WIRE ROPE HANDBOOK
Wire Rope Manufacture at Cookes Factory in Auckland. The Only Manufacturer of Wire Rope in New Zealand. 2
CONTENTS COOKES About Cookes... 4 Cookes Product Range... 6 Wire Rope Design & Construction... 10 Wire Rope Selection Engineering & General Purpose Ropes... 34 Logging Ropes... 38 Fishing Ropes... 44 Marine Ropes... 58 Crane Ropes... 72 Elevator Ropes... 78 Stay Strand & Clothes Line... 82 Services... 86 Associated Products... 90 Branches... 98 Ropes in this catalogue are manufactured in accordance with: BS 302 Parts 2, 3, 6, 7 & 8. BS EN 12385-1-4-5:2002 I.S.O. 2408:1985 Minimum breaking loads (MBL) are quoted in this catalogue in kilo Newtons. kn x 0.10197 = tonne. tonne x 9.80665 = kn. 3
New Zealand s Most Extensive Industrial Support Service. The firm of William Cooke & Company was founded in 1862 at Tinsley in the United Kingdom. An office was opened in Auckland in 1911 to handle the distribution of wire rope and associated products in New Zealand. Cookes are part of a group of Companies that includes a number of the world s leading lifting equipment manufacturers including Parsons Chain Co. (U.K.) and Crosby International (U.S.A.). Cookes operate New Zealand s only wire rope manufacturing plant. Cookes operate websling and webbing load restraint manufacturing plants in both Auckland and Christchurch. Cookes Engineering Workshop manufactures cutting edges for supply throughout New Zealand. 4
All products manufactured by Cookes meet worldwide standards such as Lloyds Register of Shipping, New Zealand Standards Association, British Standards and ISO 9001 Quality Assurance. Cookes head office and branches carry TELARC SAI Registered certification. Cookes operate load testing facilities at most branches throughout New Zealand and on-site testing vehicles in both Auckland and Christchurch. In 1992 a manufacturing plant was installed to produce the Brifen road safety barrier system for highways throughout New Zealand and export. In 1994 a 150 tonne Rotary Swaging Machine was installed to produce swaged wire rope for the logging industry and later the fishing industry. In 2001 a second swager was added to handle the increased demand for this product. 5
Product Range WIRE ROPE: Conventional, Swaged, Dyform, Dyswaged, Blue Strand, N. Z. manufacture up to 60 mm dia. Imported Casar and Korean TESTING SERVICES: Proof loading of all lifting equipment (Telarc Registered). 100 tonne test bed, non-destructive testing, telemetry load cells up to 100 tonnes. BLOCKS: Electric/manual chain blocks, pulley, crane and logging blocks,stainless steel pulleys. ESCO EARTHMOVING EQUIPMENT: Bucket teeth and adaptors, Super V, ripper shanks and tips, grader shanks and tips, end bits, cutting edges and plow bolts to suit. GRADER BLADES: Cutting edges, end bits and plow bolts. Mouldboard liners. CRUSHER PARTS: Jaws, mantles and hammers. SCREENS: Both wire and polyurethane. PENGO: Auger equipment, trencher teeth. LUBRICANTS: Brilube wire rope dressing. SLINGS: Wire and fibre rope, chain and web slings. LOG RIGGING EQUIPMENT: Marlin spikes, cee hooks, chokers, ferrules, pulley blocks, log grapples, rings, butt rigging. EYE BOLTS: Certified, all sizes available, threaded or blank. Stainless steel commercial eyebolts. 6
Product Range COOKES AGRICULTURAL EQUIPMENT: Tractor accessories and 3-point linkage parts. HOISTS: Chain lever type, Supertil wire rope hoists, travelling trolleys, plate lifting clamps. HOOKS: Crane, eye and swivel hooks, marine certified. Cee, choker, stainless steel, snap and chain grab hooks. CHAIN: Galvanised, all sizes, mooring chain, load restraint, hi tensile, lifting chain, grade 80 & grade 100 chain, chain swivels, security chain and stainless steel chain. HYDRAULIC TOOLS: Enerpac hand and powered pumps, cylinders. Extra high pressure hose. Full range of product available. TRANSMISSION: V-belts, timing belts, transmission, conveyor, feeder, attachment and agriculture chain. Saw chain and accessories. Sprockets and pulleys, automotive V-belts, chain breakers, motorcycle chain. Aqua corrosion resistant chain. WEBBING AND CARGO EQUIPMENT: Manufacturers of webslings to NZS5227, truck tiedown restraints, recovery straps, mini tiedown restraints, curtainside webbing and fittings, boat and motorcycle straps, roundslings. HOSE AND COUPLINGS: Complete range hydraulic hose and couplings. Automotive and industrial hose. 7
