grade or type metal than the rope body may experience accelerated deterioration due to an electro- chemical reaction between the two metals. This is particularly evident in salt water or brackish conditions. ZINC OR RESIN POURED SOCKET TYPE TERMINATIONS (See Rated Capacity Tables Section) Zine or resin poured sockets have traditionally been the end attachment method used to determine the actual breaking strength of a rope. Therefore, ther efficiency in.a breaking strength testis established to be 100% for all grades and constructions of wire rope. The efficiency of all other end terminations are established by compar- ison to zine or resin poured sockets. ‘When a zinc or resin poured socket assembly is used as a sling to connect a load ‘oa lifting device, the minimum design factor is 5.0. Zine or tesin poured socketed assemblies are used as boom supports and in other supporting applications where the assemblies are not defined to be slings. In these cases, the required design factor is usually 3.0. Experience in testing zinc or resin poured socketed assemblies has shown that special techniques may be required to develop 100% efficiency when socketing ‘small diameter ropes and strands. Consult the rope, fitting or socketing material ‘manufacturer for specific recommendations. Choker hitches are not used as often with poured sockets as with the other more general types of slings. When such slings are used in a choker hitch, the rated capac- ity adjustment Table 1 applies. For assemblies with poured attachments, tolerances can be somewhat more strin- gent than other types of slings. The manufacturer should be contacted and agreement reached before the order is placed. Tolerance as small as plus or minus 1/8” is not out of the ordinary for this type of assembly. Specifications such as type of fitting, pin orientation, whether zinc or resin is to be used and type of application should also be supplied to the manufacturer when ordering these types of assemblies, ‘Those inexperienced in the socketing process should not try to fabricate assem- blies without first getting expert training. It is far better to leave fabrication of this type of assembly to the experts. ASME B30.9 requires that all swaged socket and poured socket assemblies used within its scope be proof tested. The proof load is generally two (2) times the vertical rated capacity for poured socket assemblies,POURED SOCKET - SPELTER OR RESIN ‘The following socketing methods are general in nature and have been proven over years of use. Procedures for zinc and resin differ significantly, but will achieve the samme end result. Slight variations to these procedures have been used with acceptable results, however this cannot be predetermined without destructive tests. ‘There are many ways to go wrong in socketing procedures. Some of the more ‘common pitfalls that should be guarded against include: 1) Tuming back the strands - inward or outward - before the “broom” is inserted into the socket; 2) ‘Taming back the strands and seizing them to the body of the rope: 3) Turning back the strands and tucking them nto the body of the rope; 4) Tying a knot in the rope; 5) Wedging nails, spikes, bolts, etc. into the socket after the rope is inserted in an attempt to secure a tight fit. Ths isa particularly dangerous practice. IMPORTANT: Some socket manufacturers do not recommend the reattachment of used poured sockets. Consult the manufacturer for specific recommendations. ‘ZINC-POURED SPELTER SOCKETING 1. Measure the Rope Ends to be Socketed ‘The rope end should be of sufficient length so that the ends of the unlaid ‘wires (from the strands) will be atthe top of the socket basket. (Fig. 11) 2. Apply Serving at Base of Socket Apply a tight serving band for a length of two rope diameters, atthe point ‘where the socket base will be, to eliminate any distortion below the band of the wires and strands. (Figs. 12 &13) 3. Broom Out Strand Wires ‘Unlay and straighten the individual rope strands and spread them evenly so, that they form an included angle of approximately 60 degrees. Unlay the wires of each individual strand for the full length of the rope end—being careful not to disturb or change the lay ofthe wires and strands under the serving band. Unlay the wires of the independent wire rope core (TWRC) in the same manner. A fiber ccore should be cut out and removed as close to the serving band as possible. (Fig. 12) 1s4. Clean the Broomed-Out Ends Swish the broomed- out rope end in a solvent, then brush vigorously to remove all grease and dirt~making certain that the wires are clean to the very bottom of the broom up to the serving band (Fig. 13). One of the best and pre- ferred cleaning methods for rope ends prior to socketing is ultrasonic clean- ing using a suitable solvent, After this cleaning step, place the broomed-out end pointing downward, allowing it to remain until all solvent has evaporated and the wires are dry. Solvent should never be permitted to remain on the rope or on the serving band since it will run down the wires when the rope is tumed upright. ‘The continued availability of current cleaning solvents is uncertain due to federal regulations concerning ozone depleting substances. For information on available solvents, consult the solvent suppliers. CAUTION: Breathing the vapor of many solvents may be harmful; it should only be used in a well-ventilated area. Be sure to follow the solvent manufacturer's instructions, and carefully observe all instruc- tions printed on the label. 