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BS 4536 Heavy Duty Pulley Blocks
BS 4536 Heavy Duty Pulley Blocks
BS 4536 : 1970
, I
CONTENTS
Page
Co-operating organizations 4
Foreword 5
SPECIFICATION
1. Scope 5
2. Definitions 6
3. Factor of safety 6
4. Wire rope 8
5. Materials 8
6. Block shell 9
7, Head fittings 9
8. Becket 11
9. Axle pin 12
10. Sheaves 12
1 1 . Lubrication 13
12. Locking nuts 13
13. Proof load 13
14. Examination after proof loading 14
15. Marking 14
16. Certificate of test and examination 14
APPENDICES
A. Typical head fittings 15
B. Formulae for round section eyes 16
C. Proof load in relation to safe working load 17
D. Recommendations relating to contracts 18
E. Details which should be agreed between the
purchaser and the supplier 18
TABLE
1. Perniissible loading on shanks of head fittings 10
FIGURES
1 . Nonienclature of block components 7
2. Plain bearing 11
3. Ball bearing 11
CO-OPERATING ORGANIZATIONS
The Mechanical Engineering Industry Standards Committee,
under whose supervision this British Standard was prepared,
consists of representatives from the following ,Government
dcpartiiients and scientific and industrial organizations:
*Associated Offices’ Technical Committee
Association of Consulting Engineers
Association of Mining Electrical and Mechanical Engineers
Board of Trade
Uritisli Clicinical Plant Manufacturers’ Association
British Compressed Air Society
British Electrical and Allied Manufacturers’ Association
Urilisli Gear Manufacturers’ Association
British Internal Combustion Engine Manufacturers’ Association
British Mecliiinical Engineering Confederation
Ilri tisli Piimp Manufacturers’ Association
Dritisli Steel Industry
Crown Agents for Oversea Governments and Administrations
*Departnient of Employment and Productivity (H.M. Factor Inspec:torate)
*Electricity Council, the Central Electricity Generating R o a d
and the Area Boards in England and ,Wales
*Engineering Equipment Users’ Association
Gas Council
Instjtutc of Marine Eng.ineers
Institution of Civil Engineers
Institution of Gas Engineers
Institution of Heating and Ventilating Engineers
Institution of Mechanical Engineers
Institution of Mechanical Engineers (Automobile Division)
Institution of Production Engineers
Locomotive and Allied Manufacturers’ Association of Great Britain
London ‘Transport Board
Machine Tool Trades Association
híiiiistry of Defence
*híinistry of Defence, Army Department
Ministry of Power
bí/ii/stry of Public Building and Works
Ministry of Technology
Ministry of Technology-National Engineering Laboratory
Ministry of Transport
National Coal.Board
National Physical Laboratory (Ministry of Technology)
Royal Institute of British Architects
The Government departments and scientific and industrial organ-
izations marked with an asterisk in the above list, together with
tlie following, were directly represented o n the committee en-
trusted with thc preparation of this British Standard:
nritisii Constructional Steelwork Association
Cliiiin Tcsicrs’ Association of Great Britain
Council of üriiish Maniiîactiirers of Petroleum Equipment
Dock tk Harbour Authorities Association
Federation of Civil Engineering Contractors
Federation of Wire Rope Manufacturers of Great Britain
Honourable Company of Master Mariners
Institution of Plant Engineers
Lifting Equipment Manufacturers’ Association
Lloydls Register of Shipping
tvíiichine-Made Chain Manufacturers’ Association
Ministry of Defence, Navy Department
Natioiiiil Association of Iron and Steel Stockholders
National Federation of Ihiilding Trades Employers
Niitional Federation o! D$niolition Contractors
North East Coast Institution of Engineers and Shipbuilders
FOREWORD
This British Standard is one of a series for rigs and the elements (blocks, rope,
winches, etc.) of which they are composed.
