CRANE ROPES

commitment to quality and product development which has been driven by a dynamic and technically demanding marketplace.

Usha Martin Wire Ropes & Speciality

Products Division is an integral part of the globally acclaimed Usha Martin Group, active in High Carbon, Alloy & Speciality Steel, Telecom Cables & Software, Oil Drilling Services and Worldwide distribution of its products. The global success of Usha Martin Powerform compacted crane rope and Hyflex non compacted crane rope is based on an uncompromising

State of the art ISO 9001/9002 certified manufacturing facilities and tight process control from steelmaking to rod manufacture and through to finished wire rope ensure consistently high quality in the finished crane rope. All Usha Martin crane ropes are supported by an expanding global distribution network which can offer expert advice to both crane manufacturers and operators.

The wire ropes shown in this catalogue are "standard products". Usha Martin has the capability to design and manufacture according to individual customer requirements.

CONTENTS
Quality Guarantee Powerform Rope Selection Bend Fatigue Testing Guide To Application & Rope Duty Powerform 35/35P Hyflex 35/35P Powerform 18 Hyflex 18 Powerform 6/6P Powerform 8/8P Hyflex 8/8P Powerform 8PC Hyflex 4 Hyflex 6x36 Hyflex 6x19 Hyflex 6x29Fi Safety Information Conversion Tables
K.T.A.

2-3 4-5 6 7 8-9 10-11 12-13 14-15 16-17 18-19 20-21 22-23 24-25 26-27 28-29 30-31 32 33 33

Key To Abbreviations

QUALITY GUARANTEE
Guaranteed Raw Material Quality Good raw material input at the beginning of the ropemaking process combined with tight process control ensure consistently high quality in the finished rope. Usha Martin manufacture steel and rod to International standards and to even more exacting internal standards through its mini blast furnace - arc furnace - ladle furnace - vacuum degassing electromagnetic stirring - continuous casting route. A close and unique co-operation between company owned ISO 9001/9002 certified steelmaking, rod manufacturing and wire drawing facilities guarantee production feed materials which are "tailor made" to attain the required properties of ductility and tensile strength which are essential in the finished rope. Guaranteed Breaking Force As well as operating a rigorous programme of testing throughout the production process Usha Martin confirm the minimum breaking force of each and every finished rope with an actual test to destruction. The test certificate which is supplied with every rope will indicate a minimum guaranteed breaking force and the actual breaking force at which the test sample broke. The Usha Martin testing facility is approved by Lloyds Register of Shipping and The American Bureau of Shipping. Guaranteed Quality Systems Certification to ISO 9001 requires that Usha Martin document all work procedures, processes and related activities covering design, development, production, shipping and commercial activity. ISO 9001 is our customer's guarantee that we will do exactly what we say we are going to do. Wire and Wire Ropes Division at Ranchi is the first and the only one in India to receive the prestigious award for excellence in TPM from Japanese Institute of Productivity Management (JIPM).

QUALITY GUARANTEE
Guaranteed Bending Fatigue Characteristics Bending fatigue resistance is the ability of the wire rope to withstand repeated bending over a sheave under constant or fluctuating loads. The ability to withstand bending fatigue will, along with other factors, determine the life of the rope and is therefore of interest to both the ropemaker and the crane operator. Usha Martin operate an ongoing fatigue testing programme which is designed to give comparative fatigue performance for various rope constructions and to provide information relative to product improvement and development. More information on fatigue testing is available on page 6. Guaranteed Rotational Characteristics Each wire rope construction will have an inherent torque characteristic where both ends of the rope are secured and an applied force will generate torque at the fixing points. Each wire rope construction will have an inherent turn characteristic where one end of the rope is free to rotate and an applied force will cause the free end of the rope to turn. With correct rope selection these characteristics should not cause a problem in service provided the rope has been correctly "balanced" in design and manufacture. Usha Martin operate their own Torque/Turn testing machine which is used to confirm that all rotation resistant wire ropes possess the required rotational characteristics. Guaranteed Performance and Consistency A simple way to guarantee performance and consistency is to make sure that you are using an Usha Martin rope. Many wire ropes available today may look similar to Usha Martin products but offer considerably less in terms of overall quality, performance, reliability and consistency. In order to protect our customers we have adopted a policy of identifying each rope with an internal marker tape. Are you buying the "Real Thing"?

POWERFORM COMPACTED ROPE

A Powerform compacted rope is a steel wire rope which has been manufactured using individually compacted strands.During the compaction process the outside diameter of the strand is reduced and steel moves into the empty voids between the wires within the strand. The forming process also produces a very smooth exterior strand surface.

Conventional Strand

Conventional Rope

Compacted Strand

Compacted Rope

The resultant rope has a very high steel fill factor and consequently a relatively high minimum breaking force for any given diameter when compared with a conventional rope.

Compacted rope minimum = Conventional rope minimum breaking force breaking force

The compacted strand has very favourable internal contact conditions when compared with the point contact of round wires within a normal strand.

Conventional

Compacted

Exterior contact conditions are equally favourable. The smooth surface of the compacted rope offers a wider bearing surface to the sheave or drum groove.
Conventional

Inter strand contact and contact between adjacent laps of rope on the winch drum is also improved.

