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 Ropes................................................. 72
Elevator Ropes ............................................. 78
Stay Strand & Clothes Line ......................... 82
Services ........................................................ 86
Associated Products..................................... 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
I.S.O. 2408:1985
Minimum breaking loads (MBL) are quoted in this
catalogue in kilo Newtons.
kN x 0.10197 = tonne.
tonne x 9.80665 = 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.

• Cookes are part of a group of Companies that

includes a number of the world’s leading
lifting equipment manufacturers including
Parsons Chain Co. (U.K.) and
Crosby International (U.S.A.).

• 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 9001
Quality Assurance.

• Cookes head office and branches carry

TELARC SAI Registered certification.
• 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.

• 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.
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.
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.
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. 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.

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.

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 1.5 metres. This is clearly
impractical in many applications, and unnecessary if
bend fatigue does not cause the ultimate demise of
the rope.

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.
Provides excellent abrasion
Seale resistance but less fatigue
resistance. When used with
an IWRC, it offers excellent
crush resistance over
drums.

Small wires fill spaces

between large wires to
Filler produce crush resistance
Wire and a good balance of
strength, flexibility and
resistance to abrasion
14
 COOKES
Outer layer of alter-
nately large and small
wires provides good
Warrington
flexibility and strength
but low abrasion and
crush resistance.

Seale Many commonly used

Filler wire ropes use combi-
Wire Filler nations of these basic
Wire constructions
Seale

Warrington
Seale

One of the above strand

Multiple designs may be covered
Operation with one or more layers
of uniform sized wires.

15
COOKES
LAY
Regular Lay
The most common
lay in which the
wires wind in one
direction and the
strands the opposite direction (right lay shown).
Less likely to kink and untwist, easier to handle,
more crush resistant than Lang lay.

Lang Lay
Wires in strands
and strands of rope
wind the same
direction (right lay
shown). Increased resistance to abrasion, greater
flexibility and fatigue resistance than regular lay,
will kink and untwist.

Right Lay
Strands wound to
the right around the
core (regular lay
shown). The most
common construction.

16
 COOKES
LAY
Left Lay
Strands wound to
the left around the
core (regular lay
shown). Used in a
few special situations - cable tool drilling line, for
example.
Alternate Lay
Alternate strands of
right regular and
right Lang lay.
Combines the best
features of regular and Lang lay for boom hoist or
winch lines.

WIRE ROPE SIZE

The size of a wire rope is the diameter of a
circle which will just enclose all the strands.

Wrong Right

17
COOKES
FINISH
Bright finish is suitable for most applications. Gal-
vanized finish is available for corrosive environments.
Plastic jacketing is also available on some construc-
tions.
WIRE GRADES
The most common steel wire grades are: 1420-1770
N/mm², and 1860N/mm². Stainless steels and other
special grades are provided for special applications.
Most wire ropes are made with round wires. Both
triangular and shaped wires are also used for special
constructions.
Generally, the higher the strength of the wire, the
lower it’s ductility will be.
ABRASION AND BENDING

Abrasion Resistance Fatigue Resistance

DECREASES DECREASES
with smaller wires with fewer wires
ß ß
Ý Ý
INCREASES INCREASES
with larger wires with more wires
The “X-Chart”. Abrasion Resistance Vs Bending
Fatigue Resistance.
While there is a possibility, there is little likelihood
that an application can be found for which there is a
precisely suitable wire rope.
18
 COOKES
As with all engineering design proplems, feasible
solutions demand compromise to some degree. At
times is becomes neccessary to settle for less than
optimum resistance to abrasion in order to obtain the
maximum flexibility: the latter being a more impor-
tant requirement for a given job. A typical example
of this kind of trade-off would be in selecting a highly
flexible rope on an overhead crane. Conversly, in a
haulage installation, a rope with greater resistance to
abrasion would be chosen despite the fact that such
ropes are markedly less flexible.
Two compelling factors that govern most decisions
as to the selection of a wire rope are abrasion resis-
tance and resistance to bending fatigue. Striking a
proper balance with respect to these two important
characteristics demands judgement of a very high
order. A graphic presentation of just such compari-
son of qualities between the most widely used rope
constructions and others is given by means of an X-
chart.
Referring to this chart when selecting a rope, the
midpoint (at the X) comes close to an even balance
between abrasion resistance and resistance to bend-
ing fatigue. Reading up or down along either leg of
the X, the inverse relationship becomes more appar-
ent as one quality increases and the other decreases.
See next page.

