S9086-UU-STM-010 (Wire and Fiber Rope and Rigging).pdf

NAVAL SHIPS’ TECHNICAL MANUAL

CHAPTER 613

WIRE AND FIBER ROPE AND RIGGING

THIS CHAPTER SUPERSEDES CHAPTER 613 DATED 1 JULY 2008

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE. DISTRIBUTION IS UNLIMITED.

S9086-UU-STM-010

REVISION 5

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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND.

*0910LP1172418* 1 JUN 2018

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REVISION RECORD

Revision No. Date Title and/or Brief Description/Preparing Activity

4 1 JUL 2008 Safety WARNING added to PRECAUTIONS AND TECHNIQUES FOR

THE USES OF ROPES.

TMDERS/ACNS Incorporated: V68316-03-JR01 PARAGRAPHS:613-2.5.1, 613-2.5.5and613-2.5.12

5 1 JUN 2018 Revised to include TMDERs related to providing more details on the requirements for aramid and high-modulus polyethylene (HMPE) moor-ing lines.

Following sections were updated:

PARAGRAPHS:613-1.2.3, 613-1.2.4, 613-1.8.2.7, 613-1.8.3, 613-1.8.4,

613-1.8.5, 613-1.10.2.2, 613-1.10.3, 613-1.10.4, 613-1.11.2, 613-1.11.2.1, 613-1.11.2.2, 613-1.11.4.2, 613-1.11.6, 613-1.11.6.3, 613-2.1.2, 613-2.2.1, 613-2.2.4, 613-2.3.3, 613-2.3.11, 613-2.4.2.4, 613-2.4.4.2, 613-2.5.3, 613-2.8.2.1, 613-2.8.2.2, 613-2.8.2.6, 613-2.8.2.9, 613-2.8.2.11, 613-2.12.2.2, 613-2.12.4.1, 613-2.13.2, 613-2.13.3.1, 613-2.13.3.2, 613-2.13.4, 613-2.13.5, 613-2.13.11, 613-2.14.1, 613-2.14.2, 613-2.14.4, 613-2.14.5, 613-2.14.8, 613-3.9.2and613-3.9.3 FIGURES:613-1-31.and613-1-32.

TABLES: 613-2-1., 613-2-2.and613-2-6.

TMDERS/ACNS Incorporated: N65540-08-5540, R20635-11-0001, R30733-11-PT46. N65540-11-DU06, N64101-14-AH04, R22178-16-SL01 (Do Not Concur), N42192-17-MG01

FOR OPTIMAL VIEWING OF THIS TECHNICAL MANUAL THE PAGE LAYOUT IN ADOBE ACROBAT

READER SHOULD BE SINGLE PAGE. CONTINUOUS PAGE DISPLAY CAN CAUSE PROBLEMS WITH

LINK REFERENCES AND THE BOOKMARKS.

S9086-UU-STM-010

FOREWORD

NSTM Chapter 613 provides information on WIRE AND FIBER ROPE AND RIGGING and contains the following 3 sections:

SECTION 1- WIRE ROPE

SECTION 2- FIBER ROPE

SECTION 3- RIGGING

Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER

CODE 310 TMDERs

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY BLDG 1389

PORT HUENEME, CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting there-from. One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency submittals via the Naval Systems Data Support Activity Web site located at:

https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm i / (ii Blank)

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

613 WIRE AND FIBER ROPE AND RIGGING . . . . . . . . . . . . . . . . . . . . . . 613-1

SECTION 1 WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

613-1.1. FABRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 613-1.1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 613-1.1.2 COMPLEXITY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

613-1.2. PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 613-1.2.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 613-1.2.2 CORE TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 613-1.2.3 CORE MATERIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 613-1.2.4 CHOICE OF CORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

613-1.3. LAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 613-1.3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

613-1.3.2 RIGHT LAY OR RIGHT-HAND HELIX. . . . . . . . . . . . . . . . . . 1-2

613-1.3.3 LEFT LAY OR LEFT-HAND HELIX. . . . . . . . . . . . . . . . . . . . 1-3

613-1.3.4 REGULAR LAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 613-1.3.5 LANG LAY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 613-1.3.6 PITCH OR LENGTH OF LAY. . . . . . . . . . . . . . . . . . . . . . . . 1-3

613-1.4. SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

613-1.5. CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 613-1.5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 613-1.5.2 SEALE CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

613-1.5.3 WARRINGTON CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . 1-5

613-1.5.4 FILLER WIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 613-1.5.5 FLATTENED STRAND.. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 613-1.5.6 SPRING LAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

613-1.6. PREFORMED WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

613-1.7. ZINC-COATED OR WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

613-1.8. CONDITIONS OF USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 613-1.8.1 CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 613-1.8.2 USES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

613-1.8.2.1 6 by 7.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 613-1.8.2.2 6 by 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 613-1.8.2.3 6 by 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 613-1.8.2.4 6 by 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 613-1.8.2.5 6 by 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 613-1.8.2.6 6 by 3 by 19, Spring Lay Rope. . . . . . . . . . . . . . . . . 1-6 613-1.8.2.7 35 by 7, Rotation Resistant Rope. . . . . . . . . . . . . . . . 1-7 iii

