Safety Warning Insert
Contents
1. as possible the conditions under which they are to be used Because the vast majority of ropes are terminated with a splice all published strengths herein are spliced strengths All ropes are also tested spliced unless otherwise noted This assists the customer in selecting the appropriate size and strength of rope for the application and to ensure the utmost in safety and length of service life When comparing our data to that of other rope manufacturers please be sure that spliced strengths are used WORKING LOADS AND SAFETY FACTOR Working loads are the loads that a rope is subjected to under expected or typical working conditions For rope in good condition with appropriate splices and under normal service conditions working loads are based on a percentage of the breaking strength of new and unused rope of current manufacture Working loads often called working load limits WLL are calculated by dividing the rope minimum breaking strength MBS by the required safety factor sf WLL MBS ysf Safety factor recommendations vary in accordance with the different safety practices and policies typically determined through local regulatory standards industry best practices or internal safety and design criteria However for rope used under normal conditions our general recommendation which is commonly accepted for most industries is a minimum 5 1 safety factor Thus your maximum working load should be approximately 12. elongation rope such as ropes made from HMPE or aramid than on a high elongation rope such as nylon Also the load force amplification will be greater on a shorter rope than on a longer one Where shock loads sustained loads or where life limb or valuable property is involved it is recommended that an increased working load factor be used These vary by industry region and application so proper consideration should be given to ensure the rope selected is fit for purpose For dynamic loading applications that involve severe exposure conditions or for recommendations on special applications consult the manufacturer FIRMNESS CONSTRUCTION amp ABRASION Rope firmness is a characteristic that is usually dictated by the type of construction This property is not always critical but for applications that require durability when exposed to mechanical abrasion and regular wear and tear a firmer rope usually provides longer service life Soft or loosely constructed ropes will snag easily and abrade quickly causing accelerated strength loss A loosely constructed rope will typically have a higher break strength than a similar rope that is firm and holds its shape because the fibers are more effectively aligned along the axis of the rope which improves strength but compromises durability These properties should be well understood before selecting a rope construction ROPE USAGE DANGER TO PERSONNEL In any application persons shoul
3. modulus fibers that impart the strength and stretch characteristics to the rope which have tenacities greater than 15 gpd and a total stretch at break of less than 6 Typical Class II ropes are produced with HMPE Dyneema HMPP Innegra S aramid Technora LCP Vectran or PBO Zylon Both Class and Class Il ropes can be produced in various rope constructions such as 3 strand 8 strand 8x3 strand 12 strand double braids or core dependent braids USE OF SLINGS WITH WINCH LINES The winch line itself should not be used as a choker to pick up a pole or other objects The hook attached on the end of the winch line can cut deeply into the rope itself We recommend a separate line sling or strap be used as the choker and not the winch line itself END FOR ENDING Samson recommends that every line be rotated also called end for ending on a periodic basis This will vary high stress and wear points and extend useful life The recommended end for ending period will be highly dependent upon the nature of service frequency of use ability to perform the end for end process and other factors Regardless of end for end timing a visual inspection should also be performed during the rope re installation SHARP CUTTING EDGES AND ABRASIVE SURFACES Samson lines should not be exposed to sharp edges and surfaces such as steel wire gouge marks or metal burrs on equipment such as winch drums sheaves shackles thimbles w
4. rope s cross section After each use look and feel along every inch of the rope length inspecting for abrasion glossy or glazed areas inconsistent diameter discoloration and inconsistencies in texture and stiffness VISUAL INSPECTION The load bearing capacity of double braid ropes such as Stable Braid is divided equally between the inner core and the outer cover If upon inspection there are cut strands or significant abrasion damage the rope must be retired because the strength of the entire rope is decreased Core dependent double braids such as Turbo 75 and MLX have 100 of their load bearing capacity handled by the core alone For these ropes the jacket can sustain damage without compromising the strength of the load bearing core Inspection of core dependent double braids can be misleading because it is difficult to see the core In the case of 12 strand single braids such as AmSteel and AmSteel Blue each of the 12 strands carries approximately 8 33 or 1 12th of the load If upon inspection there are cut strands or significant abrasion damage to the rope the rope must be retired or the areas of damage removed and the rope repaired with the appropriate splice ABRASION When a 12 strand single braid rope such as AmSteel Blue is first put into service the outer filaments of the rope will quickly fuzz up This is the result of these filaments breaking which actually forms a protective cushion and shield for the f
