MATERIAL HANDLING

1
 WIRE ROPES
CONSTRUCTION OF WIRE ROPES

2
 WIRE ROPES
CONSTRUCTION OF WIRE ROPES

Ordinary

Seale

Warrington

Filler

3
TYPES OF LAY

4
 WIRE ROPES
MEASURING THE WIRE ROPE

INCORRECT CORRECT

5
 SELECTION OF WIRE ROPE
SERVICE DESIGN REQT.
REQUIREMENT
Strength Size, Grade Of Wire Rope &
Type Of Core
Flexibility Strands of large no.of wires
Lang Lay & Preforming
Resistance to Abrasion Large outer wires, Lang lay

Resistance to Crushing IWRC

Resistance to Rotation Special construction.
Regular lay better than Lang
Lay; IWRC
Resistance to corrosion Galvanised or stainless steel
wire rope.
6
 WIRE ROPES
INSPECTION OF WIRE ROPES

•BROKEN WIRES

•WORN OUT WIRES

•REDUCTION IN ROPE DIA.

•ROPE STRETCH

•BIRD CAGE

•KINKS

•CORE PROTRUSION
7
WIRE ROPES
BROKEN WIRES

•6 OR MORE BROKEN WIRESIN ONE LAY

•3 OR MORE BROKEN WIRES IN ONE
STRAND IN ONE LAY
•MORE THAN 5% IN ANY LENGTH OF 10
DIAMETERS

8
 WIRE ROPES
WORN AND ABRADED WIRES

9
 WIRE ROPES
REDUCTION IN ROPE DIA.
REPLACE THE WIRE ROPE IF THE DIA REDUCES BY
•1mm FOR ROPE DIA UPTO 19mm

•1.5mm FOR ROPE DIA UPTO 22-38mm

•2mm FOR ROPE DIA UPTO 32-38mm

ROPE STRETCH

150 mm PER 30m LENGTH OF SIX STRANDED ROPE

10
WIRE ROPES
BIRD CAGES

11
WIRE ROPES
CORE PROTRUSION

12
INSPECTION PROCEDURE

•Stores receives and gives a

code for every item.
•Color coding
•Once in a month
•Record in a register

13
 FACTOR OF SAFETY
Factor of safety for wire ropes - 5

Factor of safety for wire ropes when used

for carrying personnel- 10

14
THUMB RULES FOR FINDING SWL
Wire Rope:
SWL = 8*D*D
D = dia. of the rope
eg: 1/2” rope dia = 8 *1/2 *1/2 = 2MTons.

Note: Dia is in inches & result in Tons.

15
PREFORMED
SEIZING &
CUTTING

16
INSTALLATION

17
STORAGE OF WIRE ROPES

18
 Method of lubricating rope
Preferred
Temporary method since Air Blast
Winding rope opens up Application
Drum over sheave
allowing oil to
penetrate

Brush
Application

19
Dip and Swab Application
‘U’ CLAMPS

20
DISTANCE BETWEEN THE ROPE CLIPS = 6 X Dia.

CLIPS AND SPACING FOR SAFE APPLICATION

Rope Diam. Minimum No. Clips Spacing of Drop
In. for Each Rope End Forged Clips
in.
1/2 3 3
5/8 3 3.3/4
3/4 4 4.1/2
7/8 4 5.1/4
1 5 6
1.1/8 6 6.3/4
1.1/4 6 7.1/2
1.1/2 7 9

21
 SPLICING

FIVE TUCKS

22
 STRENGTH OF WIRE ROPE
SWL OF MECH. HAND BULLDOG CHOKER
WIRE ROPE SPLICED SPLICED GRIPS HITCH

100% 95% 80% 80% 80%

23
FIBER ROPES
1. Manila Rope

2. Jute rope

3. Nylon Rope

4. Polypropylene Rope 24
 FIBER ROPES
Strength of PP as per IS5175:1992
Dia. In Breaking str. Runnage in
mm mtrs./kg.
12 2210 15.20

16 3770 8.60

22 6960 4.50

24 8130 3.90

26 9410 3.20
25
 FIBER ROPES

SPLICING – 05 full tucks

26
 SWL - FIBER ROPES
SWL - Polypropylene rope:
 Change the rope diameter into eighths of an
inch.

 Square the numerator and multiply by 40

 Eg: ½ inch polyproplene rope = 4/8inch

diameter.