5. Dip the Broomed-Out Rope Ends in Fhiex Prepare a flux comparable to hot zinc-ammonium chloride; use a concen- tration of 1 1b, of zinc-ammonium chloride to 1 gallon of water; maintain the solution at a temperature of 180 degrees to 200 degrees F. Swish the broomed- ‘out end in the flux solution, then point the rope end downward until such time as the wires have dried thoroughly (Fig. 15). Figure 11 Figure 126. Close Rope Ends and Place Socket ‘Use clean seizing wire to compress the broomed-end into a tight bundle which will permit the socket to be slipped easily over the wires (Fig. 16) Before placing the socket on the rope, make certain the socket is clean and no moisture is present inside the bow of the socket. Heating the socket will dispel any resid- ual moisture and will also prevent the zinc ftom freezing or cooling prematurely. ‘Another method of placing the socket onto the rope isto first cover the end of the rope with a wrapping or split tubing; then slide the socket onto this sec- tion of covered rope, this will prevent contamination of the inner surface of the socket by the wire rope lubricant. Once the end of the wire rope is cleaned and broomed, the socket can be slid into position and the wrapping or split tubing ‘can be removed. A word of Caution: Never heat a socket after it has been placed on the rope—this could cause damage to the rope. ‘Afier the socket is on the rope, the wires should be distributed evenly in the socket basket so the zine can surround each wire. Use extreme care in aligning the socket with the rope's centerline, and in making certain there is a minimum vertical length of rope extending from the socket equal to about 30 rope diame- ters. This vertical length is necessary for rope balance. Premature wire breaks at the socket can occur if the rope is not balanced at pouring. al Tit—SSSFSFSFSFSFSeFeSese Seal the socket base with fie clay or putty but make certain the material does not penetrate into the socket base. Should this occur, it could prevent the zine from penetrating the full length of the socket basket thereby creating a void that would collect moisture after the socket is placed in service (Fig. 17) | 7. Pour the Zine | ‘The zinc used should meet ASTM Specification designation B6-49 Grade (1) Prime Wester or better. Pour the zinc at a temperature between 925° and | 975° F (Fig. 18).A word of caution: Do not heat zinc above 1000°F. j Overheating of zinc may affect its bonding properties. The zine temperature | ‘may be measured with a portable pyrometer or thermocouple. Remove all dross from the top of the zinc pool before pouring. Pour the zinc in one continuous | stream until it reaches the top of the basket and all wire ends are covered. There | should be no "capping" of the socket, unless the customer requires a smooth surface with no shrinkage on the top of the basket. The use of a pinhole in the basket may be employed to allow air and gases to escape. This helps prevent entrapment of air and voids within the zinc. 8. Remove Serving | After the zine and socket have cooled, remove the fie clay or putty and the serving band from the socket base, and check to make certain thatthe zinc has ) penetrated to the socket base (Fig. 19). 9. Lubricate the Rope Apply wire rope lubricant to the rope at the base of the socket and on any rope section where the original lubricant may have been removed, Figure 17—— RESIN-POURED SPELTER SOCKETING Before proceeding with a resin socketing procedure, check the resin manufac- turer’ instructions carefully. Each resin system has specifi procedures and steps which must be followed in the order specified for the system to give the desired results. Since any resin system depends upon a chemical reaction, the procedure becomes critically important. Give particular attention to selecting sockets designed for resin socketing. Sockets with “rings” should not be used, or if the sockets do have “rings”, they should be filled prior to pouring the resin. Also, do not use over- size sockets with resin socketing, The following steps give a general outline to fol- low for resin socketing; they should not be used as a substitute for detailed instruc- tions supplied by the resin manufacturer. 