THE rope

capping solution

Technical Data Manual

Developed & manufactured in the UK by
Millfield Enterprises (Manufacturing) Limited
Introduction
WIRELOCK is the original cold socketing compound for use
with wire ropes. With a track record spanning over 60 years
it is quite simply the best socketing solution for safety,
dependability and unparalleled fatigue performance.

At WIRELOCK we know ropes and all aspects of rope termination so

our technical service is unrivalled and comes as part of WIRELOCK’s
customer service.

Manufactured in the UK, by Millfield Enterprises (Manufacturing) Ltd,

WIRELOCK produces standard kit sizes ranging from 100cc – 2000cc
and our highly skilled workforce can create kit sizes to order for
projects large and small.

Distributed internationally WIRELOCK has a worldwide reputation

as the number one product for safe and reliable use with bridges,
structures, mining, offshore and general engineering.

WIRELOCK meets the requirements of ISO 17558 and DNV-OS-E304

and has Type Approval from DNV, Lloyds and ABS.

Bosphorus Bridge, Turkey, incorporating WIRELOCK.

 Contents
Section 1: Warning on correct application of WIRELOCK ..................................................................................................4

Section 2: Health & safety precautions for using WIRELOCK ........................................................................................4

Section 3: Selection of socket ..................................................................................................................................................................5

Section 4: Preparation of broom ............................................................................................................................................................6

Section 5: Positioning of broom & alignment of socket .......................................................................................................7

Section 6: WIRELOCK storage, kits & mixing...............................................................................................................................8

Section 7: Use of heat .....................................................................................................................................................................................9

Section 8: Pouring WIRELOCK ...............................................................................................................................................................9

Section 9: Movement ....................................................................................................................................................................................10

Section 10: Check on penetration ......................................................................................................................................................10

Section 11: Relubrication ..........................................................................................................................................................................10

Section 12: Loading.......................................................................................................................................................................................10

Section 13: Reuse of socket ...................................................................................................................................................................10

Section 14: General information ..........................................................................................................................................................11

Section 15: Approvals & NATO numbers .....................................................................................................................................13

Section 16: Guide to amount of WIRELOCK required ........................................................................................................14

Section 17: Properties of WIRELOCK .............................................................................................................................................15

Section 18: Where to find SDS information & training aid video ..............................................................................15

Appendix A: Resin socketing & steel wire rope.......................................................................................................................16

Appendix B: Technical bulletin for reuse of spelter sockets (as supplied by Crosby Group, Inc) ...............................19

Copyright© 2024 by Millfield Enterprises (Manufacturing) Limited.

All rights reserved.
Millfield Enterprises reserves the right to change product design material, specification and publications without incurring obligations.
Printed in the United Kingdom.
Manual version: 12–07/24
 Instructions
This technical data manual explains the correct use of WIRELOCK
for socketing wire rope terminations using standard taper sockets.
When reading and following these instructions, pay close attention
throughout to warning and safety information presented in bold print.
For maximum safety and efficiency, use WIRELOCK only as instructed.

Section 1: Warning on Section 2: Health &

correct application safety precautions for
of WIRELOCK using WIRELOCK
It is very important when deciding upon the use It is important that certain precautions be taken when
of WIRELOCK to note the following: using WIRELOCK for a wire rope socket termination.
When using the product be sure to read information
on product containers and note the following:
WARNING
• Incorrect use of WIRELOCK can result in an unsafe CAUTION
termination which may lead to serious injury, death,
or property damage. • WIRELOCK resin, in liquid state, is flammable.
• Crevice Corrosion will occur in the rope near the • Chemicals used in this product can give off toxic
socket rope interface, where a termination of fumes and can burn eyes and skin.
stainless steel wire rope is permanently immersed
in salt water. When using WIRELOCK within this
• Only use in well-ventilated work areas.
environment regular inspection must be carried out. • Never breathe fumes directly or for an
extended time.
• Seizing - use tinned or galvanised soft wire or strand
for galvanised rope. Use bright, tinned or galvanised • Always wear safety glasses to protect eyes.
wire or strand for bright rope.
• Always wear protective gloves to protect hands.
• Do not use copper or brass wires or strand
• Avoid direct contact with skin anywhere.
for seizing.
• Always wear a dust mask/ fume filter.
• Never use an assembly until the WIRELOCK has
gelled and cured and a successful scratch test • WIRELOCK SDS sheets can be found at wirelock.com
has been completed.
• Remove any non-metallic coating from the
broom area.
• Sockets with large grooves need to have those
grooves filled before use with WIRELOCK.
• Read, understand, and follow these instructions
and those on the product containers before
using WIRELOCK.

