MATERIAL HANDLING

WIRE ROPES
CONSTRUCTION OF WIRE ROPES
Wire
Core

Strand

Wire rope

WIRE ROPES
CONSTRUCTION OF WIRE ROPES

WIRE ROPES
MEASURING THE WIRE ROPE

INCORRECT

CORRECT

WIRE ROPES
INSPECTION OF WIRE ROPES
BROKEN WIRES
WORN OUT WIRES
REDUCTION IN ROPE DIA.
BIRD CAGE
KINKS
CORE PROTRUSION

WIRE ROPES
BROKEN WIRES
6 OR MORE BROKEN WIRESIN ONE LAY
3 OR MORE BROKEN WIRES IN ONE
STRAND IN ONE LAY
MORE THAN 5% IN ANY LENGTH OF 10
DIAMETERS

WIRE ROPES
BROKEN WIRES
6 OR MORE BROKEN WIRESIN ONE LAY
3 OR MORE BROKEN WIRES IN ONE
STRAND IN ONE LAY
MORE THAN 5% IN ANY LENGTH OF 10
DIAMETERS

WIRE ROPES
BROKEN WIRES

WIRE ROPES
WORN AND ABRADED WIRES

WIRE ROPES
BIRD CAGES

WIRE ROPES
CORE PROTRUSION

INSPECTION PROCEDURE
Stores receives and gives a
code for every item.
Color coding
Once in a month
Record in a register

FACTOR OF SAFETY
Factor of safety for wire ropes - 5
Factor of safety for wire ropes when used
for carrying personnel- 10

THUMB RULES FOR FINDING SWL

Wire Rope:
SWL = 8D2
D dia. of the rope
eg: 1/2 rope dia = 8 (1/2)2
= 2Tons.
Note: Dia is in inches & result in Tons.

INSTALLATION

STORAGE OF WIRE ROPES

Method of lubricating rope

Preferred
method since
rope opens up
over sheave
allowing oil to
penetrate

Temporary
Winding
Drum

Air Blast
Application

Brush
Application

Dip and Swab Application

U CLAMPS

DISTANCE BETWEEN THE ROPE CLIPS = 6 X Dia

CLIPS AND SPACING FOR SAFE APPLICATION
Rope Diam.
In.

Minimum No. Clips

for Each Rope End

Spacing of Drop
Forged Clips
in.

1/2
5/8
3/4
7/8
1
1.1/8
1.1/4
1.1/2

3
3
4
4
5
6
6
7

3
3.3/4
4.1/2
5.1/4
6
6.3/4
7.1/2
9

SLINGS

SLINGS
SWL

T=WxL
HxN
T = TENSION
W = WEIGHT OF THE LOAD
L = LENGTH OF SLING
N = NO. OF SLING LEGS
T = Safe Working Load (SWL)
W=TxHxN
L
W = SWL x H x N/L

SLINGS

If L is greater than S
then sling angle is OK

Safe Working Load

(SWL)

Single Leg Bridle Hitch

T=WxL
HxN
W = SWL
Capacity of Sling =
SWL of Wire rope in
vertical x (H/L) x No of
Slings

Two Leg Bridle Hitch

W = SWL (Vertical) x H x N/L

W = SWL (Vertical) x H x 2/L

Bridle Hitch

W = SWL (Vertical) x H x 2/L

Basket Hitch

W = SWL (Vertical) x H x 2/L

W = SWL (Vertical) x H x 4/L

Choker Hitch

W = SWL (Vertical) x A x 1/B

Choker Hitch

W = SWL (Vertical) x H/L x A/B x 2

SLINGS - HITCHES
BRIDLE HITCH

SLINGS - HITCHES
BASKET HITCH

SLINGS - HITCHES
CHOKER HITCH

RIGGING PRACTICES

RIGGING PRACTICES
Weather condition
Wind force
Night shift

Clearance from Electrical Lines

11 kV and below
Above 11 and below 33 kV
Above 33 and below 132 kV
Above 132 and below 275kV
Above 275 and below 400 kV

1.40m
3.60m
4.70m
5.70m
6.50m

RIGGING PRECAUTIONS

 Center of gravity

Stability of Load

RIGGING PRECAUTIONS
Sharp Bends , Pinching & crushing
avoid for slings provide packingcurve 7 lays

Never wrap a wire rope around a

hook.

Ensure that slings are

protected at all sharp corners
on heavy items
For heavy
structural
members

Radius of
contact
should be
equal to 1
rope lay

Do not permit bending near any

splice or attached fitting

Whenever 2 or more
ropes are to be placed
over a hook - use a
shackle

Use of Tag lines to control all

loads

RIGGING PRECAUTIONS

Before being unhooked all loads

must be safely landed and
properly blocked

Stay away from slings when

they are being pulled out from
under loads

On a Rigid object the load could be carried

on only 2 legs or sling while other legs only Know what the load in each sling leg will
be before the lift is made
serve to balance
Carrying Full load
Balancing

The tension in
the most heavily
loaded legs is
more important
than the total
weight