Product Range HIGH TENSILE LIFTING CHAIN: Kuplex, Weissenfels and Hercalloy chain. Complete range of fittings to suit all applications. LOADBINDERS: Lever and ratchet type chain twitches. MARINE PRODUCTS: Shackles, swivels, fibre ropes, boat trailer winch ropes, thimbles, turnbuckles, rigging screws, boat trailer winches, stainless steel rigging hardware, stainless steel chain, mooring and anchor chain. FIBRE ROPES: Full range of natural and synthetic fibre rope at wholesale prices. SHACKLES: Commercial or certified, galvanised or self colour, bow or dee. Hi-load alloy. Stainless steel dee. HEIGHT SAFETY EQUIPMENT: Full range of harnesses, lanyards, fall arrest devices and karabiners. WEARALLOY: High impact and abrasion resistant steel. All sizes available. ASK OUR STAFF FOR FURTHER DETAILS 8
This catalogue is designed to provide a non-technical guide to the selection of a suitable wire rope for various applications. Technical information is restricted to weights and breaking loads and a few formulae. Constructions and sizes shown here are those commonly available and used in New Zealand but there are many others and enquiries for special applications should be directed to your nearest Cookes branch. Wire Rope is a machine of many working parts and like most machines it must be made right, selected right for the application and used correctly in that application. Like many machines, there is a great variety of types of wire rope, each with different properties to suit it s intended use. The internal combustion engine used to power a racing car is quite different to the one powering a large truck although they both may produce the same horsepower. Like many machines it is impossible to combine the advantages of each type into one single machine. The high horsepower and low weight of a racing engine would be great in a truck. The high fuel cost and short life would not. The same with wire rope, the attributes that make one construction eminently suitable for one application could well be a total disaster in another. 9
WIRE ROPE DESIGN & CONSTRUCTION Wire ropes are composed of independent parts - wires, strands and cores - that interact with each other during service. Wire rope engineers design those parts in different steel grades, finishes and a variety of constructions to attain the best balance of strength, abrasion resistance, crush resistance, bending fatigue resistance and corrosion resistance for each application. To select the best wire rope for each application, one must know the required performance characteristics for the job and enough about wire rope design to select the optimum combination of wire rope properties. The following information is provided as a basic guide. Our expert in house staff and field service specialists are available to provide more specific recommendations. 10
The three attributes of a wire rope to consider are: (1) Strength. (2) Flexibility. (3) Robustness. In all dynamic rope applications (as opposed to static applications such as guy wires etc.) the choice is invariably a compromise. Strength can be increased by increasing the diameter of the wire rope and/or increasing the tensile strength of the individual wires and/or increasing the cross sectional steel content (by decreasing the air voids between the wires) and/or using a steel core construction. Flexibility can be increased by using more wires of a smaller diameter and/or decreasing the tensile strength of the individual wires and/or using a fibre core. Robustness, or resistance to physical damage, can be increased by using fewer wires of a larger diameter and/or using a steel core and/or by increasing the steel area exposed to sources of external damage. Coatings such as galvanizing or others can be applied to protect against corrosion. 11
In almost all cases improving one attribute distracts from another. In addition the wire rope s workplace is rarely ideal. Apart from the environment (dirt, dust, moisture and chemicals), the equipment to which the rope is fitted is rarely ideal and another set of compromises must be decided on. For example all wire rope suffers from being bent and the smaller the bend radius the shorter the rope life. For a 26mm wire rope to escape bend fatigue the winch drum or block sheaves over which it runs would need a minimum diameter of over 1.5 metres. This is clearly impractical in many applications, and unnecessary if bend fatigue does not cause the ultimate demise of the rope. Hardness of Wire Rope Tensile Brinell Rockwell C 1770mpa 425/510 45 1570mpa 400/425 43 1420mpa 380/425 41 12