4 For more information please contact us: call +44 (0) 191 264 8541
 Technical Data Manual

3.5
Section 3: Plastic coated or plastic filled wire ropes must
have all plastic material (non-metallic materials)
removed from within the broomed area.
Selection of socket 3.6 The socket basket should be examined prior to
use and any loose scale, dirt or grease removed.
3.1 WIRELOCK is recommended for use with
sockets that comply with International, Do not use oversized sockets for wire rope.
European or National (ISO, CEN) Standards. 3.7 When socketing strand, the time honoured
3.2 WIRELOCK, as with all socketing media, method of one size up when choosing the socket
depends upon the wedging action of the cone is generally still applicable in the vast majority of
within the socket basket to develop full efficiency. cases. However, caution should be exercised as
Seating is required to develop the wedging action. tests have shown that the length of the socket
Please note a rough finish inside the socket may basket should be five (5) times the strand
increase the load at which seating will occur and diameter or fifty (50) times the maximum
must be avoided. wire diameter, whichever is the greater.

3.3 Measure the rope ends to be socketed. The rope 3.8 Inserting the broom into the socket.
end should be of sufficient length so that the ends There are two procedures that can be used to
of the unlaid wires (from the strands) will be at the position the broom within the socket. The rope
top of the socket basket. can be inserted into the socket prior to brooming.
Subsequently the socket can be pulled up over
For standard taper sockets, apply the seizing one the broom. The second method requires that the
(1) socket basket length from the end of rope broom is closed and compacted to enable it to be
minus one (1) rope diameter. The length of the inserted into the socket without damaging the
seizing must be at least two (2) rope diameters rope or seizing.
long. Additional information can be secured from
your Wire Rope User’s Manual or your wire rope For a detailed explanation of resin socketing of
manufacturer’s catalogues or national standards. steel wire ropes see Appendix A on page 16.
Please note when seizing, use tinned or 3.9 WIRELOCK is available in several standard kit
galvanised soft wire or strand for galvanised sizes (100cc, 250cc, 500cc, 1000cc, and 2000cc).
rope. Use bright, tinned or galvanised wire for Specialist kits can be manufactured at higher
bright rope. volumes on request. Importantly, due to
3.4 It is very important to seize correctly. If using pear differences in formulation, 100cc and 250cc
shaped or other specialist sockets, the position of WIRELOCK should be used exclusively on
the seizing and the length of the broom may have smaller sockets, whilst larger sockets should
to be adjusted to suit the socket being used. be poured with kits above 500cc.

Figure 1: Seizing of wire rope.

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 Note: the wires must be unlaid from the end of
Section 4: the rope to the seizing because a good fill of
resin must occur to the bottom (small end) of
Preparation of broom the socket (figure 3).
Most of the load bearing capacity of the
4.1 The rope is secured in a vice directly below the termination is concentrated in the bottom
seizing to allow the strands to be unlaid down to the one third (1/3) of the socket.
seizing. They should be bent outwards to a total
included angle of approximately 60 degrees but
not exceeding 90 degrees (figure 2).
CORRECT

Figure 2: Unlay wire rope so that the angle does not exceed 90°. Figure 3: Properly broomed wire rope unlaid from the end of the
rope to the seizing.
4.2 Internal leakage of resin in ropes of 75mm (3") in
diameter and larger can occur because of gaps
between strands and the IWRC (Independent Wire
Rope Core) these gaps should be filled (before
brooming), by pushing small plugs of the
WIRELOCK putty/ clay down into the
INCORRECT
served portion.
4.3 If the rope has a fibre core, it should be cut out
ensuring that the remaining fibre core extends half
(1/2) a rope diameter into the bottom of the socket.
In the case of fibre cores, resin is the preferred
socketing medium.
4.4 If the rope has an IWRC, the IWRC should be
completely unlaid to form part of the broom.
4.5 All of the wires in each strand and the IWRC
must be unlaid completely down to the seizing
to form a broom, being careful not to disturb or
change the lay of the wires and strands under
the seizing band. The wires should not
be straightened.
Brooming is one of the most critical
parts of any socketing operation.

Figure 4: Incorrectly broomed wire rope.

