1 wire rope HANDBOOK . COOKES. wire rope Manufacture at Cookes Factory in Auckland. The Only Manufacturer of wire rope in New Zealand. 2. COOKES. CONTENTS. 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 72. Elevator Ropes .. 78. Stay Strand & Clothes Line .. 82. Services .. 86. Associated 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. 2408:1985. Minimum breaking loads (MBL) are quoted in this catalogue in kilo Newtons. kN x = tonne. tonne x = kN. 3. COOKES. 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.
2 Cookes are now part of the F. K. I. group of Companies that includes a number of the world's leading lifting equipment manufactur- ers including Parsons Chain Co. ( ) and Crosby International ( ). Cookes operate New Zealand's only wire rope manufacturing plant. Cookes operate websling and webbing load restraint manufacturing plants in both Auck- land and Christchurch. Cookes Engineering Workshop manufactures cutting edges for supply throughout New Zealand. 4. COOKES. All products manufactured by Cookes meet worldwide standards such as Lloyds Register of Shipping, New Zealand Standards Asso- ciation, British Standards and ISO 9002. Quality Assurance. Cookes head office and branches carry TELARC ISO 9002 accreditation. 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.
3 In 1994 a 150 tonne Rotary Swaging Ma- chine 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. COOKES 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.
4 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.
5 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. COOKES 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.
6 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. COOKES. This catalogue is designed to provide a non-techni- cal guide to the selection of a suitable wire rope for various applications. Technical information is re- stricted to weights and breaking loads and a few for- mulae. Constructions and sizes shown here are those commonly available and used in New Zealand but there are many others and enquiries for special ap- plications 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.
7 Like many machines, there is a great variety of types of wire rope , each with different prop- erties to suit it's intended use. The internal combus- tion engine used to power a racing car is quite differ- ent 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 horse- power 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 applica- tion could well be a total disaster in another. 9. COOKES. wire rope DESIGN & CONSTRUCTION. wire ropes are composed of independent parts - wires, strands and cores - that interact with each other dur- ing 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 resis- tance, crush resistance, bending fatigue resistance and corrosion resistance for each application.
8 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 se- lect the optimum combination of wire rope proper- ties. The following information is provided as a basic guide. Our expert in house staff and field service spe- cialists are available to provide more specific rec- ommendations. 10. COOKES. 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 in- variably 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 construc- tion. 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.
9 Robustness, or resistance to physical damage, can be increased by using fewer wires of a larger diam- eter and/or using a steel core and/or by increasing the steel area exposed to sources of external dam- age. Coatings such as galvanizing or others can be applied to protect against corrosion. 11. COOKES. In almost all cases improving one attribute dis- tracts from another. In addition the wire rope 's work- place 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 mini- mum diameter of over metres. This is clearly impractical in many applications, and unnecessary if bend fatigue does not cause the ultimate demise of the rope .
10 Hardness of wire rope Tensile Brinell Rockwell C. 1770mpa 425/510 45. 1570mpa 400/425 43. 1420mpa 380/425 41. 12. COOKES. 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 Strand wire rope Core Core 13. COOKES. 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. The basic strand has wires Single of the same size wound Size around a centre. Large outer wires with the same number of small inner wires around a core wire .