1, Measure the Rope Ends to be Socketed ‘The rope end should be of sufficient length so the ends of the unlai wires (from the strands) will be atthe top of the socket basket. Fig. 11) Apply Serving at Base of Socket Apply a tight serving band—ength of two rope diameters—at the point where the socket base will be to eliminate any distortion below the band of the 4 wires and strands. (Figs. 12 & 13) 3. Broom Out Strand Wires Unlay and straighten the individual rope strands and spread them evenly so that they form an included angle of approximately 60 degrees. Unlay the wires of each individual strand forthe full Iength of the rope end—being careful not to disturb or change the lay ofthe wires and strands under the serving band. Unlay the wires of the independent wire rope core (IWRC) inthe same manner. A fiber ‘core should be cut out and removed as close to the serving band as possible, unless otherwise recommended by the manufacturer (Fig. 12) Figure 1820 4. Clean the Broomed-out Ends ‘Swish the broomed-out rope end in a solvent, then brush vigorously to remove all grease and dirt—making certain that the wires are clean to the very bottom of the broom up to the serving band (Fig. 13). One of the best and pre ferred cleaning methods for rope ends prior to socketing is ultrasonic clean- ing using a suitable solvent. After this cleaning step, place the broomed-out end pointing downward, allowing it to remain until all solvent has evaporated and the ‘wires are dry, Solvent should never be permitted to remain on the rope or on the serving band since it will ran down the wires when the rope is tumed upright. ‘The continued availabilty of current cleaning solvents is uncertain due to federal regulations concerning ozone depleting substances. For information on available solvents, consult the solvent suppliers, CAUTION: Breathing the vapor of many solvents may be harmful; it should only be used in a well-ventilated area. Be sure to follow the solvent manufacturer's instructions, and carefully observe all instruc- tions printed on the label. 5. Clase Rope Ends and Place Socket lace rope in a vertical position with the broom end up. Close and compact the broom to permit insertion of the broomed end into the base of the socket. Slip the socket on, removing any temporary banding or seizing as required, Another method of placing the socket onto the rope isto first cover the end of the rope with a wrapping or split tubing; then slide the socket onto this sec- tion of covered rope, this will prevent contamination of the inner surface of the socket by the wire rope lubricant. Once the end of the wire rope is cleaned and broomed, the socket can be slid into position and the wrapping or split tubing, ccan be removed. A word of Caution: Never heat a socket after it has been placed on the rope—this could cause damage to the rope. Make certain the broomed wires are uniformly spaced in the basket, with the wire ends slightly below the top edge of the basket, and the axis of the rope and the fitting are aligned. Seal the annular space between the base of the socket and the rope to prevent leakage of the resin from the basket. In addition to nor- mal sealing materials, non-hardening butyl rubber-base sealant or latex glazing compounds are satisfactory for this purpose. Make sure the sealant does not enter the base of the socket so the resin will be able to fill the complete depth, of the socket basket. 6. Pouring the Resin Mix and pour the resin in strict accordance with the resin manufacturer's instructions. 7. Lubrication After Socket Attachment ‘fier the resin has cured, e-lubricate the wire rope atthe base of the socket to replace any lubricant that may have been removed during the cleaning operation. 8. Resin Properties All properties and precautions of resins should be obtained from the resin ‘manufacturers, Take special note of the “shel life” of the resin being used.CABLE LAID WIRE ROPE SLINGS (See Rated Capacity Tables Section) Cable Laid Stings are fabricated from a machine made rope comprised of seven wire ropes. The cable laid body is typically 7x77 or 7x7x19 construction, or ‘7x6x19 or 7x6x36 Classification IWRC. These slings are used where flexibility and resistance to kinking and setting are more important than resistance to abrasion. Since the rope is made up of many smaller wire ropes, the slings can bend around smaller diameters without taking a permanent set or a kink. The many stall wires are susceptible to abrasion. Due to their construction, cable laid slings are normally mechanically spliced. ‘The nominal splice efficiency of mechanical splices is shown in Table 5. Splice efficiencies for other splicing methods should be confirmed. TABLE 5 NOMINAL SPLICE EFFICIENCIES MECHANICALLY SPLICED CABLE LAID SLINGS Diameter Efficiency 1/4” through 1” 95 1/8" through 15/8” s ‘The rated capacity is calculated as follows: rc = QMBFXLXSiNA) nop DF (MBF x L x Sin A) ere = See i x CF Where: RC = Rated Capacity (Tons) CRC = Choker Rated Capacity (Tons)* inimum Breaking Force of Cable Laid Rope (Tons) Sin A = Trigonometric