TABLE OF CONTENTS - Continued

613-1.8.3 STRENGTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 613-1.8.4 FACTOR OF SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 613-1.8.5 FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

613-1.8.5.1 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 613-1.8.5.2 Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 613-1.8.5.3 System Applicability.. . . . . . . . . . . . . . . . . . . . . . . 1-9

613-1.9. CARE AND PRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 613-1.9.1 STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

613-1.9.2 UNCOILING AND UNREELING. . . . . . . . . . . . . . . . . . . . . . 1-9

613-1.9.3 KINKING AND RESULTING ROPE DAMAGE.. . . . . . . . . . . . . 1-11

613-1.9.4 DRUM WINDING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

613-1.10. INSPECTION, REPLACEMENT, AND LUBRICATION . . . . . . . . . . . . . . . . 1-14 613-1.10.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 613-1.10.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

613-1.10.2.1 External Inspection. . . . . . . . . . . . . . . . . . . . . . . . 1-14 613-1.10.2.2 Internal Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 1-14

613-1.10.3 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 613-1.10.4 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

613-1.11. SPLICING AND TERMINATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 613-1.11.1 SEIZING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

613-1.11.1.1 Temporary Seizing.. . . . . . . . . . . . . . . . . . . . . . . . 1-17 613-1.11.1.2 Permanent Seizing. . . . . . . . . . . . . . . . . . . . . . . . . 1-17 613-1.11.1.3 Electrical Sealing. . . . . . . . . . . . . . . . . . . . . . . . . 1-18

613-1.11.2 POURED ZINC SOCKET. . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 613-1.11.2.1 Need for Qualified Preinstallation Process Control. . . . . . . 1-19 613-1.11.2.2 Qualification Requirement. . . . . . . . . . . . . . . . . . . . 1-19 613-1.11.2.3 Steel Wire Rope with Steel Socket. . . . . . . . . . . . . . . . 1-19 613-1.11.2.4 In-Service Sockets. . . . . . . . . . . . . . . . . . . . . . . . . 1-27 613-1.11.2.5 System Applicabiality. . . . . . . . . . . . . . . . . . . . . . . 1-27 613-1.11.2.6 Reuse of Poured Sockets. . . . . . . . . . . . . . . . . . . . . 1-27

613-1.11.2.7 BRONZE WIRE ROPE WITH BRASS OR BRONZE

SOCKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

613-1.11.3 POURED RESIN SOCKET. . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

613-1.11.3.1 Need for Qualified Assembly Process Control. . . . . . . . . 1-27 613-1.11.3.2 Qualification Requirement. . . . . . . . . . . . . . . . . . . . 1-27 613-1.11.3.3 Steel Wire Rope with WIRELOCK® OR SOCKETFAST®

POURED RESIN SPELTER SOCKET. . . . . . . . . . . . 1-28

613-1.11.3.4 In-Service Sockets. . . . . . . . . . . . . . . . . . . . . . . . . 1-41 613-1.11.3.5 System Applicability.. . . . . . . . . . . . . . . . . . . . . . . 1-41 613-1.11.3.6 Re-use of Poured Resin Socket.. . . . . . . . . . . . . . . . . 1-41

613-1.11.4 FIEGE-TYPE (THREADED, COMPRESSION) WIRE ROPE

CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

613-1.11.4.1 Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 613-1.11.4.2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 iv

613-1.11.5 WIRE ROPE CLIPS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 613-1.11.5.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

613-1.11.6 SWAGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 613-1.11.6.1 Qualified Personnel. . . . . . . . . . . . . . . . . . . . . . . . 1-47 613-1.11.6.2 Swaging Qualification. . . . . . . . . . . . . . . . . . . . . . . 1-47 613-1.11.6.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

613-1.11.7 SPLICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48 613-1.11.7.1 Types of Splicing. . . . . . . . . . . . . . . . . . . . . . . . . 1-48 613-1.11.7.2 Rope Length Requirements. . . . . . . . . . . . . . . . . . . . 1-48 613-1.11.7.3 Short Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 613-1.11.7.4 Long Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 613-1.11.7.5 Independent Wire Rope Core Splice . . . . . . . . . . . . . . 1-55 613-1.11.7.6 IWRC Splicing Procedures. . . . . . . . . . . . . . . . . . . . 1-55 613-1.11.7.7 Eye Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 613-1.11.7.8 Liverpool Splice. . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 613-1.11.7.9 Lock-Tuck Splice. . . . . . . . . . . . . . . . . . . . . . . . . 1-60 613-1.11.7.10 Flemish Eye Splice (Molly Hogan). . . . . . . . . . . . . . . 1-62

SECTION 2 FIBER ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

613-2.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.1.2 COMPLEXITY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

613-2.2. FIBER ROPE IDENTIFICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.2.1 FIBERS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.2.2 LARGE ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.2.3 MANILA AND SISAL ROPES.. . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.2.4 SYNTHETIC ROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

