shell wire rope grease free sample

Wire rope forms an important part of many machines and structures. It is comprised of continuous wire strands wound around a central core. There are many kinds of wire rope designed for different applications. Most of them are steel wires made into strands wound with each other. The core can be made of steel, rope or even plastics.

Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or not it is preformed, by its lay, the number of strands and the number of wires in each strand.

A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small sheaves (pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through abrasives.

There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with a 1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking strength than a fiber core rope and a high resistance to crushing and deformation.

A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope core. WSC ropes are high strength and are mostly used as static or standing ropes.

Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also use plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core ropes are quite flexible and are used in many overhead crane applications.

The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope the strands twist to the right as it winds away from the observer. A left lay twists to the left. A regular lay rope has the wires in the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to have better fatigue resistance due to the flatter exposure of the wires.

Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability and for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used and are described in Table 1.

Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will straighten and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires that are shaped so that they lie naturally in their position in the strand, preventing the wires from protruding and potentially causing injury. Preformed wire ropes also have better fatigue resistance than nonpreformed ropes and are ideal for working over small sheaves and around sharp angles.

Lubricating wire ropes is a difficult proposition, regardless of the construction and composition. Ropes with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials. For this reason, it is important to carefully consider the issue of field relubrication when selecting rope for an application.

There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain a petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants penetrate slightly, sealing the outside of the cable from moisture and reducing wear and fretting corrosion from contact with external bodies.

Both types of wire rope lubricants are used. But because most wire ropes fail from the inside, it is important to make sure that the center core receives sufficient lubricant. A combination approach in which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect the outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease, petroleum oils or vegetable oil-based (Figure 3).

Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection. Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold temperature conditions.

Various types of greases are used for wire rope lubrication. These are the coating types that penetrate partially but usually do not saturate the rope core. Common grease thickeners include sodium, lithium, lithium complex and aluminum complex soaps. Greases used for this application generally have a soft semifluid consistency. They coat and achieve partial penetration if applied with pressure lubricators.

Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil type lubricants helps to wash the rope to remove abrasive external contaminants.

Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and function as a reservoir for prolonged lubrication while in service.

If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of the die that twists the wires into a strand. This allows complete coverage of all wires.

After the cable is put into service, relubrication is required due to loss of the original lubricant from loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect and preserve the rope core and wires, and thus extend the service life of the wire rope.

If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication. The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave where the rope strands have a tendency to separate slightly due to bending to facilitate maximum penetration to the core. If a pressure boot application is used, the lubricant is applied to the rope under slight tension in a straight condition. Excessive lubricant application should be avoided to prevent safety hazards.

Some key performance attributes to look for in a wire rope lubricant are wear resistance and corrosion prevention. Some useful performance benchmarks include high four-ball EP test values, such as a weld point (ASTM D2783) of above 350 kg and a load wear index of above 50. For corrosion protection, look for wire rope lubricants with salt spray (ASTM B117) resistance values above 60 hours and humidity cabinet (ASTM D1748) values of more than 60 days. Most manufacturers provide this type of data on product data sheets.

Cable life cycle and performance are influenced by several factors, including type of operation, care and environment. Cables can be damaged by worn sheaves, improper winding and splicing practices, and improper storage. High stress loading, shock loading, jerking heavy loads or rapid acceleration or deceleration (speed of the cable stopping and starting) will accelerate the wear rate.

Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If a machine is to be shut down for an extended period, the cables should be removed, cleaned, lubricated and properly stored. In service, corrosion and oxidation are caused by fumes, acids, salt brines, sulfur, gases, salt air, humidity and are accelerated by elevated temperatures. Proper and adequate lubricant application in the field can reduce corrosive attack of the cable.

Abrasive wear occurs on the inside and outside of wire ropes. Individual strands inside the rope move and rub against one another during normal operation, creating internal two-body abrasive wear. The outside of the cable accumulates dirt and contaminants from sheaves and drums. This causes three-body abrasive wear, which erodes the outer wires and strands. Abrasive wear usually reduces rope diameter and can result in core failure and internal wire breakage. Penetrating wire rope lubricants reduce abrasive wear inside the rope and also wash off the external surfaces to remove contaminants and dirt.