Sine of Smallest Horizontal Sling Angle * This Choker Rated Capacity (CRC) does not apply to multi-part slings. Please refer to the multi-part sling section for applicable equations. ‘The rated capacity adjustment Table | for choker hitches applies to cable aid slings as well. Note the difference in the efficiency factor for calculating vertical choker hitch rated capacities. Rated capacity for a basket hitch is based on a Did ratio of 10, where “a” is the diameter of the cable laid sling body. Tolerances and minimum sling lengths are also figured using the cable laid sling body diameter at| em —SsK BRAIDED MULTI-PART SLINGS (See Rated Capacity Tables Section) Mati-part braided slings are stings which are formed from 3,4 and up to as many as 48 pars of rope. Generally 3, 4,6, 8 or 9 parts are more common. They can be either flat or round. Rated Capacity Tables are included in this manual for 3-Part EEIPS slings. For other EEIPS Multi-Part slings, check with the sling manufacturer. Nominal Splice Efficiency for multi-part stings is 0.70 for component ropes 3/82" through 2" diameters. Splice efficiencies for larger component rope slings should be confirmed. The rated capacity is calculated as follows: (MBF xL x Sin A) RC = Ls XNSEXP crc = MBFXEXSDA) NSE xPxCF Where: RC = Rated Capacity (Tons) CRC = Choker Rated Capacity (Tons) ‘MBF = Minimum Breaking Force ofthe rope (Tons) L_=Number of Sling Legs Sin A =Trigonometric Sine of Smallest Horizontal Sling Angle DF = Design Factor NSE = Nominal Splice Efficiency CF = Choke Factor =.875 P= Number of parts of rope in multi-part. In a choker hitch, multi-part slings react differently than standard wire rope slings, therefore the nominal splice efficiency is present in the equation. The adjust- ‘ment in Table 1 applies to multi-part slings als. Rated Capacity for a basket hitch is based on a minimum Did ratio of 25, where ‘component rope diameter. Length tolerances for component ropes of 3/8” diameter and smaller are plus or minus 10 component rope diameters, or plus or minus 1.5% of the sling length whichever is greater. The legs of matched slings shall be within $ component rope diameters of each other. For component rope diameters 7/16” and larger, the toler- ance is plus or minus 6 component rope diameters, or plus or minus 1% of the sling Jength whichever is greater. Legs of matched sings shall be within 3 component rope diameters of each other. ‘Minimum Sling Length between loops, sockets or sleeves is recommended to ‘be 40 times the component rope diameter of the braided body. “eGROMMETS (See Rated Capacity Tables Section) Grommets are @ unique type of sling which form a continuous loop. Several types are available, such as strand laid hand tucked, strand laid mechanical, cable laid hand tucked and cable laid mechanical. The splice area should not come into contact with the load or the lifting device. Some sling manufacturers mark the splice on hand tucked grommets with paint to help the user more easily identify the area. Tolerances for Grommets are generally plus or minus 1% of the circumferential length or 6 body diameters whichever is greater. ‘A minimum inside circumference of 96 body diameters is recommended. The requirement for a minimum circumference of 96 times the body diameter for grom- mets and endless slings was based on the requirement to have at least three free rope lays on either side of the tuck of a hand spliced endless grommet prior to being bent around a hook or pin five times the body diameter. To eliminate the possibility of confusion, this requirement was adopted for mechanically spliced endless grommets as well, For smaller circumferences, consult the sling manufacturer, Since a grommet is a continuous circle, itis very important to consider Did ratio. ‘The D/d ratio must be applied to the lifting pins as well as to the load. Normally the lifting pins will be the smallest diameter in the system other than the diameter of the grommet. Rated capacities covered in this section are based on a Dd ratio of 5. If Toads are handled with a D/d rato less than 5, consult the sling manufacturer. STRAND LAID HAND TUCKED GROMMET (See Rated Capacity Tables Section) ‘A Strand Laid Hand Tucked Grommet is made from one continuous length of strand, No sleeves are used to make the join. This results in a very smooth circular sling. TABLE 6 NOMINAL SPLICE EFFICIENCIES STRAND LAID HAND TUCKED GROMMETS: Rope ‘Nominal Rope Nominal Diameter (in) Efficiency Factor Diameter_ Efficiency Factor 14 B Mp 735 5/16 B 158 730 38 B 14s DS m6 8 Vs 70 2 B 2 m5 N16 8 2s 0 518 8 2s 105 314 78 248 700 78 3B 2h 695 1 75 2548 690 Ws 765 23a 690 1 755 218 685 196 745 3 685 23ee 24 ‘To calculate the rated capacity for a strand laid hand tucked grommet, the nominal strength of the equivalent diameter, 6 strand fiber core rope, is used. ‘The equation is as follows: (MBF xL x Sina) Cre) Ln Se RK De x NSEx2 (MBF x Lx Sin A) crc = SESSA