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 Technical Data Manual

4.6 Except in the case of wire ropes of coarse

construction e.g. 6 x 7, it is not necessary or
desirable to hook the wires in the broom. When
the rope contains large numbers of wires, hooking
the ends causes congestion within the socket and
can create penetration problems for the socketing
medium although this is less of a problem with
resin than zinc or white metal.
4.7 The open broom should be thoroughly cleaned
(degreased). Be sure that the cleaning is
confined to the broom and does not extend
to the rope beyond.
4.8 The method of cleaning will depend on the
lubricant and/ or coating on the wire.
4.9 The methods and materials used for cleaning
should comply with the current environmental
protection regulations.
Figure 5: Properly positioned broom with the wire ends
4.10 Consult your wire rope supplier or the wire protruding slightly.
rope manufacturer for recommended
materials and methods. 5.2 WIRELOCK putty/ clay is required to seal the base
4.11 Do not clean wire rope broom with acid, soda, of the socket prior to pouring, thus preventing
methol hydrate, or acetone. A flux should not resin leakage which may cause voids (figure 7).
be used.
4.12 The wire rope broom, after cleaning and drying,
should be kept in a horizontal position to prevent
any grease or mixture of grease and cleaner from
running back down from the main body of the
rope and contaminating the clean wires.

Section 5:
Positioning of broom
& alignment of socket.
5.1 The broom should be inserted into the socket
Figure 6: Axes of socket and rope properly aligned.
using one of the methods described in 3.8.
Place rope in a vertical position with the broom
end up. It is recommended that there be thirty (30)
rope diameters below the socket before any
bending occurs in the rope, or twenty (20) rope
diameters if securely clamped to a beam.
Make certain the broomed wires are uniformly
spaced in the basket, with wire ends at the top
edge of the basket (figure 5), and that the
axes of the rope and the fitting are aligned
(figure 6). A centralising clamp should be used
to assist in the alignment of the axes of the
socket and the rope.
Correct alignment will avoid premature failure
of the assembly due to unequal loading of
the wires.
Figure 7: Axes of socket and rope properly aligned and sealed
with WIRELOCK putty/ clay.

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 6.5 Combining kits – For larger socket pours,
Section 6: WIRELOCK WIRELOCK’s larger kits offer the flexibility to
be combined to achieve a required volume,
storage, kits & mixing for example 2500cc = 2 x WIRELOCK 1000cc
plus 1 x WIRELOCK 500cc. WIRELOCK’s smaller
6.1 Storage – WIRELOCK should be stored in a cool, volume kits, 100cc and 250cc, have a special
dry place (10°C to 24°C/ 50°F to 75°F). Standard lower viscosity formula designed specifically for
WIRELOCK has an expiry date of 18 months from use in small socket pours and these kits MUST
the date of manufacture, whilst WIRELOCK Sling ONLY be used as an entire kit and MUST NOT
and High Volume WIRELOCK products have a be combined with other kits.
12 month shelf life, both are subject to correct 6.6 Mixing containers – Only the 100cc, 250cc and
storage. Always check the expiry date on the kits. 500cc can be mixed in the original packaging by
Never use out of date material. pouring Part A: Resin System into the container
6.2 The Importance of temperature – WIRELOCK is of Part B: Catalyst/ Frictional Component (figure
formulated for mixing and pouring in the ambient 8). In the case of other kits, a proper mixing vessel
temperature range; from -3°C to 35°C (27°F to should be used. Mixing vessels should be clean.
95°F). At lower temperatures the gel time will They can be made of metal, polythene, or
increase. See section 14.1 for further information polypropylene. Polymerisation products of
regarding temperatures and gel times. styrene, i.e. Styrofoam cups and similar
products should not be used. A flat wooden
6.3 Booster kits – Below 9°C (48°F) acceptable gel or metal paddle, not a spike or screwdriver,
times can be maintained by the use of WIRELOCK should be used as a stirrer.
Booster kits.Only use WIRELOCK Booster kits that
match the size of the WIRELOCK kit being used. 6.7 Mixing – Immediately upon pouring Part A:
Resin System into Part B: Catalyst/ Frictional
Always add the WIRELOCK Booster kit to the Component mix vigorously for two (2) minutes or
WIRELOCK Part B: Catalyst/ Frictional Component until a homogenous mixture has been obtained.
first and then add WIRELOCK Part A: Resin System. Make sure that no unmixed granular compound
WIRELOCK Booster kits compensate chemically (Part B) remains on the bottom of the mixing
for the slower gel time experienced at lower container. For larger sizes, a mechanical mixer
temperatures. At ambient temperatures below 9°C is ideal.
(48°F) and above 2°C (35°F), one (1) WIRELOCK Upon mixing, the WIRELOCK will turn to a green/
Booster kit should be used. Below 2°C (35°F) and blue colour. If the mix remains a pale straw yellow
above -3°C (27°F), two (2) WIRELOCK Booster kits colour, do not use the kit. Always mix all of Part A:
should be used. To comply with all the approvals Resin System with all of Part B: Catalyst/ Frictional
granted, WIRELOCK should not be mixed and Component. Never mix less than the total contents
poured at temperatures below -3°C (27°F). of both cans.
Please note: The ambient temperature is
important but the gel time for WIRELOCK is
also affected by the temperature at which the
WIRELOCK kit, socket and wire ropes are all
stored. For example, if the socket, rope and
CAUTION
WIRELOCK kit are all stored at normal room
temperature, 18°C to 21°C (65°F to 70°F), for at • Chemicals used in this product can give off toxic
least 24 hours immediately prior to pouring but fumes and can burn eyes and skin.
the termination is being carried out in an ambient • Always check the expiry date on the cans.
temperature below 9°C (48°F) but above -3°C Never use out of date material.
(27°F), then it may not be necessary to use
Booster kits – in such circumstances WIRELOCK’s • Use only in well ventilated work areas.
technical team can advise on the amounts of • Never breathe fumes directly or for an
Booster kit required. extended time.
6.4 Hotter temperatures – If the ambient temperature • Always wear safety glasses to protect eyes.
during termination is 35°C (95°F) or above, the
WIRELOCK kit should be refrigerated for two (2) • Always wear protective gloves to protect hands.
hours before use. • Avoid direct contact with skin anywhere.
• Always wear a dust mask/ fume filter.

