the Rope User`s Manual
Contents
1. 40 Single Braid Retirement Checklist 44 Double Braid Retirement Checklist 48 THE STRONGEST NAME IN TABLE OF CONTENTS SECTION A ROPE SELECTION Importance of Proper Rope Selection Handling Inspection and Retirement Maximizing the safety and service life begins with selecting the right rope managing its proper functionality through optimal handling practices and retiring it from service at the appropriate time dictated by the characteristics of its application Ropes are serious working tools and when used properly they will give consistent and reliable service PAGE 4 Maximizing the safety and service life begins with selecting the right rope managing its proper functionality through optimal handling practices and retiring it from service at the appropriate time ROPE SELECTION Select the right rope for the job 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 for2. Guide to Rope Se Selection 1 15 SamsonRope com COMMERCIAL FISHING VEHICL OFFSHORE TOW OUT WINCH es m ka L IMPORTANT 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 BE ADVISED The most current and accurate content regarding rope use inspection and retirement can be found at SamsonRope com The information found at SamsonRope com may supersede the information in this and previous printed manuals ABOUT SAMSON For 130 years Samson has been recognized as a worldwide leader in the development and manufacture of high performance ropes Among its many innovations Samson invented the double braid and pioneered the first high modulus polyethylene fiber ropes Today Samson engineers continue to pioneer the use of new fiber technology and the development of innovative coatings and constructions to produce ropes with unprecedented performance characteristics Samson s research and development team is meeting an ever expanding market need for products with exceptional performance in critical applications ROPE SELECTION 5 Working Loads amp Safety Factor 6 Elongatoty RE 7 Diameter and Weight 8 Dyn
3. The Samson Splice Training comes complete with a pusher instructions for a double braid eye splice and two lengths of double braided ropes With some knots ropes can JOINING TWO ROPES lose approximately 50 EYE TO EYE SPLICE CONNECTION An eye to eye connection retains of their strength However the highest percentage typically 90 of new rope breaking strength This connection cannot this number can be higher 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 construction and fibers used without excessive strength loss or lower based on rope 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 ropes of similar size Cow hitch connection Cow hitch connection PAGE 33 ROPE HANDLING TERMINATIONS JOINING TWO ROPES SECTION C ROPE HANDLING USAGE PAGE 34 STRENGTH DEGRADATION FROM ULTRAVIOLET LIGHT Prolonged exposure Prolonged exposure of synthetic ropes to ultraviolet UV radiation from sunlight and other sources of synthetic ropes to may cause varying degrees of stren
4. Hydraulic Fluid Kerosene Gasoline Glacial Acetic Acid 1 M Hydrochloric Acid 5 M Sodium Hydroxide Ammonium Hydroxide 29 Hypophosphite Solution 5 Perchloroethylene 10 Detergent Solution Bleach PAGE 35 ROPE HANDLING UV DEGRADATION CHEMICAL EXPOSURE SECTION C ROPE HANDLING USAGE D PAGE 36 REMOVING ROPE FROM REEL OR COIL Synthetic fiber ropes are normally shipped on reels for maximum protection while 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 from the deck Rope should never be taken from a reel lying on its side If the rope is supplied on coil it should always be uncoiled from the inside so that the first turn comes off the bottom in a counterclockwise direction Synthetic fiber rope should be removed from the reel by pulling it off the top while the reel is free to rotate 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 and braided ropes should be coiled in a clockwise direction or
5. F 272 C 930 500 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 Never let ropes under stuck or non rolling sheaves or rollers Each rope s construction and fiber type will yield a different tension rub together coefficient of friction resistance to slipping in a new or used state It is important to understand or move relative to one the operational demands and take into account the size of the rope construction and fiber type another With enough heat to minimize localized heat buildup due to rope hardware friction Be aware of areas of heat buildup and take steps to minimize them Melting damage on AmSteel Blue ROPE HANDLING TWIST TEMPERATURE buildup the fibers can melt causing the rope to fail unexpectedly similar to being cut with a knife PAGE 31 SECTION C ROPE HANDLING USAGE 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 tha