Compacted

6x36

Usha Martin compacted ropes are referred to as "Powerform " and are available in a number of constructions.

18x7

35x7

POWERFORM SELECTION
Optimised crane design
The high breaking load to size relationship can allow crane manufacturers to optimise the design of crane components such as the winch drum and sheaves whilst still complying with international crane design standards.

Long life
Laboratory fatigue testing indicates that it is possible to achieve up to two times normal rope life when comparing a Powerform rope with a conventional rope of equivalent construction.

Greater resistance to crushing in multi-layer coiling situations

Powerform ropes are recommended for all multi-layer coiling situations where crushing on lower layers is inevitable. The more solid cross section of the Powerform rope offers much greater resistance to this type of damage.

More effective resistance to crushing at crossover points

Because of the higher steel fill factor Powerform ropes offer much better resistance to crushing damage at crossover points on the winch drum.

Greater resistance to "Interference" at the drum

Abrasive wear between adjacent laps of rope which is normally most severe where the rope moves on and off the drum can be minimised by using a Powerform rope.

Reduced wear on sheaves

The smooth exterior of the Powerform rope can lead to reduced abrasive wear on both the sheave and rope.

BEND FATIGUE TESTING

Resistance to bend fatigue is a key factor in determining the service life of wire rope and is therefore of great interest to both the rope manufacturer and the crane operator. Extensive comparative bend fatigue testing is carried out at Usha Martin in order to continuously develop and improve crane rope products. Fatigue testing involves cycling a length of rope through a sheave at a constant tension. The number of operating cycles is recorded at a point where the rope is rejectable under recommended discard levels specified under ISO 4309. The test continues until the rope under test is unable to sustain the load any longer and again the number of cycles is recorded. Based on results obtained from an ongoing bend fatigue testing programme the following charts give an indication of the likely comparative performance which can be obtained from various rope constructions. The lower charts show the importance of lubrication in-service and the relative improvement in performance as sheave diameter (D:d ratio) increases.

250 200 150

Comparative bending fatigue resistance of single layer ropes

Rope failure Discard

200

Comparative bending fatigue resistance of rotation resistant ropes

Rope failure Discard

Cycles to failure (000's)

Cycles to failure (000's)

150

8P

POWERFORM

HYFLEX 6x29Fi

POWERFORM

HYFLEX 6x36

HYFLEX 6x19

POWERFORM

POWERFORM

100 50 0

35

18

100

HYFLEX 8P

HYFLEX 35

50

200

Effect of manufacturing lubricant and in-service lubrication on bending fatigue resistance

Lubrication in manufacture & in-service lubrication

Effect of D:d ratio on wire rope service life

100 90 80 70 60 50 40 30 20 10 0

Cycles to failure (000's)

150

No Lubrication

100

50

Comparative rope life

Lubrication in manufacture

5 10 15 20 25 30 35 40 45 50 55 60 65

D:d ratio

HYFLEX 18

GUIDE TO APPLICATION & ROPE DUTY

MOBILE TOWER

DOCKSIDE

OFFSHORE PEDESTAL

CONTAINER

LATTICE BOOM

PILING

DECK CRANE

STEELWORKS LADLE

UNLOADER

SWIMGRAB MAIN HOIST BOOM HOIST TROLLEY/RACKING ROPE WHIP HOIST

POWERFORM 35/35P
Powerform 35/35P has the highest strength of all low rotation hoist ropes. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values. Maximum resistance to rotation.
Powerform 35

Suitable for use on single part and multi-part hoist reeving systems. High fatigue life resulting from the unique compaction process. Increased resistance to crushing. Recommended for multi-layer spooling operations. Increased abrasion resistance resulting from the unique compaction process. Optional plastic impregnation. (P) signifies full plastic impregnation of the Steel Core. Fully lubricated in manufacturing.

Powerform 35P

Standard Characteristics Powerform 35/35P Construction 10mm-40mm 35xK7(16xK7:6xK7+6xK76xK7-1x7) 42mm-60mm 35xK19S(16xK19S:6xK19S+ 6xK19S-6xK19S-1x19S)
Compacted Tensile Grade Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria N/mm2 Yes u 1960 u Bright u Right Hand u Ordinary 74.5 0.2 6.0 x NRD Refer to ISO 4309:1990 Langs u 2160 u Galvanised u Left Hand No

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX.* MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1960 N/mm2 kN tonnes 2160 N/mm2 kN tonnes

Typical Applications
MOBILE

1/2 13 14 16 18 19 20 21 22 7/8 24 1 26 28 1-1/8 30 32 35 36 38 40 42 44 1-3/4 46 48 50 2 52 1-1/2 1-1/4 1-3/8 3/4 5/8

81.1 85.0 98.6 129 163 182 201 222 243 249 290 325 340 394 411 453 515 616 652 726 805 887 974 994 1064 1159 1258 1298 1360

148 155 180 233 300 331 372 402 444 453 531 591 621 720 748 827 944 1125 1185 1326 1477 1485 1618 1646 1765 1935 2078 2150 2256