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 Technical Data Manual

Section 8:
Pouring WIRELOCK
8.1 Once the WIRELOCK is mixed, it should be
poured immediately (figure 9) into the socket to
ensure good penetration, preferably down one
side of the socket to allow air to escape.

Figure 8: Some kits can be mixed in the original packaging.

Section 7:
Use of heat
7.1 Do not apply heat to sockets to accelerate the
curing process prior to pouring. The application Figure 9: Upon mixing the compound should be poured immediately.
of external heat may cause the resin to gel before
it reaches the bottom of the socket and lead to Immediate pouring will ensure that the gelling
assembly failure. Used sockets cleaned out by stage occurs in the socket and not in the mixing
heating (see Appendix B on page 19) should container. Sufficient WIRELOCK should be mixed
be allowed to cool to room temperature so that the socket can be completely filled in
before reuse. one pour. WIRELOCK is designed to gel in
approximately 20 minutes at 18°C (65°F).
Hot sockets must not be used.
Gelling is the transition point from liquid to solid.
To allow an adequate safety margin, no load
should be applied to the wire rope assembly until
a minimum of one (1) hour has elapsed from the
time the WIRELOCK has gelled in the socket and
a successful scratch test completed.
As WIRELOCK cures, a chemical (exothermic)
reaction occurs, causing a considerable rise in
temperature. Temperatures in excess of 100°C
(212°F) may be reached in large volume kits in the
mixing container. In the socket where the wires of
the rope and the socket itself act as a heat sink,
the maximum temperature likely to be achieved
will be in the order of 70°C to 80°C (160°F
to 175°F).

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 Section 9: Movement Section 12: Loading
9.1 Movement of the resin poured sockets may 12.1 The rope can be put into service or proof loaded
damage the soft resin and reduce the efficiency of one (1) hour after the material in the socket has
the termination. Resin poured sockets should not gelled and a successful scratch test has been
be moved for a minimum of ten (10) minutes completed (figure 11).
after the material in the socket has gelled.
To carry out a scratch test take a sharp instrument,
press hard and pull over the surface of the resin.
A clear, white score should be evident. On a small
Section 10: socket it is quite normal to have a very thin tacky
layer on the surface of the resin and the scratch
Check on penetration test can be carried out through this layer.

10.1 A visual check for penetration of the resin into

the socket bottom can be made by removing the
centralizing clamp and the WIRELOCK putty/ clay.
Seizing on the rope adjacent to the neck of the
socket should be removed up to the point where
it enters the socket.

Section 11:
Relubrication
11.1 After removing the rope from the vice, any
degreased area of the rope below the socket
should be relubricated (figure 10).

Figure 11: Scratch testing the material in the socket one hour
after it has gelled.

12.2 Whenever possible, the assembly should be

proof loaded.

Section 13:
Reuse of socket
13.1 Please consult socket manufacturer for additional
information on reuse of sockets. See Appendix B
on page 19 for guidelines issued by The Crosby
Group Inc.

Figure 10: Relubrication of the rope below the socket after

removing from the vice.

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 Technical Data Manual

Section 14:
General information

Figure 12: WIRELOCK standard kit sizes and other kit sizes available.