x NSE xCFx2 Where: RC = Rated Capacity (Tons) ‘CRC = Choker Rated Capacity (Tons) MBF = Minimum Breaking Force of the rope (Tons) L=Number of Sling Legs Sin A = Trigonometric Sine of Smallest Horizontal Sling Angle DF = Design Factor Nominal Splice Efficiency CF = Choke Factor = .70 Ina choker hitch, grommet slings react differently than standard wire rope slings, therefore the presence of the nominal splice efficiency factor is in the equation. Rated capacity adjustment in Table 1 applies. STRAND LAID MECHANICAL SPLICE GROMMET (See Rated Capacity Tables Section) Strand Laid Mechanical Splice grommets are made from one continuous length of wire rope joined by pressing or swaging one or more sleeves over the rope junc- ture. This type of grommet is not as smooth as the hand tucked version. An advan- tage is that the swaged sleeves give clear indication of the splice area.‘The rated capacity is calculated as follows: (MBF xL x Sin A) RC = MBFxLxSinAé NSEx2 = x NSEx crc = MBEXL*SA) Nop xcPx2 DF Where: RC = Rated Capacity (Tons) CRC = Choker Rated Capacity (Tons) MBF = Minimum Breaking Force of the rope (Tons) L =Number of Sling Legs Sin A = Trigonometric Sine of Smallest Horizontal Sling Angle DF = Design Factor e NSE = Nominal Splice Efficiency, =.78 (CF = Choke Factor =.70 Rated capacity adjustment Table 1 applies. CABLE LAID HAND TUCKED GROMMET (See Rated Capacity Tables Section) Cable Laid Hand Tucked Grommets are fabricated in the same manner as strand Jaid hand tucked grommets except one continuous length of wire rope is used. This iakes for a flexible smooth sling. The body diameters are somewhat odd sized because the grommet body is built up from a standard diameter component rope. ‘TABLET NOMINAL SPLICE EFFICIENCIES CABLE LAID HAND TUCKED GROMMETS Grommet Body Nominal Grommet Body __ Nominal Diameter (in) Efficiency Factor Diameter. Efficiency Factor 38 3B 116 750 916 3B 1-788 745 58 8 24 735 34 75 2518 725 15/16 770 3 m5 1-18 765 3/8 705 12 755 25—_— ‘The rated capacity is calculated as follows: (MBF x Lx Sin) RC = = x NSEx2x6 crc = MBFXLESINA) NSE xCFx2x6 DF Where: RC = Rated Capacity (Tons) CRC = Choker Rated Capacity (Tons) MBF = Minimum Breaking Force of the rope (Tons) L = Number of Sling Legs Sin A = Trigonometric Sine of Smallest Horizontal Sling Angle DF = Design Factor NSE = Nominal Splice Efficiency (Table 7) CF = Choke Factor = 65 Rated capacity adjustment Table I applies. CABLE LAID MECHANICAL SPLICE GROMMET (See Rated Capacity Tables Section) Cable Laid Mechanical Splice Grommets are fabricated from one continuous length of eable laid wire rope withthe ends joined by one or more mechanical sleeves, ‘They are similar to strand laid mechanical splice grommets, but offer greater flexibility ‘The rated capacity is calculated as follows: (MBF x L x SinA) e SEx2 RC DF x NS crc = MBEXLSINA) . NsExcRx? DF Where: RC= Rated Capacity (Tons) CRC = Choker Rated Capacity (Tons) MBF = Minimum Breaking Force of the rope (Tons) L=Number of Sling Legs Sin A = Trigonometric Sine of Smallest Horizontal Sling Angle DF = Design Factor NSE = Nominal Splice Efficiency =.78 CF = Choke Factor= 65 Rated capacity adjustment Table | applies. 266 Physical Properties ELASTIC PROPERTIES OF WIRE ROPE The following discussion relates to conventional 6- or 8-strand ropes that have either fiber or steel cores; itis not applicable to rotation-resistant ropes since these constitute a separate case. Wire rope is an elastic member, it stretches or elongates under load. This stretch derives from two sources: 1) constructional, and 2) elastic In actuality, there may be a third source of stretch—a result ofthe rope rotating on its own axis. Such elongation, which may occur either asa result of using a swivel, or from the effect of a free-turning load, is brought about by the unlaying of the rope strands. Because the third source is a subject that is beyond the scope of this publi- cation, discussion will be directed to constructional and elastic stretch CONSTRUCTIONAL STRETCH ‘When a load is applied to wire rope, the helically-laid wires and strands act in a constricting manner thereby compressing the core and bringing all the rope ele- ‘ments into closer contact. The result is a slight reduction in diameter and an accom- panying lengthening of the rope. ‘Constructional stretch is influenced by the following factors: 1) ype of core (fiber or steel) 2) rape construction (6 x 7,6 x 25 FW, 6x 41 WS, 8 x 19S, etc.) 3) length of lay, 4) material Ropes with wire strand core (WSC) or independent wire rope core (IWRC) have less constructional stretch than those with fiber core (FC). The reason for this is the fact thatthe steel cannot compress as much as the fiber core. Usually, constructional stretch will cease at an early stage in the rope's life. However, some fiber core ropes, if lightly loaded (as in the case of elevator ropes), may display a degree of constructional stretch over a