| Ropes>>Wire Ropes |
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| Wire Rope Components |
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Method of Measuring Rope Diameter |
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| Rope Size |
| Measure the circle just touching the extreme outer limits (crown) of the strands. |
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| Single Layer |
| Single wire centre with six wires of the same diameter |
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| Seale |
| Equal number of wires in each layer. All wires in each layer are of the same diameter. Large outer wires rest in the valley between the small inner wires |
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| Filler Wire |
| Inner layer having half the number of wires as the outer layer. Small filler wires, equal in number to the inner layer, are laid in the valleys of the inner layer. between the small inner wires |
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| Warrington |
| One diameter of wire in the inner layer Two diameters of wire alternating large and small in the outer layer The large outer layer wire rest in the valleys and the smaller ones on the crowns of the inner layer |
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| Combined |
| Combination of above construc-tions. Eg Seale-Filler, Warrington-Seale etc. |
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LAY
Direction of Wire & Strand Helix |
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Right Hand Regular Lay (RHRL/RHO/sZ) |
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Left Hand Regular Lay (LHRL/LHO/zS) |
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Right Hand Langs Lay (RHLL/RHL/zZ) |
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Left Hand Langs Lay (LHLL/LHL/sS) |
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Alternate Lay (Combination of Langs & Regular) |
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Special Alternate Lay (2 Langs 1 Regular) |
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| Ideal Pulley Groove |
| Greater contact area between the rope and the pulley reduces abrasion and enhances service life. |
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Wrong
Sheave groove too wide |
Wrong
Sheave groove too narrow |
Right
Sheave groove of correct size |
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| Pulley / Rope Bending Ratio (D/d Ratio) |
Note:
The ratios are based on Max. rope speed of 60 meters/min. For each increase in 30 meters/min. in excess of 60 meters/min., add 5% to the drum diameter. |
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| Sr.No. |
Construction |
D:d Ratio |
| Recommended |
Minimum |
| 1 |
6x7 (6-1) |
64 |
42 |
| 2 |
6x19S (9-9-1) |
48 |
42 |
| 3 |
6x26SW (10-5+5-5-1) |
45 |
30 |
| 4 |
6x25F (12-6F-6-1) |
39 |
26 |
| 5 |
6x31SW (12-6+6-6-1) |
39 |
26 |
| 6 |
6x37SF (12-12-6F-6-1) |
39 |
26 |
| 7 |
6x36SW (14-7+7-7-1) |
33 |
22 |
| 8 |
6x43SF (14-14-7F-7-1) |
33 |
22 |
| 9 |
6x50SFS (14-14-7F-7-7-1) |
33 |
22 |
| 10 |
6x41SW (16-8+8-8-1) |
30 |
20 |
| 11 |
6x49SW (16-8+8-8-8-1) |
30 |
20 |
| 12 |
6x49SF (16+16+8F-8-1) |
30 |
20 |
| 13 |
6x46SW (18-9+9-9-1) |
27 |
18 |
| 14 |
6x52SW (18-9+9-9/6-1) |
27 |
18 |
| 15 |
6x55SF (18-18-9F-9/6-1) |
27 |
18 |
| 16 |
8x19S (9-9-1) |
39 |
26 |
| 17 |
8x26SW (10-5+5-5-1) |
36 |
24 |
| 18 |
8x25F (12-6F-6-1) |
33 |
22 |
| 19 |
8x31SW (12-6+6-6-1) |
33 |
22 |
| 20 |
8x37F (12-12-6F-6-1) |
33 |
22 |
| 21 |
8x36SW (14-7+7-7-1) |
29 |
19 |
| 22 |
8x50SFS (14-14-7F-7-7-1) |
29 |
19 |
| 23 |
17x7 (11:16-1) |
52 |
34 |
| 24 |
18x7 (12:6-FC) |
52 |
34 |
| 25 |
19x7 (12:6-1) |
52 |
34 |
| 26 |
34x7 (17:11/6-FC) |
45 |
30 |
| 27 |
35x7 (16:6+6-6-1) |
61 |
40 |
| 28 |
6x25FS (12/12/D) |
48 |
32 |
| 29 |
6x8FS (7/D) |
73 |
48 |
| 30 |
6x28FS (15/12/D) |
45 |
30 |
| 31 |
Locked Coil Winding Rope |
152 |
100 |
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| Spooling / Anchorage of Rope on Drum |
| Ropes are supplied with zero internal torque Improper spooling induces torque in rope, reducing rope life |
Right Hand Lay
(Use right hand) |
Left Hand Lay
(Use left hand) |
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Overwind
Left to Right |
Overwind
Right to Left |
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Right Hand Lay
(Use right hand) |
Left Hand Lay
(Use left hand) |
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Underwind
Right to Left |
Underwind
Left to Right |
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| Note: |
Recommended angle
Grooved drum: a £ 2.5°
Flat drum: 0.5° £ a £ 1.5° |
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| Rope Cutting Procedure |
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1. Seizing |
2. Twisting |
3. Cutting |
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| Note: |
| Seizing wire recommendation |
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- for ungalvanised rope - use annealed wire
- for galvanised rope - use soft, zinc-coated wire.