5. 5th or 20 of the quoted spliced rope breaking strength This factor helps to provide greater safety and extends the service life Normal working loads do not necessarily account for dynamic conditions such as shock loads or long term sustained loads nor do the above recommendations cover where life limb or valuable property are involved In these cases a high safety factor should be used A lower safety factor or higher working load may be selected only with expert knowledge of conditions and professional estimates of risk if the rope has been inspected and found to be in good condition and if the rope has not been subject to dynamic loading Such as sudden drops snubs or pickups excessive use elevated temperatures or extended periods under load If these details are insufficient to make an informed design or product decision for the application contact Samson IMPORTANT It is important to note that many industries are subject to state and federal regulations on work load limits that supersede the manufacturer s recommendation It is the responsibility of the rope user to be aware of and adhere to those laws and regulations ELONGATION Elongation properties of synthetic ropes are primarily driven by the elastic properties of the fiber type acting as the primary strength member Modern synthetic fibers have significantly lower elastic elongation higher modulus when compared to traditional synthetic fibers SamsonRope
6. Class II construction for splicing and testing purposes Class ropes are produced with traditional fibers such as olefins polypropylene or polyethylene nylon or polyester These fibers impart the strength and stretch SPLIT DRUM WINCHES When determining the length of rope to be installed allow enough rope that when working there is always a minimum of eight wraps on the working side of the winch drum This ensures that the crossover point of the rope to the storage drum does not undergo significant tension SINGLE DRUM WINCHES In order to avoid a full working load from being applied to the winch connection attention should be paid to define an appropriate minimum rope wrap and or minimum layer count on the drum The suggested minimums will depend on the width of the winch drum and the effective coefficient of friction but proper consideration will ensure that the connection point of the rope to the drum does not undergo significant tension As the rope is used the wrap tensions may loosen If this is experienced it is suggested that the rope to be re tensioned at original installation loads to prevent potential downward wrap slippage WINDING ONTO A WINCH LEVEL WINDING Using the appropriate amount of tension wind the rope evenly without spaces across the drum of the winch The next level should wind over the previous layer of rope and follow the valley between turns on the previous level This pattern is followed fo
7. Cow hitch connection similar size STRENGTH DEGRADATION FROM ULTRAVIOLET LIGHT Prolonged exposure of synthetic ropes to ultraviolet UV radiation from sunlight and other sources may Cause varying degrees of strength degradation Samson designs products with coatings fibers and other attributes to combat such effects However the best way to avoid UV degradation is to limit exposure STORAGE All rope should be stored in a clean dry area out of direct sunlight and away from extreme heat It should be kept off the floor and on racks to provide ventilation underneath Never store rope ona concrete or dirt floor and under no circumstances should cordage and acid or alkalis be kept in the same vicinity Some synthetic rope in particular polypropylene and polyethylene may be severely weakened by prolonged exposure to ultraviolet UV rays unless specifically stabilized and or pigmented to increase UV resistance UV degradation is indicated by discoloration and the presence of splinters and slivers on the surface of the rope AVOID CHEMICAL EXPOSURE Every rope is subject to damage by chemicals Consult the manufacturer for specific chemical exposure such as solvents acids and alkalis Consult the manufacturer for recommendations when a rope will be used where chemical exposure either fumes or actual contact can occur REMOVING ROPE FROM REEL OR COIL Synthetic fiber ropes are normally shipped on reels for maximum protection whi
8. DUAL STRENGTH Samson offers customers residual strength testing of our ropes Periodic testing of samples taken from ropes currently in service ensures that retirement criteria are updated to reflect the actual conditions of service Inspection and Retirement Pocket Guide Request a copy of this handy reference tool from your Samson representative Samson App For the iPhone and iPad this handy app features gt Inspection and retirement criteria gt Internal and external abrasion inspection information gt Splice Instructions p i Download it from the Apple store L THE STRONGEST NAME IN ROPE