613-2.3. FIBER ROPE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.3.1 TWISTED FIBER ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 613-2.3.2 LARGE LAID ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 613-2.3.3 PLAIN-LAID ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 613-2.3.4 CABLE-LAID ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 613-2.3.5 PLAITED ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 613-2.3.6 BRAIDED ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 613-2.3.7 DOUBLE BRAIDED ROPES. . . . . . . . . . . . . . . . . . . . . . . . 2-4 613-2.3.8 SMALL CORDAGE ROPES. . . . . . . . . . . . . . . . . . . . . . . . . 2-5 613-2.3.9 MARLINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 613-2.3.10 POLYETHYLENE ROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 613-2.3.11 SIGNAL HALYARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

613-2.4. PRECAUTIONS AND TECHNIQUES FOR THE USES OF ROPES . . . . . . . . . 2-6

613-2.4.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

613-2.4.2 UNCOILING AND UNREELING. . . . . . . . . . . . . . . . . . . . . . 2-6

613-2.4.2.1 Uncoiling Natural Fiber-Laid Ropes. . . . . . . . . . . . . . . 2-6 v

613-2.4.2.2 Uncoiling Synthetic Fiber-Laid Ropes. . . . . . . . . . . . . . 2-6 613-2.4.2.3 Unreeling Synthetic Fiber Ropes. . . . . . . . . . . . . . . . . 2-7 613-2.4.2.4 Unwinding Aramid/Spectra Lines. . . . . . . . . . . . . . . . 2-7

613-2.4.3 RECOILING AND REREELING. . . . . . . . . . . . . . . . . . . . . . 2-7

613-2.4.4 ELONGATION AND PERMANENT STRETCH. . . . . . . . . . . . . . 2-7

613-2.4.4.1 Natural Fiber Ropes. . . . . . . . . . . . . . . . . . . . . . . . 2-7 613-2.4.4.2 Synthetic Fiber Ropes. . . . . . . . . . . . . . . . . . . . . . . 2-7

613-2.4.5 SHRINKAGE AND SWELLING . . . . . . . . . . . . . . . . . . . . . . 2-7

613-2.4.5.1 Natural Fiber Ropes. . . . . . . . . . . . . . . . . . . . . . . . 2-7 613-2.4.5.2 Synthetic Fiber Ropes. . . . . . . . . . . . . . . . . . . . . . . 2-7

613-2.5. PRECAUTIONS AND TECHNIQUES FOR THE USES OF ROPES . . . . . . . . . 2-8

613-2.5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

613-2.5.2 EYE SPLICE IN PLAIN-LAID ROPE. . . . . . . . . . . . . . . . . . . 2-8

613-2.5.2.1 Natural Fiber Ropes. . . . . . . . . . . . . . . . . . . . . . . . 2-8

613-2.5.3 EYE SPLICE IN 4-STRAND ARAMID/SPECTRA FIBER ROPE. . . . 2-9

613-2.5.4 EYE SPLICE IN PLAITED ROPE.. . . . . . . . . . . . . . . . . . . . . 2-9

613-2.5.5 EYE SPLICE IN DOUBLE BRAIDED ROPE. . . . . . . . . . . . . . . 2-10

613-2.5.6 SHORT SPLICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 613-2.5.9 LONG SPLICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

613-2.5.10 LONG SPLICE OF PLAIN-LAID ROPES. . . . . . . . . . . . . . . . . 2-14

613-2.5.11 LONG SPLICE OF PLAITED ROPE. . . . . . . . . . . . . . . . . . . . 2-15

613-2.5.12 LONG SPLICE OF DOUBLE-BRAIDED ROPE. . . . . . . . . . . . . . 2-19

613-2.5.13 THROAT SEIZING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

613-2.6. WHIPPING AND SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 613-2.6.1 WHIPPING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 613-2.6.2 SEALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

613-2.7. EFFECTS OF SECURING ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 613-2.7.2 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 613-2.7.2 KNOTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 613-2.7.3 ROUND TURNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 613-2.7.4 FIGURE-EIGHT BENDS. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 613-2.7.5 OVERRIDING TURNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

613-2.8. EXTENDING ROPE’S SERVICE LIFE. . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 613-2.8.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 613-2.8.2 DAMAGING CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . 2-22

613-2.8.2.1 Excessive Pull. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 613-2.8.2.2 Surface Abrasion.. . . . . . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.3 Chafing Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.4 Deck Fittings.. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.5 Gritty Material. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.6 Effects of a Freezing Environment. . . . . . . . . . . . . . . . 2-26 613-2.8.2.7 Sharp Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.8 Shearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 vi

613-2.8.2.9 Rope Kinks and Cockles. . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.10 Bending.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 613-2.8.2.11 Drag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

613-2.9. EFFECT OF AGING ON FIBER ROPES. . . . . . . . . . . . . . . . . . . . . . . . . 2-27 613-2.9.1 NATURAL FIBER ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 613-2.9.2 SYNTHETIC FIBER ROPES.. . . . . . . . . . . . . . . . . . . . . . . . 2-27

613-2.10. ROPE REPLACEMENT AND USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

613-2.11. ROPE STOWAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 613-2.11.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