15.1 15.8 18.3 23.8 30.6 33.7 37.9 41.0 45.3 46.2 54.1 60.2 63.3 73.4 76.2 84.3 96.2 115 121 135 151 151 165 168 180 197 212 219 230

160 167 192 252 321 358 399 434 484 490 572 640 661 788 810 904 1035 1216 1286 1437 1588

16.3 17.0 19.6 25.7 32.7 36.5 40.7 44.2 49.3 49.9 58.3 65.2 67.4 80.3 82.6 92.2 106 124 131 146 162

MAIN HOIST

TOWER

MAIN HOIST

LATTICE BOOM

MAIN HOIST

DOCKSIDE

MAIN HOIST

OFFSHORE PEDESTAL

MAIN HOIST WHIP HOIST

MAIN HOIST WHIP HOIST

* Mass per unit length of POWERFORM 35P increases by approx. 3% Note:

l l

POWERFORM 35P is available on special request and prior confirmation. Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

HYFLEX 35/35P
Hyflex 35 is a high strength flexible hoist rope. Maximum resistance to rotation verified by testing on the in-house torque/turn machine. Suitable for use on single part and multi-part hoist reeving systems. Langs lay construction offers maximum resistance to wear. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values. Optional plastic impregnation (P) signifies full plastic impregnation of the steel core. Fully lubricated in manufacturing.

Hyflex 35

Hyflex 35P
Standard Characteristics Hyflex 35 Construction Compacted Tensile Grade Finish Lay Direction Lay Type
Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter)

35x7(16x7:6x7+6x7-6x7-1x7) Yes N/mm2 1960 Bright Right Hand u Ordinary u

63.5 0.2 6.0 x NRD

No u 2160 u Galvanised u Left Hand Langs u

Discard Criteria

Refer to ISO 4309:1990

10

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX.* MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1960 N/mm2 kN tonnes 2160 N/mm2 kN tonnes

Typical Applications
MOBILE

10 11 12 1/2 13 14 16 18 19 20 21 22 7/8 24 1 26 28 1-1/8 30 32 35 36 38 40 42 44 1-3/4 46 48 50 2 52 1-1/4 1-3/8 1-1/2 5/8 3/4

44.8 54.2 64.5 72.0 76.0 88.0 115 145 162 179 198 217 221 258 289 303 351 366 403 459 549 581 647 717 790 867 885 948 1032 1120 1156 1211

76.0 91.0 107 123 128 148 194 242 277 301 335 370 376 441 491 517 599 621 679 769 945 983 1078 1202 1227 1347 1375 1472 1603 1740 1796 1881

7.7 9.3 10.9 12.5 13.0 15.1 19.8 24.7 28.2 30.7 34.1 37.7 38.3 45.0 50.1 52.7 61.1 63.3 69.2 78.4 96.3 100 110 123 125 137 140 150 163 177 183 192

86.5 104 125 137 146 168 221 277 312 337 370 412 418 498 546 581 681 704 775 865 1044 1085 1205 1335

8.8 10.6 12.7 14.0 14.9 17.1 22.5 28.2 31.8 34.4 37.7 42.0 42.6 50.8 55.7 59.2 69.4 71.8 79.0 88.2 106 111 123 136

MAIN HOIST

TOWER

MAIN HOIST

OFFSHORE PEDESTAL

MAIN HOIST WHIP HOIST

MAIN HOIST WHIP HOIST

* Mass per unit length of HYFLEX 35P increases by approx. 3% Note:

l l

HYFLEX 35P is available on special request and prior confirmation. Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

11

POWERFORM 18
Powerform 18 is a high strength rotation resistant hoist rope. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values. Good resistance to rotation verified by testing on the in-house torque/turn machine. Suitable for use on single part and multi-part hoist reeving systems.
Powerform 18

High fatigue life resulting from the unique compaction process. Increased resistance to crushing. Recommended for multi-layer spooling operations. Increased abrasion resistance resulting from the unique compaction process.
Fully lubricated in manufacturing.

Standard Characteristics Powerform 18 Construction 6mm-19mm 20mm-32mm Compacted Tensile Grade N/mm2 Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria 18xK7(12xK7:6xK7-1x7) 18xK19S(12xK19S:6xK19S -1x19S) Yes u 1960 u Bright Right Hand u Ordinary 66.3 4 6.25 x NRD Refer to ISO 4309:1990 Langs u Galvanised u Left Hand 2160 No

12

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1960 N/mm2 2160 N/mm2 kN tonnes kN tonnes

Typical Applications
MOBILE

6 7 8 9 10 11 12 1/2 13 14 15 16 17 18 3/4 20 22 7/8 24 1 26 28 30 32 1-1/4 5/8

17.5 23.8 31.0 39.3 48.5 58.7 69.8 78.2 82.0 95.1 109 124 140 157 175 194 235 240 279 313 328 380 437 497

29.4 38.0 51.8 64.6 80.8 101 116 135 141 160 182 209 237 266 291 320 379 387 462 517 542 632 721 820

3.0 3.9 5.3 6.6 8.2 10.3 11.8 13.8 14.4 16.3 18.6 21.3 24.2 27.1 29.7 32.6 38.6 39.4 47.1 52.7 55.2 64.4 73.5 83.6 111 127 148 155 177 201 232 262 295 322 359 424 433 523 585 613 710 809 920 11.3 12.9 15.1 15.8 18.0 20.5 23.6 26.7 30.1 32.8 36.6 43.2 44.1 53.3 59.6 62.5 72.4 82.5 93.8

MAIN HOIST

DOCKSIDE

MAIN HOIST

OFFSHORE PEDESTAL

MAIN HOIST WHIP HOIST

MAIN HOIST WHIP HOIST

Note : For higher lifting heights consideration should be given to using a 35x7 construction with improved rotational ch a r a c t e r i s t i c s .