19
COOKES

The “X Chart”

6 6x7
LE

ST
NUMBER OF OUTSIDE WIRES PER STRAND

AS

E
AT
9 6x19S
T

RE
Ü
RE

G
SI

10 6x21FW
NÞ
ST

O
AN

SI
RA
CE

12 Flattened Strand
AB
TO
BE

12 6x26FW
ND
IN
TO

12 6x31WS
FA
CE

TI
AN

G
UE
ST

14 6x36WS
SI

Þ
RE

G
RE

16 6x49FWS
Ü

AT
T
AS

6x64
E
LE

ST

18 SFWS

20
 COOKES
EFFECT OF SHEAVE SIZE
Wire Ropes are Manufactured in a great variety of
constructions to meet the varying demands of wire
rope usage. Where abrasion is an important factor,
the rope must be made of a coarse construction con-
taining relatively large wires. In other cases, the great
amount of bending to which a rope is subjected is
more important. Here, a more flexible construction,
containing many relatively small wires, is required.
In either case, however, if the rope operates over in-
adequate size sheaves, the severe bending stresses
imposed will cause the wires to break from fatigue,
even though actual wear is slight. The smaller the
diameter of the sheave, the sooner these fatigue breaks
will occur and the shorter rope life becomes.
Another undesirable effect of small sheaves is accel-
erated wear of both rope and sheave groove. The pres-
sure per unit of rope on sheave for a given load is
inversely proportional to the size of the sheave. In
other words the smaller the sheave the greater the
rope pressure per unit area on the groove. Using the
proper diameter sheave for the size and construction
of rope can obviously prolong both sheave and rope
life.
Sheave diameter can also influence rope strength.
When a wire rope is bent around a sheave, there is a
loss of effective strength.
21
COOKES
This is due to the inability of the individual strands
and wires to adjust themselves entirely to their
changed position. Tests show that rope strength effi-
ciency decreases to a marked degree as the sheave
diameter is reduced with with respect to the diam-
eter of the rope.
Therefore, it is evident that a definite relationship
exists between rope service and sheave size. As a
guide to rope users, wire rope manufacturers have
established standards for sheave sizes to be used with
various rope constructions. To secure the most eco-
nomical service, it is important that the suggested
size of sheaves given on the following page be used.
As a rope is run through a groove, both become
smaller. A used groove can be too small for a new
rope, thus accelerating rope wear. A compromise
between rope life and machining frequency must be
made.
Grooves should have an arc of contact with the wire
rope between 135 and 150 degrees. They should be
tapered to permit the rope to enter and leave the
groove smoothly. Field inspection groove gauges are
made to the nominal diameter of the rope plus 1/2 of
the allowable rope oversize tolerance. When the
gauge fits perfectly, the groove is
at the minimum permissible con-
tour

22
 COOKES
PROPER SHEAVE AND DRUM SIZES
Suggested Minimum
Construction D/d* ratio D/d* ratio
6x7 72 42
19x7 or 18x7
Rotation resistant 51 34

6x19 Seale 51 34

6x27 H Flattened strand 45 30

6x31V Flattened strand 45 30

6x21 Filler wire 45 30

6x25 Filler wire 39 26

6x31 Warrington Seale 39 26

6x36 Warrington Seale 35 23

8x19 Seale 41 27

8x25 Filler wire 32 21

6x41 Warrington Seale 32 21

6x42 Filler 21 14

*D = tread diameter of sheave.

d = nominal diameter of rope.
23
COOKES
DRUM WINDING
It is very important to have a rope wind evenly
and tightly on a smooth drum. Due to lay direction
and tension, rope has a tendency to rotate or roll as it
approaches a winch drum. This characteristic is used
to advantage by establishing the winding direction
and dead end location so the rope will rotate in the
direction of the preceding wrap. Tightly packed wraps
on the all-important first layer will ensure proper
winding for additional layers.
If the drum attachment and direction of wraps
are not correctly selected, the first layer of rope will
not wind evenly or tightly, causing the second layer
to pinch down between the wraps of the first layer.
The resultant uneven winding will become worse with
each succeeding layer and result in abnormal scuff-
ing and abrasion. If there are sufficient layers the rope
will pile up and “fall over” on itself with disastrous
results.
The hand rule is a convenient way to check
the correct lay for an installation. The extended thumb
points to the flange to which the rope is terminated
while the extended forefinger represents the rope
leaving the drum. A palm up hand represents
underwind and palm down overwind. If the right hand
meets the conditions, use right hand lay rope and vice
versa.
24
 COOKES
RIGHT HAND - RIGHT LAY ROPE
Overwind Underwind

Right hand, palm down Right hand, palm up

LEFT HAND - LEFT LAY ROPE
Overwind Underwind

Left hand, palm down Left hand, palm up

Left lay is not always readily available so design
equipment to accept right lay if possible.