613-2.11.2 NATURAL FIBER ROPE STOWAGE.. . . . . . . . . . . . . . . . . . . 2-27

613-2.11.3 SYNTHETIC FIBER ROPE STOWAGE. . . . . . . . . . . . . . . . . . 2-27

613-2.12. ROPE-USE PRECAUTIONS, INSTRUCTIONS, AND INSPECTIONS . . . . . . . . 2-28 613-2.12.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 613-2.12.2 PRACTICES TO AVOID. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

613-2.12.3 INSPECTING NATURAL FIBER ROPES FOR DAMAGE. . . . . . . . 2-28

613-2.12.4 SYNTHETIC ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

613-2.12.4.1 Advantages of Synthetic Ropes.. . . . . . . . . . . . . . . . . 2-29 613-2.12.4.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 613-2.12.4.3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

613-2.13. SYNTHETIC ROPE; GENERAL USAGE . . . . . . . . . . . . . . . . . . . . . . . . 2-30 613-2.13.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 613-2.13.2 HEAVY LOADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 613-2.13.3 SYNTHETIC ROPE STRETCH. . . . . . . . . . . . . . . . . . . . . . . 2-30

613-2.13.3.1 Tattle-tales. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 613-2.13.3.2 Aramid/Spectra Line Failure Indicators. . . . . . . . . . . . . 2-31

613-2.13.4 MOORING LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

613-2.13.5 ELONGATION AND PAIRING OF DISSIMILAR ROPES. . . . . . . . 2-33

613-2.13.6 SYNTHETIC ROPE STOPPERS.. . . . . . . . . . . . . . . . . . . . . . 2-33 613-2.13.7 COILING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

613-2.13.8 REDUCING ABRASION AND MINIMIZING SURGING. . . . . . . . 2-33

613-2.13.9 CAPSTANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 613-2.13.10 TOWING END FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 613-2.13.11 SPECIAL THIMBLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 613-2.13.12 THIMBLES AND SHACKLES.. . . . . . . . . . . . . . . . . . . . . . . 2-34 613-2.13.13 THIMBLE USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

613-2.14. PRECAUTIONS FOR USING SYNTHETIC FIBER ROPES . . . . . . . . . . . . . . 2-34 613-2.14.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 613-2.14.2 SINGLE-PART HANDLING. . . . . . . . . . . . . . . . . . . . . . . . . 2-35 613-2.14.3 ROPE ELONGATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

613-2.14.4 REBONDING OF BITT AND CAPSTAN LINES. . . . . . . . . . . . . 2-35

613-2.14.5 SURGING ON BITT AND CLEAT LINES. . . . . . . . . . . . . . . . . 2-35

vii

613-2.14.6 EASING-OUT AND CHECKING LINES. . . . . . . . . . . . . . . . . . 2-35

613-2.14.7 MAKING A SIDE TOW HITCH. . . . . . . . . . . . . . . . . . . . . . . 2-35

613-2.14.8 DOUBLING-UP SYNTHETIC MOORING LINES. . . . . . . . . . . . 2-36

613-2.14.9 STOPPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

613-2.14.10 SYNTHETIC FIBER ROPE’S LIFE EXPECTANCY.. . . . . . . . . . . 2-36

613-2.15. CRITERIA FOR ESTIMATING USED ROPE SERVICEABILITY . . . . . . . . . . 2-36 613-2.15.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 613-2.15.2 ROPE WEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 613-2.15.3 BREAKING STRENGTH LOSS. . . . . . . . . . . . . . . . . . . . . . . 2-37 613-2.15.4 CHAFING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 613-2.15.5 STRETCHOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 613-2.15.6 CUTTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 613-2.15.7 COCKLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 613-2.15.8 RUST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

613-2.15.9 CUMULATIVE EFFECT OF SERVICEABILITY FACTORS. . . . . . . 2-38

613-2.15.10 INSPECTION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . 2-39

SECTION 3 RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

613-3.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

613-3.2. STANDING RIGGING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.2 SPLICING AND SERVING. . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.3 PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.4 WORMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.5 PARCELING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.6 SERVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 613-3.2.7 DOUBLE SERVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

613-3.3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

613-3.4. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

613-3.5. INSULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

613-3.6. GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

613-3.7. CHARRING OF WOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

613-3.8. INSULATION AND GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

613-3.9. REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 viii

LIST OF TABLES

Table Title Page

613-1-1. WIRE ROPE ACCEPTANCE BREAKING STRENGTH . . . . . . . . . . . . . . . . 1-8

613-1-2. WIRE ROPE ALLOWABLE DIAMETER REDUCTION . . . . . . . . . . . . . . . . 1-15

613-1-3. SEIZINGS FOR WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

613-1-4. TEMPERATURE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

613-1-5. Compound Quantities for WIRELOCK® . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

613-1-6. Compound Quantities for SOCKETFAST® . . . . . . . . . . . . . . . . . . . . . . . . 1-37