TERMINOLOGY Wire rope consists of a number of strands laid up usually over a central core. Each strand is made from a number of individual wires. Wire Strand Rope Core CORES Almost all wire rope is laid up over a core, Fibre Core (natural or synthetic), Independent Wire Rope Core or Wire Strand Core (FC, IWRC or WSC): Fibre Core Independent Wire Rope Core Wire Strand Core 13
STRAND CONSTRUCTIONS. Strands are designed with various combinations of wires and wire sizes to produce the desired resistance to fatigue and abrasion. Generally, a small number of large wires will be more abrasion resistant and less fatigue resistant than a large number of small wires. Single Size The basic strand has wires of the same size wound around a centre. 14 Seale Filler Wire Large outer wires with the same number of small inner wires around a core wire. Provides excellent abrasion resistance but less fatigue resistance. When used with an IWRC, it offers excellent crush resistance over drums. Small wires fill spaces between large wires to produce crush resistance and a good balance of strength, flexibility and resistance to abrasion
Warrington COOKES Outer layer of alternately large and small wires provides good flexibility and strength but low abrasion and crush resistance. Seale Filler Wire Filler Wire Seale Many commonly used wire ropes use combinations of these basic constructions Warrington Seale Multiple Operation One of the above strand designs may be covered with one or more layers of uniform sized wires. 15
LAY Regular Lay The most common lay in which the wires wind in one direction and the strands the opposite direction (right lay shown). Less likely to kink and untwist, easier to handle, more crush resistant than Lang lay. Lang Lay Wires in strands and strands of rope wind the same direction (right lay shown). Increased resistance to abrasion, greater flexibility and fatigue resistance than regular lay, will kink and untwist. Right Lay common construction. Strands wound to the right around the core (regular lay shown). The most 16
LAY Left Lay Strands wound to the left around the core (regular lay shown). Used in a few special situations - cable tool drilling line, for example. Alternate Lay Alternate strands of right regular and right Lang lay. Combines the best features of regular and Lang lay for boom hoist or winch lines. WIRE ROPE SIZE The size of a wire rope is the diameter of a circle which will just enclose all the strands. Wrong Right 17
FINISH Bright finish is suitable for most applications. Galvanized finish is available for corrosive environments. Plastic jacketing is also available on some constructions. WIRE GRADES The most common steel wire grades are: 1420-1770 N/mm², and 1860N/mm². Stainless steels and other special grades are provided for special applications. Most wire ropes are made with round wires. Both triangular and shaped wires are also used for special constructions. Generally, the higher the strength of the wire, the lower it s ductility will be. ABRASION AND BENDING Abrasion Resistance DECREASES with smaller wires ß Fatigue Resistance DECREASES with fewer wires ß Ý Ý INCREASES INCREASES with larger wires with more wires The X-Chart. Abrasion Resistance Vs Bending Fatigue Resistance. While there is a possibility, there is little likelihood that an application can be found for which there is a precisely suitable wire rope. 18
As with all engineering design proplems, feasible solutions demand compromise to some degree. At times is becomes neccessary to settle for less than optimum resistance to abrasion in order to obtain the maximum flexibility: the latter being a more important requirement for a given job. A typical example of this kind of trade-off would be in selecting a highly flexible rope on an overhead crane. Conversly, in a haulage installation, a rope with greater resistance to abrasion would be chosen despite the fact that such ropes are markedly less flexible. Two compelling factors that govern most decisions as to the selection of a wire rope are abrasion resistance and resistance to bending fatigue. Striking a proper balance with respect to these two important characteristics demands judgement of a very high order. A graphic presentation of just such comparison of qualities between the most widely used rope constructions and others is given by means of an X- chart. Referring to this chart when selecting a rope, the midpoint (at the X) comes close to an even balance between abrasion resistance and resistance to bending fatigue. Reading up or down along either leg of the X, the inverse relationship becomes more apparent as one quality increases and the other decreases. See next page. 19