- Diameter of wire: 8 - 24 mm = 1 mm
- 25 - 36 mm= 1.6 mm
- 38 - 56 mm = 2 mm
- Recommended sizing length. = 1xdmin or 10 wraps
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| Rope Clamping |
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| Note: |
| Improper fixing of clamps may lead to safety hazards. For proper clamping standards, refer applicable standards or OEM recommendations. |
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| In-Use Lubrication |
- Usha Martin ropes are supplied with a special
lubricant
- Periodic lubrication during usage is necessary to
derive enhanced performance
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Continuous Bath |
Dripping |
Pouring |
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Swabbing |
Painting |
Spray Nozzle |
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In-use lubrication pays rich dividends |
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| Storage |
- Must be stored in a well ventilated shed.
- Free from moisture, dust and fumes.
- Suitable lubricant to be applied very 3 months to the outer layers.
- Reel containing ropes to be rolled through 90 degree after every 3 months.
- Protect wooden reels from the attack of termites.
- In no case the reels should b put on ground or uncemented floor.
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| Handling - The right way |
- Use spindle through the reels for loading / unloading
or put the rope on a swift with brake arrangement.
- Allow clearance for free rotation of reel when the rope
end is pulled.
- Maintain constant tension during haul off.
- Prevent crossing of rope laps on the reel.
- Avoid possible kink, which is a permanent damage
to a rope.
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Wire Rope Characteristics
BEND FATIGUE AND ABRASION RESISTANCE |
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- More wires - better fatigue resistance
- Less wires -better abrasion resistance
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| COMMONLY USED ROPE (NON-COMPACTED) CHARACTERISTICS SIMPLY STATED. |
- More wires in the outer strand (14 for 36WS) will
improve bend fatigue
- Less wires in the outer strands (9 for 19S) improve
wear/abrasion resistance characteristics
- Steel core (IWRC) resists drum crushing better than
fibre core
- Langs lay resists interference at drum better than
ordinary lay
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| Abrasion Resistance |
| Comparison of outer wire sizes for 25 mm diameter rope as illustration |
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6 x 7 |
6 outer wires |
2.54 mm |
6 x 19S |
9 outer wires |
2.11 mm |
6 x 25F |
12 outer wires |
1.70 mm |
6 x 36 |
14 outer wires |
1.49 mm |
6 x 41 |
16 outer wires |
1.34 mm |
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| COMPARISON OF ROTATION RESISTANCE |
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| COMPACTED ROPES CHARACTERISTICS SIMPLY STATED |
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- Increased breaking force
- Increased performance
- Improved characteristics
- Improved wear resistance
- Improved crushing resistance
- Improved Bend Fatigue resistance
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| High breaking load per unit area |
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Compacted rope
minimum breaking force |
Conventional rope minimum
breaking force |
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| High Abrasion Resistance |
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| High Crushing Resistance |
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At cross-over points due to
high fill factor |
At lower layers in multilayer
operation |
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| Greater bend fatigue resistance |
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| PLASTICATED ROPE CHARACTERISTICS SIMPLY STATED (Cushion Core - Compacted outer strands) |
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- Plastic impregnation of core (IWRC)
- Greater resistance to drum crushing
- Increases abrasion resistance
- Smoother exteriors and greater surface area resulting in reduced sheave wear
- Reduced IWRC and outer-strand nicking & crosscutting
- High fatigue life
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Typical Example |
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| Comparison of bend fatigue illustration |
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| PLASTICATED ROPE CHARACTERISTICS SIMPLY STATED (plastic Valley Filled) |
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- Full Plastic impregnation
- Reduces wire contact stress & interstrand nicking
- Retains lubrication inside & does not require in-service lubrication
- Prevents ingress of solid abrasives & reduces internal corrosion
- Provides greater and better wear & abrasion resistance
- Minimizes bend stress over sheaves and increases fatigue life
- Ideally suitable for mining application
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| Comparison of service life (mining application) |
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TERMINATION FAILURE |
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FATIGUE FAILURE |
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BIRD CAGE |
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SHOCK LOADING |
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ABRASION |
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THERMAL DAMAGE |
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CORROSION |
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| DISCARD CRITERIA |
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- For single-layer construction, if the
reduction in diameter is greater than 8%
(eg. 6x7).