613-1-7. MINIMUM NUMBER OF CLIPS REQUIRED . . . . . . . . . . . . . . . . . . . . . 1-47

613-1-8. LENGTH OF UNLAYED ROPE REQUIRED . . . . . . . . . . . . . . . . . . . . . . 1-48

613-2-1. FIBER ROPE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

613-2-2. SMALL CORDAGE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

613-2-3. STRANDED AND BRAIDED ROPE MINIMUM BREAKING STRENGTH (LBS) . 2-24

613-2-4. DIMENSIONS FOR TATTLE-TALE LINES . . . . . . . . . . . . . . . . . . . . . . . 2-31

613-2-5. SUBSTITUTION OF ARAMID ROPE FOR OTHER SYNTHETIC ROPES . . . . . 2-32

613-2-6. ROPE INSPECTION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ix

LIST OF ILLUSTRATIONS

Figure Title Page

613-1-1. Wire Rope Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

613-1-2. Core Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

613-1-3. Wire Rope Lays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

613-1-4. Length of Rope Lays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

613-1-5. Measuring Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

613-1-6. Common Wire Rope Construction, Examples . . . . . . . . . . . . . . . . . . . . . . . 1-4

613-1-7. Uncoiling Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

613-1-8. Unreeling Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

613-1-9. Improper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

613-1-10. Wire Rope Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

613-1-11. Wire Rope Kink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

613-1-12. Kink Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

613-1-13. Overwind Reeving Attachment Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

613-1-14. Underwind Reeving Attachment Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

613-1-15. Seizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

613-1-16. Seizing Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

613-1-17. Permanent Seizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

613-1-18. Socket Pouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

613-1-19. Level of Poured Zinc and Zinc Penetration . . . . . . . . . . . . . . . . . . . . . . . . 1-24

613-1-20. Rotation of Socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

613-1-21. Axial Movement of Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

613-1-22. Seizing of Wire Rope.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

613-1-23. Unlay of Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

613-1-24. Properly Broomed Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

613-1-25. Socket Properly Sealed with Fireclay. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

613-1-26. Properly Positioned Socket with Wire Rope Ends Protruding. . . . . . . . . . . . . . . 1-33 x

LIST OF ILLUSTRATIONS - Continued

613-1-27. Proper Vessel and Wooden Paddle Used in Mixing. . . . . . . . . . . . . . . . . . . . 1-35

613-1-28. Proper Mixing of the WIRELOCK® Compound. . . . . . . . . . . . . . . . . . . . . 1-36

613-1-29. Mixing of the SOCKETFAST® Catalyst to Resin Mixture. . . . . . . . . . . . . . . . 1-38

613-1-30. Pouring of SOCKETFAST® Compound into the Socket. . . . . . . . . . . . . . . . . 1-40

613-1-31. Fiege-Type Electroline (Threaded Compression) Assembly (Sheet 1 of 3) . . . . . . 1-43

613-1-32. Clip Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

613-1-33. Seizing Long Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

613-1-34. Strand Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

613-1-35. Relaying Strands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

613-1-36. Cutting Strand Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

613-1-37. Binding the Long Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

613-1-38. Long Splice Tuck Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

613-1-39. Preparing for Tuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

613-1-40. Cutting the Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

613-1-41. Removing the Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

613-1-42. Laying in Strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

613-1-43. Rope Ready for Tucking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

613-1-44. Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

613-1-45. Butting IWRC Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

613-1-46. Initial Tuck Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

613-1-47. IWRC Tuck Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

613-1-48. Vice Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

613-1-49. Finishing IWRC Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

613-1-50. Finished IWRC Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

613-1-51. First Three Tucks of Liverpool Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59

613-1-52. Strands Four, Five, and Six of Liverpool Splice . . . . . . . . . . . . . . . . . . . . . 1-59 xi

613-1-53. Working the Strands of Liverpool Splice . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

613-1-54. Lock-Tuck Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61

613-1-55. Lock-Tuck Splice Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62

6113-1-56. Flemish Eye Splice (Molly Hogan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

613-2-1. Synthetic Fiber Plain-Laid Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

613-2-2. Synthetic Fiber Cable-Laid Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

613-2-3. Plaited Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

613-2-4. Synthetic Fiber Double Braided Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

613-2-5. Fids Used for Splicing Double-Braided Line . . . . . . . . . . . . . . . . . . . . . . . 2-5

613-2-6. Eye Splice in Plain-Laid Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

613-2-7. Sailmaker’s Eye Splice for 4-Strand Rope (Preferred Method) . . . . . . . . . . . . . 2-9

613-2-8. Eye Splice in Plaited Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

613-2-9. Extracting the Core from Double-Braided Rope . . . . . . . . . . . . . . . . . . . . . 2-11

613-2-10. Putting Cover Inside Core of Double-Braided Rope . . . . . . . . . . . . . . . . . . . 2-11

613-2-11. Reinserting Core Into Cover of Double-Braided Rope . . . . . . . . . . . . . . . . . . 2-12

613-2-12. Double-Braided Rope Eye Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

613-2-13. Short Splice of Plain-Laid Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

613-2-14. Short Splice of Plaited Rope (8 Strand) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

613-2-15. Long Splice of Plain-Laid Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

613-2-16. Preparing Plaited Rope for Long Splice . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

613-2-17. Marrying Plaited Rope Strands for Long Splice . . . . . . . . . . . . . . . . . . . . . 2-17