Many types of machines and structures use wire ropes, including draglines, cranes, elevators, shovels, drilling rigs, suspension bridges and cable-stayed towers. Each application has specific needs for the type and size of wire rope required. All wire ropes, regardless of the application, will perform at a higher level, last longer and provide greater user benefits when properly maintained.

Lubrication Engineers, Inc. has found through years of field experience, that longer wire rope life can be obtained through the use of penetrating lubricants, either alone or when used in conjunction with a coating lubricant. Practical experience at a South African mine suggests that life cycles may be doubled with this approach. At one mine site, the replacement rate for four 44-mm ropes was extended from an average 18.5 months to 43 months. At another mine, life cycles of four 43-mm x 2073 meter ropes were extended from an average 8 months to 12 months.

In another study involving 5-ton and 10-ton overhead cranes in the United States that used 3/8-inch and 5/8-inch diameter ropes, the average life of the ropes was doubled. The authors attribute this increased performance to the ability of the penetrating lubricant to displace water and contaminants while replacing them with oil, which reduces the wear and corrosion occurring throughout the rope. A good spray with penetrating wire rope lubricant effectively acts as an oil change for wire ropes.

In these examples, the savings in wire rope replacement costs (downtime, labor and capital costs) were substantial and dwarfed the cost of the lubricants. Companies who have realized the importance of proper wire rope lubrication have gained a huge advantage over those who purchase the lowest priced lubricant, or no lubricant at all, while replacing ropes on a much more frequent basis.

This grease remains stable and in place under high pressure, heavy loads, and shock loads. It"s often used for demanding mining, construction, and automotive applications.

NLGI viscosity grade is a rating of a grease"s consistency. NLGI 1 is about the consistency of tomato paste. NLGI 2 is about the consistency of peanut butter.

Weld load measures a grease"s ability to withstand pressure in kilograms of force (kgf). The higher the rating, the more pressure the grease can withstand.

Grease lubricates most efficiently within the listed temperature range. Melting temperature is the point at which grease will fail and run out of equipment, leaving it to run dry.

At working temperatures, speeds and pressures, Shell Gadus S2 OG 40 forms a protective cushion between the large gear (girth, bull etc) and pinion teeth.

Heavily loaded open gears, particularly those found in grinding mills, kilns, shovels, draglines, ship loaders, stackers and reclaimers and excavator applications. When choosing a product to suit your ambient temperature conditions, always consult with your Shell representative for the appropriate grade.

Multi service lubricant that can be used as the one grease (multi-purpose and open gear) for the entire machine on most shovels, excavators and draglines (excluding electrical motors bearings).

6-1. INTRODUCTION. Section I of this chapter discusses blocks which are among the most important fittings used aboard ship on the deck, in the engine department, and in other operations. Section II covers elements of wire rope rigging which cargo handlers in a terminal service company must know. It details the care and use of wire rope, procedures for computing the safe working load and breaking strength, and inspection and handling. Section III covers marlinespike seamanship, which is a general term for handling and caring for fiber line and wire rope used aboard ship or in other marine operations.

6-2. COMPONENTS OF WOODEN BLOCKS. A wooden block, as shown in Figure 6-1, consists of one or more sheaves (pulleys). Each block has one or more steel straps which strengthen the block and support the sheave pin. Personnel may suspend the block or apply a load by means of a hook or shackle inserted in the top of the strap. The strap may continue through the block and form a projection, called the becket, to attach another line. The becket usually has a thimble to prevent chafing of the line. The front of the block is called its face and the sides of the shell are called cheeks. The opening between the top of the sheave and the block where the line is passed through the block is called the swallow. The breech is the opening between the bottom of the sheave and the block and serves no definite purpose. Line is never passed through the breech of a block except for a small tail line used to keep the block from bouncing on the deck. The entire wooden portion of a block is called the shell; it protects the sheave and line.

