What is Wire Rope Socketing?
Wire rope socketing is a method used to terminate the end of a wire rope by attaching a fitting, known as a socket, to create a strong and secure connection. This process ensures the rope can be safely used in lifting, rigging, or structural applications.
Common Socketing Methods:
- Hydraulic pressure crimping
- Pouring epoxy resin or molten metal
- Mechanical wedge socketing
Each method offers specific advantages based on the application’s requirements, load conditions, and environmental factors.
Wire Rope Socketing Procedure
- Measure the Socket Bowl
- Measure the socket bowl from bottom to top.
- The rope end should be long enough so that, when broomed, the wire tips reach the top of the socket bowl.
- Slide Socket onto Wire Rope
- Slide the socket approximately 1 meter down the rope to allow room for brooming and preparation.
- Apply Seizing Wire
- Apply seizing wire one socket bowl length from the rope end, moving away from the rope tip.
- The seizing should extend to at least 2 rope diameters in length for stability.
- Feather the Wire Rope End
- Use a marlin spike to split the strands.
- Bend each strand outward at a 60-degree angle using a short pipe, creating a broom-like appearance.
- Clean the Wire Rope End
- Dip the broomed end in a solvent and clean thoroughly from the broom’s base up to the seizing band.
- Let the rope dry upside down to prevent solvent accumulation near the seizing.
- Insert Broom into Socket
- Raise the socket over the broomed end.
- Distribute wires evenly inside the socket bowl.
- Align the rope and socket coaxially, and ensure no wires protrude below the socket’s base.
- Seal Socket Base and Mix Resin
- Fill the voids with socketing putty and cover with electrical tape.
- Knead the resin pouch for 30 seconds to mix contents before pouring into a mixing container.
- Add hardener and mix thoroughly for 60 seconds, ensuring complete integration using a paddle.
- Pour Resin into Socket
- Use the included funnel to pour resin along the socket wall, minimizing air entrapment.
- Fill the socket up to the top edge.
- Do not add additional resin once the original mix begins to cure.
- Allow the resin to fully harden before handling or moving the assembly.
- Final Steps
- Re-lubricate the wire rope to restore any lost lubrication.
- Perform proof load testing per ASME B30.9 standards—typically twice the Safe Working Load (SWL)—before putting the assembly into service.
Wire Rope Destructive Testing
What is Destructive Testing?
Destructive testing, such as tensile testing, involves applying a load to a wire rope or fitting until it breaks. This process reveals:
- The breaking point
- The object’s behavior under extreme stress
- The Working Load Limit (WLL)
Purpose of Destructive Testing:
- To validate new designs or components
- To assess whether long-term use has weakened the rope or fitting
- To meet compliance with third-party certification agencies (e.g., DNV-GL)
Destructive testing is essential when engineers need to guarantee the safety and performance of lifting components before they are used in the field.