9. THE IMPROPER USE OF ROPE MAY BE DANGEROUS Because of the wide range of factors potentially affecting product performance you are urged to implement the guidelines and instructions set forth herein regarding rope use inspection and retirement gt Use the right size and rope construction for the job Make sure you use the rope safely Never stand in line with the rope under tension Avoid abrasive surfaces Do not overload rope Do not shock load rope Do not bend rope over sharp corners Check temperature rating before using rope in hot environments See inside for additional information on safe usage of rope BE ADVISED The most current and accurate content regarding rope use inspection and retirement can be found at SamsonRope com or in the Samson Rope User s Manual The information found at SamsonRope com may supersede the information in this and previous printed materials THANK YOU for selecting rope manufactured by Samson VvVvVvVVVV Vv The use of rope for any purpose subjects it to varying levels and modes of tension bending friction and mechanical damage as well as a wide range of environmental variables such as temperature chemical exposure etc Regardless of application as fiber rope is exposed to particular service conditions it will begin to suffer some level of degradation Maximizing rope performance and safety involves selecting the correct rope using optimal handling during its use and retiring it fr
10. com Email CustServ SamsonRope com Tel 1 360 384 4669 When considering rope elongation properties care should be taken to ensure the selected product is fit for purpose Ropes with higher elastic elongation are typically used to provide a form of energy absorption in a system while ropes with relatively low elongation i e ropes made from high modulus polyethylene HMPE fiber such as AmSteel Blue provide increased position control and less stored energy at a given load DYNAMIC LOADING Working loads as described herein are not applicable when rope has been subjected to shock loading Whenever a load is picked up stopped moved or swung there is an increased force caused by the dynamic nature of the movement The force increases as these actions occur more rapidly or suddenly which is often referred to as shock loading Shock loading results in peak loads that may be higher than the MBS of the rope which could result in line failure Depending on the product a rope that has undergone shock loading can fail at a later time even though it is loaded within the working load range Examples of applications where shock loading occurs include ropes used as a tow line picking up a load on a slack line or using rope to stop a falling object In extreme cases the force put on the rope may be significantly higher than the weight of the object involved by a factor of three or more times Shock loading effects are greater on a low
11. d be warned against the serious danger of standing in line with a rope under tension Should the rope part it may recoil with considerable force and speed In all cases where any such risks are present or where there is any question about the load involved or the condition of use the design safety factor should be substantially increased and the rope properly inspected before every use ROPE INSTALLATION CONSIDERATIONS Prior to use application specifics should be reviewed to understand the method of installation needed to ensure proper rope performance Depending on the intended use installation considerations may include but are not limited to gt Establishing proper tension and length i e static applications gt Connection mechanism winch drum spliced thimble gt Back tension required to ensure effective spooling Rope performance will be influenced by the level of attention given to these factors during the installation process It is highly recommended that the rope manufacturer be consulted if the user has no experience handling and installing high performance synthetic ropes Specific installation considerations are provided in the following sections INSTALLING TENSIONING WINCH LINES Installing synthetic rope onto winches requires several specific considerations Improper installation may prevent the rope from spooling effectively during use causing a wide range of potential operational problems Install lines
12. diameter should be no less than 10 greater than the rope diameter The sheave groove should be round in shape Sheaves with V shaped grooves should be avoided as they tend to pinch and damage the rope to cause a parting or braided ropes should be no less than eight times the through excessive Groove friction and crushing Diameter lt _ __ _ gt of the rope fibers Sheave surfaces should be kept smooth and free of burrs and gouges Bearings should be maintained to ensure smooth rotation No less than l 10 greater SamsonRope com Email CustServ SamsonRope com Tel 1 360 384 4669 INSPECTION AND RETIREMENT One frequently asked question is When should retire my rope The obvious answer is Before it breaks But without a thorough understanding of how to inspect it and knowing the load history you are left making an educated guess Unfortunately there are no definitive rules nor are there industry guidelines to establish when a rope should be retired because there are so many variables that affect rope strength Factors like load history bending radius abrasion chemical exposure or some combination of those factors make retirement decisions difficult Inspecting your rope should be a continuous process of observation before during and after each use In synthetic fiber ropes the amount of strength loss due to abrasion and or flexing is directly related to the amount of broken fiber in the