613-2-18. Tucking Plaited Rope Strands for Long Splice . . . . . . . . . . . . . . . . . . . . . . 2-18

613-2-19. Completing Plaited Rope Long Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

613-2-20. Extracting Cores from Double Braided Rope, Long Splice . . . . . . . . . . . . . . . 2-19

613-2-21. Putting Covers Inside Cores of Double Braided Rope, Long Splice . . . . . . . . . . 2-20

613-2-22. Reinserting Core Into Covers of Double Braided Rope, Long Splice . . . . . . . . . . 2-20 xii

613-2-23. Burying the Exposed Cores of Double Braided Rope, Long Splice . . . . . . . . . . . 2-20

613-2-24. Completing the Double Braided Rope, Long Splice . . . . . . . . . . . . . . . . . . . 2-21

613-2-25. Throat Seizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

613-2-26. Correct Method of Securing on H-Bitts with Round Turns . . . . . . . . . . . . . . . 2-22

613-2-27. Overriding Turns on a Capstan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

613-2-28. Relaxed Synthetic Fiber Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

613-2-29. Synthetic Fiber Rope Maximum Workload . . . . . . . . . . . . . . . . . . . . . . . . 2-31

613-2-30. Towing Thimble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

613-2-31. Correct Method of Making a Side-Tow Hitch. . . . . . . . . . . . . . . . . . . . . . . 2-36

613-2-32. Correct Method for Doubling-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

613-2-33. Synthetic Rope Showing Fuzzy Nap as a Result of Normal Wear . . . . . . . . . . . 2-37

613-2-34. Synthetic Rope Containing a Cockle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

613-2-35. Synthetic Rope Showing Cut Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

613-2-36. Synthetic Rope Showing Surface Fusion and Chafing . . . . . . . . . . . . . . . . . . 2-38

613-2-37. Rope Showing Rust Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 xiii / (xiv Blank) xiv

SAFETY SUMMARY

Specific warnings and cautions applying to the system/equipment covered by this manual are summarized below. These warnings and cautions appear elsewhere in the manual following paragraph headings and immedi-ately preceding the text to which they apply. They are repeated here for emphasis.

When cleaning wire rope with PD-680 type III, it is mandatory that safety goggles, gloves, and protective clothing be worn. Use a well ventilated area, preferably open air, to reduce the possibility of fume inhalation. SeeNSTM Chapter 670, Stowage, Handling, and Disposal of Hazardous General Use Consumables.

Page 1-16

When cleaning wire rope, it is mandatory that eye protection, gloves, and pro-tective clothing be worn. Use a well ventilated area, preferably open air, to reduce the possibility of fume inhalation. SeeNSTM Chapter 670.

Page 1-21

Do not etch galvanized wire with acid.

Page 1-21

Always add acid to water, never water to acid.

Page 1-22 xv

Do not use oversized sockets for Wire Rope.

Page 1-28

When cleaning wire rope, it is mandatory that safety goggles, gloves and protec-tive clothing be worn. Use a well ventilated area, preferably open air, to reduce the possibility of fume inhalation. See NSTM Chapter 670.

Page 1-30

Do not clean the wire rope broom with acid, soda, methyl hydrate, or acetone. A flux should no be used.

Page 1-31

Always check expiration date on the cans and never use out of date material. It is mandatory to that safety goggles, gloves and protective clothing be worn. Use only in well ventilated work areas, preferably open air, to reduce the possibility of fume inhalation.

Page 1-33

Hot sockets must not be used. Do not apply heat to sockets to accelerate the cur-ing process prior to pouring. The application of external heat may cause the resin to gel before it reaches to the bottom of the socket and lead to assembly failure.

Used sockets cleaned out by heating should be allowed to cool to room tempera-ture before re-use.

Pages 1-36, 1-39 xvi

Always check expiration date on the cans and never use out of date material. It is mandatory that safety goggles, gloves and protective clothing be worn. Use only in a well-ventilated work area, preferably open air, to reduce the possibility of fume inhalation.

Page 1-37

The newly poured sockets should not be moved for a minimum of 10 minutes after the material in the socket has gelled.

Page 1-40

Do not pull test poured resin sockets until a minimum of one hour has passed since the pour was completed.

Page 1-40

Heat is not recommended as a means to remove the resin cone for metallurgical, medical and environmental reasons.

Page 1-41

For setting of all splices, use only fittings rated higher than the breaking strength of the rope.

Do not use mooring bitt staples or padeyes for setting splices.

Page 2-8 xvii

Tattle-tales cannot be used on aramid/Spectra fiber ropes due to their low stretch.

The load should be carefully controlled on aramid/Spectra lines to avoid exces-sive tension of the line. This is best accomplished by having linehandlers″check the line″ frequently until they have a feel for the load. Checking means allowing only enough line to render around the bitts to prevent the line from parting. It is NEVER prudent seamanship toHOLD a line while a ship has movement.

Remember, a parted line serves no useful purpose and is definitely a safety haz-ard.

Page 2-30

Thimbles shall fit snugly into the rope’s eye, and a throat seizing shall be applied to the rope at the base of the thimble to prevent slippage.

