NEWS

Steel wire ropes are critical for lifting, rigging, and load-securing applications across industries like construction, marine, and mining. Proper termination ensures safety, durability, and compliance with load-bearing requirements. Below, we outline six standardized connection methods, their technical specifications, and safety guidelines.

 

1. Splicing Method

Splicing involves interweaving rope strands to create a secure, flexible joint.

Manual Splicing

l Minimum splice length: 20× rope diameter or 300mm (whichever is longer).

l Interlacing requirements: Each strand must be interlaced ≥5 times, with ≥3 full-strand passes.

l Smooth transitions: Trim partial strands for final interlacing to avoid bulkiness.

 

Mechanical Splicing

l Interlacing pattern: 3 strands interlaced 4 times + 3 strands interlaced 5 times (total 27 passes).

l Post-processing: Melt strand ends to prevent fraying.

l Quality checks:

No exposed core.

Strands tightly packed with no looseness.

Trimmed ends smooth and untwisted.

 

2. Clamp Connection Method

Ideal for non-lifting applications (e.g., temporary rigging).

Specifications

Wire Rope Diameter (mm)	≤10	10–20	21–26	28–36	36–40	45–55
Minimum Clamps	3	4	5	6	7	21*
Clamp Spacing (mm)	80	140	160	220	220	10

*For 45–55mm ropes, use plate-type clamps.

 

Safety Rules

Clamp base plates must face the rope’s long end.

Connection strength ≥85% of rope’s breaking force.

Inspect clamps regularly for tightness.

 

3. Compression Sleeve Method

Uses aluminum alloy sleeves for high-strength, permanent connections.

Technical Requirements

l Materials: 3A21H112 or 5A02H112 aluminum alloy (thermally extruded, defect-free).

l Testing: Ultrasonic inspection to exclude cracks, voids, or impurities.

l Dimensions (example for 24mm rope):

Sleeve length: ~101mm.

Thickness: 11.2mm.

 

Load capacity:

Static load: ≥90% of breaking force.

Shock load: 15–30% of breaking force.

 

Installation:

Minimum distance between sleeves: 40× rope diameter.

Operating temperature: -40°C to +150°C.

The distance L from the joint to the inner edge of the sleeve must be greater than or equal to 3 times the hook width B or 15 times the steel wire rope diameter.

 

4. Wedge Socket Fixation

A wedge locks the rope within a steel sleeve, suitable for ropes ≤40mm.

Key Parameters

Strength: 75–85% of rope’s breaking force.

Wedge material: High-grade steel.

Avoid bending at the connection point.

 

5. Lead Pouring Method

A traditional method (rarely used today) where molten lead secures the rope in a tapered socket.

Steps:

Fan out rope strands and insert into a conical socket.

Pour molten lead to bind strands.

Cool and solidify.

 

Strength: Must match rope’s breaking force.

 

6. Pressure Plate Fixation

Commonly used for securing rope ends on hoist drums or pulleys.

Installation Steps:

Thread rope through the drum’s end plate.

Fold and align strands.

Secure with a grooved pressure plate.

Bolt the plate tightly to the drum.

Plate design: Grooved surface to grip the rope.

 

General Safety Guidelines

Pre-Installation Checks:

Inspect for corrosion, wear, or deformation.

Verify certifications (CE, ISO 4309).

Load Testing:

Gradually apply load; avoid sudden shocks.

Environmental Limits:

Avoid temperatures beyond -40°C to +150°C.

Maintenance:

Lubricate connections in corrosive environments.

Replace components showing ≥10% wear.

 

Choosing the Right Method

Method	Best For	Strength Retention
Splicing	Flexible, reusable connections	100%
Compression Sleeve	Permanent, high-stress lifts	90–100%
Wedge Socket	Medium-duty, easy disassembly	75–85%
Clamps	Temporary applications	85%

 

Conclusion

Selecting the appropriate termination method depends on load requirements, environmental conditions, and regulatory compliance. Always prioritize pre-use inspections and adhere to manufacturer guidelines. For certified wire rope solutions tailored to your industry, consult professionals to ensure safety and performance.