13. ibers underneath This condition should stabilize not progress ADDITIONAL RESOURCES SamsonRope com We ve put all our information here for easy downloading for anyone with access to the web We think it is the best resource for information on high performance synthetic ropes available anywhere gt Rope specifications gt Product breakdowns by application and industry gt Technical bulletins gt Case studies gt Splicing instructions REGISTERED TRADEMARK NOTICES AmSteel is a registered trademark of Samson Rope Technologies Inc Dyneema is a registered trademark of Royal DSM N V Dyneema is DSM s high performance polyethylene product Innegra S is a registered trademark of Innegrity LLC Technora is a registered trademark of Teijin Ltd Vectran is a registered trademark of Kurary Co Ltd Zylon PBO is a registered trademark of Toyobo Co Ltd 2015 Samson Rope Technologies Inc All rights reserved SWwD 108990 7 2015 If the surface roughness increases excessive abrasion takes place and strength is lost When inspecting the rope look closely at both the inner and outer fibers When either is worn the rope is obviously weakened Open the strands and look for powdered fiber which is one sign of internal wear Estimate the internal wear to estimate total fiber abrasion If total fiber loss is 20 then it is safe to assume that the rope has lost 20 of its strength as a result of ab
14. ire slings etc Our winch lines are made from synthetic fibers and as such can be cut or damaged by sharp edges When replacing winch lines care must be exercised to ensure that the rope is not coming in contact with hardware that has been scored and chewed by previously used wire lines When replacing steel wire rope in most cases it will be necessary to repair surface conditions of sheaves shackles thimbles and other equipment that may contact the rope Other surfaces should be carefully examined and dressed if necessary MINIMIZE TWIST IN THE LINE Braided ropes are inherently torque neutral and therefore will not induce torque when tension is applied However it is important to prevent significant twist from being induced into the rope by outside factors such as handling installation or use in conjunction with a wire rope Braided ropes that have been twisted can suffer from strength loss and accelerated degradation and therefore twist should be monitored and removed when identified The impact of twisting braided lines is highly dependent on amount of twist and the size of the rope When in doubt Samson has helpful references at SamsonRope com or contact Samson directly TEMPERATURE High and low temperatures can influence rope performance in a variety of ways Ambient temperature conditions should be well understood and within the limits outlined in Table 1 Generally speaking extremely cold temperatures commonly wil
15. l not have a negative impact on rope performance However moisture and subsequent freezing will impact a rope s handling and flexibility with no known negative long term impact on rope life High temperatures can reduce a rope s strength and fatigue resistance If temperatures exceed the limits shown in Table 1 special care should be taken to ensure the product is fit for purpose High temperatures can also be a more localized phenomenon as a result of the rope moving through equipment in the system where heat is generated by friction In order to minimize this heat generation ropes with appropriate coefficient of friction i e grip should be chosen based on the needs of the system and or application High temperatures can be generated when checking rope on hardware or running them over stuck or non rolling sheaves or rollers Each rope s construction and fiber type will yield a different coefficient of friction resistance to slipping in a new or used state It is important to understand the operational demands and take into account the size of the rope construction and fiber type to minimize localized heat buildup due to rope hardware friction Be aware of areas of heat buildup and take steps to minimize them TABLE 1 THE CRITICAL AND MELTING TEMPERATURES FOR SYNTHETIC FIBERS FIBER TYPE CRITICAL TEMP MELTING TEMP HMPE 150 F 65 C 300 F 150 z Polypropylene 250 F 120 330 F 165 120 C Nyl
16. le in transit The rope should be removed from the reel by pulling it off the top while the reel is free to rotate This can be accomplished by passing a pipe through the center of the reel and jacking it up until the reel is free Synthetic fiber rope should be removed from the reel by pulling it off the top while the from the deck Rope should 72 fs free to rotate never be taken from a reel lying on its side If the rope is supplied on a coil it should always be uncoiled from the inside so that the first turn comes off the bottom in a counterclockwise direction ROPE STORAGE COILING FLAKING AND BAGGING Great care must be taken in the stowing and proper coiling of 3 strand ropes to prevent the natural built in twist of the line from developing kinks and hockles Braided ropes on the other hand have no built in twist and are far more resistant to kinking Even if kinks do develop they cannot develop further into hockles Three strand fn gt and braided SS SS LA S AN ropes should D 7 be coiled ina Hockle in a twisted rope clockwise direction or in the direction of the lay of the rope and uncoiled ina counterclockwise direction to avoid kinks An alternate and perhaps better method is to flake out the line ina figure eight This avoids putting twist in the line in either direction and lessens the risk of kinking Bagging is the most common method of storing braided or twisted lines The r