14.1 WIRELOCK is designed to gel (change from a 14.2 WIRELOCK is available in standard kit sizes
liquid to a solid) in approximately 20 minutes at ranging from 100cc to 2000cc. Other kit sizes
18°C (65°F). To ensure the kits are not adversely can be made to order for any specific project.
affected by storage, they should be kept in a dry Technical expertise is available by telephone
place at a temperature of between 10°C and 24°C 44 (0) 191 2648541 or [email protected]
(50°F and 75°F) and away from any source of
The specific gravity of WIRELOCK is 1.73
direct heat. WIRELOCK, like all polyester resins,
therefore, 1000cc’s will weigh 1.73kg or 3.81lbs.
is temperature sensitive. An increase in
250cc will weigh:
temperature of 10°C (18°F) will halve the gel time.
A further increase of 10°C (18°F) will halve the gel
time again. A decrease in temperature of 10°C 1.73 x 250
–––– = 0.43kg or 0.95lbs
(18°F) lengthens the gel time by approximately 1000
100%. A further decrease in temperature of 10°C
(18°F) will lengthen the gel time by approximately
100% again.

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 14.3 WIRELOCK wire rope assemblies are 14.8 When cured, WIRELOCK has a Barcol hardness
100% efficient when used with steel wire rope, of approximately 40 to 50. When the resin has set
galvanised wire ropes and stainless steel wire fully (opaque green or mustard colour) only a
ropes. We do not advise the use of stainless steel slight scratch mark will be seen when a sharp
wire rope permanently immersed in a salt water object, such as a screwdriver blade, is scraped
(marine environment) without regular inspection. over the surface of the resin. On a small socket,
In the presence of an electrolyte, i.e. sea water, it is quite normal to have a very thin tacky layer on
electrolytic degradation of the stainless steel wire the surface of the resin. The scratch test can be
rope can occur. This phenomenon, known as carried out through this layer.
Crevice Corrosion will impair the integrity of the
14.9 Radial cracks, which may appear on the top of the
rope in the region near to the neck of the socket.
cured cone, are surface crazing only and are a
Crevice Corrosion also occurs when white metal
result of heat stresses and shrinkage upon a thin
is used for socketing (zinc should not be used to
layer of unfilled resin covering the tops of the
socket stainless steel rope). However, the onset of
wires. The crazing does not affect the strength
Crevice Corrosion in resin sockets appears to be
of the termination within the socket.
faster than when white metal is used. Other rope
types do not exhibit this behaviour. See figure 13. 14.10 Shrinkage of the WIRELOCK cone may leave a
gap between the cone and the socket wall in large
sockets. This is normal, particularly with large
sockets and high ambient temperatures. This in
no way affects the efficiency of the assembly.
Upon loading, the cone will, with the onset of
plastic flow, be seated perfectly in the socket.
The shrinkage of WIRELOCK is between 1.5
to 2.5%. In high volume WIRELOCK, they
shrinkage is about 0.5%.
14.11 Excessive numbers of horizontal rings in the
socket may increase the load required to
‘seat’ and wedge the cone within the socket.
They should be avoided whenever possible and a
proof load applied (not exceeding 40% of MBL) if
they must be used. Alternatively they should be
filled in with WIRELOCK putty/ clay, prior to
placing the socket on the rope.
14.12 WIRELOCK poured sockets should not be used in
environments of strong caustic or acid solutions.
WIRELOCK is not affected by oils, grease or
salt water.
Figure 13: Typical example of the swelling of stainless steel 14.13 WIRELOCK is, by design, a compressive resin.
rope due to Crevice Corrosion. Therefore, when removed from the socket a
WIRELOCK cone, if hit by a hammer, may shatter.
14.4 WIRELOCK is approximately 20% the weight In a socket, even under extreme loads or shock
of zinc. loads, the WIRELOCK cone remains solid and
14.5 The strength of WIRELOCK, in its cured state, 100% efficient.
is not adversely affected by cold temperatures. 14.14 The shelf life of each WIRELOCK kit is clearly
14.6 WIRELOCK must be mixed and poured (see 6.3) marked on the label. Standard WIRELOCK kits
within the temperature range of -3°C to 35°C have a shelf life of 18 months from the date of
(27°F to 95°F). The kits are not adversely affected manufacture, subject to correct storage (always
by storage at temperatures below -3°C (27°F). check the labels). The shelf life of WIRELOCK
WIRELOCK kits should be stored in a cool High volume or Sling kits is 12 months from the
dry place. date of manufacture, subject to correct storage
(always check the label before use).
14.7 The operating temperature of WIRELOCK
is +115°C to -54°C (+240°F to -65°F).

12 For more information please contact us: call +44 (0) 191 264 8541
 Technical Data Manual

Section 15: WIRELOCK meets the requirements of ISO 17558

and DNV-OS-E304.

Approvals & WIRELOCK has Type Approval from Lloyds,

DNV and ABS.

NATO numbers
Approvals
To maintain WIRELOCK’s premier position in the
marketplace we continually strive to refine and improve
the product. We operate a monitoring programme to
ensure that the quality of WIRELOCK never varies.
WIRELOCK is manufactured under ISO 9001 NATO numbers
accreditation. 100cc ................................................................8030-21-902-1823
250cc ................................................................8030-21-902-1824
500cc ................................................................8030-21-902-1825
1000cc ..............................................................8030-21-902-1826

WIRELOCK is used extensively offshore.