The X Chart NUMBER OF OUTSIDE WIRES PER STRAND 6 9 10 12 12 12 14 16 18 LEAST Ü RESISTANCE TO BENDING FATIGUEÞ GREATEST LEAST Ü RESISTANCE TO ABRASIONÞ GREATEST 6x7 6x19S 6x21FW Flattened Strand 6x26FW 6x31WS 6x36WS 6x49FWS 6x64 SFWS 20
EFFECT OF SHEAVE SIZE Wire Ropes are Manufactured in a great variety of constructions to meet the varying demands of wire rope usage. Where abrasion is an important factor, the rope must be made of a coarse construction containing relatively large wires. In other cases, the great amount of bending to which a rope is subjected is more important. Here, a more flexible construction, containing many relatively small wires, is required. In either case, however, if the rope operates over inadequate size sheaves, the severe bending stresses imposed will cause the wires to break from fatigue, even though actual wear is slight. The smaller the diameter of the sheave, the sooner these fatigue breaks will occur and the shorter rope life becomes. Another undesirable effect of small sheaves is accelerated wear of both rope and sheave groove. The pressure per unit of rope on sheave for a given load is inversely proportional to the size of the sheave. In other words the smaller the sheave the greater the rope pressure per unit area on the groove. Using the proper diameter sheave for the size and construction of rope can obviously prolong both sheave and rope life. Sheave diameter can also influence rope strength. When a wire rope is bent around a sheave, there is a loss of effective strength. 21
This is due to the inability of the individual strands and wires to adjust themselves entirely to their changed position. Tests show that rope strength efficiency decreases to a marked degree as the sheave diameter is reduced with with respect to the diameter of the rope. Therefore, it is evident that a definite relationship exists between rope service and sheave size. As a guide to rope users, wire rope manufacturers have established standards for sheave sizes to be used with various rope constructions. To secure the most economical service, it is important that the suggested size of sheaves given on the following page be used. As a rope is run through a groove, both become smaller. A used groove can be too small for a new rope, thus accelerating rope wear. A compromise between rope life and machining frequency must be made. Grooves should have an arc of contact with the wire rope between 135 and 150 degrees. They should be tapered to permit the rope to enter and leave the groove smoothly. Field inspection groove gauges are made to the nominal diameter of the rope plus 1/2 of the allowable rope oversize tolerance. When the gauge fits perfectly, the groove is at the minimum permissible contour 22
PROPER SHEAVE AND DRUM SIZES Construction 6x7 19x7 or 18x7 Rotation resistant 6x19 Seale Suggested D/d* ratio 72 51 51 Minimum D/d* ratio 42 34 34 6x27 H Flattened strand 6x31V Flattened strand 6x21 Filler wire 6x25 Filler wire 6x31 Warrington Seale 6x36 Warrington Seale 8x19 Seale 8x25 Filler wire 6x41 Warrington Seale 6x42 Filler 45 45 45 39 39 35 41 32 32 21 30 30 30 26 26 23 27 21 21 14 *D = tread diameter of sheave. d = nominal diameter of rope. 23
DRUM WINDING It is very important to have a rope wind evenly and tightly on a smooth drum. Due to lay direction and tension, rope has a tendency to rotate or roll as it approaches a winch drum. This characteristic is used to advantage by establishing the winding direction and dead end location so the rope will rotate in the direction of the preceding wrap. Tightly packed wraps on the all-important first layer will ensure proper winding for additional layers. If the drum attachment and direction of wraps are not correctly selected, the first layer of rope will not wind evenly or tightly, causing the second layer to pinch down between the wraps of the first layer. The resultant uneven winding will become worse with each succeeding layer and result in abnormal scuffing and abrasion. If there are sufficient layers the rope will pile up and fall over on itself with disastrous results. The hand rule is a convenient way to check the correct lay for an installation. The extended thumb points to the flange to which the rope is terminated while the extended forefinger represents the rope leaving the drum. A palm up hand represents underwind and palm down overwind. If the right hand meets the conditions, use right hand lay rope and vice versa. 24