25
COOKES
FLEET ANGLE
Excessive fleet angles can cause serious
damage to wire rope, sheaves and grooved drums.
Severe scuffing results when rope wears against
groove walls, grinding them down causing the rope
to become bruised and crushed.

Fleet angles on equip-

ment should preferably
be kept between 1° and
Fleet 1.5° and should not
Angle exceed 2° for smooth
drums or 4° for grooved
Sheave drums. To ensure the
C/line rope crossing back and
starting the second layer
Rope properly without
C/line Fleet assistance the fleet
Angle angle should not be less
than 1°.
The fleet angle is that
angle between the
centre line of the first
fixed sheave and the
centre line of the rope
leading to the drum.

26
 COOKES

CALCULATION OF DRUM CAPACITIES

Capacity in metres = (A+B) x A x C x N
The value of N is taken from the table below
Rope Rope Rope
dia. N dia. N dia. N
6 87.226 16 12.271 32 3.068
10 31.416 19 8.702 35 2.565
11 25.963 22 6.491 38 2.176
13 18.589 26 4.647 40 1.963
14 16.028 28 4.007 44 1.623

ALTERNATIVE METHOD
Rope length (m) = (A + B) x A x C x p x 106
d²
Where A, B & C are quoted in metres and d in mm
27
COOKES
MULTIPLE PULLEY SYSTEMS
Under static conditions the tension in each
part of a rope in a multi-reeved system will be the
total load to be lifted divided by the number of
parts supporting the load. When the load is raised it
is necessary to take into account forces required to
overcome friction in the sheave bearings and the
resistance to bending of the rope as it passes over
the sheave. These additional forces are cumulative
and vary with the type of bearing and the sheave
tread:rope diameter ratio.
Sheave:rope Plain Ball/Roller
dia ratio Bearing Bearing
t about 15:1 8%/sheave 5%/sheave
about 20:1 6%/sheave 4%/sheave
> 25:1 5%/sheave 3%/sheave

No of Percent per Sheave

parts 3% 4% 5% 6% 8%
1 1.030W 1.040W 1.050W 1.060W 1.080W
2 0.523W 0.530W 0.538W 0.545W 0.561W
3 0.354W 0.360W 0.367W 0.374W 0.388W
4 0.269W 0.276W 0.282W 0.289W 0.302W
5 0.218W 0.225W 0.231W 0.237W 0.250W
6 0.185W 0.191W 0.197W 0.203W 0.216W
7 0.161W 0.167W 0.173W 0.179W 0.192W
8 0.143W 0.149W 0.155W 0.161W 0.174W

28
 COOKES
SAFE WORKING LOADS
The safe working load (SWL) of a wire rope
or a sling made from it is calculated by dividing
the particular wire rope’s minimum breaking load
(MBL) by the safety factor to be used. This safety
factor depends on the application and may be
determined by legislation or other codes of prac-
tice. A common safety factor is 5:1 which means
the SWL of the rope is 1/5th of it’s MBL. Where
the load is evenly supported by more than one
length of rope the SWL can be increased as shown:

Load carried Load carried

on two parts equally on two parts
at 90° at 30º = SWL x 2
= SWL x 1.4 at 60º = SWL x 1.8
at 90º = SWL x 1.4
at 120º = SWL x 1

Load carried Load carried

on two parts on four parts
= SWL x .8 at 90°
= SWL x 2.1

29
COOKES
Incorrect installation or handling prior to in-
stallation can damage a wire rope and cause failure
before it is even put to work. Care must be taken to
avoid putting a kink in the rope and thus permanently
damaging it. DO NOT lie the coil on it’s side or the
reel on it’s flange and lift the wraps off the top! The
following illustrations demonstrate correct methods:

30
COOKES

31
COOKES

Ensure that wire rope always passes around

winch drums and sheaves in the same direction (al-
ways clockwise or always anticlockwise) and ensure
that the rope is loaded to equipment in the same di-
rection as supplied i.e. top of reel (or coil) to top of
winch drum or bottom to bottom, never top to bot-
tom or vice versa:

32
 COOKES

Wire Rope
Selection

33
COOKES

34
 COOKES

Engineering &
General Purpose Ropes

35
COOKES

Engineering & General

Purpose Ropes
6 x 19
9/9/1
1770 N/mm²

6 x 31
12/6&6/6/1 Fibre Core IWRC
1770 N/mm²

6 x 36
14/7&7/7/1
1770 N/mm²
Galvanised

6 x 41
16/8&8/8/1
1770 N/mm²
Galvanised

Specifications facing page

36
 COOKES
Dia MBL (kN*) Weight (kg/m)
(mm) FC IWRC FC IWRC
8 37.40 40.31 .231 .255
9 47.30 50.99 .292 .322
10 58.40 62.96 .361 .398
11 70.70 76.20 .437 .482
12 84.10 90.71 .520 .573
13 98.70 105.91 .610 .673
14 114.00 123.56 .708 .780
16 150.00 160.83 .924 1.02
18 189.00 203.98 1.17 1.29
19 211.00 226.53 1.30 1.44
20 234.00 252.03 1.44 1.59
22 283.00 304.99 1.75 1.93
24 336.00 362.85 2.08 2.29
26 395.00 425.61 2.44 2.69
28 458.00 494.26 2.83 3.12
32 598.00 644.30 3.70 4.08
35 716.00 771.78 4.42 4.88
36 757.00 816.89 4.68 5.16
38 843.00 910.06 5.21 5.75
40 935.00 1008 5.78 6.37
44 1131.00 1220 6.99 7.71
48 1346.00 1452 8.32 9.17
52 1579.00 1704 9.76 10.76
54 1703.00 1737 10.53 11.61
56 1832.00 1976 11.32 12.48
60 2103.00 2268 13.00 14.33

* kN x 0.10197 = tonne
37
COOKES

38
 COOKES

Logging Ropes

39
COOKES

Logging Ropes

6 x 19 IWRC
9/9/1
1770 N/mm²
Standard

6 x 31 IWRC
12/6&6/6/1
1770 N/mm²
Standard

6 x 26 IWRC
10/5&5/5/1
1770 N/mm²
Dyform

Specifications facing page

40
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) Std. Dyform Std. Dyform
13 106.00 120 .673 .78
14 124.00 140 .780 .90
16 161.00 185 1.02 1.17
18 204.00 236 1.29 1.48
19 227.00 258 1.44 1.66
20 252.00 295 1.59 1.82
22 305.00 350 1.93 2.17
24 363.00 415 2.29 2.66
26 426.00 481 2.69 3.13
28 494..00 560 3.12 3.59
32 645.00 732 4.08 4.69
35 772.00 4.88
38 910.00 5.75

* kN x 0.10197 = tonne
41
COOKES

Logging Ropes (Cont.)

Swaged
6 x 19 IWRC
9/9/1

6 x 26 IWRC
10/5&5/5/1

6 x 31 IWRC
12/6&6/6/1
1770 N/mm²

Specifications facing page

42
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) Swaged Swaged
13 147 .84
16 237 1.2
19 340 1.5
23 437 2.1
26 574 2.9
28 659 3.3
32 812 5.2
Dyswaged available on request

* kN x 0.10197 = tonne
43
COOKES

44
 COOKES

Fishing Ropes

45
COOKES

Fishing Ropes

Standard Dyform
3 x 19F
12/6+6F/1
1420/1770
N/mm²
Galvanised
3 x 26
10/5&5/5/1
1420/1770
N/mm²
Galvanised
3 x 31
12/6&6/6/1
1420/1770
N/mm²
Galvanised

Specifications facing page

46
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) Std. Dyform Std. Dyform
2.50 4.58 .0233
8.00 34.30 .24
9.00 50.16 .30
10.00 59.20 .36
11.00 73.15 .44
12.00 83.02 .52
13.00 87.00 .62
14.00 115.52 117.12 .71 .744
16.00 158.47 162.30 .95 1.00
18.00 184.42 196.35 1.20 1.23
19.00 213.45 230.44 1.30 1.42
20.00 216.00 250.00 1.48 1.55
22.00 280.00 298.84 1.78 1.90
24.00 330.30 356.94 2.04 2.30
26.00 372.02 428.42 2.41 2.79
28.00 461.90 485.05 2.85 2.99

* kN x 0.10197 = tonne
47
COOKES

Fishing Ropes (Cont.)