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 Section 16: 6.5mm (1/4") ..................................................................................9cc
8mm (5/16") .................................................................................17cc

Guide to amount of 9.5mm (3/8") ...............................................................................17cc

11mm (7/16")...............................................................................35cc
WIRELOCK required 12.5mm (1/2") .............................................................................35cc

Formula to estimate cc’s required to pour 14mm (9/16")...............................................................................52cc

standard spelter sockets: 16mm (5/8") ................................................................................52cc
19mm (3/4") ................................................................................86cc
2

( D+d
––
4 ) x H x 3.142 = cc
22mm (7/8") ..............................................................................125cc
25m (1") ....................................................................................160cc
28.5mm (11/8")........................................................................210cc
D cm
32mm (11/4") ...........................................................................350cc
35mm (13/8") ...........................................................................350cc
38mm (11/2") ...........................................................................420cc
41mm (15/8") ...........................................................................495cc
44.5mm (13/4")........................................................................700cc
47.5mm (17/8")........................................................................700cc
51mm (2") .............................................................................1265cc
H cm 54mm (21/8") .........................................................................1265cc
57mm (21/4") .........................................................................1410cc
60mm (23/8") .........................................................................1410cc
63.5mm (21/2") .....................................................................1830cc
66.5mm (25/8") .....................................................................1830cc
70mm (23/4") .........................................................................2250cc
76mm (3") .............................................................................3160cc
82.5mm (31/4") .....................................................................3795cc
d cm
89mm (31/2") .........................................................................4920cc
Figure 14: Socket measurements needed to estimate the 95mm (33/4") .........................................................................5980cc
amount of WIRELOCK required.
101.5mm (4") .......................................................................7730cc

Note: approximate measurements (U.S.A.)

250cc Kit ...................................................................................1 cup
500cc Kit ...................................................................................1 pint
1000cc Kit ..............................................................................1 quart
Depending on gel time (ambient temperature) do not
pour more than two sockets from a mix.

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 Technical Data Manual

Section 17: The individual wires of the rope are retained by a

combination of bonding and frictional forces.
The frictional forces are the result of:
Properties • Shrinkage during the curing of the resin.

of WIRELOCK • Coefficient of friction between the resin and

the individual wires.
WIRELOCK in its liquid state is flammable. Flash point The particle size of the silica has been carefully selected
31°C (88°F). Please note: flash point is not the auto to maximise the frictional grip. This is illustrated in figure
ignition (spontaneous combustion) temperature, but the 15, where it is shown that when the bonds strength has
temperature above which the material will give off a been exceeded the frictional grip continues to hold
significant amount of vapour. the load.
Additional forces develop due to the wedging action
Performance criteria within the socket as the rope is loaded.
As WIRELOCK cures, it shrinks by between 1.5% and
Compressive strength Min. 100 N/mm2 2.5% (WIRELOCK High Volume by less than 0.5%) and
Modulus of elasticity Min. 6000 N/mm2 with the introduction of a hard inert filler of specific
Barcol hardness Min. 36 grain size, a high coefficient is obtained.

Specific gravity 1.55 - 1.95 WIRELOCK has excellent penetrating qualities and can
flow through the densest wire rope broom, which would
impact the flow of zinc.

Staining rate: 0.062 in/mm The WIRELOCK system is designed to have a minimal
300
amount of creep, which ceases once the wedging and
frictional forces develop for any given load.
WIRELOCK excels in its ability to resist the action of
fatigue in a wire rope assembly, which is normally
250
prevalent in the rope close to the neck of the socket.
WIRELOCK will minimize such problems.

200

Section 18:
150 Where to find
SDS information
100
& training aid video
50 See www.wirelock.com
Load: lb

for information on:

• WIRELOCK testing documents
0 0.05 0.10 0.15
• WIRELOCK SDS part A & B
Withdrawal distance: in
• WIRELOCK training aid video outlining the
Figure 15: Pull out characteristic for single wire embedded in
correct socketing procedure when using
polyester resin/ silica. standard taper sockets.