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

13

HYFLEX 18
Hyflex 18 is a high quality rotation resistant hoist rope. Good resistance to rotation verified by testing on the in-house torque/turn machine. Consistent performance. Fully lubricated in manufacturing. Also available in fibre core construction.
Hyflex 18

A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values.

Standard Characteristics Hyflex 18

Construction
Compacted Tensile Grade N/mm2 Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria

18x7(12x7:6x7-1x7)
Yes 1960 u Bright Right Hand u Ordinary 61.5 5 6.25 x NRD Refer to ISO 4309:1990 Langs u No u 2160 u Galvanised u Left Hand

14

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 2160 N/mm2 1960 N/mm2 kN tonnes kN tonnes

Typical Applications
MOBILE

6 7 8 9 10 11 12 1/2 13 14 15 16 17 18 3/4 20 22 7/8 5/8

14.6 19.9 26.0 32.9 40.6 49.1 58.5 65.5 68.6 79.6 91.4 104 117 132 147 162 197 201

25.0 34.0 45.0 56.5 70.0 84.0 101 113 118 137 157 180 203 226 253 279 339 346

2.5 3.5 4.6 5.8 7.1 8.6 10.3 11.5 12.0 14.0 16.0 18.3 20.7 23.0 25.8 28.4 34.6 35.3

27.0 36.7 48.6 61.0 75.6 90.7 109 121 127 148 169 194 219 244 273 301 366 374

2.8 3.7 5.0 6.2 7.7 9.2 11.1 12.3 12.9 15.1 17.2 19.8 22.3 24.9 27.8 30.7 37.3 38.1

MAIN HOIST

TOWER

MAIN HOIST

MAIN HOIST

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

Note : For higher lifting heights, consideration should be given to using a 35x7 construction with improved rotational ch a r a c t e r i s t i c s .

15

POWERFORM 6/6P
Powerform 6 is a high strength rugged six strand rope ideal for situations where longer service life is required. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values. Powerform 6 can be substituted for any six strand construction to improve service life and reduce total cost.
Powerform 6

High fatigue life resulting from the unique compaction process. Maximum resistance to crushing. Recommended for multi-layer spooling operations. Increased abrasion resistance resulting from the unique compaction process. Fully lubricated in manufacturing.
Optional plastic impregnation (P) signifies full plastic impregnation of the steel core.
Standard Characteristics Powerform 6/6P

Powerform 6P

Construction Compacted Tensile Grade Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria N/mm2

6xK36SW(14-7+7-7-1)-CWR 6xK41SW(16+8+8-8-1)-CWR Yes u 1770 u Bright u Right Hand u Ordinary u 67.5 58 6.5 x NRD Refer to ISO 4309:1990 1960 u Galvanised u Left Hand u Langs No

Warning : Powerform 6/6P in Langs lay must only be used in applications where both ends are secured and are unable to rotate.

16

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1770 N/mm2 kN tonnes 1960 N/mm2 kN tonnes

Typical Applications
CONTAINER

10 11 12 13 14 15 16 17 18 19 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 1/2

46.4 56.1 66.8 74.8 78.4 90.9 104 119 134 150 168 186 225 229 267 299 314 364 418 475 518 581 647 717 790 867 948 1032 1120 1211 1306 1405 1507 1613

69.5 83.8 100 113 118 137 157 178 201 225 251 278 336 343 400 449 470 545 626 712 804 901 1004 1112 1226 1246 1362 1483 1609 1741 1877 2019 2166 2317

7.1 8.5 10.2 11.5 12.0 14.0 16.0 18.1 20.5 22.9 25.6 28.3 34.3 35.0 40.8 45.8 47.9 55.6 63.8 72.6 82.0 91.8 102 113 125 127 139 151 164 177 191 206 221 236

85.7 98.6 114 140 147 170 195 218 246 276 304 335 400 408 489 552 578 657 757 846 916 1065 1165 1295 1425 1505 1665 1885 1975 2135 2325 2475 2650 2810

8.7 10.1 11.6 14.3 15.0 17.3 19.9 22.2 25.1 28.1 31.0 34.1 40.8 41.6 49.8 56.3 58.9 67.0 77.2 86.2 93.4 109 119 132 145 153 170 192 201 218 237 252 270 286

MAIN HOIST BOOM HOIST TROLLEY

5/8

LATTICE BOOM

3/4

7/8 1

MAIN HOIST * BOOM HOIST

DOCKSIDE

1-1/4

BOOM HOIST

1-1/2

STEELWORKS LADLE

MAIN HOIST

OFFSHORE PEDESTAL

BOOM HOIST

* Mass per unit length of POWERFORM 6P increases by approx. 3% Note:

l l

UNLOADER

Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation. POWERFORM 6P ia available only for 16 mm and above on special request and prior confirmation.
MAIN HOIST BOOM HOIST RACKING

BOOM HOIST MAIN HOIST RACKING/TROLLEY

* For higher lifting heights a rotation resistant rope should be selected.