RIGHT HAND - RIGHT LAY ROPE Overwind Underwind Right hand, palm down Right hand, palm up LEFT HAND - LEFT LAY ROPE Overwind Underwind Left hand, palm down Left hand, palm up Left lay is not always readily available so design equipment to accept right lay if possible. 25
FLEET ANGLE Excessive fleet angles can cause serious damage to wire rope, sheaves and grooved drums. Severe scuffing results when rope wears against groove walls, grinding them down causing the rope to become bruised and crushed. Rope C/line Fleet Angle Sheave C/line Fleet Angle Fleet angles on equipment should preferably be kept between 1 and 1.5 and should not exceed 2 for smooth drums or 4 for grooved drums. To ensure the rope crossing back and starting the second layer properly without assistance the fleet angle should not be less than 1. The fleet angle is that angle between the centre line of the first fixed sheave and the centre line of the rope leading to the drum. 26
CALCULATION OF DRUM CAPACITIES Capacity in metres = (A+B) x A x C x N The value of N is taken from the table below Rope dia. 6 10 11 13 14 N 87.226 31.416 25.963 18.589 16.028 Rope dia. 16 19 22 26 28 N 12.271 8.702 6.491 4.647 4.007 Rope dia. 32 35 38 40 44 N 3.068 2.565 2.176 1.963 1.623 ALTERNATIVE METHOD Rope length (m) = (A + B) x A x C x p x 10 6 d² Where A, B & C are quoted in metres and d in mm 27
MULTIPLE PULLEY SYSTEMS Under static conditions the tension in each part of a rope in a multi-reeved system will be the total load to be lifted divided by the number of parts supporting the load. When the load is raised it is necessary to take into account forces required to overcome friction in the sheave bearings and the resistance to bending of the rope as it passes over the sheave. These additional forces are cumulative and vary with the type of bearing and the sheave tread:rope diameter ratio. t No of parts 1 2 3 4 5 6 7 8 28 3% 1.030W 0.523W 0.354W 0.269W 0.218W 0.185W 0.161W 0.143W Sheave:rope dia ratio about 15:1 about 20:1 > 25:1 4% 1.040W 0.530W 0.360W 0.276W 0.225W 0.191W 0.167W 0.149W Plain Bearing 8%/sheave 6%/sheave 5%/sheave Percent per Sheave 5% 1.050W 0.538W 0.367W 0.282W 0.231W 0.197W 0.173W 0.155W 6% 1.060W 0.545W 0.374W 0.289W 0.237W 0.203W 0.179W 0.161W Ball/Roller Bearing 5%/sheave 4%/sheave 3%/sheave 8% 1.080W 0.561W 0.388W 0.302W 0.250W 0.216W 0.192W 0.174W
SAFE WORKING LOADS The safe working load (SWL) of a wire rope or a sling made from it is calculated by dividing the particular wire rope s minimum breaking load (MBL) by the safety factor to be used. This safety factor depends on the application and may be determined by legislation or other codes of practice. A common safety factor is 5:1 which means the SWL of the rope is 1/5th of it s MBL. Where the load is evenly supported by more than one length of rope the SWL can be increased as shown: Load carried on two parts at 90 = SWL x 1.4 Load carried equally on two parts at 30º = SWL x 2 at 60º = SWL x 1.8 at 90º = SWL x 1.4 at 120º = SWL x 1 Load carried on two parts = SWL x.8 Load carried on four parts at 90 = SWL x 2.1 29
Incorrect installation or handling prior to installation can damage a wire rope and cause failure before it is even put to work. Care must be taken to avoid putting a kink in the rope and thus permanently damaging it. DO NOT lie the coil on it s side or the reel on it s flange and lift the wraps off the top! The following illustrations demonstrate correct methods: 30
31
Ensure that wire rope always passes around winch drums and sheaves in the same direction (always clockwise or always anticlockwise) and ensure that the rope is loaded to equipment in the same direction as supplied i.e. top of reel (or coil) to top of winch drum or bottom to bottom, never top to bottom or vice versa: 32
Wire Rope Selection 33
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Engineering & General Purpose Ropes 35
Engineering & General Purpose Ropes 6 x 19 9/9/1 1770 N/mm² 6 x 31 12/6&6/6/1 1770 N/mm² 6 x 36 14/7&7/7/1 1770 N/mm² Galvanised 6 x 41 16/8&8/8/1 1770 N/mm² Galvanised Fibre Core IWRC 36 Specifications facing page