6. ROPE CLASS SECTION B TECHNICAL INFORMATION ELONGATION STRETCH ELASTIC ELONGATION EE Refers to the portion of stretch or extension of a rope Each type of synthetic that is immediately recoverable after the load on the rope is released This recoverable tendency is fiber inherently displays a a primary result of the fiber s used as opposed to the rope construction Each type of synthetic fiber inherently displays a unique degree of elasticity Relatively speaking HMPE fiber has an extremely unique degree of elasticity low elasticity compared to nylon fiber Relatively HMPE fiber has ELASTIC HYSTERESIS Refers to a recoverable portion of stretch or extension over a an extremely low elasticity period of time after a load is released In measuring elastic recovery it is the recovery that occurs compared to nylon fiber immediately when a load is removed Thereafter a remaining small percentage of recovery will occur slowly and gradually over a period of hours or days This retardation in recovery is measured on a length time scale and is known as hysteresis or recovery over time PERMANENT EXTENSION PE WHILE WORKING The amount of extension that exists when stress is removed but no time is given for hysteresis recovery It includes the non recoverable and hysteretic extension as one value and represents any increase in the length of a rope in a continual working situation such as during repeated surges in towing or other similar
7. gt Cycled elongation tension fatigue gt Determination of diameter gt Wet testing gt Determination of lay pitch picks per inch gt Stiffness gt Linear density gt Abrasion resistance gt Breaking force gt Reporting procedures gt Initial elongation uncycled elongation Samson was one of the first U S rope manufacturers to receive ISO 9001 certification a natural progression of our existing quality assurance program that incorporates gt Integrated product development and production software that translates engineering specifications into production orders for manufacturing gt Specialized production documents for processing high modulus fibers gt Standardized procedures for inspection analysis and testing of in process product as well as finished goods gt Individual specifications for all products PAGE 18 Samson test methodology covers a wide range of rope characteristics Samson was one of the first U S rope manufacturers to receive ISO 9001 certification TYPE APPROVAL CERTIFICATIONS Based on our Quality Assurance Program Samson has received product type approval certifications from 4 1 f CORDAGE Y ABS American Bureau of Shipping INSTITUTE Fi DNV Det Norske Veritas SUPPORTING QUALITY LR Lloyds Register NK Nippon Kaiji Kyokai Product certifications are available upon request with order placement As a longstanding active member of the Cordage Institute Samson
8. 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 7 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 1 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 longterm 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 h
9. 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 New rope 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 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 fibers underneath This condition should stabilize not progress 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
10. L is expressed in feet PAGE 28 Formula to calculate the capacity of a winch drum 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 Every winch line should 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 HEIDI period will be highly dependent upon the nature of service frequency of use ability to perform end for ending on a the end for end process and other factors Regardless of end for end timing a visual inspection periodic basis 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 wire slings Check all winch drum etc Our winch lines are made from synthetic fibers and as such can be cut or damaged by sheaves thimbles and sharp edges When replacing winch lines care must be exercised to ensure that the rope is not wire sling surfaces for coming in contact with hardware that
11. all layers of rope with each layer of turns slightly offset from the layer below LEVEL WINDING WINDING ONTO A WINCH 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 HANDLING WINDING ON A WINCH CROSS WINDING First Cross CROSS WINDING Second Cross CROSS WINDING Level Layer PAGE 27 SECTION C ROPE HANDLING USAGE 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 C lt _A gt 9 din 42 Traverse stored feet 15 3 rope dia Where A B C and rope Barrel B Flange diameter are expressed T Diameter Diameter in inches and length
12. 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 Used rope wear to estimate total fiber abrasion If total fiber loss is 20 then it is safe to assume that the rope has Severely abraded rope lost 20 of its strength as a result of abrasion 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 PAGE 41 INSPECTION amp RETIREMENT VISUAL INSPECTION SECTION D INSPECTION amp RETIREMENT PAGE 42 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 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