The wire rope pulley blocks specified in this standard are intended for heavy
duty, and have sheaves with groove diameters of not less than 15 times the rope
dianieter. This makes adequate provision for a good expectation of rope life.
Single sheave blocks to the present standard are for use only as lead blocks.
In the design of the blocks to this standard, the working stresses and design
requirements may be assumed to cover any additional loading arising from
frictional resistance and acceleration of the load. It is pointed out, however, that
when considering the size of the wire rope for which the sheaves are designed,
the effect of frictional resistance on the hauling tension at the winch barrel
should Lie taken into account*.
if reduced weight and bulk of the pulley block is of greater importance than
long rope life, as may well be the case with pulley blocks having safe working
loads of less than 25 tonnes, reference should be made to BS 4018, ' Pulley blocks
for use with wire rope for a maximum lift of 25 tonf in combination '.
For ships' cargo blocks, reference should be made to BS 408t.
NOTE. Information concerning SI units is given in BS 350, ' Conversion factors and tables '
and in PD 5686, ' Tlie use of SI units '.
SPECIFICATION
1. SCOPE
This British Standard specifies requirements for heavy duty pulley blocks for
use with wire rope, with sheave diameter (measured at the bottom of the rope
groove) not less than 15 times the rope diameter.
For the purposes of this standard, single blocks are regarded only as lead
blocks.
* Information on frictional resistance in pulley blocks, and the resulting rope tensions when
hoisting and lowering, is given in BS Handbook No. 4, ' Lifting tackle ', Part 1, ' Ropes and
fittings '.
t BS 408, ' Ships' cargo blocks'.
5
2. DEIIINITIONS
For the purposes of this British Standard, the following definitions apply (see
also Fig. 1):
( I ) Pulley block. A block with sheave(s) for use with steel wire rope and
forming a wire rope purchase.
(2) Sìtrgle, double, treble, fowjXi, jivefold, sixfold block. A block with 1, 2,
3, 4, 5 or 6 sheaves.
(3) Lead block. A single block changing the direction of the haulage part of
the rope.
(4) Headfitting. The means by which the block is attached to its anchorage
or to the load being lifted, (Typical head fittings are shown in Appendix A.)
( 5 ) Becket. The fitting on the block to which the rope used in the rig may be
anchored. (See Fig. 1.)
(6) Safe workitrg load (S.W.L.). The maximum load which can safely be
applied to the block.
(7) Proof load The load (on the head fitting) to which every block is tested.
(8) Resriltniir load. The load imposed on the head fitting of the block by
application of tlie safe working load when the block is rigged as follows:
Single block rigged as a lead block.
Double block rigged as top block of a 2/2 combination.
Treble block rigged as top block of a 3/3 combination.
it-fold block rigged as top block of an n/it combination.
(9) Ultiniate streiigtlz. The load at which the block fails by releasing the load.
(10) Iirspector. The representative of the purchaser or of a certifying body.
3. FACTOR OF SAFETY
For the purposes of this British Standard, thefactor of safety is the ratio between
the ultimate strength of tlie block as a unit, and the load imposed on the block,
neglecting frictional resistance and acceleration of the load.
The factor of safety as so defined shall not be less than 5 for safe working
loads up to and including 100 t (tonnes)*, nor less than 4 for safe working loads
over 100 t.
It is further required that the permissible working stresses specified in
Clauses 6, 7, 8 and 9, which make due allowance for friction and acceleration,
shall not be exceeded in the design of the block.
* 1 t = 1000 kg
6
4. IVìRE ROPE
The design of the block shall be based on the minimum breaking load of the
following wire rope:
Roiiiid strand equal lay 6 x 26 to 6 x 41 series, independent wire rope core,
complying with BS 302*.
5. MATERIALS
5.1 Specifications. The following materials are suitable for the construction of
engineering blocks to this standard.