17

POWERFORM 8/8P
Powerform 8P is a high strength eight strand rope with plastic impregnated core ideal for situations where longer service life is required. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values. High fatigue life resulting from the unique compaction process. Maximum resistance to crushing. Recommended for multi-layer spooling operations.
Powerform 8

Increased abrasion resistance resulting from the unique compaction process. Greater surface contact area resulting from the eight strand construction and compacted finish give longer rope life and reduced sheave wear. Fully lubricated in manufacturing. Optional plastic impregnation of the steel core. (P) signifies full plastic impregnation of the steel core.
Standard Characteristics Powerform 8/8P

Powerform 8P

Construction Compacted Tensile Grade Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria N/mm2

8xK26SW(10-5+5-5-1)-CWR 8xK36SW(14-7+7+7-1)-CWR Yes u 1960 u Bright u Right Hand u Ordinary u 65.5 94 6.5 x NRD Refer to ISO 4309:1990 Galvanised u Left Hand u Langs 2160 No

Warning : Powerform 8/8P in Langs lay must only be used in applications where both ends are secured and are unable to rotate.

18

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1960 N/mm2 kN tonnes 2160 N/mm2 kN tonnes

Typical Applications
CONTAINER

10 11 12 1/2 13 14 15 16 17 18 19 20 22 7/8 24 1 26 28 1-1/8 30 32 34 36 38 40 42 44 1-3/4 46 48 50 2 52 1-1/2 1-1/4 3/4 5/8

46.0 55.7 66.2 74.2 77.7 90.2 104 118 133 149 166 184 223 227 265 297 318 368 384 423 481 543 609 679 752 847 929 948 1016 1106 1200 1239 1298

87.8 106 126 142 148 172 198 225 254 284 317 351 425 434 506 567 594 688 717 790 899 1013 1138 1268 1405 1535 1700 1735 1858 2023 2200 2266 2374

9.0 10.8 12.8 14.5 15.1 17.5 20.2 22.9 25.9 29.0 32.3 35.8 43.3 44.2 51.6 57.8 60.6 70.1 73.1 80.5 91.6 103 116 129 143 156 173 177 189 206 224 231 242

94.0 114 135 152 159 184 211 241 272 304 339 376 455 464 541 606 635 737 767 846 960 1083 1218 1357 1503 1651 1819 1856 1985 2162 2349 2425 2541

9.6 11.6 13.8 15.5 16.2 18.8 21.5 24.6 27.7 31.0 34.6 38.3 46.4 47.3 55.1 61.8 64.7 75.1 78.2 86.2 97.9 110 124 138 153 168 185 189 202 220 239 247 259

MAIN HOIST BOOM HOIST TROLLEY

LATTICE BOOM

BOOM HOIST

DOCKSIDE

BOOM HOIST

OFFSHORE PEDESTAL

BOOM HOIST

UNLOADER

MAIN HOIST MAIN HOIST BOOM HOIST RACKING

SWIMGRAB

MAIN HOIST BOOM HOIST

* Mass per unit length of POWERFORM 8P increases by 3% Note:

l l

Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation. POWERFORM 8P is available for rope diameter 16 mm and above on special request and prior confirmation.

BOOM HOIST MAIN HOIST RACKING/TROLLEY

19

HYFLEX 8/8P
Hyflex 8P is a flexible high strength eight strand

steel wire rope with plastic impregnated core.

A sample of rope from each production batch is Good bending fatigue life. Greater surface contact area resulting from the

tested to destruction in order to confirm compliance with catalogue breaking force values.

eight strand construction.

Fully lubricated in manufacturing.

Hyflex 8

Optional plastic impregnation of the steel core. (P) signifies full plastic impregnation of the steel core.

Standard Characteristics Hyflex 8/8P

Hyflex 8P

Construction Compacted Tensile Grade Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria N/mm2

8x26SW(10-5+5-5-1)-CWR 8x36SW(14-7+7-7-1)-CWR Yes No u 1960 u Bright u Right Hand u Ordinary u 59.8 87 6.5 x NRD Refer to ISO 4309:1990 Galvanised u Left Hand u Langs 2160

Warning : Hyflex 8/8P in Langs lay must only be used in applications where both ends are secured and are unable to rotate.