Page 2-34

Synthetic rope may fail without warning, which could be catastrophic. To prevent serious injury or death from snapback action, personnel shall not stand in direct line of pull under any load.

Page 2-35

Personnel tending lines on bitts or capstans shall stand clear of the area within 45 degrees either side of the straight line path to prevent injury from snapback action.

Page 2-35

Since the stretch properties of spring lay rope are different from fiber or wire rope, do not mix spring lay with these ropes.

Page 1-6 xviii

Continue to heat socket to clean remaining zinc from socket basket; temperature of socket shall not exceed 900°F.

Page 1-27

Be sure that the cleaning is confined to the broom and does not extend to the rope beyond.

Page 1-31

Socket temperatures above 100 degrees F may cause premature hardening of the resin.

Page 1-36 xix / (xx Blank) xx

CHAPTER 613

WIRE AND FIBER ROPE AND RIGGING

SECTION 1

WIRE ROPE

613-1.1. FABRICATION

613-1.1.1 GENERAL. Wire rope is a highly specialized precision product which is adaptable to many uses and to varied conditions of operation. To meet the exacting requirements of different types of service, it is designed and manufactured in a number of constructions and grades.

613-1.1.2 COMPLEXITY. Wire rope is a complex machine, composed of a number of precise, moving parts which are designed and manufactured to bear a very definite relationship to one another. In fact, many wire ropes contain more moving parts than most mechanisms that fall within the broad general term of machines. For example a six-strand rope, consisting of approximately 46 wires per strand, contains a total of 276 individual wires, all of which must be able to move with respect to one another if the rope is to have the necessary flex-ibility during operation.

613-1.2. PARTS

613-1.2.1 GENERAL. Wire rope is composed of three parts: wires, strands, and core. The basic unit is the wire. A predetermined number of wires of proper size are fabricated in a uniform geometric arrangement of defi-nite pitch or lay to form a strand of required diameter. The required number of strands are then laid together symmetrically around a core to form the ropeFigure 613-1-1).

613-1.2.2 CORE TYPE. In general, wire rope cores are of three types: fiber, wire strand, and independent wire rope (IWRC) as illustrated inFigure 613-1-2. Each type of core serves the basic purpose of affording sup-port to the strands laid around it.

Figure 613-1-1. Wire Rope Construction

613-1-1

613-1.2.3 CORE MATERIAL. Fiber core applies to any natural or synthetic fibrous material that is woven into a rope of its own. Fiber cores are generally made of polypropylene or a hard fiber such as manila (abaca) or sisal. Strand cores and independent wire rope cores are composed of steel wires.

613-1.2.4 CHOICE OF CORE. The use of fiber cores has continued to decrease due to increased variety of steel core rope types that offer increased flexibility with a greater breaking strength. For conditions where a fiber core rope is inadequate, a wire strand or independent wire rope core is used. For service where high operating pressures are encountered, where resistance to heat, additional strength, or minimum stretch is a prerequisite, either a strand core or an independent wire rope core is used.

613-1.3. LAYS

613-1.3.1 GENERAL. The type of lay describes the direction of the twist of the wires in a strand and of the strands in a rope. Strand and rope lays are described in the following paragraphs (Figure 613-1-3).

613-1.3.2 RIGHT LAY OR RIGHT-HAND HELIX. The strands in the wire rope are laid to form a helix about the core similar to the threads in a right-hand screw. When viewed lengthwise, the strands are wound helically away from the observer in a clockwise direction.

Figure 613-1-2. Core Construction

Figure 613-1-3. Wire Rope Lays

613-1-2

613-1.3.3 LEFT LAY OR LEFT-HAND HELIX. The strands in the wire rope are laid to form a helix about the core similar to the threads in a left-hand screw. When viewed lengthwise, the strands are wound helically away from the observer in a counterclockwise direction.

613-1.3.4 REGULAR LAY. The wires in the strands and the strands in the rope are laid in opposite direc-tions.

613-1.3.5 LANG LAY. The wires in the strands and the strands in the rope are laid in the same direction.

613-1.3.6 PITCH OR LENGTH OF LAY. The length of a rope lay is that distance measured parallel to the axis or centerline of a rope in which a strand makes one complete spiral or turn around the rope. The length of a strand lay is the distance measured parallel to the axis or centerline of the strand in which one wire makes one complete spiral or turn around the strand. The distance is illustrated inFigure 613-1-4.

613-1.4. SIZE

613-1.4.1 The diameter of a wire rope is the diameter of the circle which will just enclose all of the strands.

In the case of strands, the diameter is that of the circle which will just enclose all of the wires. The correct diam-eter is the greatest diameter of the rope or strand.Figure 613-1-5shows the correct and incorrect ways of mea-suring wire rope.

Figure 613-1-4. Length of Rope Lays

613-1-3

613-1.5. CONSTRUCTION.

613-1.5.1 GENERAL. The design arrangement of the component parts of the wire rope is called the construc-tion. To date, nearly 100 different constructions have been manufactured.Figure 613-1-6shows some of the more typical wire rope constructions. Construction of wire rope is designated first by the number of strands and then by the number of wires in a strand; therefore a 6 by 7 rope has six strands with seven wires per strand. When wire rope contains wires of different sizes, the construction is usually designated by name as well as by number.