Swaged

Fibre Core
4 x 30
12/6+6/6/F
1420/1770 N/mm²
Galvanised

Specifications facing page

48
 COOKES

Dia (mm) MBL (kN*) Weight (kg/m)

10 73.00 .43
12 105.00 .58
14 132.00 .80
16 174.00 1.078
18 224.00 1.430
19 254.00 1.695
20 276.00 1.780
22 326.56 2.012
24 356.00 2.433

* kN x 0.10197 = tonne
49
COOKES

Fishing Ropes (Cont.)

Standard
6 x 15
7/7/1

6 x 17
8/8/1

6 x 19
9/9/1 Fibre Core IWRC
6 x 21
10/5+5f/1

6 x 26
10/5&5/5/1

6 x 31
12/6&6/6/1
1420/1770
N/mm²
Galvanised Specifications facing page
50
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) Fibre IWRC Fibre IWRC
8 33.13 39.37 0.23 .24
9 47.31 43.00 0.29 .323
10 54.00 56.88 0.36 0.41
11 68.20 67.67 0.44 0.48
12 82.70 81.16 0.52 0.57
13 87.60 94.50 0.61 0.67
14 102.00 110.00 0.71 0.78
16 133.00 143.00 0.92 1.02
18 179.00 181.00 1.17 1.27
19 187.00 204.00 1.30 1.39
20 207.00 224.00 1.44 1.59
22 251.00 271.00 1.75 1.93
24 298.00 363.00 2.08 2.29
26 350.00 387.00 2.44 2.69
28 406.00 484.07 2.83 3.12
30 468.32 521.18 2.97 3.51
32 567.97 591.80 3.44 4.06

* kN x 0.10197 = tonne
51
COOKES

Fishing Ropes (Cont.)

Dyform

6 x 19
9/9/1

6 x 26 Fibre Core IWRC

10/5&5/5/1

6 x 31
12/6&6/6/1
1420/1770
N/mm²
Galvanised

Specifications facing page

52
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) Fibre IWRC Fibre IWRC
10 57.86 61.88 .36 .42
11 72.12 78.67 .449 .521
12 82.88 90.62 .518 .601
13 89.84 108.92 .621 .722
14 122.00 121.60 .703 .827
16 143.00 168.27 .963 1.12
18 193.27 211.60 1.21 1.40
19 204.54 220.00 1.37 1.54
20 231.55 250.35 1.51 1.73
22 278.18 301.30 1.91 2.09
24 328.99 354.98 2.13 2.47
26 402.00 413.00 2.52 2.93
28 442.45 479.09 2.85 3.32
29 464.00 3.25
30 515.50 591.77 3.40 3.98
32 574.77 623.66 3.69 4.31

* kN x 0.10197 = tonne
53
COOKES

Fishing Ropes (Cont.)

Dy/Swaged

6 x 19
9/9/1
Fibre Core IWRC
6 x 26
10/5&5/5/1

6 x 31
12/6&6/6/1
1420/1770
N/mm²
Galvanised

Specifications facing page

54
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) Fibre IWRC Fibre IWRC
10 65.20 69.99 .43 .49
12 92.94 99.84 .613 .694
13 110.22 119.08 .726 .831
14 128.33 137.15 .848 .998
16 165.32 184.40 1.09 1.25
18 222.30 246.51 1.45 1.64
19 229.30 253.65 1.50 1.73
20 266.03 310.74 1.74 1.97
22 313.82 336.95 2.08 2.36
24 364.12 391.73 2.40 2.72
26 451.98 483.30 2.98 3.36
28 497.72 539.10 3.56 3.8
30 570.02 616.10 3.78 4.3
32 671.27 725.03 4.53 5.13

* kN x 0.10197 = tonne
55
COOKES

Fishing Ropes (Cont.)

Combination Ropes

6 x Decitex/9/f
6 x Decitex/15/9/f
Polyprop Core
IWRC
Galvanised

Specifications facing page

56
 COOKES

MBL (kN*) Weight (kg/m)

Dia Fibre IWRC Fibre IWRC
mm
12 35.00 50.00 .268 .324
14 40.00 53.50 .366 .460
16 49.00 59.54 .380 .491
18 55.25 69.09 .580 .620
20 68.71 101.0 .688 .873
22 78.72 115.0 .720 .950
24 101.5 161.0 .880 1.10
26 117.0 176.0 1.02 1.32
28 143.0 213.0 1.61 1.61
60 610.0 904.0 4.68 6.42

* kN x 0.10197 = tonne
57
COOKES

58
 COOKES

Marine Ropes

59
COOKES

Marine Ropes
Stainless 316

1 x 19
12/6/1

Specifications facing page

60
 COOKES

Dia. (mm) MBL (kN*) Weight (kg/m)

1.5 1.8 .011
2.0 3.3 .020
2.5 5.2 .031
3.0 7.4 .044
4.0 13.1 .079
5.0 20.6 .124
6.0 29.7 .178
7.0 40.4 .243
8.0 52.8 .317
9.0 66.8 .401
10.0 82.4 .495
11.0 101.0 .599
12.0 118.6 .713

* kN x 0.10197 = tonne
61
COOKES

Marine Ropes (Cont.)