20

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1960 N/mm2 kN tonnes 2160 N/mm2 kN tonnes

Typical Applications
CONTAINER

10 11 12 1/2 13 14 15 16 17 18 19 20 22 7/8 24 1 26 28 1-1/8 30 32 34 36 38 40 42 44 1-3/4 46 48 50 2 52 1-1/2 1-1/4 3/4 5/8

43.5 52.6 62.6 70.2 73.5 85.3 97.9 111 126 141 157 174 211 215 251 281 297 345 359 396 451 509 570 635 704 785 862 879 942 1025 1113 1148 1203

72.9 86.1 105 123 124 143 164 187 211 239 269 295 356 360 423 470 500 572 596 656 747 843 935 1043 1162 1305 1412 1441 1543 1680 1833 1882 1972

7.4 8.8 10.7 12.5 12.6 14.6 16.7 19.1 21.5 24.4 27.4 30.1 36.3 36.7 43.1 47.9 51.0 58.3 60.8 66.9 76.1 85.9 95.3 106 118 133 144 147 157 171 187 192 201

81.4 96.5 117 131 138 160 183 208 239 267 300 331 400 402 475 525 562 642 665 733 836 945 1053 1172 1313 1462 1577 1613 1731 1885 2065 2101 2202

8.3 9.8 11.9 13.4 14.1 16.3 18.7 21.2 24.4 27.2 30.6 33.7 40.8 41.0 48.4 53.5 57.3 65.4 67.8 74.7 85.2 96.3 107 119 134 149 161 164 176 192 210 214 224

MAIN HOIST BOOM HOIST TROLLEY

SWIMGRAB

MAIN HOIST

BOOM HOIST MAIN HOIST TROLLEY

* Mass per unit length of HYFLEX 8P increases by approx. 3% Note:

l l

Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation. HYFLEX 8P ia available for rope diameter 16 mm and above on special request and prior confirmation.

21

POWERFORM 8PC
Powerform 8PC is a high strength parallel closed steel wire rope. High fatigue life resulting from the unique compaction process and the parallel closed construction. Maximum resistance to crushing. Recommended for multi-layer spooling operations. Increased abrasion resistance resulting from the unique compaction process.
Powerform 8PC

Greater surface contact area resulting from the eight strand construction and compacted finish give longer rope life and reduced sheave wear. Fully lubricated in manufacturing. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values.
Standard Characteristics Powerform 8PC Construction 5mm-9mm 10mm-50mm Compacted Tensile Grade Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria N/mm2 Yes u 1960 Bright u Right Hand u Ordinary u 70.5 64 6.5 x NRD Refer to ISO 4309:1990 2160 u Galvanised u Left Hand u Langs 8xK7-CWRP(F4x7-4x7-1x7) 8xK26SW-CWRP (F4x7-4x19W-1x7) No

Warning : Powerform 8PC must only be used in applications where both ends of the rope are secured and unable to rotate. Powerform 8PC should not be used in any reeving system where the fleet angle exceeds 1.5 degrees.

22

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 2160 N/mm2 1960 N/mm2 kN tonnes kN tonnes

Typical Applications
CONTAINER

8 9 10 11 12 1/2 13 14 15 16 17 18 19 20 22 7/8 24 1 26 28 3/4 5/8

31.7 40.1 49.5 59.9 71.3 79.8 83.7 97.0 111 127 143 160 179 198 240 245 285 319 335 388

60.5 76.6 94.7 112 138 152 159 181 213 239 269 300 341 375 448 457 527 592 620 735

6.2 7.8 9.7 11.4 14.1 15.5 16.2 18.5 21.7 24.4 27.4 30.6 34.8 38.2 45.7 46.6 53.7 60.3 63.2 74.9

66.5 84.2 103 121 150 164 172 197 232 260 292 326 371 408 487 497 574 646 677 801

6.8 8.6 10.5 12.3 15.3 16.7 17.5 20.1 23.6 26.5 29.8 33.2 37.8 41.6 49.6 50.7 58.5 65.9 69.0 81.7

TROLLEY

LATTICE

BOOM HOIST

DOCKSIDE

BOOM HOIST

OFFSHORE PEDESTAL

BOOM HOIST

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.
BOOM HOIST TROLLEY

23

HYFLEX 4
Rugged 4 strand steel wire rope. Good rotation resistance. Recommended for severe applications. Fully lubricated in manufacturing. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values.

Hyflex 4

Standard Characteristics Hyflex 4 Construction Compacted Tensile Grade N/mm2 Finish Lay Direction Lay Type Average Fill Factor (%) Discard Criteria 4x39(15-15/9-CFS)-CFS Yes 1770 Bright u Right Hand u Ordinary u 50.8 Refer to ISO 4309:1990 Left Hand Langs No u 1960 u Galvanised

Warning : Hyflex 4 in Langs lay must only be used in applications where both ends are secured and are unable to rotate.