37 COOKES (mm) 8 9 10 11 12 13 14 16 18 19 20 22 24 26 28 32 35 36 38 40 44 48 52 54 56 60 FC 37.40 47.30 58.40 70.70 84.10 98.70 114.00 150.00 189.00 211.00 234.00 283.00 336.00 395.00 458.00 598.00 716.00 757.00 843.00 935.00 1131.00 1346.00 1579.00 1703.00 1832.00 2103.00 IWRC 40.31 50.99 62.96 76.20 90.71 105.91 123.56 160.83 203.98 226.53 252.03 304.99 362.85 425.61 494.26 644.30 771.78 816.89 910.06 1008 1220 1452 1704 1737 1976 2268 FC.231.292.361.437.520.610.708.924 1.17 1.30 1.44 1.75 2.08 2.44 2.83 3.70 4.42 4.68 5.21 5.78 6.99 8.32 9.76 10.53 11.32 13.00 MBL (kn*) Weight (kg/m) IWRC.255.322.398.482.573.673.780 1.02 1.29 1.44 1.59 1.93 2.29 2.69 3.12 4.08 4.88 5.16 5.75 6.37 7.71 9.17 10.76 11.61 12.48 14.33 Dia * kn x 0.10197 = tonne
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Logging Ropes 39
Logging Ropes 6 x 19 IWRC 9/9/1 1770 N/mm² Standard 6 x 31 IWRC 12/6&6/6/1 1770 N/mm² Standard 6 x 26 IWRC 10/5&5/5/1 1770 N/mm² Dyform 40 Specifications facing page
41 COOKES (mm) 13 14 16 18 19 20 22 24 26 28 32 35 38 Std. 106.00 124.00 161.00 204.00 227.00 252.00 305.00 363.00 426.00 494..00 645.00 772.00 910.00 Std..673.780 1.02 1.29 1.44 1.59 1.93 2.29 2.69 3.12 4.08 4.88 5.75 MBL (kn*) Weight (kg/m) Dia Dyform 120 140 185 236 258 295 350 415 481 560 732 Dyform.78.90 1.17 1.48 1.66 1.82 2.17 2.66 3.13 3.59 4.69 * kn x 0.10197 = tonne
Logging Ropes (Cont.) Swaged 6 x 19 IWRC 9/9/1 6 x 26 IWRC 10/5&5/5/1 6 x 31 IWRC 12/6&6/6/1 1770 N/mm² 42 Specifications facing page
Dia (mm) 13 16 19 23 26 28 32 MBL (kn*) Swaged 147 237 340 437 574 659 812 Dyswaged available on request Weight (kg/m) Swaged.84 1.2 1.5 2.1 2.9 3.3 5.2 * kn x 0.10197 = tonne 43
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Fishing Ropes 45
Fishing Ropes 3 x 19F 12/6+6F/1 1420/1770 N/mm² Galvanised 3 x 26 10/5&5/5/1 1420/1770 N/mm² Galvanised 3 x 31 12/6&6/6/1 1420/1770 N/mm² Galvanised Standard Dyform 46 Specifications facing page
47 COOKES Std. 4.58 34.30 50.16 59.20 73.15 83.02 87.00 115.52 158.47 184.42 213.45 216.00 280.00 330.30 372.02 461.90 Std..0233.24.30.36.44.52.62.71.95 1.20 1.30 1.48 1.78 2.04 2.41 2.85 MBL (kn*) Weight (kg/m) Dia Dyform 117.12 162.30 196.35 230.44 250.00 298.84 356.94 428.42 485.05 Dyform.744 1.00 1.23 1.42 1.55 1.90 2.30 2.79 2.99 * kn x 0.10197 = tonne (mm) 2.50 8.00 9.00 10.00 11.00 12.00 13.00 14.00 16.00 18.00 19.00 20.00 22.00 24.00 26.00 28.00
Fishing Ropes (Cont.) Swaged 4 x 30 12/6+6/6/F 1420/1770 N/mm² Galvanised Fibre Core 48 Specifications facing page
Dia (mm) 10 12 14 16 18 19 20 22 24 MBL (kn*) 73.00 105.00 132.00 174.00 224.00 254.00 276.00 326.56 356.00 Weight (kg/m).43.58.80 1.078 1.430 1.695 1.780 2.012 2.433 * kn x 0.10197 = tonne 49
Fishing Ropes (Cont.) 6 x 15 7/7/1 6 x 17 8/8/1 Standard 6 x 19 9/9/1 6 x 21 10/5+5f/1 6 x 26 10/5&5/5/1 Fibre Core IWRC 6 x 31 12/6&6/6/1 1420/1770 N/mm² Galvanised 50 Specifications facing page
51 COOKES (mm) 8 9 10 11 12 13 14 16 18 19 20 22 24 26 28 30 32 Fibre 33.13 47.31 54.00 68.20 82.70 87.60 102.00 133.00 179.00 187.00 207.00 251.00 298.00 350.00 406.00 468.32 567.97 Fibre 0.23 0.29 0.36 0.44 0.52 0.61 0.71 0.92 1.17 1.30 1.44 1.75 2.08 2.44 2.83 2.97 3.44 MBL (kn*) Weight (kg/m) Dia IWRC 39.37 43.00 56.88 67.67 81.16 94.50 110.00 143.00 181.00 204.00 224.00 271.00 363.00 387.00 484.07 521.18 591.80 IWRC.24.323 0.41 0.48 0.57 0.67 0.78 1.02 1.27 1.39 1.59 1.93 2.29 2.69 3.12 3.51 4.06 * kn x 0.10197 = tonne
Fishing Ropes (Cont.) Dyform 6 x 19 9/9/1 6 x 26 10/5&5/5/1 6 x 31 12/6&6/6/1 1420/1770 N/mm² Galvanised Fibre Core IWRC 52 Specifications facing page
53 COOKES (mm) 10 11 12 13 14 16 18 19 20 22 24 26 28 29 30 32 Fibre 57.86 72.12 82.88 89.84 122.00 143.00 193.27 204.54 231.55 278.18 328.99 402.00 442.45 464.00 515.50 574.77 Fibre.36.449.518.621.703.963 1.21 1.37 1.51 1.91 2.13 2.52 2.85 3.25 3.40 3.69 MBL (kn*) Weight (kg/m) Dia IWRC 61.88 78.67 90.62 108.92 121.60 168.27 211.60 220.00 250.35 301.30 354.98 413.00 479.09 591.77 623.66 IWRC.42.521.601.722.827 1.12 1.40 1.54 1.73 2.09 2.47 2.93 3.32 3.98 4.31 * kn x 0.10197 = tonne
Fishing Ropes (Cont.) Dy/Swaged 6 x 19 9/9/1 6 x 26 10/5&5/5/1 6 x 31 12/6&6/6/1 1420/1770 N/mm² Galvanised Fibre Core IWRC 54 Specifications facing page