6-3. COMPONENTS OF METAL BLOCKS. Metal blocks have basically the same part as wooden blocks. The metal block has bolts to hold its cheeks together and a metal shell. The parts of a metal block are shown in Figure 6-2. This figure shows the diamond and roller bearing block.

The head or heel block has a cast metal shell, roller bearings, and a grease fitting in the sheave pin. The cargo runner can pass over these blocks at the head and heel of the cargo boom. These high-speed blocks must be lubricated every time they are used. A good winch operator can pass the cargo runner over the sheaves of these blocks at a rate of 500 feet per minute.

b. Every tackle system contains a fixed block attached to some solid support and may have a traveling block attached to the load (see Figure 6-4). The single rope leaving the tackle system is called the fall line. Personnel apply the pulling force to the fall line which may be led through a leading block.

6-5. SIZES OF BLOCKS. Users can determine the size of blocks by measuring the length of the cheek in inches. Blocks are designated for use with a specific line size. Bending line over a sheave that is too small causes distortion and strain, resulting in the line wearing on the shell. Personnel can use line smaller than that designated for a sheave with no damage, but should never use line of a larger size.a. To determine the size wooden block to use with line of a known size, personnel may follow these formulas:

b. The size metal block to use with wire rope depends on the diameter of the sheave. The sheave is never less than 20 times the diameter of the wire. For example, personnel can determine the size block to use with 3/4-inch wire rope as follows:

b. To disassemble a roller bearing block, personnel loosen the set screws and remove the retaining nuts. Next, they take out the bolt holding the shell together and remove the shell, closure snap rings, adjusting nut, closure washer, and closure. The sheave pin and the bearings from the sheave are removed last.

6-8. REEVING TACKLES. Personnel reeving tackles reeve each type differently. If a tackle is rove improperly, too much friction and possible binding of the falls can result when lifting or lowering a load, creating a safety hazard. It is important to use the proper method of reeving each type of tackle up to and including a threefold purchase.

6-10. FRICTION. A certain amount of the force applied to a tackle is lost through friction. Friction occurs in a tackle when lines rub against each other or against the frame or shell of the block, and pass over the sheaves. This loss in efficiency of the block and tackle (roughly 10 percent of the load per sheave) must be added to the weight being lifted to determine the total weight. For example, to determine the total weight of a load when lifting a load of 500 pounds with a twofold purchase, personnel use the following formula and compute:TW = W x (1 + Friction) or (1 + F)

* This table is computed in pounds for new line. For line that has been used these figures will decrease. Old line may have only 60 percent of the strength shown in pounds for a given size of line.b. To determine the SWL for a line of known size to be rove into a tackle, personnel should use one of the following formulas as appropriate, where "C" denotes circumference and "D" denotes diameter. The formulas for manila and nylon will give the SWL in pounds. The formulas for wire rope will be in tons.

c. If personnel are unsure which type of wire rope they are using, they must always use the formula for mild steel when figuring the SWL. This will ensure ultimate safety since the different strengths of wire rope cannot be identified visually.

6-12. CARE AND USE OF WIRE ROPE. Wire rope is made of steel except for its core which is likely to be fiber. The grades of wire rope in descending order of strength are: Extra improved plow, improved plow, plow, and mild plow steel. Of these four grades, the Army uses improved plow steel extensively and plow steel to a lesser extent. The manufacturer stamps the grade on the reel. Because the grade of wire rope is not visually apparent, it should always be considered as plow steel when in doubt.