considerable portion of their life, ‘A definite value for determining constructional stretch cannot be assigned since it is influenced by several factors. The following table gives some idea of approximate stretch as a percentage of rope length under load, Rope construction Approximate Stretch* 6 strand FC. 1/2% - 3/4% 6 strand IWRC 1/A% - 172% 8 strand FC 314% = 1% *Varies withthe magnitude of the loading.ELASTIC STRETCH Elastic stretch results from recoverable deformation of the metal itself. Here, again, a quantity cannot be precisely calculated. However, the following equation can provide a reasonable approximation for a good many situations, ‘Change in load (Ib) x Length (ft) (Changes in length (ft) = Change in load (1D) x Length (f)_ ‘Area (inches*)x Modulus of Elasticity (psi) ‘The modulus of elasticity is given in Table 17, and the area can be found in Table 18. TABLE 17 APPROXIMATE MODULUS OF ELASTICITY* (pounds per square inch) Rope Classification Zero through 20% Loading 21% to 65% Load 6x7 with fiber core 11,700,000 13,000,000 6x 19 with fiber core 10,800,000 12,000,000 6x 37 with fiber core 9,900,000 11,000,000 8x 19 with fiber core 8,100,000 9,000,000 6x 19 with IWRC 13,500,000 6x37 with IWRC 12,600,000 ‘Applicable to new rope with constructional sich removed. EXAMPLE: How much elastic stretch may occur in 200 ft of 1/2 inch 6 x 25 FW IPS FC rope when loaded to 20% of its nominal strength: Nominal strength = 10.7 tons (21,400 Ib) 20% of which = 4,280 Ib. Area of 1/2 inch is found by squaring the diameter and multiplying it by the area of 1 inch rope given in Table 18 under the "Fiber Core” heading and opposite 6 x 25 FW, ie,, 12x 1/2x 417=.104. ‘The modulus of elasticity is found in Table 17 opposite the 6 x 19 fiber core (because 6 x 25FW is a member of this class) and under the "Zero through 20% Loading.” Substituting these values, the equation reads as follows: 4280 x 200 -104 x 10,800,000 = 76 Ft (9.1 inches) ‘A word of caution conceming the use of Table 17: the higher modulus given under the "21% to 65% Loading’ is based on the assumption that both the initial and the final load fall within this range. Ifthe above example were restated to the effect that the load was 35% (or 7,490 Ib) of the nominal strength, it would be incorrect to rework the problem simply by making two substitutions: the new load and the higher modulus of 12,000,000 psi. To do so would ignore the greater stretch that occurs at the lower modulus during the initial loading. (Change in length =—_— TABLE 18 APPROXIMATE METALLIC AREAS OF ONE-INCH ROPE. OF VARIOUS CONSTRUCTIONS* SS Fiber re Cable Construction Core wsc Laid 3x7 390 437 6x6 320 386 6x7 384 431 6x12 232 6x 1912/7 376 442 6x 19S 404 470 * Values given are based on 3% 6x19W 416 482 oversize because this is a com- 6x21 FW 412 438 ‘mon design “target.” But, this 6x21S All ATT Se fen vate ands ntio 6x24 15/9 329 Shernspeticconincions, 6x25 FW ai7 483 also vary, thus the given values 6x 26 WS 409 476 ue approximate. They are, how 6x29 FW 420 486 ‘ever, Within the range of accura- 6x31 1219 385 452 cy ofthe entire method that is.in_©X 31 WS Al4 481 itself, approximate 6x33 FW 4B 490 6x36 WS 419 485 As indicated, it is necessary to 6x 37 18/19 W 393 459 ‘know the rope area in order to 6x37FW. 427 493 solve the previously given 6x41 SFW 425 491 stretch equation For diameter han ich, 6x al WS a 450 ‘multiply the area given in this 6x 42 Tiller 231 table by the square of the nomi 6x43 FWS 392 nal rope diameter. 6x 46 SEW 425 Example: To find the area of 6x46 WS A26 12" 6x 36 WS IWRC 6x61 FWS 408 From the table: 485 7x7 Diameter squared: (1/2)*=1/4 or 7x19 1977 Sx.5=.25 7x19W Multiply table value by diameter 8x7 343 ‘saosred 8x 19S 359 ‘Area:=.25 x 485=.121 inches* 8x19W 366 le: To find the area of 8x25 FW 368 1-1/8" 6 x25 FW FC 8x 19FW 366 Answer: (1.25) x .417=1.563 x 18x7 422 ‘ EE D 417-652 inches T9x7 3 6x3x19 Tx7x7 ee al)WIRE ROPE EFFICIENCY OVER SHEAVE (TACKLE BLOCK SYSTEM) ‘Some portion of a wire rope's strength—when operating over sheaves—is expended in tuming the sheaves and in flexing. This lost strength is not available to lift the load, and in multi-part tackle block system (Fig. 63) this loss factor can be significant The load on the lead line (fast line) under static (no-movernent) conditions can be readily calculated if the load is divided by the number of parts of line as expressed. in the following formula: Fast line load =Total load (incl. slings, containers, etc.) No. of parts of line For example, in a four-part system (Fig. 634) to lift 6000 Ib, the lead line load will equal: £9000 or 1500 Ib. |. ONE-PART LINE 8. TWO-PART LINE C._ THREE-PART UNE 0, FOURLPRRTLINE. Figure 63. Commonly used single- and muliple-sheave block (tackles) Static loading on the rope is: A) equal t, B) 1/2 of, C) 1/3 of, D) 1/4 of, and E) 1/5 of the supported load.x “Moreover, if this system has ball or roller bearings in the sheaves, the lead line load will increase to 1650 Ib. when the load starts to move. On the other hand, ifthe sheaves have plain bearings such as bronze bushings, the lead line load will increase to 1854 Ib. In an 8-part system with plain bearings, the lead line load jumps from 750 Ib. to 1086 Ib.