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 Appendix A: In practice, it has been found that the wires in the rope
broom, which is about to be socketed, are rarely clean
enough to achieve anything approaching a good bond
The background strength. Indeed, it will be shown later, when dealing
with uncleaned wires, that the frictional grip alone is
on resin socketing enough to seat the cone. Either the bond strength of
the resin to the wire or the frictional grip of the resin

& steel wire rope. on the wire, is sufficient on their own to seat the cone.
Between them they offer a comforting reassurance that
the wire will hold and the cone will seat even if the
By J.M. Dodd B.Sc: wire has not been cleaned properly.
creator of WIRELOCK
The modulus of elasticity was measured and found
and founder of
to be 6085 Mpa (BS63 19 Part 6, 1984).
Millfield Enterprises
(Manufacturing) Ltd. It very soon became apparent, that the bonding action
between the socketing medium and the wire was not in
The concept is not new.
itself sufficient to break the rope. Therefore the focus
The first published data
was moved to the shape of the socket, the wedging
on this topic were
action it would produce and the mechanism by which
produced in the early
this occurred.
sixties. In essence,
these two papers by The usual ‘total included angle’ in sockets is between
Doherty and Campbell, 14/15 degrees and experiments were carried out over
stated that the resin the range 9/25 degrees total included angle. It was
filled sockets under predicted that the narrower the angle, the lower the
either static tension load at which movement occurred and the greater that
(tensile) or fluctuating movement would be. In general, this prediction was
tension (fatigue) could confirmed, although in the case of the lower angles,
offer strengths that were the straight line relationship experienced on the wider
comparable with those of the rope itself. angles was not found. See figure II in all cases, the rope
ultimately broke. This confirms that the system will
There is a dearth of information on socketing and the
cope with a fairly wide deviation from standard
mechanisms by which it works, so it was necessary to
socket dimensions.
establish some basic knowledge before a resin
socketing system could be designed.
Staining rate: 0.062 in/mm
In theory, the requirements for a successful system are:
300
1. High bond strength between resin and wire
2. High modulus of elasticity
To ascertain the bond strength and the magnitude of 250
the predicted frictional grip, tests were done on a single,
straight wire cast into a cylindrical block of resin.
The embedded length being such, that the wire when
200
loaded would slip rather than break. The cylindrical
resin termination was chosen so that there would be
no distortion of the figures, due to the mechanical lock,
inherent in a conical termination. The results are 150
shown in figure I.
The graph shows that high bond strengths are
achievable between the resin and the wire and that 100
shrinkage of the resin and the inclusion of hard silica
in the resin gave a very high frictional grip on the wire.
The classic slip/ grip peaks and troughs on the right
hand side of the loading curve show that the frictional 50
grip is very nearly of the same magnitude as the
Load: lb

bond strength.

0 0.05 0.10 0.15

Withdrawal distance: in

Figure I: Pull out characteristic for single wire embedded

in polyester resin/ silica.

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 Technical Data Manual

30 When the load is applied the rope, any adhesion of the

resin to the socket will shear and the cone, which is now
slightly smaller, will begin to engage the socket wall at
the neck of the socket, thereby generating pressure.
25°
14° Although it still retains a high modulus, the resin in
20 contact with the socket is subject to plastic deformation
and some flow is possible, allowing more of the cone to
share in the loading process. This participation in load
9° bearing diminishes as we proceed up the cone.
See figures IV & V.
10
Load: kN

Slip Slip
1" 6 x 36 I.W.R.C

0 1 2 3 4
Movement: mm

Figure II: Movement within the socket under load for the two Pressure
extreme angles & the standard 14° taper.

The mechanism of this movement and wedging

action were investigated by looking at the distribution
of pressure through the socket. This showed that
approximately two thirds of the total pressure within
the socket was concentrated in the bottom third of the
socket. Whilst pressure at the top of the socket was
very low indeed.
It is necessary to explain why any movement is
possible within the socket and to link it with the
pressure distribution findings above.
When the resin is first poured into the socket there is Load
a perfect match between the shape of the socket and Figure IV: Load causes the cone to slip at the socket interface and
the resin cone. Once the resin has cured, however, the pressure generated locks the cone within the socket.
shrinkage occurs and in an exaggerated form the
effect is as below (figure III).

Figure V: Distribution of pressure on the cone within the socket.

If we examine the forces present in figure IV we

can see that when load is applied, the cone will seat
progressively generating forces normal to the socket
face. These forces are transmitted through the resin
to the wire surface. We are, in effect, creating a wire
reinforced composite wedge on the end of the rope,
which is capable of withstanding the ultimate strength
of the rope.

Figure III: Exaggerated relationship between cone and socket

after the resin has cured.