 SWL= 4*4*40= 640lb.

27
 FIBER ROPES -INSPECTION
 Broken fibres and yarns, cuts, nicks, signs of abrasion, burns,
unlaying and reduction in diameter.

 Interior of the rope -Interior of the rope should be as bright and clean
as when it was new. Check for broken yarns, excessively loose
strands and yarns, or an accumulation of a powder like dust, which
indicates excessive internal wear between the strands as the rope is
flexed back and forth in use.

28
 FIBER ROPES
Pull out a couple of long fibres from the end of the rope and try
to break them. If they break easily then the rope should be
replaced.

Rope has lost its life and elasticity, it should not be used for
hoisting purpose

29
SLINGS

30
 SLINGS
TENSION ON SLINGS

T=WxL
HxN

T = TENSION

W = WEIGHT OF THE LOAD

L = LENGTH OF SLING

N = NO. OF SLING LEGS

31
 SLINGS
TENSION ON SLINGS

If L is greater than S
then sling angle is OK 32
SLINGS - HITCHES
BRIDLE HITCH

33
SLINGS - HITCHES
BASKET HITCH

34
SLINGS - HITCHES
CHOKER HITCH

35
 If you force the eye
down

450

Let the eye ride higher and

keep this angle approx. 450 or
more

Get severe loading in slings

because of low sling angles
36
RIGGING PRACTICES

37
 RIGGING PROCEDURES

 Planning

Skill gang - Leader

Rigging equipments

 Inspection procedure –

Once in a month – color code

38
39
Electrical lines

Weather condition
Wind force
Night shift

40
41
42
 RIGGING PRECAUTIONS

Weight of ALL loads

Allowances for unknown factor

Capacity of equipment & marked

43
 Center of gravity

Stability of Load

44
 RIGGING PRECAUTIONS

Sharp Bends , Pinching & crushing

–avoid for slings –provide packing-
curve 7 lays

Never wrap a wire rope around a

hook.

45
 Ensure that slings are protected at
all sharp corners on heavy items

For heavy
structural
members

Radius of
contact
should be
equal to 1
rope lay
46
Do not permit bending near any
splice or attached fitting

47
 RIGGING PRECAUTIONS
LIFTING BY CRANE
Suspended loads –securely slung & properly balanced
Tag Line
Safely landed & blocked
Lifting beams –SWL marked.
Hoist rope – don’t wrap it around the load.
Multiple part lines –don’t twist
Slack rope condition –ensure it is seated properly on the
drum
Stand clear of the load
48
49
 Whenever 2 or more ropes
are to be placed over a hook
Use of tag lines to control all loads
- use a shackle

50
51
 RIGGING PRECAUTIONS
Erection
Before lifting check the sling is properly attached to the
rope.
Avoid impact / jerk load
Never ride on a load
Never allow load to be carried over the head of personnel
Never work under suspended load.
Ensure all personnel stand clear while load is lifting,
lowered and the sling is removed.
Never leave a load suspended in air when the crane/ hoist is
unattended.

52
Before being unhooked all loads Stay away from slings when
must be safely landed and they are being pulled out from
properly blocked under loads

53
 RIGGING PRECAUTIONS
ERECTION
No temporary repairs on slings
In multi leg slings –secure the unused slings.Never point
load a hook
Remove or secure all loose materials from the load
Ensure load is free before lifting & all legs are taking the
load.
Lower the loads on to adequate blocking to prevent damage
to the slings.

54
On a Rigid object the load could be carried
on only 2 legs or sling while other legs only Know what the load in each sling leg will
serve to balance be before the lift is made

The tension in
Carrying Full load the most heavily
Balancing loaded legs is
more important
than the total
weight

55