-an increase of 45%! Derricks often use 8 or more parts in the boom support system. The schematic diagram (Fig. 64) shows 4-part reeving. This system has the same number of sheaves as there are parts of Fine. ‘The following procedure presumes this condition throughout. Provision for extra lead sheaves are given at the end of this discussion. “To calculate the lead-line load, the combined load of the container, contents and lifting attachments is multiplied by the lead time factor as follows: Lead line load = lead-line factor x load TABLE 16 LEAD-LINE FACTORS* Figure 64, Schematic representation ofa four-part reving system, Nathe ‘number of pars of line supporting the load (W), and S=the number of rotating sheaves, Pants With Plain With Roller of Line Bearing Sheaves Bearing Sheaves 1 1.09) 1.04 2 568 530 3 395 300 4 309 275 5 257 225 6 223 191 7 199 167 8 181 148 9 167 135 10 156 123 n 147 4 12 140 106 13 133 10 4 128 095 ‘ 15 124 090 "In using this table, the user should note tat itis based on the assumption thatthe numberof parts of line (') is equal 10 the numberof sbeaves (8). When exceeds N, refer tothe text.Fig. 65 shows a similar 4-part system with an additional lead-in sheave. In such cases, for each additional sheave the tabulated value is multiplied by 1.09 for plain bearings, of 1.04 for anti-frition bearings. Example: What is the lead-line factor for a plain bearing tackle block system of ‘5 parts of line and two extra lead-in sheaves? The tabulated value is .257. Since there are two additional sheaves, the computation is: 257 x 1,09 x 1.09 = .305 ‘What is the lead-line toad on this system when the load is 5000 Ibs? 5000 x 305 = 1525 tb It should be emphasized that the "dead-end of the rope may also be subjected to this augmented load, Systems in which both rope ends are attached to a drum, as found in some overhead cranes are not within the scope of this discussion. It is suggested, there- fore, that information on such systems be obtained directly from a wire rope ‘manufacturer. Figure 65. Schematic representation of a “part reeving system with an extra (idler) sheave.Appendix G i VALUES OF CONSTANT K No. of Wire Rope Pars__K n 2 8 36 34 150 BLOCK SPINNING 7 Since the invention ofthe crane, one problem has been prevalent during many lift- ing operations—spinning ofthe load or rotation of the traveling blocks. While spin- ning of the load can occur at any fall length, block rotation usually does not pose a problem until a certain height is reached. In either case, lifting can be severely limit- ed or halted due to these conditions. ‘The formula, shown below, predicts the length at which “cabling” of multiple-part reevings will occur. This formula incorporates the variables of rope spacing at both the point and traveling block sheaves; the torque provided by the rope; length of fall; and the number of parts of line. Lz SixS"xsing KxTf i Rope Spacing at Boom Point—Inches Rope Spacing at Traveling Block Sheaves—Inches Variable for Number of Parts of Line ‘Torque Factor of Rope—Inch Pound Per Pound @ = Angle of Block Rotation-Degrees ‘The definition of cabling is that point at which the blocks spin to entangle the hoist line, This point has been defined to be when the traveling block has tumed 90 degrees from its neutral position. The equation can therefore be reduced to the fol- owing to indicate at what point cabling is likely to occur, L = S88" _ sin 90 Degrees = SS" Kx Tt KxTf It should be noted that this formula neglects the effects of load, but is only correct above a certain minimum load. This load is that force required to overcome the inter- nal frictional force of the rope and inertia ofthe traveling block. That is, this formula is invalid until the rope has been loaded to the point that allows the extemal rope strands to act independently of the intemal core strands, thus producing sufficient torque to rotate the blocks. Once this minimum load has been reached, loads above this value have no effect on block rotation. This formula then becomes valid and approximates the fall ength at which cabling occurs. This minimum load is approxi- mately 10% of the nominal rope strength, or any design factor greater than 10 to 1. ‘The torque values of rope constructions vary mostly because of the physical char- acteristics of the design. That is, 6x 25 Filler Wire, Independent Wire Rope Core rope is designed so thatthe outer rope strands and the strands of the core are laid in the same direction. Thus, whenever a load is applied, both the rope and the core have a tendency to unlay in the same direction. Conversely, when a Rotation- resistant rope is tensioned, the unlaying