If other materials are used, their suitability is the responsibility of the block
niaiiiifnctiirer, Wrought steels shall be selected from BS 970 Part i t or
Part 2$ and stress-bearing components shall be marked with the grade.
( i ) Forgitigs
CI. Mild steel: Grade 070M20.t. (For the large sizes when higher
tensile steel is not obtainable,)
6. Higher tensile steel: 080M27t, 080A30t, 080A32t, ' 30 ' carbon steel.
150bf19t, 150M28t carbon-manganese steel.
c. Alloy steel: 605M36$ manganese-molybdenum steel.
945M38$ low alloy steel.
(2) hfaclrirre ports 070M55t ' 55 ' carbon steel.
653M31 $ 3% nickel-chromium steel.
Any of the steels listed for forgings.
(3) Strrictrrrc (block shell) Any of the steels listed for forgings.
(4) Costirigs (steel) BS 592 8, Grade A, B or C.
(5) Cmtirgs (/ron) BS 1452II, minimum grade 12.
BS 27897, S.G. iron.
5.2 Heat treatiiient. Prior to machining operations all forgings, e.g. úead fittings
and forged beckets and pins, shall be either normalized or hardened and tempered
in the temperature range appropriate to the material.
* BS 302, ' Wire ropes for cranes, excavators and general engineering purposes ',
t BS 970, ' Wrought stccls, Part 1, ' Carbon and carbon iiinnganese steels '
1 BS 970, ' Wrought stecls ', Part 2, ' Direct hardening~.
alloy steels ',
NOTE. Until publication of the revision of BS 970 the following references apply.
080M27 -
070M20 = Eii3A
080A30 = Bii5B
EnSA
080A32 = En5C
ISOM19 or 150M28 = Enl4A
60SM36 = En16
915M38 = En100
070MS5 = En9
653M31 = En23
'.
!j BS 592. Included in BS 3100, ' Steel castings for general engineering purposes
II BS 1452, ' Grey iron castings '.
'.
71 BS 2789, ' Iron castings with spheroidal or nodular graphite
8
COPYRIGHT British Standards Institution on ERC Specs and Standards
Licensed by Information Handling Services
BS453G: I970
6. BLOCK SHELL
6.1 Design. The side and partition plates shall project beyond the sheaves to
provide adequate protection for the rope, and the design of the block shall be
such that there is no possibility of the rope jamming between the side plates
and the sheaves.
6.2 Shearing stress in tlirougli bolts. The shearing stress shall not exceed 6.2 hbar
(hectobar)* for mild steel, nor 7.7 hbar for higher tensile steel.
6.3 Worltinariship. The plates shall be free from distortion and all edges shall
be smoothly finished. All through holes in side and partition plates shall be in
true alignment.
7. HEAD FITTINGS
7.15 Other Iiemijttiigs. Head fittings other than the above are permissible to
suit particular applications. Typical head fittings are shown in Appendix A.
7.2 Sliaiilm
7.2.1 Protlrrctioii. The shanks of head fittings shall be machined from solid
forgings, and when threaded shall be fitted with screwed collars or nuts, the
depth of either being not less than the full diameter of the screwed shank.
7.2.2 Teirsile stress. The average tensile stress in the shanks of head fittings shall
be based on the minimum core area (n/., x square of minimum core diameter).
Tlie average tensile stress due to the resultant load on the shank shall not
exceed the values given in Table 1.
hbar *
Up to 50 6.2
55 6.5
60 6.8 8.5
(all sizes)
65 7.1
70 74
75 and over 7-7
7.2.3 Screw tlirearls. The screw threads on the shanks of head fittings shall
conform to an appropriate British Standard.
depth of thread
The ratio of __I---- shall not be less than 0.040.
diameter nt top of thread
The portion of the shank adjacent to the shoulder shall have an undercut and
fillet in accordance with the recommendations for the undercut Form A, Grade 1,
in BS 1936f.