- For multiplayer construction, if the
reduction in diameter is greater than 5%
(eg. 6x19, 6x36 etc.)
- Total no. of visible broken wires exceed
10% of total no. of wires in the rope, in a
length of 8 x dia. of rope or 3 or more
adjacent broken wires in a stand.
- Evidence of considerable plastic wear
or surface embrittlement.
- Localised distortion, damage or kink,
bird-caging, crushing.
- Localised diameter reduction or lay
variation associated with waviness.
Collapsed core or one strand broken
coupled with wire looseness and
bulging.
- Corrosion / chain pitting & associated fatigue of wires.
- Damage due to heat / fire.
- Rope has been subjected to severe
shock load or overload due to some
accident with equipments.
- End-fitting / attachments damaged or
cracked or deformed or worn out.
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| Note: |
| The inspector should also refer to International Standards like ISO 4309 and BS 6570 or any other relevant standard for the purpose, as a tool, for discarding a wire rope. |
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| RECOMMENDED DO'S & DON'TS DO’S |
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- Lubricate ropes with good quality acid
free and moisture free lubricant.
- Regularly inspect the sheaves, rollers or
pulleys-the life of a rope largely
depends on their conditions.
- Inspect ropes and fittings / terminations
periodically.
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| DONT’S |
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- Do not allow ropes in store to
deteriorate
- Do not mishandle ropes when uncoiling
or unreeling & allow kinks to form.
- Do not use Langs lay with a swivel
- Do not cut a rope without seizing.
- Do not use rope which is not sufficiently
flexible for he size of drum or pulley.
- Do not load the rope beyond its safe
working load. Reduction of safety factor
may jeopardise not only rope, but also
equipment, job and men.
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| Note: |
| Remember - Care in handling, installation, and careful inspection gives more life and enormous dividends. |
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| Mining Ropes (Underground & Opencast) |
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| APPLICATION |
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| GENERAL ENGINEERING |
Construction |
Page Ref. |
6 x 7 & 7 x 7 |
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6 x 19M |
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6 x 19F |
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6 x 19S |
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6 x 29F |
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6 x 36SW |
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6 x 37M |
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| CRANE |
Construction |
Page Ref. |
Powerform 35/35P |
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Hyflex 35/35P |
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Powerform 18 |
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Hyflex 18 |
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Powerform 6/6P |
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Powerform 8/8P |
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Hyflex 8/8P |
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Powerform 8PC |
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Hyflex 4 |
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Hyflex 6 x 36 |
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Hyflex 6 x 19 |
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Hyflex 6 x 29F |
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| OIL FIELD |
Construction |
Page Ref. |
TITAN Anchor |
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Mooring75 |
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TITAN Drilling |
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Lines79 |
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TITAN Riser |
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Tensioner96 |
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35 x 7 for cranes |
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| SHIPPING |
Construction |
Page Ref. |
6 x 37 |
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6 x 24 |
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| ELEVATOR |
Construction |
Page Ref. |
6 x 19F (CFN) |
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6 x 24 |
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8 x 19S (CFN) |
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8 x 19S + IWRC |
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(8 x 7 + CF)
Governor Rope |
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| WHY USHA MARTIN ROPE? |
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| GUARANTEED RAW MATERIAL QUALITY |
- Developed, manufactured and quality certified by own Steel Plant.
- Tailor made raw materials to ensure consistent
rope quality and desired end-properties.
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| GUARANTEED PRODUCT QUALITY |
- State-of-the-art pickling plant.
- State-of-the-art patenting furnaces.
- Latest generation wire-drawing machinery
- Computerised rope design.
- In-house developed rope making machinery for manufacturing high-performance ropes.
- Breaking load and fatigue test equipment to guarantee desired performance and quality.
