WIRE ROPE HANDBOOK - Bridon

1 wire rope HANDBOOK2 COOKESWire rope Manufacture at CookesFactory in Only Manufacturer of wire rope inNew Cookes .. 4 Cookes Product Range .. 6 wire rope Design & Construction .. 10 wire rope SelectionEngineering & 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 inaccordance with:BS 302 Parts 2, 3, 6, 7 & EN 12385-1-4-5 2408:1985 Minimum breaking loads (MBL) are quoted in thiscatalogue in kilo x = x = Zealand s Most ExtensiveIndustrial Support Service. The firm of William Cooke & Company wasfounded in 1862 at Tinsley in the UnitedKingdom. An office was opened in Aucklandin 1911 to handle the distribution of wire ropeand associated products in New Zealand.

2 Cookes are part of a group of Companies that includes a number of the world s leading lifting equipment manufacturers including Parsons Chain Co. ( ) andCrosby International ( ). Cookes operate New Zealand s only wirerope manufacturing plant. Cookes operate websling and webbing loadrestraint manufacturing plants in both Auck-land and Christchurch. Cookes Engineering Workshop manufacturescutting edges for supply throughout All products manufactured by Cookes meetworldwide standards such as Lloyds Registerof Shipping, New Zealand Standards Asso-ciation, British Standards and ISO 9001 Quality Assurance. Cookes head office and branches carryTELARC SAI Registered certification. Cookes operate load testing facilities at mostbranches throughout New Zealand and on-sitetesting vehicles in both Auckland andChristchurch.

3 In 1992 a manufacturing plant was installedto produce the Brifen road safety barriersystem for highways throughout New Zealandand export. In 1994 a 150 tonne Rotary Swaging Ma-chine was installed to produce swaged wirerope for the logging industry and later thefishing industry. In 2001 a second swager wasadded to handle the increased demand for RangeWIRE rope : Conventional, Swaged, Dyform,Dyswaged, Blue Strand, N. Z. manufacture up to60 mm dia. Imported Casar and KoreanTESTING SERVICES: Proof loading of alllifting equipment (Telarc Registered). 100 tonnetest bed, non-destructive testing, telemetry loadcells up to 100 : Electric/manual chain blocks, pulley,crane and logging blocks,stainless steel EARTHMOVING equipment : Bucketteeth and adaptors, Super V, ripper shanks and tips,grader shanks and tips, end bits, cutting edges andplow bolts to BLADES: Cutting edges, end bits andplow bolts.

4 Mouldboard PARTS: Jaws, mantles and : Both wire and : Auger equipment , trencher : Brilube wire rope : wire and fibre rope , chain and RIGGING equipment : Marlin spikes,cee hooks, chokers, ferrules, pulley blocks, loggrapples, rings, butt BOLTS: Certified, all sizes available,threaded or blank. Stainless steel RangeAGRICULTURAL equipment : Tractoraccessories and 3-point linkage : Chain lever type, Supertil wire ropehoists, travelling trolleys, plate lifting : Crane, eye and swivel hooks, marinecertified. Cee, choker, stainless steel, snap andchain grab : Galvanised, all sizes, mooring chain, loadrestraint, hi tensile, lifting chain, grade 80 & grade100 chain, chain swivels, security chain andstainless steel TOOLS: Enerpac hand andpowered pumps, cylinders. Extra high pressurehose.

5 Full range of product : V-belts, timing belts,transmission, conveyor, feeder, attachment andagriculture chain. Saw chain and and pulleys, automotive V-belts, chainbreakers, motorcycle chain. Aqua corrosionresistant AND CARGO equipment :Manufacturers of webslings to NZS5227, trucktiedown restraints, recovery straps, mini tiedownrestraints, curtainside webbing and fittings, boatand motorcycle straps, AND COUPLINGS: Complete rangehydraulic hose and couplings. Automotive andindustrial RangeHIGH TENSILE LIFTING CHAIN: Kuplex,Weissenfels and Hercalloy range of fittings to suit all : Lever and ratchet type PRODUCTS: Shackles, swivels, fibreropes, boat trailer winch ropes, thimbles,turnbuckles, rigging screws, boat trailer winches,stainless steel rigging hardware, stainless steelchain, mooring and anchor ROPES: Full range of natural andsynthetic fibre rope at wholesale : Commercial or certified, galvanisedor self colour, bow or dee.