6-13. MAKEUP OF WlRE ROPE. The basic unit of wire rope is the individual wire. Wires are laid together to form strands. The number of wires in a strand varies according to the purpose for which the rope is intended. Strands are laid around a core to form the wire rope itself. With preformed plow steel wire rope, the core may be hemp or polypropylene, a synthetic fiber. The core is a foundation to keep the wire rope round, to act as a shock absorber when the wire rope contracts under strain, and to serve as a reservoir for lubricant. Figure 6-7 shows a cross section of wire rope.

b. Strand Construction. In most wire rope used today, the wires and strands are preformed. Preforming means presetting wires in the strands into a permanent corkscrew form which they will have in the completed rope. As a result, preformed wire rope does not have the internal stresses found in nonpreformed wire rope, does not untwist as readily as nonpreformed wire rope, and is more flexible.

c. Types of Lay. Lay refers to the direction of winding of the wires in the strands and the strands in the rope. Both may be wound in the same direction or in opposite directions.(1) In regular lay, the strands and wires are wound in opposite directions. Most common is the right regular lay in which the strands are wound right and the wires wound left. This lay is used in marine operations.

6-15. MEASUREMENT. Whatever its grade, wire rope is usually measured by its diameter. Figure 6-8 shows the correct method of measuring the diameter of wire rope. To measure wire rope correctly, personnel should place it in the caliper so that the outermost points of the strands will be touching the jaws of the caliper.

6-16. SAFE WORKING LOAD AND BREAKING STRENGTH. The SWL and BS formulas are listed in the paragraphs below.a. Formulas for determining the SWL of several grades of wire rope have constants that are not to be confused with safety factors. For example, the formula for the SWL in STONs (2,000 pounds) for extra improved plow steel wire rope is diameter squared multiplied by 10, or SWL = D2 x 10. The formula to find the SWL of 1-inch, 6 x 19, extra improved plow steel wire rope is as follows: SWL = D2 x 10 = 1 x 1 x 10 = STONs.

b. A figure relatively constant in marine operations, especially for new wire rope, is the SF, which is 5. The SF is used with the SWL to find the BS.

6-17. INSPECTION OF WIRE ROPES. Wire ropes should be inspected frequently and replaced if frayed, kinked, worn, or corroded. The frequency of inspection depends on how often the rope is used. Wire rope used 1 or 2 hours a week requires less frequent inspection than one used 24 hours a day.a. Common causes of wire rope failures are as follows:Using rope of incorrect size, construction, or grade.

b. Carefully inspect weak points and points of greatest stress. Worn or weak spots show up as shiny, flat spots on the wires. If the outer wires have been reduced in diameter by one-half, the wire rope is unsafe.

c. Inspect broken wires, since they show where the greatest stress occurs. If individual wires are broken next to each other, unequal load distribution at this point will make the rope unsafe. Broken wires are called fishhooks. To determine the extent of damage to the wire rope, users can slide a finger along one strand of wire for one complete turn, equal to the length of one wire rope lay. Next, count the number of fishhooks. If six or more fishhooks are discovered, the wire rope is unsafe and should be replaced immediately.

6-18. HANDLING. There are different handling methods for wire rope. These methods are listed below.a. Kinking. When loose wire rope is handled, small loops frequently form in the slack portion of the rope. If personnel apply tension to the rope while these loops are in position, the loops will not straighten out but will form sharp kinks, resulting in unlaying of the rope. Personnel should straighten these loops out of the rope before applying a load. After a kink has formed in wire rope, it is impossible to remove it, and the strength of the rope is seriously damaged at the point where the kink occurs.

b. Unreeling. When removing wire rope from a reel or coil, personnel should be sure to rotate the reel or coil. If the reel is mounted, the wire rope may be unwound by holding the end and walking away from the reel. If a wire rope is in a small coil, personnel may stand the coil on end and roll it along the deck, barge, wharf, or ground. Remove any loops that may form, although rotating the reel or coil usually avoids causing loops to form.

c. Seizing. Personnel should seize (lash together) all wire rope before cutting it. If the ends of the rope are not properly secured, the original balance of tension is disturbed. Maximum use cannot be made on wire rope when some strands carry a greater load than others.