13. has been a major contributor in developing standards and specifications on behalf of the Cordage Institute For a full list of Samson s technical references visit www SamsonRope com PAGE 19 TECHNICAL INFO TESTING METHODOLOGY CERTIFICATIONS SECTION C ROPE HANDLING USAGE PAGE 20 ROPE HANDLING USAGE Use the rope properly 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 from 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 Proper use and handling of the rope will extend service life and maximize safety DANGER TO PERSONNEL In any application persons should 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 pres
14. 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 sharp edges before use of sheaves shackles thimbles and other equipment that may contact the rope Other surfaces with a Samson winch line should be carefully examined and dressed if necessary PAGE 29 ROPE HANDLING WINCH CAPACITY END FOR ENDING SECTION C ROPE HANDLING USAGE 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 PAGE 30 BE ui UR Example of twist in a line As few as 3 4 turns per meter can have significant impact on the strength of a braided rope Also the effective strength loss due to twisting a braided rope is dependent on the size of the rope While larger braided ropes are more resistant to being twisted due to their larger mass they ca
15. in the direction of the lay of the rope and uncoiled in a counterclockwise direction to avoid kinks An alternate and perhaps better method is to flake out the line in a 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 rope is allowed to fall into its natural position without deliberate direction ROPE HANDLING STORAGE Figure eight Coiling flaking twisted ropes a F E The mm Pay E es Wo SS e 4 a a ED F T Hockle in a twisted rope PAGE 37 SECTION C ROPE HANDLING USAGE PAGE 38 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 Where a rope bends more or failure In sizing the radius of bitts fairleads sheaves and chocks for best performance than 10 degrees around bitts the following guidelines are offered or chocks or any surface Where is deflected more than 10 degrees around a surface i e bitts or chocks the the diameter of that surface 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 should be at least 3 times diameter Even larger diameters would be b
16. indicate core or internal damage from overloading or shock loads and is usually sufficient reason to 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 RESIDUAL 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 Compare surface yarns with internal yarns Inspection and Retirement Checklist Any rope that has been in use for any period of time will show normal wear and tear Some characteristics of a used rope will not reduce strength while others will Below we have defined normal conditions that should be inspected on a regular basis If upon inspection you find any of these conditions you must consider the following before deciding to repair or retire it gt the length of the rope gt the time it has been in service gt the type of work it does gt where the damage is and gt the extent of the damage In general it is recommended that you gt Repair the rope if the observed damage is in localized areas gt Retire the rope if the damage is over extended areas REFERENCES Cordage Institute International International Guideline 2001 04 Fiber Rope Inspection and Retirement Criteria Gu
17. 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 For applications requiring accurate fit within equipment i e sheaves or passing through parts close attention should be paid to the exact sizes involved as all rope products will behave slightly differently Shock loading results in peak loads that may be higher than the MBS of the rope which could result in line failure 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 Where shock loads more times Shock loading effects are greater on a low elongation rope such as ropes made from aramid than high elongation rope such as nylon Also the load force amplification sustained loads or where will be greater on a shorter rope than on a longer one life limb or valuable Where shock loads sustained loads or where life limb or valuable property is involved it is property Is involved it recommended that an increased working load f
18. spooling effectively during use causing a wide range of potential operational problems Install lines 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 Example of applying tension care should be given to ensure lines are not running over rough surfaces or slipping around during installation 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 For new rope installations 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 a greater the number of tension will minimize or prevent subsequent wraps from diving or burying down into lower wraps wraps layers installed In certain instances cross winding subsequent layers will help minimize line diving under the suggested See page 27 for information on cross winding tension will minimize or prevent subsequent wraps from diving or burying down into lower wraps SPLIT DRUM WINCHES When determini