effect of the outer rope strands is greatly reduced due tothe fact thatthe strands of the core are laid in opposite direction toAppendix G — the outer rope strands. But even rotation-resistant ropes twist due to the greater torque applied by the outer strands over the core strands, With rotation-resistant ropes, the torque factors vary according to the number and lay length of outer strands, the construction and lay length of the core and the lay type (Regular or Lang) of the rope and core. Bands are used to cover the rotational properties ofthe various ropes. The bands ‘on the graph in figure G1 display the approximate limitations of the three ropes in a ‘multi-part system. Four independent variables are used as parameters and are used in pairs to locate a reference point on the graph. They are grouped as follows: L/S= Length of fall per unit rope spacing D/é= Average pitch diameter of block and crown sheaves per unit rope diameter, (For 2-fall system, with parallel falls, the ratio is the pitch diameter of the sheave divided by the nominal rope diameter.) Various constructions of rope shown in the graph indicate the limited conditions for torsional stability with the angular displacement of the hoist block to maximum ‘0f 90 degrees. When the operating conditions fora particular installation lie above the appropriate wire rope construction band, then cabling of the falls most likely will occur, If the operating conditions lie below any particular band, then cabling of the falls will most likely not occur. If the operating conditions for any particular installation fall within the band, cabling is unpredictable, EXAMPLE A 2-fall crane uses 3/4” diameter hoist rope and a block with a pitch diameter of 18 inches. The rope spacing is assumed to be parallel and the height of lift required is 100 feet. Based upon these conditions we would have the following values: 1=.75 inches D=I8 inches S=15 feet L=100 feet LS=66.7 Djd=24 Using these numbers and entering the graph, we find that it would be a borderline condition for six-stranded, regular lay rope; however, there should be no trouble using one of the Rotation-Resistant ropes. "L" is the length of fall (feet) and is measured from the centerline of point sheave | to the centerline of the sheave in the traveling block. "S” is the spacing of the outer | 151Appendix G ropes on even-part systems (2, 4, 6, 8...) In odd-part systems (3, 5,7,9...),the measurement of "S" is reduced by a factor below the next lowest even-part system as shown in Table 5. "D" is the average pitch diameter (inches) of the point and block sheaves, and "A" is the nominal wire rope diameter (inches). TABLE G5 COMPUTING "Ss", 2-Part System=Average Pitch Diameter of Point and Block Sheave 3-Part System=2/3 of 2-Part System 4-Part System=Diagonal Distance of Rope Parts 5-Part System=4/5 of 4-Part System, i ‘6-Part System-Diagonal Distance of Rope Parts | 7 Part System-6/7 of 6-Part System In summary, the four variables, which can be established for a given condition, are to be used to calculate the probability of cabling. It must be remembered that this ‘concept is based upon proper handling and reeving of the wire rope on the machine. ‘Any undue twist which is in the rope during operation will affect the torsional prop- erties ofthe line. Suggestions as to proper handling of the rope in the field can be obtained from any wire rope producer. It should also be noted that differences in rope manufacturing may be sufficient to yield variations in the results. All lifts ‘where cabling may occur should be approached with caution. j i | 152Appendix G WIRE ROPE CABLING BANDS SYSTEM STABLE BELOW, UNSTABLE ABOVE, UNCERTAIN WITHIN BAND. 200 J] TT US = LENGTH OF FALL (FT) / AVERAGE ROPE SPACING (FT) 1a0-{— Dis = AVERAGEPITCHDIA (NOMINAL ROPE IA.) | FerzPantening, $ = Averaged For Sartreoing, § = 260 2Pan 160-f— ForaParreevng, § = Dagonal Disanceo Rope Pars ForSPatreeing, § = 4B 014-Pan | 7] ee | f | tex7 | isx19 140 Rot es. 120 Bx 19Cless. o 4 ot Res 2 g = 100 SJ ex190ess 20 60 40 | 20 | a | o 3 6 8 2 6 we a mm 7 30 0 ow nario Figure G1 153,Appendix G The following steps tend to reduce cabling: + Reduce wire rope length. Longer wire rope lengths cause more rotation, due to unlaying, than shorter wire rope lengths. + Replace fiber core wire rope with an IWRC wire rope. Fiber core wire ropes have a higher torque factor than IWRC wire ropes. + Eliminate odd-part reeving, Even number of parts is more stable than odd. + In installations where the wire rope dead end is on the load block, rereeve to the next higher number of parts, and dead end the wire rope on the fixed block. + While maintaining the same design factor, use a smaller size wire rope. + Increase the spread between the wire rope falls, Use either larger sheaves, e or dead end the wire rope away from the the wire rope falls (check the integrity of the structure). + Restrain the load block with a tag line. 154