It i s recommended that the screw threads be gauged with an appropriate
gauge made to the relevant specification in BS 91 9$.
crosshead of the block, the diameter of the collar shall not be less than I*6D,
where D is the diameter of the screwed shank.
Swivel head fiftings with shanks shall turn freely by hand when not under
load.
7.3 Crossheads. The extreme fibre stress at the centre of the length of tlie cross-
head when housing a swivel head fitting shall not exceed 7.7 hbar* for bild
steel, nor 9.3 hbar for higher tensile steel. This stress is related to the resuftant
load on the crosshead when supporting the safe working load, taking into
account the stress concentration at the cross section at the central hole recelving
the shank of the head fitting.
For the purpose of calculation, the reactions may be assumed to act at the
positions shown in Figs. 2 and 3.
8. BECEET
The becket shall be cleanly forged or machined from the solid.
Tiie breaking load of the becket shall be at least equal to the minimum
breaking load of the wire rope for which the block is designed. (See Clause 4.)
The load imposed on the becket when proof loading the block is acceptable
as a proof load on the becket.
BS 4536 : 1970
9. AXLE PIN
9.1 Workniansliip. The surface finish of the axle pin shall be appropriate to the
bearings. The axle pin shall be positively secured against rotation and lateral
movement, by a means which permits it to be withdrawn for inspection.
i
9.2 penring stress in tlie axle pin. The bearing pressure between any slieaw bush
and the axle pin shall not exceed 3.9 libar* for single sheave blocks, nor 3.1 hbar
for multiple sheave blocks. (These limitations of pressure are imposed to permit
adequate lubrication.)
If proprietary buslies are used tlie bearing maker’s recommendations shall
be followed.
The pressure between the axle pin and the stress-bearing members (Le. straps
and supporting partitions) of the block shall not exceed 16 hbar.
For the foregoing requirements, the projected area of the axle pin in contact
shall be taken, Le. area = appropriate length x diameter.
9.3 Sliearing stress in the axle pin. The shearing stress shall not exceed 6.2 hbar*
for mild steel, nor 7.7 hbar for higher tensile steel.
9.4 Bending stress in the axle pin. Adequate support shall be provided fpr the
axle pin to prevent excessive bending stress, and the design of the axle pin and
supports shall be such that there is no visible permanent set after the removal
of the proof load.
10. SHEAVES
10.1 Material, Sheaves shall be of steel except that those whose diameter at the.
bottom of the groove is 300 mm or less may alternatively be iron castings.
(See 5.1 .)
10.2 Porni and diiiicnsions. The diaineter of the sheave, measured at the bottom
of the rope groove, shall not be less than 15D, where D is the diameter of the
wire rope for which the sheave is designed.
The overall breadth of any part of the sheave shall be at least 1.5 mm less
than the boss (Le. 0.75 nun at either side).
10.3 Bcnrings. Sheaves shall be provided either with bail or roller bearings, or
with phosphor bronze or other anti-friction bushes.
Ball or roller bearings shall be in accordance with an appropriate British
Standard and shall conform to the bearing maker’s recommendations as tp duty
and fittings. They shall withstand the required proof load on the block vithout
I
injury,
Sheaves shall rotate freely by hand.
10.4 Boss, The face of the boss shall be machined.
10.5 Groove. Tlie sheave groove shall be machined to a depth of not less than
the diameter of the rope for which the sheave is designed, and not more than
1% times this diameter. It shall be smoothly finished and free from rough
surface defects liable to injure the rope. The edges of the groove shall be radiiised.
Tlie angle of flare of the sides of the groove shall be 52". (See Fig. I.)
The contour at the bottom of the groove shall be circular over an angle of
128", and the radius of the groove shall be larger than the nominal radius of I
11. LUBRICATION
Provision shall be made for lubricating all bearings and swivel head fittings.
Unprotected oil holes are not permitted. Plain bearings or their shafts shall have
oil or grease grooves to distribute the lubricant over the bearing surfaces. Ball
and roller bearings shall be packed with grease during the initial assembly.