6 Hi-load alloy. Stainlesssteel SAFETY equipment : Full range ofharnesses, lanyards, fall arrest devices : High impact and abrasionresistant steel. All sizes OUR STAFF FOR FURTHER DETAILS9 COOKESThis catalogue is designed to provide a non-techni-cal guide to the selection of a suitable wire rope forvarious applications. Technical information is re-stricted to weights and breaking loads and a few for-mulae. Constructions and sizes shown here are thosecommonly available and used in New Zealand butthere are many others and enquiries for special ap-plications should be directed to your nearest rope is a machine of many working parts andlike most machines it must be made right, selectedright for the application and used correctly in thatapplication. Like many machines, there is a greatvariety of types of wire rope , each with different prop-erties to suit it s intended use.

7 The internal combus-tion engine used to power a racing car is quite differ-ent to the one powering a large truck although theyboth may produce the same horsepower. Like manymachines it is impossible to combine the advantagesof each type into one single machine. The high horse-power and low weight of a racing engine would begreat in a truck. The high fuel cost and short life wouldnot. The same with wire rope , the attributes that makeone construction eminently suitable for one applica-tion could well be a total disaster in rope DESIGN & CONSTRUCTIONWire ropes are composed of independent parts - wires,strands and cores - that interact with each other dur-ing rope engineers design those parts in differentsteel grades, finishes and a variety of constructionsto attain the best balance of strength, abrasion resis-tance, crush resistance, bending fatigue resistance andcorrosion resistance for each select the best wire rope for each application, onemust know the required performance characteristicsfor the job and enough about wire rope design to se-lect the optimum combination of wire rope following information is provided as a basicguide.

8 Our expert in house staff and field service spe-cialists are available to provide more specific three attributes of a wire rope to consider are:(1) Strength.(2) Flexibility.(3) all dynamic rope applications (as opposed to staticapplications such as guy wires etc.) the choice is in-variably a can be increased by increasing the diameterof the wire rope and/or increasing the tensile strengthof the individual wires and/or increasing the crosssectional steel content (by decreasing the air voidsbetween the wires) and/or using a steel core can be increased by using more wires of asmaller diameter and/or decreasing the tensilestrength of the individual wires and/or using a , or resistance to physical damage, canbe increased by using fewer wires of a larger diam-eter and/or using a steel core and/or by increasingthe steel area exposed to sources of external dam-age.

9 Coatings such as galvanizing or others can beapplied to protect against 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 towhich the rope is fitted is rarely ideal and another setof compromises must be decided on. For example allwire rope suffers from being bent and the smaller thebend radius the shorter the rope life. For a 26mmwire rope to escape bend fatigue the winch drum orblock sheaves over which it runs would need a mini-mum diameter of over metres. This is clearlyimpractical in many applications, and unnecessary ifbend fatigue does not cause the ultimate demise ofthe of wire RopeTensileBrinellRockwell C1770mpa425/510451570mpa400/425431420mpa 380/4254113 COOKESWireStrandRopeCoreTERMINOLOGYWire rope consists of a number of strands laid upusually over a central core.

10 Each strand is madefrom a number of individual all wire rope is laid up over a core, FibreCore (natural or synthetic), Independent wire RopeCore or wire Strand Core (FC, IWRC or WSC):Fibre CoreWire StrandCoreIndependentWire rope Core14 COOKESSTRAND are designed with various combinations ofwires and wire sizes to produce the desired resistanceto fatigue and abrasion. Generally, a small numberof large wires will be more abrasion resistant andless fatigue resistant than a large number of basic strand has wiresof the same size woundaround a outer wires with thesame number of small innerwires around a core excellent abrasionresistance but less fatigueresistance. When used withan IWRC, it offers excellentcrush resistance wires fill spacesbetween large wires toproduce crush resistanceand a good balance ofstrength, flexibility andresistance to abrasion15 COOKESW arringtonOuter layer of alter-nately large and smallwires provides goodflexibility and strengthbut low abrasion andcrush commonly usedwire ropes use combi-nations of these basicconstructionsOne of the above stranddesigns may be coveredwith one or more layersof uniform sized LayLang LayRight LayThe most commonlay in which thewires wind in onedirection and thestrands the opposite direction (right lay shown).