) e pre TETHLEHEM Se Ogr@ @ WIREROPE “@Q@ for bridges, towers, ) aerial tramways, Ce , e @ and structures @ oo & » Be @: @® 70-@ eo @ @> $ eve ee =| @©20:-@ aeSECTION 3 Prestretching Wire Rope and Strand 24 PRESTRETCHING WIRE ROPE AND STRAND ‘As compared with most steel prod- ucts, wire rope is a relatively elastic product, and for most service require- ments the normal as-manufactured condition provides safe and satisfactory service life. For certain requirements, however, such as for main cables and suspenders of suspension bridges, guy ropes for high towers, cable supported roof struc- tures, and similar applications, the wire rope or strand should approach closely a condition of true elasticity. To secure this condition, stretching ofthe as-man- ufactured rope or strand is necessary. Reasons for Prestretching Prestretching may be defined as the application of a predetermined tension to a finished wire rope or strand for the following reasons: 1. To make the rope or strand truly clastic by removing the "constructional looseness” inherent in the product as it comes from the stranding or closing ‘This is essential for most suspended cor guyed structures, since it enables the designer to predict better the elastic, behavior of the rope or strand after its crection in the structure. In a suspen- sion bridge, for example, the elonga- tions of the main cables undor load ‘ust be nearly alike, and at a predict able rate, so that the midspan sag may be uniform. 2, To permit measuring and mack- ing, under prescribed loads, of the proper spacing on the rope or strand of such locations as the centers of towers and suspenders. ‘The clongation of a wire rope or strand under tension is due to: (1) The elastic or recoverable stretch of the steel itself. (2) The non-elastic construc- tional or permanent stretch, which is 2 variable quantity depending upon the size of the stranding and closing equip- ‘ment used in manufacture, the arrange- ‘ment of the wires, and the length of the lays of the rope or strand—factors which are responsible for the inherent condition sometimes described by the term “constructional looseness.” ‘The elastic stretch of the steel per- mits a full recovery to the original condition and length, upon release of, ‘an applied tension, provided the tension does not exceed the elastic limit of the steel wires, Constructional stretch, on the other hand, results in a permanent set of increase in length when tension is applied and then released Removal of Stretch ‘The amount of constructional stretch in rope or strand can be minimized by the use of the proper sizes of wire and lengths of lay, and by fabrication on heavy, rugged machinery, but it cannot be entirely eliminated, Ifthe construc- tional stretch must be reduced to mit ‘mum amounts, the rope or strand must besubjected to tension afer fabrication. ‘Removal of constructional stretch is effected by repeated applications of ten- sion to the rope or strand, the number and duration of the applications de- pending on design factors and charac teristics of the rope and strand. The first application removes nearly all of the “looseness” inherent in the rope, A second application produces only a sight additional permanent stretch, and the third losding usually proves that the second has done its job. This repeated stretching forees the compo- nent wires and strands to seat them- selves in closer contact, and the rope is left with well-defined and uniform ela tie properties similar to the ste! itself ‘With constructional stretch elimi: nated, any given working tension, or Toad of predetermined relation thereto, ccan be applied, and overall lengths and fitting positions can be measured and located within close tolerances. Tn the ease of suspension bridge cables, loca- tions forall cable-band and tower ee ters can be accurately measured and| marked, thus facilitating orection of the bride. The operation of prestretching is 2s | follows: One end of the rope or strand fs fasted toa fixed crosshead, andthe other end is attached to the head of a| horizontal tensioning machine. The necessary tension i then applied. How ever, the ned to stretch rope in diam- eters up t0 4 inches and lengths of 5000 or more feet, with proper strss- strain recording Fcilities, requires ex- tensive heavy-duty equipment Prestretching Facilities The prestretching facilities at the Williamsport plant are modern in de- sign and are capable of complying with the most stringent demands of the trade, Two separate prestretching units are available. ‘An Olsen horizontal tensioning ma- chine with a 254{0 screw take-up is located at the inner end of the pre stretching track. The machine has a tensioning capacity of 750,000 Ib. The prestretching track consists of two parallel wide-lange steel beams which extend a distance of 1610 ft. The pro- stretching facilities are equipped with special clamps or grips which are ca- able of holding the rope or strand under prestretching tensions. The grip- ping elements are designed so that perfect contacts of large arcas are ob- tained, thus permitting gripping with- ‘out damage to the rope or strand. ‘A second Olsen horizontal tension= ing machine with a 20-ft screw take-u sand a tensioning capacity of 300,000 Ib supplements the larger prestretching. facilities at the Williamsport plant. The | prestretching track for this machine consists of two parallel wide-fange steel beams which extend a distance of 500.‘Because ofthe large, rugged equip- | record automatically modulus of elas- | over the sheave might not move and eee em ge aravccning [sdistieto wreasiy w teey |SEGTION 3 fire rope are made, rope as large as | operation. Proof of the results of pre- | as the remainder. Also some of the | Prestretchi Se er a rks fanned nth orm | ees of presttching are Tox when | Prestetehing Giarseter are made with less looseness. | of loading curves the outer end of the zope or strand is | Wire Rope than was previously consider attain- | Wireropeand strand of considerable | pulled around the sheave in reeling ue Subic tute propentcs can con. length may be prestched in 16001 | Bethlehem’ straight-line method ove- | nd Strand Sequently be attained with smaller | “bites” which overlap atthe ends. In | comes these objections Toadings of shorter duration than isthe | this manner 3000 ft or even longer | _ Stres-strain data taken from 1600- case with rope or strand made on less [lengths may be processed, the Limit | lengths (or shorter full lengths) of being governed by the capacity of the | strand or rope during. prestretching largest shipping reels that can be han- | are mult more accurate than those designer to specify presteichivg ded by the railroads. taken from a 100-in. gage length, of detailed prestretching_ provedu 5 ‘The eflects of variables du to sock {is sufficient to specify only shat rane Straight-Line Method ting, Joss of lay, and looseness intro- of sitand_be-prestisiched, in-a-pia- | The Bethlehemmethod of prestretch- | duced by the handiing of such short ‘draiaimam modulus ofelasticity | ing long ropes does away with the | lengths are practically eliminated and to uniform elastic propectiss, The | possibilty, when ropes arc prestretched | Williamsport also bas facilities for Dresisetching facilities are equipped to | over large sheaves, that the portion | making tests on 100sin. gage lengths. Prestretching track at Willamsport plant is 1610 ft long.