Stainless 316

7x7
6/1

7 x 19
12/6/1
or
9/9/1

Specifications facing page

62
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) 7x7 7 x 19 7x7 7 x 19
1.5 1.30 .0096
2.0 2.37 2.2 .0170 .018
2.5 3.71 3.4 .027 .026.
3.0 5.34 5.0 .037 .038
3.5 7.60 7.0 .049 .050
4.0 9.46 8.9 .065 .068
5.0 14.8 13.9 .094 .093
6.0 21.4 20.0 .136 .134
7.0 29.1 27.3 .185 .182
8.0 38.0 35.6 .242 .238
10.0 59.3 55.6 .378 .372
12.0 85.4 80.0 .545 .535
13.0 84.4 .579
14.0 117.0 109.0 .741 .728

* kN x 0.10197 = tonne
63
COOKES

Marine Ropes (Cont.)

6 x 19 Fibre Core IWRC

12/6/1

6 x 19
(9/9/1)

1420/1770
N/mm²
Galvanised

Note
The above ropes can be manufactured
with a P.V.C. covering
up to 32:00mm outside dia.
Specifications facing page
64
 COOKES

MBL (kN*) Weight (kg/m)

Dia
(mm) Fibre IWRC Fibre IWRC
8 33.13 39.37 0.23 0.24
9 41.91 43.00 0.29 0.32
10 53.89 56.88 0.36 0.41
11 65.86 67.67 0.44 0.48
12 77.43 80.61 0.52 0.57
13 87.42 94.63 0.61 0.67
14 101.79 109.83 0.71 0.78
16 132.72 143.18 0.92 1.02
18 167.65 192.77 1.17 1.27
19 186.61 202.00 1.30 1.39
20 206.57 224.57 1.44 1.59
22 250.47 269.44 1.75 1.93
24 297.38 333.43 2.08 2.29
26 349.27 377.21 2.44 2.69
28 405.16 484.00 2.83 3.12
32 544.35 606.75 3.44 4.06

* kN x 0.10197 = tonne
65
COOKES

Marine Ropes (Cont.)

6x7 Fibre Core WSC

6/1

7x7
6/1
1770 N/mm²
Galvanised

Note
The above ropes can be manufactured with
a P.V.C. covering
up to 32:00mm outside dia.
Specifications facing page
66
 COOKES

MBL (kN*) Weight (kg/m)

Dia 6x7 7x7 6x7 7x7
mm Fibre WSC Fibre WSC
2.0 2.35 2.54 .0138 .0152
2.5 3.66 4.28 .0196 .0236
3.0 5.29 5.72 .0311 .0343
4.0 9.40 10.20 .0554 .0610
5.0 14.70 15.90 .0865 .0953
6.0 21.20 22.90 .125 .137
7.0 28.80 31.10 .170 .187
8.0 37.60 40.70 .221 .244
9.0 47.60 51.50 .280 .309
10.0 58.80 63.50 .346 .381
11.0 71.10 76.90 .419 .461
12.0 84.60 91.50 .498 .549
13.0 99.30 107.00 .585 .644
14.0 115.00 125.00 .678 .747
16.0 150.00 163.00 .886 .975
18.0 190.00 206.00 1.12 1.23
19.0 212.00 229.00 1.25 1.38
20.0 236.00 254.00 1.38 1.52
22.0 284.00 308.00 1.67 1.84
24.0 338.00 366.00 1.99 2.19
26.0 397.00 430.00 2.34 2.58
28.0 461.00 498.00 2.71 2.99

* kN x 0.10197 = tonne
67
COOKES

Marine Ropes (Cont.)