(2) There are three formulas for determining the number and length of seizings and the space between them. When a calculation results in a fraction, the next larger whole number is used. The following formulas are based on a 3/4-inch diameter wire rope.(a) The number of seizings required equals about three times the diameter of the rope. For example: 3 x 3/4 = 2 1/4 or 3 seizings. Because the rope will be cut, six seizings are required so that there will be three on each rope end after the cut.

d. Cutting. Wire rope may be cut with a wire rope cutter, a cold chisel, a hacksaw, bolt clippers, or an oxyacetylene cutting torch. When cutting wire rope, personnel should follow the procedures outlined below.(1) To seize the wire rope, insert it into the cutter with the blade between the two central seizings, close the locking device, then close the valve on the cutter. The handle should be pumped to build up enough pressure to force the blade through the rope.

(2) Use the bolt clippers on wire rope of fairly small diameter. Use the oxyacetylene torch on wire of any diameter. Cutting with the hacksaw and cold chisel is slower than cutting with the other tools and equipment.

e. Coiling. Personnel may need to take a length of wire rope from a reel and coil it down before using it. Small loops or twists will form if the wire rope is coiled in a direction opposite to the lay. To avoid loops, users should coil right lay wire rope clockwise and left lay wire rope counterclockwise. When a loop forms in the wire, they should put a back turn in as shown in Figure 6-10.

Figure 6-10. Putting a back turn in wire ropef. Size of Sheaves and Drums. When a wire is bent over a sheave or drum, two things happen: Each wire is bent to conform to the curvature, and the wires slide against each other lengthwise because the inside arc of the rope against the sheave or drum is shorter than the outside arc. The smaller the diameter of the sheave or drum, the greater the bending and sliding. Personnel should keep this bending and moving of wires to a minimum to reduce wear. The minimum recommended sheave and drum diameter is 20 times the diameter of the rope. For example, for 5/8-inch rope: 20 x 5/8 = 12 1/2-inch sheave. If a 12 1/2-inch sheave is not on hand, personnel should use the next larger size, never a smaller size.

g. Lubrication. Wire rope is lubricated as it is manufactured. The lubricant generally does not last throughout the life of the rope, which makes relubrication necessary. Crater "C" compound is recommended, but personnel may use oil on hand rather than delay lubrication. Crater "C" compound should be heated before it is put on the wire rope. Personnel should use a brush if possible to apply lubricant. If a brush is not available, they may use a sponge or cloth, but they should look out for fishhooks or broken wires.

h. Reversing Ends. It is sometimes advisable to reverse or cut back ends to get more service from wire rope. The wear and fatigue on a rope frequently is more severe at certain points than at others. Reversing distributes stronger parts of the rope to the points getting wear and fatigue. To reverse ends, personnel remove the drum end, put it in the attachment, and then fasten the end taken from the attachment to the drum. Cutting back the ends has a similar effect, but not as much change is involved. In reversing ends, personnel should cut off short lengths of both ends to remove the sections with the greatest local fatigue.

i. Storing. Wire rope should be coiled on a spool for storage. Its grade, size, and length are noted on a tag attached to the rope or spool. Wire rope should be stored in a dry place to reduce corrosion. Personnel should not store it with chemicals or where chemicals have been stored because chemicals and their fumes can attack the metal. Personnel should always clean and lubricate wire rope before storing it.

j. Cleaning. Personnel can remove most of the dirt or grit on a used wire rope by scraping or steaming. Rust should be removed at regular intervals by wire brushing. Personnel must clean the rope carefully before lubricating to remove foreign material and old lubricant from the valleys between the strands and from the spaces between the outer wires. This permits the newly applied lubricant to freely enter the rope.

6-19. CHARACTERISTICS AND FIBER LINE. To be able to work with fiber line, personnel must know its characteristics and properties. They must be able to handle and care for the line, and tie basic knots, bends, and hitches.a. Materials for Fiber Line. Fiber line is made of either vegetable or synthetic fibers. Vegetable fibers include manila, sisal, hemp, cotton, and flax. Synthetic fibers include nylon, Dacron, polyethylene, and polypropylene. The Army primarily uses nylon synthetic fiber line, so this manual covers only that synthetic fiber.(1) Manila is a strong fiber that comes from the leaf stems of the abaca plant, a part of the banana family. Varying in length from 4 to 15 feet in their natural state, the fibers have the length and quality which gives manila rope relatively high elasticity, strength, and resistance to wear and deterioration.