Examples of some typical construction types are contained in paragraphs613-1.5.2through613-1.5.6.

613-1.5.2 SEALE CONSTRUCTION. Each strand consists of three rings of wire. The first ring of wires around the center wire of the strand is of smaller diameter than the center and outer wires.

Figure 613-1-5. Measuring Wire Rope

Figure 613-1-6. Common Wire Rope Construction, Examples

613-1-4

613-1.5.3 WARRINGTON CONSTRUCTION. Each strand has two layers of wire about a center wire. The outer layer consists of wires that are alternately large and small.

613-1.5.4 FILLER WIRE. Filler wire has small wires filling the voids between the rings of wire in the strand.

These small wires are not counted when designating the number of wires in the strand.

613-1.5.5 FLATTENED STRAND. Strands are somewhat triangular in shape, sometimes formed around a triangular center wire.

613-1.5.6 SPRING LAY. The spring lay is composed of six main strands laid around a fiber core. Each main strand consists of three preformed wire strands and three fiber strands laid alternately around a fiber center. The function of the fiber parts is to provide a cushion for the wire strands and results in a rope having great flexibil-ity and elasticity.

613-1.6. PREFORMED WIRE ROPE

613-1.6.1 Preformed wire rope is rope whose wires and strands have been preshaped to conform to the cur-vature which they take in the finished rope. Preforming eliminates the locked up stress and strain existing in non-preformed wire rope, prevents the rope from flying apart when cut or broken, and resists kinking. Preforming helps to eliminate the tendency of a rope to rotate about its own axis. Preformed wire rope is more easily spliced since the strands fit perfectly into place. However, owing to the permanent helical shape of the strands, the tech-nique of tucking the ends differs from that of nonpreformed wire rope. This type of wire rope is designed to give extra life when used for operating ropes, particularly when used over small sheaves and when operating with small safety factors. Preforming is of greatest value when normal failures occur through fatigue. Preformed wire rope is of no advantage when used as standing rigging, or in applications where the chief cause of failure is abra-sion or corrosion.

613-1.7. ZINC-COATED OR WIRE ROPE

613-1.7.1 In order to protect wire rope against the action of salt water and other corrosive elements, and to prevent rust, wire is galvanized (zinc-coated) or tinned, as the case may require. Wire rope so treated is gener-ally used for standing rigging. It may also be used for running rigging and for wheel (steering) ropes on ships.

This type of service does not cause ropes to wear rapidly. Wire rope subjected to constant bending around drums and sheaves, such as in hoisting service, is not usually so treated because the constant flexing of the rope will cause the protective coating to peel.

613-1.8. CONDITIONS OF USE

613-1.8.1 CHARACTERISTICS. Different types and constructions of rope have been developed over the years to meet special conditions of use. Initially, ropes were used for hauling purposes where flexibility was not a requirement. Simple ropes, such as the 6 by 7 and 8 by 7, were constructed of rather large wires. This produced a rope well qualified to resist abrasion, but not particularly well adapted for service where flexibility was essen-tial. In most cases, use a 6 by 7 rope with a relatively high safety factor since its reserve strength is low. When wire ropes started being used for hoisting purposes, it became necessary to increase the number of wires, which for a given diameter of rope means smaller wires and greater flexibility. In general, flexibility increases with the number of wires. The Seale, Warrington, and filler wire types were developed to increase the total metallic area for a given diameter rope. The average increase is about 10 percent, though in the Seale construction this is accomplished at some sacrifice of flexibility. The problem of rope wear when used over sheaves soon becomes apparent. The smaller the diameter of the bearing (outer) wires, the greater the number of those wires which may break during wear. Accordingly, the flattened strand type of construction was developed which, for a given total metallic cross-sectional area, provides a greater bearing surface resulting in more wear distribution.

613-1-5

613-1.8.2 USES. For naval installations, the types and uses of wire ropes may, generally, be grouped as described in paragraphs613-1.8.2.1through613-1.8.2.6.

613-1.8.2.1 6 by 7. Only the galvanized type is specified. This construction is the stiffest of all the wire rope varieties made available by specifications. It is not suitable for general hoisting, but is mainly applicable for per-manent standing guys.

613-1.8.2.2 6 by 12. This construction with a fiber core and a fiber center in each strand is more flexible than either the 6 by 19 or 6 by 37 construction, but it is not as strong. When made of galvanized steel wire, it may be used for guys, ridge ropes, boat ladders, Jacob’s ladders, boom pendants, and running rigging. It is desired for running rigging service where extreme flexibility is required and exposure to moisture is frequent. It may also be used for wire mooring lines. When made of phosphor bronze wire, it may be used for life lines, wheel ropes, or rigging, where either noncorrosive or nonmagnetic properties are required.

613-1.8.2.3 6 by 19. When made of ungalvanized steel wire, this rope is principally used where great strength is required, particularly on derricks and dredges. It is the stiffest and strongest construction of the types of wire ropes suitable for general hoisting purposes.