17. om service before it creates a dangerous situation Ropes are serious working tools and when used properly they will give consistent and reliable service The cost of replacing a rope is extremely small when compared to the physical damage or injury to personnel a worn out rope can cause ROPE SELECTION Selecting a rope involves evaluating a combination of factors Some of these factors are straightforward like comparing rope specifications others are not easily quantified such as a preference for a specific color or how a rope feels in your hand Due to this complexity it is important for users to consider which variables are critical for their application in order to select rope products that are truly fit for purpose The most common considerations are outlined in detail below STRENGTH Rope tensile strength is one of the characteristics most commonly utilized for selecting rope products In general it is important to match a rope s strength to the requirements of the application Oftentimes such requirements are clearly stipulated by regulatory and certification bodies or other safety requirements The strength should always be some factor greater than the intended working load for a given application While there is a tendency to select products with the highest tensile strength possible care should be taken to assure other performance properties are not sacrificed Our published strengths and test results reflect as accurately
18. on 325 F 162 C 425 F 218 176 C 5 Polyester 350 F 176 480 F 250 C Aramid 520 F 272 C 930 F 500 C Critical Temperature is defined as the point at which degradation is caused by temperature alone While the term melting does not apply to this fiber it does undergo extreme degradation in these temperatures and they char TERMINATIONS Samson recommends splicing as the preferred rope termination method Knots can decrease a rope s strength by as much as 60 while in most cases splicing maintains 100 of the specified rope strength EYE SPLICES The standard eye splice cannot be pulled out under tension However some splice methods can be pulled out by hand when the line is in a relaxed state To prevent such tampering it is recommended that lock stitching be applied to the throat of the splice Lock stitching may also prove advantageous on some splices to prevent no load opening due to mishandling The material required is one fid length of nylon whipping twine approximately the same size diameter as the strands in the rope you are lock stitching You may download lock stitch instructions from our website SamsonRope com find them on our mobile app or call customer service to receive them by mail KNOTS While it is true that a knot reduces rope strength itis also true that a knot is a convenient way to terminate a rope for attachment to other hardware equipment The st
19. ope is allowed to fall into its natural position without deliberate direction Coiling twisted ropes Figure eight flaking BENDING RADIUS Sizing the Radius of Bitts Fairleads and Chocks Any sharp bend in a rope under load decreases its strength and may cause premature damage or failure In sizing the radius of bitts fairleads sheaves and chocks for best performance the following guidelines are offered Where a rope is deflected more than 10 degrees around a surface i e bitts or chocks the effective diameter of that surface should not be less than three times the diameter of the rope Stated another way the diameter of the surface should be at least three times the rope diameter Even larger diameters would be better yet because the durability of the rope increases substantially as the diameter of the surface over which it is worked increases This angle is more than 10 degrees The ratio of the length of an eye splice to the diameter of the object over which the eye is to be placed for example bollard bitt cleat etc should be a minimum 3 1 relationship larger is always preferred to improve durability By using this ratio the angle of the two legs of the eye at its throat ey gt will not be so severe as tearing action at this point thimbles are normally designed with a 3 1 ratio SHEAVE RECOMMENDATIONS To ensure maximum efficiency and safety sheaves for rope diameter The sheave groove