Small Cords

6 x 19 6 x 19 7 x 19 or
& Fibre 6 x 19 WSC
7 x 19

9/9/1
&
12/6/1

1770 N/mm²
Galvanised

Specifications facing page

68
 COOKES

Dia MBL (kN*) Weight (kg/m)

mm Fibre WSC Fibre WSC
3.0 4.89 5.29 .0311 .0343
3.5 6.64 7.85 .0378 .0465
4.0 8.69 9.40 .0554 .0610
4.5 10.98 12.95 .0612 .0762
5.0 13.60 14.70 .0865 .0953
5.5 16.40 19.42 .0913 .114
6.0 19.60 21.20 .125 .137
6.5 22.95 27.07 .130 .154
7.0 28.60 30.90 .177 .195
7.5 30.50 36.00 .185 .219

* kN x 0.10197 = tonne
69
COOKES

Marine & Lashing Ropes.

6 x 12 Fibre Core
12/f
1420 N/mm²

6 x 24
15/9/f

6 x 24
12/12/f

1420/1770
N/mm²
Galvanised

Note
The above ropes can be manufactured with a braid
cover.

Specifications facing page

70
 COOKES

MBL (kN*) Weight (kg/m)

Dia 12/12/f 12/12/f
(mm) 12/f 15/9/f 12/f 15/9/f
8 19.00 28.10 .127 .200
9 24.00 35.60 .160 .253
10 29.70 44.00 .194 .314
11 35.90 53.20 .254 .380
12 42.70 63.30 .300 .457
13 50.11 74.30 .346 .531
14 58.20 86.20 .400 .616
16 76.00 113.00 .643 .803
18 96.10 142.00 .670 1.028
19 107.30 159.00 .745 1.132
20 118.66 176.00 .820 1.255
22 143.18 213.00 .974 1.520
24 170.64 253.00 1.145 1.805
26 200.00 297.00 1.380 2.122
28 232.42 345.00 1.590 2.458
30 266.74 396.00 1.800 2.521
32 304.00 450.00 2.120 3.213

* kN x 0.10197 = tonne
71
COOKES

72
 COOKES

Crane Ropes

73
COOKES

Crane Ropes

18 x 7
6/1
1770 N/mm²

Dyform 18
18 x 19
9/9/1
1960 N/mm²

Specifications facing page

74
 COOKES

Dia MBL (kN*) Weight (kg/m)

(mm) 18 x 7 Dyform 18 18 x 7 Dyform 18
5.0 14.02 0.10
6.5 23.73 0.16
8.0 37.12 0.25
9.0 46.91 0.32
10 58.10 .390
11 70.06 0.47
12 83.60 .562
13 97.90 124.00 0.66 0.83
14 113.77 135.33 0.76 0.85
16 148.69 193.00 1.00 1.18
18 187.61 213.00 1.26 1.49
19 209.57 226.00 1.41 1.66
20 232.00 285.00 1.56 1.85
22 280.42 353.00 1.89 2.28
24 334.00 413.00 2.25 2.68
26 391.18 475.00 2.64 3.08
28 441.00 2.96

* kN x 0.10197 = tonne
75
COOKES

Crane Ropes (Cont.)

EUROLIFT

Casar 40 x 7
6/1
1960 N/mm²

Specifications facing page

76
 COOKES
Dia (mm) MBL (kN*) Weight (kg/m)
10 89.6 0.49
11 108.8 0.593
12 130.8 0.705
13 152.7 0.821
14 179.1 0.949
15 204.0 1.091
16 230.6 1.257
17 257.9 1.406
18 293.9 1.601
19 329.0 1.768
20 362.2 1.956
21 396.1 2.142
22 441.4 2.373
23 471.8 2.609
24 524.3 2.813
25 567.9 3.076
26 614.9 3.285
27 654.2 3.530
28 712.9 3.846
29 754.6 4.062
30 817.4 4.347
32 930.0 5.011
34 1045.0 5.641
36 1185.0 6.306
38 1319.0 7.081
40 1462.0 7.831
* kN x 0.10197 = tonne
77
COOKES

78
 COOKES

Elevator Ropes

79
COOKES

Elevator Ropes

Natural
Fibre Core
8 x 19
9/9/1
1370/1770 N/mm²

Specifications facing page

80
 COOKES

Dia (mm) MBL (kN) Weight (kg/m)