(3) Hemp is a tall plant that has useful fibers for making rope and cloth. It was used extensively before manila was introduced. Now hemp"s principal use is in fittings such as ratline and marline. Because hemp is absorbent, the fittings are tarred to make them more water-resistant.

6-23. WHIPPING LINE. Personnel must never cut a line or leave the end of a line dangling loose without a whipping to prevent it from unlaying. A line without whipping will unlay of its own accord. Whenever a line or hawser has to be cut, whippings should be put on first, on each side of the cut. To prevent fraying, a temporary or plain whipping can be put on with any type cordage, even rope yarn. Figure 6-12 shows one of the several methods that can be used for putting a temporary whipping on a line.

e. French Bowline. A French bowline is used as a sling for lifting an injured person. For this purpose one loop is used as a seat and the other loop is put around the body under the arms, with the knot drawn tight at the chest. Even an unconscious person can be hoisted safely in a properly secured French bowline, because the weight applied will keep the two loops tight so that the individual will not fall out. Personnel must not allow the loop under the person"s arms to catch on any projections. The French bowline may also be used if a person is working alone and needs both hands free. The two loops of the knot can be adjusted to the required size. Figure 6-18 shows the step-by-step procedure for tying the French bowline.

Figure 6-20. Clove hitchh. Stopper Hitch. A slight defect of a clove hitch is that it can slide along the cylindrical object to which it is tied. To guard against this, personnel should use a stopper hitch (commonly called a rolling hitch) which is illustrated in Figure 6-21. This figure shows fiber rope; with wire rope, personnel would use a small chain.

6-25. SPLICING THREE-STRAND FIBER LINE. Splicing is a method of permanently joining the ends of two lines or of bending a line back on itself to form a permanent loop or an eye. If two lines are to be spliced, strands on an end of each line are unlaid and interwoven with those of the standing part of the line. Small stuff can be spliced without a fid, which is a tapering length of hard wood used in splicing larger lines. A knife is used to cut off the ends of the strands.a. Short Splice. The short splice is as strong as the rope of which it is made. However, the short splice increases the diameter of the rope and can be used only where this increase in diameter will not affect operation. The splice is frequently used to repair damaged ropes or where two ropes of the same size are to be joined together permanently. Damaged parts of the rope are cut out and the sound sections are spliced. Personnel should follow these steps-(1) Untwist one end of each line five complete turns. Whip or tape each strand. Bring these strands tightly together as in Figure 6-22, view 1, so that each strand of one line alternates with a strand of the other line. Put a temporary whipping on the lines where they join to keep them from suddenly coming apart. Do this procedure with small lines until you are skilled enough to hold them together while you tuck.

6-26. PUTTING AN EYE IN WIRE ROPE. This paragraph discusses how to put both a temporary eye and a permanent eye in wire rope. A temporary eye can be put in wire rope by using wire rope clips or by using a field expedient known as a "hasty eye" or "Molly Hogan" splice. A liverpool splice is the accepted method for putting a permanent eye in the end of a wire rope. With the proper equipment, and a bit of practice, a liverpool splice can be put in wire rope in less than 15 minutes.a. Splicing Tools. With the exception of the wire cutters, Figure 6-24 shows the tools needed for splicing. The marlinespike is used for opening the strands in the standing part of the wire rope and for working the strands to be spliced into the standing part. The wire cutters are used for cutting the strands after the splice is complete. The hydraulic wire rope cutter is used to cut the length of wire rope that will be spliced. A thimble is used to keep the wires from moving and the rigger"s vise from crushing them when a soft eye is made. After the soft eye is spliced, the thimble is removed. When an eye is to have a thimble as a permanent part, the thimble is the size of the eye desired.