19. 49 260 C 166 C 149 C 329 C 499 C Critical 325 F 350 F 250 F 150 F 300 F 520 F Temperature p xr E C aO C mun C SN C Specific Gravity 1 098 98 6 MEE Application Creep Negligible Negligible Negligible Negligible Char temperature does not melt 1 TENACITY is the measurement of the ultimate tensile stress of the fiber ELONGATION refers to percent of fiber elongation at break 3 COEFFICIENT OF FRICTION describes the rope s resistance to slipping CRITICAL TEMPERATURE is defined as the point at which degradation is caused by temperature alone SPECIFIC GRAVITY is the mass density g cm Water has a specific gravity of 1 Specific gravity less than 1 floats 6 CREEP is defined as a material s slow deformation that occurs while under load over a long period of time Creep is mostly non reversible For some synthetic ropes permanent elongation and creep are mistaken for the same property and used interchangeably when in fact creep is only one of the mechanisms that can cause permanent elongation PAGE 16 PUBLISHED STRENGTHS AND TESTING Because our ropes are asked to perform in the real world our published strengths and test results reflect as accurately as possible the conditions under which they are intended to be used Since nearly all ropes in actual use are terminated with a splice publishing unspliced strengths does not allow the customer to select the
20. E HANDLING ELONGATION SECTION B TECHNICAL INFORMATION PAGE 14 COMPONENTS OF STRETCH ON A LOADED ROPE Published Elastic Elongation Applied id Savara Hour Data All reported percentages are averages based tests of new rope where tested ropes were stabilized by being cycled 50 times at each stated A loaded rope will exhibit three components of stretch elastic elongation hysteresis and permanent Loaded Length 40 ft New length of rope After elongation 32 ft lt Initial Length 30 ft percentage of its average elongation break strength PERMANENT ELONGATION c 5 Several a Bg hours E 25 5 later n AA NEL 5 5 ze os 2 8 5 Eo E x Load Released 2 FIBER ELONGATION AT BREAK 30 0 Q 2 5 25 0 3 3 3 6 o 20 0 Aramid 4 6 t w 15 0 10 0 5 5 0 0 0 PBO LCP HMPE Aramid Polyester Polypropylene Nylon PAGE 15 TECHNICAL INFO ELASTIC ELONGATION amp FIBER ELONGATION AT BREAK SECTION B TECHNICAL INFORMATION COMPARISON OF FIBER a GENERIC FIBER TYPE NYLON POLYESTER POLYPROPYLENE HMPE ARAMID Melting Point 425 490 F 480 500 F 330 F 300 F 625 F 930 F 218 254 2
21. Strands DOUBLE BRAID Repair or retire GORE DEPENDENT May not affect strength WHAT gt Two or more cut strands in proximity CAUSE gt Abrasion gt Sharp edges and surfaces gt Cyclic tension wear CORRECTIVE ACTION f possible remove affected section and re splice with a standard end for end splice If re splicing is not possible retire the rope Reduced Volume DOUBLE BRAID Repair or retire CORE DEPENDENT May not affect strength WHAT gt 50 volume reduction CAUSE gt Abrasion gt Sharp edges and surfaces gt Cyclic tension wear CORRECTIVE ACTION DOUBLE BRAID If there is a 50 volume reduction or more the rope should be retired CORE DEPENDENT If no damage to the core has occurred the jacket can be repaired Discoloration REPAIR OR RETIRE WHAT gt Fused fibers gt Brittle fibers gt Stiffness CAUSE gt Chemical contamination CORRECTIVE ACTION f possible remove affected section and re splice with a Standard end for end splice If re splicing is not possible retire the rope PAGE 49 INSPECTION amp RETIREMENT DOUBLE BRAID INSPECTION SECTION D INSPECTION amp RETIREMENT DOUBLE BRAIDS CONTINUED Melted or Glazed REPAIR OR RETIRE PAGE 50 WHAT gt Fused fibers gt Visibly charred and melted fibers yarns and or strands gt Extreme stiffness gt Unchanged by flexing CAUSE gt Exposure to excessive heat shock load or a sustained
22. actor be used These vary by industry region and is recommended that an application so proper consideration should be given to ensure the rope selected is fit for purpose increased working load For dynamic loading applications that involve severe exposure conditions or for recommendations factor be used on special applications consult the manufacturer PAGE 9 ROPE SELECTION WEIGHT DYNAMIC LOADING D PAGE 10 SECTION A ROPE SELECTION FIRMNESS CONSTRUCTION AND 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 ga 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 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 a bearing su
23. amic Loading 8 Firmness Construction and Abrasion 10 RODE CASS 555555 EE 11 TECHNICAL INFO Elastic Elongation 12 Components of Stretch 14 Fiber Elongation at Break 15 Comparison of Fiber Characteristics cem ets 16 Published Strengths amp Testing 17 Testing and Certifications 18 ROPE HANDLING Danger to Personnel 21 Installation Considerations 22 Attaching Line to a Winch Drum 23 Tensioning Winch Lines 24 Winding onto a Winch 26 Rope Capacity of a Winch Drum 28 Use of Slings with Winch Lines 29 End Por 29 SamsonRope com Sharp Cutting Edges and Abrasive Surfaces 29 Minimize Twist the Line 30 Temperature 31 Terminations Splices Knots 32 Joining Two Ropes 33 Strength Degradation from UV Light 34 S 34 Avoid Chemical Exposure 35 Removing Rope from a Reel Coil 36 Coiling Flaking and Bagging 3 Bending Radius 38 Sheave Recommendations 39 ROPE INSPECTION amp RETIREMENT Visual Inspection