9.5 39.71 .310
11 53.20 .420
13 74.30 .586
16 113.00 .888

* kN x 0.10197 = tonne
81
COOKES

Horticultural High Tensile Galvanised Strand

Prefabricated loop. No tools required Þ

82
 COOKES

Stay Strand
& Clothes Line

83
COOKES

Stay Strand
& Clothes Line

1x7
Galvanised

Specifications facing page

84
 COOKES

Strand Wires/ MBL Tensile kg/m Equiv

Dia + Dia Grade Wire
(mm) (mm) (kN*) Gauge
3.55 5/1.25 _ 386 .057 18G
4.8 7/1.6 14.02 1080 .110 16G
6.0 7/2.0 27.46 1200/1300 .170 14G
7.5 7/2.5 42.17 1200/1300 .300 12G
9.5 7/3.15 58.84 1200/1300 .430 10G

4.8 7/1.6 9.85 700/800 .110 16G

6.0 7/2.0 15.40 700/800 .170 14G
7.5 7/2.5 23.53 700/800 .300 12G
9.5 7/3.15 38.20 700/800 .430 10G
12.0 7/4.0 61.70 700/800 .690 8G

+ Approximate Diameter
* kN x 0.10197 = tonne
85
COOKES

Services

1,000 tonne talurit press at Auckland

rigging loft.

86
 COOKES

Hand Splice

Mechanical Splice
Mechanical Splice

87
COOKES

Hand Splice with Thimble

Mechanical Splice with Thimble

88
 COOKES

Test bed for proof loading and certification

of all types of lifting equipment. On site
service includes installation, maintenance
and non-destructive testing.

89
COOKES

Associated Products
Lubricating
& protective
coatings, each specially fomulated for
particular wire rope applications

Turnbuckles &
Rigging Screws

Shackles
Rope Grips
Thimbles
Twitches/
Load Binders

90
 COOKES

Chain

Chain
Blocks
&
Lever
Hoists

91
COOKES

Wire
Rope
Hoists

Wire
Rope
Safety
Fence

92
 COOKES

Web
Slings

Load
Restraints
& Web-
bing
Hardware

93
COOKES

Height
Safety &
Fall
Arrest
Equip-
ment

Synthetic
& Natural
Fibre
Rope

94
 COOKES

Whangarei
Auckland
Branches Tauranga
Rotorua
New Plymouth
Napier

Nelson Wellington

Christchurch
Ashburton
Timaru
Dunedin

Invercargill

95
COOKES
NOTES

96
 COOKES
NOTES

97
COOKES
BRANCHES
Head Office & Factory Rotorua
6-10 Greenmount Dr Marguerita Street
East Tamaki P O Box 633
P O Box 14-422 Phone (07) 348-3043
Panmure Fax (07) 346-3283
AUCKLAND Email:
Phone (09) 274-4299 rotsales@cookes.co.nz
Fax (09) 274-7982
Email: Napier
salesadmin@cookes.co.nz 182A Hyderabad Rd
P O Box 12-003
Whangarei Ahuriri
Lower Port Road Phone (06) 834-0690
P O Box 708 Fax (06) 834-0872
Phone (09) 438-8964 napsales@cookes.co.nz
Fax (09) 438-9272 New Plymouth
Email: 75 Corbett Road
whgsales@cookes.co.nz Bell Block
Phone (06) 755-04513
Tauranga Fax (06) 755-0419
1 Marsh Street Email:
P O Box 14-204 nplysales@cookes.co.nz
Phone (07) 578-0605
Fax (07) 578-0604 Palmerston North
Email: Resident Representative
tausales @cookes.co.nz Phone (027) 445-3902
Fax/Tel: (06) 354-0644
98
 COOKES
BRANCHES
Wellington Ashburton
2 Udy Street 120 Moore Street
P O Box 38-696, Petone P O Box 407
Phone (04) 568-4384 Phone (03) 308-9778
Fax (04) 568-4381 Fax (03) 308-3875
wtnsales@cookes.co.nz ashsales@cookes.co.nz
Timaru
Nelson 14 Bank Street
8 Akerston Street P O Box 918
P O Box 5030 Phone (03) 684-7494
Phone (03) 548-0719 Fax (03) 684-8476
Fax (03) 548-0105 timsales@cookes.co.nz
nelsales@cookes.co.nz Dunedin
2A Orari Street
P O Box 626
Christchurch Phone (03) 455-3966
124C Waterloo Road Fax (03) 455-3966
P O Box 16289 dunsales@cookes.co.nz
Hornby Invercargill
Phone (03) 349-30 137 Clyde Street
Fax (03) 349-300 P O Box 118
chcsales@cookes.co.nz Phone (03) 218-4682
Fax (03) 218-4187
invsales@cookes.co.nz
www.cookes.co.nz

99
WIRE ROPE HANDBOOK