b. Temporary Eye. A temporary eye may be put in wire by using wire rope clips. Figure 6-25 shows the correct way of using these clips. As the illustration shows, a wire rope clip consists of two parts: the U-bolt and the roddle, the part into which the U-bolt is inserted. Personnel should always put the U-bolt over the bitter end and the roddle on the standing part. This procedure protects the live or stress-bearing end of the rope against crushing. The roddle protects the rope and, therefore, should always be placed against the live end.(1) To obtain maximum strength from the temporary eye splice, use the correct size and number of wire clips, and the correct spacing between them. Size is stamped on the roddle between the two holes. Personnel may use the following formula to determine the number of clips: 3 x diameter of wire rope + 1 = number of clips. For example, the number of clips needed for l-inch wire rope is: 3 x 1 + 1 = 4. To determine the correct space between clips, multiply the diameter of the rope by six. For example, the space between clips to be put on 1-inch rope is: 6 x 1 = 6 inches. Measure the space from the center of one clip to the center of the next one. If the calculation for either the number or the space results in a fraction, round off to the next higher whole number.

(2) The improved type of wire rope clips shown in Figure 6-26 has a few advantages over the older type. Both halves are identical and provide a bearing surface for both parts of the rope. Thus, it cannot be put on wrong and does not distort the wire. It also allows a full swing with a wrench.

c. Hasty Eye (Molly Hogan) Splice. Occasionally it becomes necessary to construct a field expedient, called the hasty eye or Molly Hogan splice. This splice can be quickly made, but it is limited to about 70 percent of the strength of the wire rope. It should not be used to lift heavy loads. This splice can be used only when working with preformed wire rope. To make a hasty eye splice, personnel should follow these steps:(1) Using a marlinespike, screwdriver, or, if necessary, a nail, separate the wire rope into two three-strand sections. These sections should be unlaid four times the diameter of the desired eye. If you want a l-foot diameter eye, unlay the sections back 4 feet.

d. Liverpool Splice. The liverpool splice is the easiest and most common of the wire splices to make. It is the primary splice used when a permanent eye is required. Personnel should follow these instructions:(1) Forming the eye. To find the distance, the strands should be unlaid for an eye splice; then, multiply the diameter of the wire by 36 inches. (For example, to determine the distance of a 5/8-inch wire rope: multiply 5/8 x 36/1 = 180/8 = 22 1/2 or 23 inches.) Measure off that distance on the wire rope and put a seizing at that point. Cut the end seizing and carefully unlay the strands. Whip the ends of each strand with either sail twine or friction tape. Form the desired size eye and put the eye in the rigger"s vise with the unlaid strands to your right as you face the vise. Stretch out the standing part of the wire, clamp and lash it and you are ready to start.

NOTE: When splicing wire, always insert the marlinespike against the lay of the wire, and make sure not to shove it through the core. The core must be on the left-hand side of the spike.(2) Making the first tuck of strands one, two, and three. In the liverpool splice, the first strand goes under three strands, the second strand goes in the same opening but only under two strands, and the third strand goes in the same opening but only under one strand. All of the strands go in at the same point, but come out at different places (Figure 6-27). At this time, run the spike behind the three strands under which the first three are tucked, but above the first three tucked strands. Holding the marlinespike at a 90-degree angle to the standing part, turn the spike counterclockwise about one fourth of a turn and insert the core through the standing part. This is called "dipping the core." Make sure that the core is inserted under the marlinespike. Pull the core down and run it down into the splice.

(5) Tucking strands one, two, and three. To finish the splice, tuck number three, two, and one. Each is tucked three times in a row, ending up with an overall total of four tucks for each. To avoid kinking the strands on the last tucks, insert the spike and run it up the wire. Follow the spike up with the strand, shove it under the spike, and pull taut. Keeping a strain on the strand, work the spike and strand back around and down together. Hold the strand there and work the spike back up the wire. Follow up with the strand and take the last tuck. Work the strand back down and hold it there. Before pulling out the spike, run it back up until the strands of the standing wire bind the working strand in place. Make the second and third tucks with the remaining strands in the same way.