24

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1770 N/mm2 1960 N/mm2 kN tonnes kN tonnes

Typical Applications
PILING

10 12 14 16 18 19 20 22 7/8 24 25 1 26 28 30 32 34 36 38 40 42 44 45 1.1/2 1.1/4 3/4 5/8

44.8 65.4 88.8 117 149 167 183 214 218 253 275 284 298 346 398 456 512 574 640 709 782 859 898

64.0 92.3 125.5 164.5 207.5 231.5 256.5 310 317 369 399 413 433 502 576 656 740 830 924 1002 1102 1212 1272

6.5 9.4 12.8 16.8 21.2 23.6 26.2 31.6 32.3 37.6 40.7 42.1 44.2 51.2 58.7 66.9 75.5 84.6 94.2 102 112 124 130

69.4 99.9 136.5 177.4 224.5 250.5 277.5 336 343 400 432 448 469 544 624 689 802 898 1002 1082 1192 1312 1372

7.1 10.2 13.9 18.1 22.9 25.5 28.3 34.3 35.0 40.8 44.1 45.7 47.8 55.5 63.6 70.3 81.8 91.6 102 110 122 134 140

MAIN HOIST

DECK CRANE

MAIN HOIST BOOM HOIST

BOOM HOIST MAIN HOIST

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

25

HYFLEX 6X36
High quality flexible 6x36 class crane rope. Consistent performance. Fully lubricated in manufacturing. Independent wire rope core. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values. Supplied in high strength 1960n/mm2 tensile steel as standard.
Hyflex 6x36

Standard Characteristics Hyflex 6X36 Construction Compacted Tensile Grade Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria N/mm2 6X36(14-7+7-7-1)-CWR 6x41(16-8+8-8-1)-CWR Yes 1770 Bright u Right Hand u Ordinary u 60.9 56 6.5 x NRD Refer to ISO 4309:1990 No u 1960 u Galvanised u Left Hand u Langs

Warning : Hyflex 6x36 in Langs lay must only be used in applications where both ends are unable to rotate.

26

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1770 N/mm2 1960 N/mm2 kN tonnes kN tonnes

Typical Applications
CONTAINER

8 9 10 11 12 1/2 13 14 16 18 20 22 7/8 24 26 28 32 36 40 44 48 52 56 60 2.3/8 1.7/8 1.1/4 15/16 1 5/8

26.1 33.2 40.8 49.4 58.8 66.0 69.2 80.2 104 132 163 197 201 235 263 276 320 418 531 655 793 943 1111 1281 1471

40.3 51.0 63.0 76.2 90.7 102 107 124 161 204 252 305 311 363 407 426 494 645 817 1010 1220 1450 1700 1980 2270

4.1 5.2 6.4 7.8 9.2 10.4 10.9 12.6 16.4 20.8 25.7 31.1 31.7 37.0 41.5 43.4 50.4 65.8 83.3 103 124 148 173 202 231

44.7 56.5 69.8 84.4 101 113 118 137 179 226 279 338 345 402 450 472 547 715 904 1120 1350 1610 1890 2190 2510

4.6 5.8 7.1 8.6 10.3 11.5 12.0 14.0 18.3 23.0 28.4 34.5 35.2 41.0 45.9 48.1 55.8 72.9 92.2 114 138 164 193 223 256

MAIN HOIST BOOM HOIST TROLLEY

LATTICE BOOM

MAIN HOIST *

STEELWORKS LADLE

MAIN HOIST

UNLOADER

MAIN HOIST MAIN HOIST BOOM HOIST RACKING

BOOM HOIST MAIN HOIST RACKING/TROLLEY

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.
* For higher lifting heights a rotation resistant rope should be selected.

27

HYFLEX 6X19
High quality flexible 6x19 class crane rope. Good resistance to abrasion. Consistent performance. Fully lubricated in manufacturing. Independent wire rope core. A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values.
Hyflex 6x19

Standard Characteristics Hyflex 6X19 Construction 6x19S(9-9-1)-CWR 6x19W(6+6-6-1)-CWR 6x25F(12-6F-6-1)-CWR 6x26SW(10-5+5-5-1)-CWR Yes N/mm2 1770 Bright u Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria Right Hand u Ordinary u 59.6 42 6.5 x NRD Refer to ISO 4309:1990 No u Tensile Grade Finish 1960 u Galvanised u Left Hand u Langs

Compacted

Warning : Hyflex 6x19 in Langs lay must only be used in applications where both ends are unable to rotate.

28

NOM. ROPE DIA. mm

NOM. ROPE DIA. in

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED & UNGALVANISED ROPE GRADE 1960 N/mm2 1770 N/mm2 kN tonnes kN tonnes

Typical Applications
LATTICE BOOM

6 7 8 9 10 11 12 1/2 13 14 16 18 20 22 7/8 24 26 28 32 36 40 44 48 52 56 60 1.7/8 1.1/4 15/16 1 5/8

14.3 19.5 25.5 32.2 39.8 48.2 57.3 64.2 67.3 78.0 102 129 159 193 197 229 257 269 312 408 516 637 771 917 1076 1248 1433

22.7 30.9 40.3 51.0 63.0 76.2 90.7 102 107 124 161 204 252 305 311 363 407 426 494 645 817 1010 1220 1450 1700 1980 2270

2.3 3.1 4.1 5.2 6.4 7.8 9.3 10.4 10.9 12.6 16.4 20.8 25.7 31.1 31.7 37.0 41.5 43.4 50.4 65.8 83.3 103 124 148 173 202 231

25.1 34.2 44.7 56.5 69.8 84.4 101 113 118 137 179 226 279 338 345 402 450 472 547 715 904 1120 1350 1610 1890 2190 2510

2.6 3.5 4.6 5.8 7.1 8.6 10.3 11.5 12.0 14.0 18.3 23.0 28.4 34.5 35.2 41.0 45.9 48.1 55.8 72.9 92.2 114 138 164 193 223 256

BOOM HOIST

DOCKSIDE

BOOM HOIST

BOOM HOIST

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

29

HYFLEX 6/29Fi
High quality flexible crane rope. Consistent performance. Fully Lubricated in manufacturing. Independent wire rope core.