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 We now have to consider two different scenarios to Both samples went on to achieve the full breaking
establish the key to this mechanism. In the first case, strength of the rope and almost identical breaking
when the load is applied, the wire slips at the resin/wire loads were achieved.
interface before the cone slips at the cone/ socket
This highlights the fact that the frictional grip on the wires
interface. In the second case, upon application of the
is highly efficient. If we take an overview of the whole
load, the cone slips in the socket/resin interface before
situation, it becomes apparent that the key operation in
the wire slips within the resin.
the resin socketing process is the brooming of the rope.
In the first case, we have a disaster, as the rope will pull Indeed this operation is vital for zinc and white metal
out. In the second case we have success, as the rope will as well.
break. What is it that determines which will occur?
Surface area of wire is vital, especially in the highly loaded
Assuming that the coefficient of friction between the wire section at the neck of the socket. From a quality point of
and the resin and the resin and the socket are of the view the broom should be opened right down to the
same order (an over simplification, but it does produce a seizing. Very often we see brooms which look very pretty
simple model), the factor that determines which of the and are nicely opened at the top but the strands remain
above scenarios will occur is the relationship between the substantially closed near the seizing. This state of affairs
surface area of the wire (S1) and the surface area of the does not produce a quality assembly, even though it may
inside of the cone (S2). If S1 is greater than S2 then the break the rope.
cone will seat and the rope will break. If S2 is greater than
One further point on the production of a quality assembly,
S1 the assembly will fail.
is that care should be taken to ensure that the neck area
If, for example, we take a 13mm diameter 6 x 19 IWRC of the socket has been sealed with clay or putty.
rope, the relationship between S1 and S2 is of the order Any leaks could cause voids in the neck area of the
of 6:1, for a 36mm diameter 6 x 36 IWRC 9:1 and for a socket. These voids are able to form because the resin
52mm diameter 6 x 41 IWRC 10:1. These figures give an starts to gel – harden – in the centre of the mass and if
indication of the margins of safety involved when resin resin leaks out at the neck of the socket, the resin above
socketing is employed. It also shows that the degreasing it during gel is no longer liquid and is, therefore, unable to
would have to be disastrously bad to reduce the flow down to fill the void.
coefficient of friction at the wire/ resin interface to a critical
It is not necessary to hook wires when resin socketing
level. One factor that has been ignored in this simple
except in the case of coarse construction wire rope
model, is that the unstraightened wires in the broom
such as 6 x 7.
produce deformation forces when any attempt is made to
induce slip, thus increasing the grip of the resin on the In use, the resin socketed assembly offers a higher
wire and giving a further factor of safety. This wire in the achievable tensile strength and a better fatigue
cast cone, also tends to prevent any significant degree of performance of the assembly. In general, this can be
axial extension of the cone during loading and the cone attributed to two factors; the excellent penetration of resin,
remains almost a constant length. ensuring a complete cone and secondly, the fact that
there is no annealing of the wires due to heat from molten
It would be useful, at this point, to examine the Federal
metal. A further benefit that is derived from lack of heat,
Specification socket which has grooves or rings internally.
is that the lubricant in the rope remains intact and is not
It is obvious that these rings must shear before the
burned off. It is an easy matter to replace the lubricant on
‘locking’ mechanism can operate and as such, are a
the outside of the rope, but very difficult to replace the
hindrance to that process. Incidentally, in the case of zinc
lubricant in the centre of the rope. It is, as it does not
and white metal, this rupturing of the rings is also required
require any heat, acid etching or neutralising, an
before the rope will break. The only justification for these
inherently safe method, for the rigger to use both in the
rings is to stop the cone ‘backing out’ of the socket.
shop and on site. Finally, the quality and reliability of this
In fact, once ‘seating’ of the cone within the socket has
method is, without question, superior to other methods of
occurred, it is not reversible and the cone is then
socketing. It also avoids the damage caused to ropes by
locked into position.
other mechanical methods of attachment of end fittings,
This irreversibility offers the bonus that the stresses which may affect both the tensile and fatigue potential.
created within the socket are fixed and because there is
no fluctuation, it follows that the opportunities for fatigue Bibliography
within the socket are reduced.
Dodd J.M
Let us return to the question of clean and uncleaned wire. Resin as a socketing medium
A series of tests were carried out by A.I.F. in France, in Wire Industry, May 1981
which two samples of each of a series of rope sizes
and constructions were broomed. One sample was Chaplin Dr C.R & Sharman P.C
degreased with trichlorethane and the other sample Load transfer mechanics in resin socketing
was left uncleaned. Wire Industry, Oct 1984
Cordon Dr C.R.R.
The use of resin for man riding in mine shafts
IMEMME, March 1987

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 Technical Data Manual

Appendix B: Technical
bulletin for reuse of
spelter sockets. Kito Crosby
2801 Dawson Road, Tulsa, OK 74110
Telephone: (918) 834-4611

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 The London Eye, UK, incorporating WIRELOCK.

For more information about WIRELOCK please contact us:

+44 (0) 191 264 8541 [email protected] wirelock.com

16 Shelley Road, Newburn Industrial Estate, Newcastle upon Tyne NE15 9RT