(6) Completing a splice. Remove the wire from the vise, use a hammer to pound the splice into shape, and cut off the ends of the tucking strands close to the splice.

Wire rope grease is made of organic thickener and high viscosity refined mineral oil, with various additives such as anti-oxidation, anti-corrosion, anti rust, anti extreme pressure, etc. This grease is designed for the lubrication and protection of ropes and heavy-duty cables under various climatic conditions, providing the best anti-wear, anti-corrosion and lubricity for the inner and outer surfaces of the ropes.

This report contains market size and forecasts of Wire Rope Grease in global, including the following market information:Global Wire Rope Grease Market Revenue, 2017-2022, 2023-2028, ($ millions)

The global Wire Rope Grease market was valued at million in 2021 and is projected to reach US$ million by 2028, at a CAGR of % during the forecast period.

The global key manufacturers of Wire Rope Grease include Total S.A., Sinopec, Shell Global, Kluber Lubrication, Bel-Ray Company, LanoPro, ROCOL, Castrol and SUMICO LUBRICANT CO., LTD. and etc. In 2021, the global top five players have a share approximately % in terms of revenue.

We surveyed the Wire Rope Grease manufacturers, suppliers, distributors and industry experts on this industry, involving the sales, revenue, demand, price change, product type, recent development and plan, industry trends, drivers, challenges, obstacles, and potential risks.

The global Wire Rope Lubricants market was valued at million in 2021 and is projected to reach US$ million by 2028, at a CAGR of % during the forecast period.

The global key manufacturers of Wire Rope Lubricants include Exxon Mobil Corporation, Total S.A., Shell Global, Kluber Lubrication, Lubrication Engineers, Castrol, ROCOL, Bel-Ray Company and Whitmore, etc. In 2021, the global top five players have a share approximately % in terms of revenue.

MARKET MONITOR GLOBAL, INC (MMG) has surveyed the Wire Rope Lubricants manufacturers, suppliers, distributors and industry experts on this industry, involving the sales, revenue, demand, price change, product type, recent development and plan, industry trends, drivers, challenges, obstacles, and potential risks.

Wire Rope GreaseMarket study performed by market reports insights that examine market growth prospects and opportunities. The research contains an industry summary, requirements, product description, goals, and industry analysis. The major goal of the research is to give broad exposure to industry competitors, market trends, growth rates, and other important statistics as well as the overall current market scenario. The report contains a comprehensive market and vendor landscape including a competitive analysis of the key vendors.

The Wire Rope Grease market is segmented by types, applications, key players, and region to get a closer look at the market threats and opportunities which will enable the buyers to make strategic improvements in their businesses.

Total S.A., Sinopec, Shell Global, Kluber Lubrication, Bel-Ray Company, LanoPro, ROCOL, Castrol, SUMICO LUBRICANT CO., LTD., COSMO OIL LUBRICANTS CO., LTD.

North America(the United States, Canada, and Mexico),Europe(Germany, France, UK, Russia, and Italy),Asia-Pacific(China, Japan, Korea, India, and Southeast Asia),South America(Brazil, Argentina, Colombia, etc.),The Middle East and Africa(Saudi Arabia, UAE, Egypt, Nigeria, and South Africa)

The research analyst has explored the key barriers to market growth, such as how the global Wire Rope Grease market provides new opportunities. The development techniques, growth forecasts, manufacturing plans, revenue and gross margin analysis, and cost structures are all thoroughly explained in this report. The report will include detailed consumption information, as well as vital statistics from regional and global markets.

The main objective of the report is to categorize opportunities. The research analysis further explains important leading factors affecting the performance of a company or business and end-user necessities are also discussed in the Wire Rope Grease market report to gain solutions to major roadblocks. The estimated future revenue is also given in the report. It also explains different business models, keybusinessstrategies, the current level of marketdevelopment, market share and size, and the current level of competition in the market.

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