20. r all layers of rope with each layer of turns slightly offset from the layer below CROSS WINDING When the rope is placed under load it can dive or push into the previously wrapped level below it To avoid diving cross winding is recommended When cross winding start with two layers of level wound rope using the appropriate back tension At the end of the second layer pull the rope quickly across the drum allow it to wind one full turn at the side of the drum then quickly pull it back to the opposite side of the drum This will force the rope to cross in the middle and form a barrier that will prevent the rope from diving into the lower layers of the drum when placed under load Follow the cross wound layer with two layers of level wound turns then form another cross Repeat this pattern until the length of rope is fully spooled onto the winch ROPE CAPACITY OF A WINCH DRUM EFFECT OF ROPE DIAMETER ON DRUM CAPACITY The formula for determining the length of rope that will fit on a winch drum is LENGTH TO BE A B C STORED FEET 15 3 rope diameter EE Where A B C and rope diameter are C Barel e B Fanse expressed in inches and length L is expressed in feet SamsonRope com Email CustServ SamsonRope com Tel 1 360 384 4669 characteristics to the rope which have tenacities of 15 grams per denier g den or less and a total stretch at break of 6 or greater Class Il ropes are produced with high
21. rasion As a general rule for braided ropes when there is 25 or more wear from abrasion or the fiber is broken or worn away the rope should be retired from service For double braid ropes 50 wear on the cover is the retirement point and with 3 strand ropes 10 or more wear is accepted as the retirement point GLOSSY OR GLAZED AREAS Glossy or glazed areas are signs of heat damage with more strength loss than the amount of melted fiber indicates Fibers adjacent to the melted areas are probably damaged from excessive heat even though they appear normal It is reasonable to assume that the melted fiber has damaged an equal amount of adjacent unmelted fiber ey Ne aN z TRANDS ULETE ossible ci wi 2090 Thornton Street Ferndale WA 98248 Phone 1 800 227 7673 or 1 360 384 4669 Fax 1 360 384 0572 SamsonRope com DISCOLORATION With use all ropes get dirty Be on the lookout for areas of discoloration that could be caused by chemical contamination Determine the cause of the discoloration and replace the rope if it is brittle or stiff INCONSISTENT DIAMETER Inspect for flat areas bumps or lumps This can indicate core or internal damage from overloading or shock loads and is usually sufficient reasonto replace the rope INCONSISTENT TEXTURE Inconsistent texture or stiff areas can indicate excessive dirt or grit embedded in the rope or shock load damage and is usually reason to replace the rope RESI
22. rength loss is a result of the tight bends that occur in the knot With some knots ropes can lose up to 50 of their strength However this number can be higher or lower based on rope construction and fibers used It is vital that the reduction in strength by the use of knots be taken into account when determining the size and strength of a rope to be used in an application To avoid knot strength reduction it is recommended that a rope be spliced according to the manufacturer s instructions Splice terminations are used in all our ropes to determine new and unused tensile strengths Therefore whenever possible spliced terminations should be used to maximize the rope strength for new and used ropes JOINING TWO ROPES EYE TO EYE SPLICE CONNECTION An eye to eye connection retains the highest percentage typically 90 of new rope breaking strength This connection cannot be removed without re splicing the ropes however splicing single braids is simple and easily performed in the field In many cases eye to eye splices are preferable If the ropes being joined are dramatically different sizes consult with Samson to confirm suitability of such a connection without excessive strength loss COW HITCH CONNECTION Ropes can be attached with a cow hitch connection This allows ropes to be disconnected without having to re splice However this is a less efficient method and results in strength loss of approximately 15 for OPES of
23. under proper tension a minimum load of 100 200 Ibs 45 90 kg If a controlled method for applying back tension is available at the time of installation it is beneficial to install lines at higher tensions approaching the intended working load of the system However specific care should be given to ensure lines are not running over rough surfaces or slipping around contact surfaces that can cause unnecessary damage in the form of melting or fiber degradation Depending on the number of layers of rope on the drum installation of the bottom layers under maximum tension will help remove as much constructional elongation as possible from the rope and help avoid voids from forming during service which can increase the likelihood of rope diving For new rope installations a greater the number of wraps layers installed under the suggested tension will minimize or prevent subsequent wraps from diving or burying down into lower wraps In certain instances cross winding subsequent layers will help minimize line diving It is important to choose the right rope construction for your application because it affects resistance to normal wear and abrasion Braided ropes have a round smooth construction that tends to flatten out somewhat on a bearing surface This distributes the wear over a much greater area as opposed to the crowns of a 3 strand or to a lesser degree an 8 strand rope ROPE CLASS Samson categorizes its ropes as a Class or
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