55 COOKES (mm) 10 12 13 14 16 18 19 20 22 24 26 28 30 32 Fibre 65.20 92.94 110.22 128.33 165.32 222.30 229.30 266.03 313.82 364.12 451.98 497.72 570.02 671.27 Fibre.43.613.726.848 1.09 1.45 1.50 1.74 2.08 2.40 2.98 3.56 3.78 4.53 MBL (kn*) Weight (kg/m) Dia IWRC 69.99 99.84 119.08 137.15 184.40 246.51 253.65 310.74 336.95 391.73 483.30 539.10 616.10 725.03 IWRC.49.694.831.998 1.25 1.64 1.73 1.97 2.36 2.72 3.36 3.8 4.3 5.13 * kn x 0.10197 = tonne
Fishing Ropes (Cont.) Combination Ropes 6 x Decitex/9/f 6 x Decitex/15/9/f Polyprop Core IWRC Galvanised 56 Specifications facing page
Dia mm 12 14 16 18 20 22 24 26 28 60 MBL (kn*) Fibre IWRC 35.00 40.00 49.00 55.25 68.71 78.72 101.5 117.0 143.0 610.0 50.00 53.50 59.54 69.09 101.0 115.0 161.0 176.0 213.0 904.0 Weight (kg/m) Fibre IWRC.268.366.380.580.688.720.880 1.02 1.61 4.68.324.460.491.620.873.950 1.10 1.32 1.61 6.42 * kn x 0.10197 = tonne 57
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Marine Ropes 59
Marine Ropes Stainless 316 1 x 19 12/6/1 60 Specifications facing page
Dia. (mm) 1.5 2.0 2.5 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 MBL (kn*) 1.8 3.3 5.2 7.4 13.1 20.6 29.7 40.4 52.8 66.8 82.4 101.0 118.6 Weight (kg/m).011.020.031.044.079.124.178.243.317.401.495.599.713 * kn x 0.10197 = tonne 61
Marine Ropes (Cont.) Stainless 316 7 x 7 6/1 7 x 19 12/6/1 or 9/9/1 62 Specifications facing page
Dia (mm) 1.5 2.0 2.5 3.0 3.5 4.0 5.0 6.0 7.0 8.0 10.0 12.0 13.0 14.0 MBL (kn*) 7 x 19 7 x 7 1.30 2.37 3.71 5.34 7.60 9.46 14.8 21.4 29.1 38.0 59.3 85.4 117.0 2.2 3.4 5.0 7.0 8.9 13.9 20.0 27.3 35.6 55.6 80.0 84.4 109.0 Weight (kg/m) 7 x 7 7 x 19.0096.0170.018.027.026..037.038.049.050.065.068.094.093.136.134.185.182.242.238.378.372.545.535.579.741.728 * kn x 0.10197 = tonne 63
Marine Ropes (Cont.) 6 x 19 12/6/1 6 x 19 (9/9/1) 1420/1770 N/mm² Galvanised Fibre Core IWRC Note The above ropes can be manufactured with a P.V.C. covering up to 32:00mm outside dia. 64 Specifications facing page
65 COOKES Dia (mm) 8 9 10 11 12 13 14 16 18 19 20 22 24 26 28 32 * kn x 0.10197 = tonne MBL (kn*) Weight (kg/m) Fibre 33.13 41.91 53.89 65.86 77.43 87.42 101.79 132.72 167.65 186.61 206.57 250.47 297.38 349.27 405.16 544.35 IWRC 39.37 43.00 56.88 67.67 80.61 94.63 109.83 143.18 192.77 202.00 224.57 269.44 333.43 377.21 484.00 606.75 IWRC 0.24 0.32 0.41 0.48 0.57 0.67 0.78 1.02 1.27 1.39 1.59 1.93 2.29 2.69 3.12 4.06 Fibre 0.23 0.29 0.36 0.44 0.52 0.61 0.71 0.92 1.17 1.30 1.44 1.75 2.08 2.44 2.83 3.44
Marine Ropes (Cont.) 6 x 7 6/1 7 x 7 6/1 1770 N/mm² Galvanised Fibre Core WSC Note The above ropes can be manufactured with a P.V.C. covering up to 32:00mm outside dia. 66 Specifications facing page
Dia mm 2.0 2.5 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 16.0 18.0 19.0 20.0 22.0 24.0 26.0 28.0 MBL (kn*) 6 x 7 Fibre 2.35 3.66 5.29 9.40 14.70 21.20 28.80 37.60 47.60 58.80 71.10 84.60 99.30 115.00 150.00 190.00 212.00 236.00 284.00 338.00 397.00 461.00 7 x 7 WSC 2.54 4.28 5.72 10.20 15.90 22.90 31.10 40.70 51.50 63.50 76.90 91.50 107.00 125.00 163.00 206.00 229.00 254.00 308.00 366.00 430.00 498.00 Weight (kg/m) 6 x 7 7 x 7 Fibre WSC.0138.0152.0196.0236.0311.0343.0554.0610.0865.0953.125.137.170.187.221.244.280.309.346.381.419.461.498.549.585.644.678.747.886.975 1.12 1.23 1.25 1.38 1.38 1.52 1.67 1.84 1.99 2.19 2.34 2.58 2.71 2.99 * kn x 0.10197 = tonne 67
Marine Ropes (Cont.) Small Cords 6 x 19 & 7 x 19 9/9/1 & 12/6/1 1770 N/mm² Galvanised 6 x 19 Fibre 7 x 19 or 6 x 19 WSC 68 Specifications facing page
Dia mm 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 MBL (kn*) Fibre 4.89 6.64 8.69 10.98 13.60 16.40 19.60 22.95 28.60 30.50 WSC 5.29 7.85 9.40 12.95 14.70 19.42 21.20 27.07 30.90 36.00 Weight (kg/m) Fibre.0311.0378.0554.0612.0865.0913.125.130.177.185 WSC.0343.0465.0610.0762.0953.114.137.154.195.219 * kn x 0.10197 = tonne 69
Marine & Lashing Ropes. 6 x 12 12/f 1420 N/mm² Fibre Core 6 x 24 15/9/f 6 x 24 12/12/f 1420/1770 N/mm² Galvanised Note The above ropes can be manufactured with a braid cover. 70 Specifications facing page
71 COOKES MBL (kn*) Weight (kg/m) * kn x 0.10197 = tonne 12/12/f 15/9/f 28.10 35.60 44.00 53.20 63.30 74.30 86.20 113.00 142.00 159.00 176.00 213.00 253.00 297.00 345.00 396.00 450.00 12/f.127.160.194.254.300.346.400.643.670.745.820.974 1.145 1.380 1.590 1.800 2.120 12/f 19.00 24.00 29.70 35.90 42.70 50.11 58.20 76.00 96.10 107.30 118.66 143.18 170.64 200.00 232.42 266.74 304.00 Dia (mm) 8 9 10 11 12 13 14 16 18 19 20 22 24 26 28 30 32 12/12/f 15/9/f.200.253.314.380.457.531.616.803 1.028 1.132 1.255 1.520 1.805 2.122 2.458 2.521 3.213