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| GUARANTEED QUALITY SYSTEMS |
- ISO 9001:2000
- API
- OTIS
- ABS
- LLOYDS
- NKK
- JIPM
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| QUALITY POLICY |
| “Our quality policy is to fulfil customers’ requirement through reliable products and services meeting all regulatory requirements and through continual improvement of our quality management system. |
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| ROBUST PROCESS CONTROL |
| Qualified supervisors & operators trained in own institution on product process and equipment.
Regular training of operations staff at HRD center.
Visual display of process parameters at each stage of processing.
Stringent quality control at every stage of manufacturing. |
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| TPM policy |
| “It is our policy to induce change in all
employees by delegation, empowerment
and motivation to achieve total
participation towards zero accident, zero
defect and zero failure.” |
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| HOW TO ORDER A ROPE |
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- Nominal Diameter and tolerance.
- onstruction/Class/Brand Name.
- Finish (galvanized or ungalvanised)
- Tensile Strength
- Minimum Breaking load requiement.
- Core-Fibre/IWRC/WSC.
- Lay-eg. Right hand regular lay.
- Lubrication
- Packing wooden reel/steel reel/coils.
- Particulars of fittings
- Performed / Non-preformed
- Exact length per reel / coil etc (special length tolerance, if any)
- Delivery time
- Special requirements
- Pre-stretching
- Packaging
- Identification
- Third-party inspection
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| SAFETY INFORMATION |
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- Wire rope will fail if worn out, shock loaded,
overloaded, misused, damaged, improperly
maintained or abused.
- Always inspect wire rope for wear, damage or
abuse before use.
- Never use a wire rope which is worn out,
damaged, corroded or abused.
- Never overload or shock load a wire rope.
- Use the correct design factor for the application.
- Inform yourself : Read and understand the
machinery manufactures handbook and
guidance from the wire rope manufacturer.
- Refer to applicable directives, regulations,
standards and codes concerning inspection,
examination and rope removal criteria.
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Note: Note: All statements, technical information and
recommendations contained herein are believed to
be reliable, but no guarantee is given as to their
accuracy and/or completeness. The user must
determine the suitability of the product for his own
particular purpose, either alone or in combination
with other products and shall assume all risk and
liability in connection therewith.
Whilst every attempt has been made to ensure
accuracy in the content of the tables, the information
contained in this catalogue does not form any part a
contract. |
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METRIC - IMPERIAL DIAMETER CONVERSION |
in. |
mm. |
in. |
mm. |
in. |
mm. |
5/32 |
3.97 |
15/16 |
23.8 |
2-1/2 |
63.5 |
3/16 |
4.76 |
1 |
25.4 |
2-3/4 |
69.9 |
1/32 |
5.56 |
1-1/16 |
27.0 |
3 |
76.2 |
1/4 |
6.35 |
1-1/8 |
28.6 |
3-1/4 |
82.6 |
5/16 |
7.94 |
1-3/16 |
30.2 |
3-1/2 |
88.9 |
3/8 |
9.53 |
1-1/4 |
31.8 |
3-3/4 |
95.3 |
7/16 |
11.1 |
1-3/8 |
34.9 |
4 |
101.6 |
1/2 |
12.7 |
1-1/2 |
38.1 |
4-1/4 |
108.0 |
9/16 |
14.3 |
1-5/16 |
41.3 |
4-1/2 |
114.3 |
5/8 |
15.9 |
1-3/4 |
44.5 |
4-3/4 |
120.7 |
11/16 |
17.5 |
1-7/8 |
47.6 |
5 |
127.0 |
3/4 |
19.0 |
2 |
50.8 |
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13/16 |
20.6 |
2-1/8 |
54.0 |
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7/8 |
22.2 |
2-1/4 |
57.2 |
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CONVERSION TABLE |
| Length |
1m |
=1000 mm |
=3,281 ft |
=39,37 inch |
| Force |
1kN |
=101,97kp |
=0,10197 MT-f |
=224lbs-f |
| Tensile Strength |
1N/mm |
=0,10197kp/mm2 |
=145,04 p.s.i. |
=10 bar |
| Cross Section |
1mm |
=0,00155 in |
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| Weight |
1 metric t |
=1000 kg |
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=1,102 short t |
=09,842 longt |
=2204,6 lbs |
| Weight per Length Unit |
1 kg/m |
=0,672 lbs/ft |
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