All lubricationnipples shall be readily accessible. BS 1486*, Type II nipples
are siritable for lubrication.
The shanks of head fittings shall be provided with efficient means of lubri-
cation.
All nuts shall be securely locked by a means which permits removal for the
purpose of examination or repair of the block.
. .
The completed block shall be subjected to its proof load (see Appendix C).
. Tlìe testing machine shall be verified in accordance with the requirements of
BS 16IOf and maintained within Grade B. Its full load shall not be more than
10 times the proof load.
The testing machine shall be balanced in the presence of the Inspector before
the tests are made.
* BS 1486, ' Lubricating nipples ', Part 1, * Lubricating nipples and adaptors for use on
machinery and vehicles '*
t ES 1610, ' Methods for the load verification of testing machines
13
BS 4536 : 1970
After proof loading the block, and prior to dismantling it, the sheaves shall be
checked for free rotation.
Tlie block shall then be thoroughly exaniined by a competent person. The
block complies with this standard if found free from visible deformation, crhcks,
flaws, or other defects.
After re-assernbly or at the end of the examination, the shanks of the head
fittings and sheaves shall rotate freely by hand.
15. MARKING
Each block shall be permanently and legibly marked with an individual dis-
tinguishing number or mark, and with the safe working load of the rig for which
it is intended, which is governed by the ratios to proof load given in Appendix C.
Single sheave blocks shall be marked with half of the working load QP the
head fitting indicated in Appendix C , since the load is assumed to be attached
to the rope.
Tlie block maker or supplier shall provide a certificate with each coiisigqment
of blocks, giving the following information for each one:
(1) Distinguishing number or mark (to enable the particular block to be
identified)
(2) Description
(3) Head fitting: type, material, heat treatment (Clause 5 and Appendix A)
(4) Axle pin: material, heat treatment (Clause 5 )
( 5 ) Becket (if fitted): material, heat treatment (Clauses 5 and 8)
(6) Wire rope: diameter
(7) Number tested
(8) Proof load (Clause 13 and Appendix C)
The certificate shall declare that each block was proof loaded iii accordance
I
with Clause 13 and was subsequently examined by a competent persori, and that
it coinplies with BS 4536. It shall also state the name and address of the testing
establishment and the status of the signatory.
The certificate may be the appropriate statutory form provided that the
above information is given.
14
APPENDIX A
TYPICAL HEAD FITTINGS
v--
Round eye Siud eye Elongated eye
15
NOTE. In tlic abovc formulac, tlic cíìèct of thc collar has been ncsutned to add 71/2% to
tlic strength of an equivalent link, and 20% to the strength of an equivalent ring.
1 hbar = lo7 N/m*
16
APPENDIX C
The following table is taken from the International Labour Office pamphlet
No, 188, ' Safety and health in dock work '.
Safe working load W Exccss load Proof load*
(resultant on head fitting:
-
t % t t MNt
25 or less 100 IV 2 w 0~020IV
30 85 25 55 0.55
35 30 65 065
40 75 30 70 0.70
45 30 75 0.75
50 65 35 85 0.85
55 35 90 0.90
60 60 35 95 0.95
65 35 100 1.00
70 55 40 110 1.10
75 40 115 1.15
80 50 40 120 1-20
85 40 125 1.25
90 46 40 130 1.30
95 40 135 1.35
17
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Licensed by Information Handling Services
APPENDIX D
D.1 Proof loading. The manufacturer shall proof load the blocks in accordance
with the requirements of this standard at his own cost.
D.2 Inspection. The representative of the purchaser shall have access to the
works of the manufacturer at all reasonable times; he shall be at liberty to
inspect the manufacture of the blocks at any stage, the testing machine and
methods of examination, and to reject any blocks being made to his order which
do not conform to the requirements of this standard.
APPENDIX E
18