72
Crane Ropes 73
Crane Ropes 18 x 7 6/1 1770 N/mm² Dyform 18 18 x 19 9/9/1 1960 N/mm² 74 Specifications facing page
Dia (mm) 5.0 6.5 8.0 9.0 10 11 12 13 14 16 18 19 20 22 24 26 28 MBL (kn*) Dyform 18 18 x 7 14.02 23.73 37.12 46.91 58.10 70.06 83.60 97.90 113.77 148.69 187.61 209.57 232.00 280.42 334.00 391.18 441.00 124.00 135.33 193.00 213.00 226.00 285.00 353.00 413.00 475.00 Weight (kg/m) 18 x 7 Dyform 18 0.10 0.16 0.25 0.32.390 0.47.562 0.66 0.83 0.76 0.85 1.00 1.18 1.26 1.49 1.41 1.66 1.56 1.85 1.89 2.28 2.25 2.68 2.64 3.08 2.96 * kn x 0.10197 = tonne 75
Crane Ropes (Cont.) EUROLIFT Casar 40 x 7 6/1 1960 N/mm² 76 Specifications facing page
77 COOKES Dia (mm) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 36 38 40 * kn x 0.10197 = tonne Weight (kg/m) 0.49 0.593 0.705 0.821 0.949 1.091 1.257 1.406 1.601 1.768 1.956 2.142 2.373 2.609 2.813 3.076 3.285 3.530 3.846 4.062 4.347 5.011 5.641 6.306 7.081 7.831 MBL (kn*) 89.6 108.8 130.8 152.7 179.1 204.0 230.6 257.9 293.9 329.0 362.2 396.1 441.4 471.8 524.3 567.9 614.9 654.2 712.9 754.6 817.4 930.0 1045.0 1185.0 1319.0 1462.0
78
Elevator Ropes 79
Elevator Ropes 8 x 19 9/9/1 1370/1770 N/mm² Natural Fibre Core 80 Specifications facing page
Dia (mm) 9.5 11 13 16 MBL (kn) 39.71 53.20 74.30 113.00 Weight (kg/m).310.420.586.888 * kn x 0.10197 = tonne 81
Horticultural High Tensile Galvanised Strand Prefabricated loop. No tools required Þ 82
Stay Strand & Clothes Line 83
Stay Strand & Clothes Line 1 x 7 Galvanised 84 Specifications facing page
Strand Dia + (mm) 3.55 4.8 6.0 7.5 9.5 Wires/ Dia (mm) 5/1.25 7/1.6 7/2.0 7/2.5 7/3.15 MBL (kn*) _ 14.02 27.46 42.17 58.84 Tensile Grade 386 1080 1200/1300 1200/1300 1200/1300 kg/m.057.110.170.300.430 Equiv Wire Gauge 18G 16G 14G 12G 10G 4.8 6.0 7.5 9.5 12.0 7/1.6 7/2.0 7/2.5 7/3.15 7/4.0 9.85 15.40 23.53 38.20 61.70 700/800 700/800 700/800 700/800 700/800.110.170.300.430.690 16G 14G 12G 10G 8G + Approximate Diameter * kn x 0.10197 = tonne 85
Services 1,000 tonne talurit press at Auckland rigging loft. 86
Hand Splice Mechanical Splice Mechanical Splice 87
Hand Splice with Thimble Mechanical Splice with Thimble 88
Test bed for proof loading and certification of all types of lifting equipment. On site service includes installation, maintenance and non-destructive testing. 89
Associated Products Lubricating & protective coatings, each specially fomulated for particular wire rope applications Turnbuckles & Rigging Screws Shackles Rope Grips Thimbles Twitches/ Load Binders 90
Chain Chain Blocks & Lever Hoists 91
Wire Rope Hoists Wire Rope Safety Fence 92
Web Slings Load Restraints & Webbing Hardware 93
Height Safety & Fall Arrest Equipment Synthetic & Natural Fibre Rope 94
Branches Whangarei Auckland Tauranga Rotorua New Plymouth Napier Nelson Wellington Christchurch Ashburton Timaru Dunedin Invercargill 95
NOTES 96
NOTES COOKES 97
Head Office & Factory 6-10 Greenmount Dr East Tamaki P O Box 14-422 Panmure AUCKLAND Phone (09) 274-4299 Fax (09) 274-7982 Email: salesadmin@cookes.co.nz Whangarei Lower Port Road P O Box 708 Phone (09) 438-8964 Fax (09) 438-9272 Email: whgsales@cookes.co.nz Tauranga 1 Marsh Street P O Box 14-204 Phone (07) 578-0605 Fax (07) 578-0604 Email: tausales @cookes.co.nz 98 BRANCHES Rotorua Marguerita Street P O Box 633 Phone (07) 348-3043 Fax (07) 346-3283 Email: rotsales@cookes.co.nz Napier 182A Hyderabad Rd P O Box 12-003 Ahuriri Phone (06) 834-0690 Fax (06) 834-0872 napsales@cookes.co.nz New Plymouth 75 Corbett Road Bell Block Phone (06) 755-04513 Fax (06) 755-0419 Email: nplysales@cookes.co.nz Palmerston North Resident Representative Phone (027) 445-3902 Fax/Tel: (06) 354-0644
Wellington 2 Udy Street P O Box 38-696, Petone Phone (04) 568-4384 Fax (04) 568-4381 wtnsales@cookes.co.nz Nelson 8 Akerston Street P O Box 5030 Phone (03) 548-0719 Fax (03) 548-0105 nelsales@cookes.co.nz Christchurch 124C Waterloo Road P O Box 16289 Hornby Phone (03) 349-30 Fax (03) 349-300 chcsales@cookes.co.nz BRANCHES COOKES Ashburton 120 Moore Street P O Box 407 Phone (03) 308-9778 Fax (03) 308-3875 ashsales@cookes.co.nz Timaru 14 Bank Street P O Box 918 Phone (03) 684-7494 Fax (03) 684-8476 timsales@cookes.co.nz Dunedin 2A Orari Street P O Box 626 Phone (03) 455-3966 Fax (03) 455-3966 dunsales@cookes.co.nz Invercargill 137 Clyde Street P O Box 118 Phone (03) 218-4682 Fax (03) 218-4187 invsales@cookes.co.nz www.cookes.co.nz 99
WIRE ROPE HANDBOOK