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1.

Learn about wire rope construction – wire rope lays, regular lay and lang lay, wire rope lay
length, wire rope sizing grades, strand classification etc.

2. Learn about breaking strength of wire rope:


a) Diameter squared multiplied by the breaking strength of a one inch fibre or wire core rope. i.e.
D² x B.S. of 1 inch wire rope.
D² x 42 fibre core
D² x 45 wire core.
6 x 19 x 1 inch fibre core wire rope has a breaking strength of 42 tons.
6 x 19 x 1 inch wire core wire rope has a breaking strength of 45 tons.

3. Breaking strength examples:


1. ½ inch wire rope (fibre rope core): D² x 42= Breaking strength.
½ x ½ x 42 = 42/4 = 10.5 tons.
2. ½ inch wire rope (wire rope core): D² x 45= Breaking strength.
½ x ½ x 45 = 42/4 = 11.25 tons.
(All breaking strength formulas are based on a diameter of one inch and in a tonnage ratio).

4. Safe Working Load: Most hoisting jobs use of a safe working load based on a 5:1 safety factor
of wire trope breaking strength. This safety factor should go high if there is possibility of injury or
death due to breakage. For example elevators are based on 20:1 safety factor.
Safe working load = breaking strength divided by safety factor.
Example: 1 inch I.W.R.C wire rope has a breaking strength of 45 Tons
S.W.L. = 45/5 = 9 Tons
5. Rule of thumb for S.W.L : D² x 8 = (S.W.L) in tons.(this is based on safety factor of 5)
Example: safe working load of ½ inch wire rope = ½ x ½ x 8 = 2 tons
(These formulas cannot be used in metric systems).
Mobile cranes have minimum wire rope safety factors of 2.5 to 1, 3 to 1 3.5 to 1 depending upon
location of and/or usage.

Having come so far now we have to go deeper in understanding selection criteria for a crane
hoisting rope.
1.Wire rope drums: At least three full wraps should remain on a drum in all service conditions.
Some areas the requirement may be five.
2.Wire rope blocks: These blocks are much lighter than the hook blocks. They are equipped with
cheek straps.
3.Mechanical Advantage ; The mechanical advantage of a machine is the amount by which the
machine multiplies the force applied to it in order to lift or move a load.Here the machine is the
pulley or a combination of pulleys forming a block and tackle system
4.Calculate the mechanical advantage of a block system ; Count the number of lines supporting
the load, with the exemption of the lead line when it comes down over the top block. The lead line
pulling down is not counted for mechanical advantage. If the lead line comes up to the winch from
the travelling block it will be counted as a supporting line and included in the mechanical
advantage.
5.The amount of wire rope needed for the system is determined by multiplying the number of
parts of line by travel distance of the load plus enough wire rope to go to the winch and have at
least five full wraps on the winch drum.

There are charts available to calculate parts of line and if parts of line is taken to calculate the
maximum load.

Hope you get some insight from this note and It is too long to explain all these here.

A SIMPLE FORMULA:

SWL or WLL = ( F x K ) ÷ ( 9.80665 x Z )

F = minimum breaking force of wire rope


K = splicing efficiency factor ( 0.8 for hand splicing or 0.9 for mechanical splicing )
* = constant for converting kN to tonne.
Z = coefficient of utilisation = 5

3.4 Safe Working Loads

Manila and Sisal ropes have a stated manufacturers 'Mean Breaking Load' (MBL) which is
determined by testing the rope to specifications laid down by Australian Standards. The 'Safe
Working Load' (SWL) is determined by dividing the MBL by a Safety Factor (SF) of 7 for rescue
purposes. This gives the Safe Working Load for a new rope.

eg:

ROPE SIZE

MBL

SF

SWL (APPROX)

12mm Manila

930kg
7

133kg

16mm Manila

1800kg

257kg

24mm Manila

3980kg

568kg

A good field rule of thumb method of determining the SWL of new Manila or Sisal is as follows:

Square the rope diameter in millimetres, the answer is the SWL in kilograms.

ie: D²mm = SWL (kg)

eg:

ROPE SIZE

SQUARE DIAMETER

SAFE WORKING LOAD

12mm

12x12

144kg
16mm

16x16

256kg

24mm

24x24

576kg

These calculations are for new unused rope.

After natural fibre rope has been used, it is classed as previously used rope and the following
calculations apply.

D²mm x 2/3 = SWL (kg)


The SWL of previously used rope is 2/3 the value of new rope.

eg: A new 12mm diameter Manila rope can support 144kg safely. Previously used 12mm Manila
rope would only support 96kg safely.

When tying a knot or knots in a rope or tying around a circular object, a further reduction to 2/3 of
the safe working load will apply.

eg: When using a previously used rope around a circular object with a knot or knots in the rope,
the calculations for a 12mm rope to support a load safely would be:

New rope value = 12x12 = 144kg


Previously used = 144x2/3 = 96kg
Knots & circular bend = 96x2/3 = 64kg
Should a turn have to be taken around a square object or over a sharp edge, a value of one half
(1/2) would be used as the deduction instead of 2/3, however, sharp edges should be padded or
rounded if at all possible, to eliminate this additional deduction.

The following safety points MUST be adhered to when estimating the safe working loads of any
rope:

(a) Fibre rope held by hand for load hauling or life support purposes, must not be less than 16mm
in diameter.
(b) Ropes must be carefully inspected before any use and prior to return to the vehicle or store.

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