A sample of rope from each production batch is tested to destruction in order to confirm compliance with catalogue breaking force values.
Hyflex 6X29Fi

Standard Characteristics Hyflex 6X29Fi Construction Compacted Tensile Grade N/mm2 Finish Lay Direction Lay Type Average Fill Factor (%) Turn value at 20% of breaking force degrees/rope lay Nominal rope lay length (NRD = Nominal Rope Diameter) Discard Criteria 6X29F(14-7F-7-1)-CWR Yes 1620 Bright u Right Hand u Ordinary u 61.2 52 6.5 x NRD Refer to ISO 4309:1990 Left Hand u Langs No u 1770 u Galvanised

Standard

JIS G. 3525

Warning : Hyflex 6x29Fi in Langs lay must only be used in applications where both ends are unable to rotate.

30

NOM. ROPE DIA. mm

APPROX. MASS kg/100m

MINIMUM BREAKING FORCE GALVANISED AND UNGALVANISED 1620 N/mm2 1770 N/mm2 GRADE A GRADE B kN kN

Typical Applications
CONTAINER

10 11.2 12.5 14 16 18 20 22.4 25 28 30 31.5 33.5 35.5 37.5 40 42.5 45 47.5 50 53 56 60

44 55.2 68.8 86.3 113 143 176 221 275 345 396 437 494 555 619 704 795 891 993 1100 1240 1380 1580

63.6 79.8 99.4 125 163 206 254 319 398 499 573 631 714 802 895 1020 1150 1290 1440 1590 1790 2000 2290

67.7 84.9 106 133 173 219 271 340 423 531 609 672 760 853 952 1080 1220 1370 1530 1690 1900 2120 2440

MAIN HOIST BOOM HOIST TROLLEY

BOOM HOIST MAIN HOIST TROLLEY

Note: Rope Sizes and Breaking Force not shown in the standard table, may be available on request and prior confirmation.

31

SAFETY INFORMATION
Wire rope will fail if worn out, shock loaded, overloaded, misused, damaged, improperly maintained or abused. Always inspect wire rope for wear, damage or abuse before use. Never use a wire rope which is worn out, damaged, corroded or abused. Never overload or shock load a wire rope. Use the correct design factor for the application. Inform yourself : Read and understand the machinery manufacturers handbook and guidance from the wire rope manufacturer. Refer to applicable directives, regulations, standards and codes concerning inspection, examination and rope removal criteria.

All statements, technical information and recommendations contained herein are believed to be reliable, but no guarantee is given as to their accuracy and/or completeness. The user must determine the suitability of the product for his own particular purpose, either alone or in combination with other products and shall assume all risk and liability in connection therewith. Whilst every attempt has been made to ensure accuracy in the content of the tables, the information contained in this catalogue does not form any part of a contract.

32

METRIC IMPERIAL DIAMETER CONVERSION

in. /32 /16 7/ 32 1/ 4
5 3

mm. 3.97 4.76 5.56 6.35 7.94 9.53 11.1

in. /2 /16 5/ 8 11/ 16

1 9 13

mm. 12.7 14.3 15.9 17.5 19.0 20.6 22.2

in. /16 1 11/16 11/8

15

mm. 23.8 25.4 27.0 28.6 30.2 31.8 34.9

in. 11/2 15/16 13/4 17/8 2 21/8 21/4

mm. 38.1 41.3 44.5 47.6 50.8 54.0 57.2

in. 21/2 23/4 3 31/4 31/2 33/4 4

mm. 63.5 69.9 76.2 82.6 88.9 95.3 101.6

in. 41/4 41/2 43/4 5

mm. 108.0 114.3 120.7 127.0

/16 /8 7/ 16
5 3

/4 /16 7/ 8
3

13/16 11/4 13/8

CONVERSION TABLE
Length Force Tensile Strength Cross Section Weight Weight per Length Unit 1m 1kN 1N/mm2 1 mm2 1 metric t 1 kg/m = 1000 mm = 101,97kp = 0,10197 kp/mm2 = 0,00155 sq.inch = 1000 kg = 1,102 short t = 0,672 lbs/ft = 0,9842 long t = 2204,6 lbs = 3,281ft = 0,10197 t metric-f = 145,04 p.s.i. = 39,37 inch = 224lbs-f = 10 bar

KEY TO ABBREVIATIONS
K P/PI S W SW CWS CWR CFS CWRP Compacted Full Plastic Impregnation of the Steel Core Seale Construction Warrington Construction Seale Warrington Construction Wire Strand Core Wire Rope Core Core man made fibre (Poly) Core Strand closed parallel with outer strands of rope

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USHA MARTIN LIMITED

March 2008

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