24. and melted fibers yarns and or strands gt Extreme stiffness gt Unchanged by flexing CAUSE gt Exposure to excessive heat shock load or a sustained high load CORRECTIVE ACTION f possible remove affected section and re splice with a Standard end for end splice If re splicing is not possible retire the rope PAGE 45 INSPECTION amp RETIREMENT SINGLE BRAID INSPECTION SECTION D INSPECTION amp RETIREMENT o PAGE 46 SINGLE BRAIDS CONTINUED Discoloration REPAIR OR RETIRE WHAT gt Fused fibers gt Brittle fibers gt Stiffness CAUSE gt Chemical contamination CORRECTIVE ACTION f possible remove affected section and re splice with a standard end for end splice If re splicing is not possible retire the rope Inconsistent Diameter REPAIR OR RETIRE WHAT gt Flat areas gt Lumps and bumps gt Shock loading WHAT gt Broken internal strands CORRECTIVE ACTION f possible remove affected section and re splice with a standard end for end splice If re splicing is not possible retire the rope Abrasion REPAIR OR RETIRE WHAT gt Broken filaments and yarns WHAT gt Abrasion gt Sharp edges and surfaces gt Broken internal strands CORRECTIVE ACTION Consult abrasion images and rate internal external abrasion level of rope Evaluate rope based on its most damaged section Minimal strength loss continue use Significant strength loss consult Samson B Sev
25. appropriate size and strength rope for his application and ensure the utmost in safety and length of service life Throughout this document and wherever strengths are noted all published data are for spliced ropes This ensures that you are selecting sizes and strengths based on real world conditions When comparing our data to other strengths please ensure that spliced strengths are used TESTING METHODS AT SAMSON Testing is a critical stage in the design and manufacture of new ropes and in determining retirement criteria for used ropes Samson has established test methods that comply with industry standard methods like Cl 1500 and 1502307 with more stringent specifications and testing instructions to eliminate wide tolerances or generalized procedures The result is more consistent reliable data for our customers and more accurate assessment of retirement criteria Samson R amp D maintains the largest capacity testing machine for synthetic rope in the industry capable of testing rope to failure up to 1 1 million pounds The machine is fully computer controlled provides automated cycle loading and precise elongation measurements All data is acquired stored calculated and reported automatically All ropes are tested spliced unless otherwise noted TECHNICAL INFO FIBER CHARACTERISTICS amp PUBLISHED STRENGTHS TESTING SECTION B TECHNICAL INFORMATION SAMSON S TESTING METHODOLOGY COVERS gt Sampling of test specimens
26. as 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 Working loads often called working load limits WLL are calculated by dividing the rope minimum breaking strength by the required safety factor 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 Normal working loads do not necessarily account for dynamic conditions such as shock loads or longterm sustained loads 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 See fiber characteristics information on page 16 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 rop
27. cyclical operations The percentage of PE over the working load range is approximately four to six percent and two to three times as much for laid ropes However it will vary slightly with different fibers and rope constructions Allowances must be made for this factor in applications such as subsurface mooring or when using devices that demand precise depth location and measurement PERMANENT EXTENSION PE RELAXED That portion of extension which For some synthetic ropes due to construction deformation compacting of braid and helical changes and some plastic permanent elongation deformation of the yarn fibers prevents the rope from returning to its original length and creep are mistaken CREEP A material s slow deformation that occurs while under load over a long period of time for the same property Creep is mostly non reversible For some synthetic ropes permanent elongation and creep are mistaken for the same property and the terms are used interchangeably when in fact creep is and the terms are used only one of the mechanisms that can cause permanent elongation interchangeably when CONSTRUCTIONAL ELONGATION The elongation of a loaded rope that results in fact creep is only one from compaction as the fibers and strands align and adjust of the mechanisms that SPLICE SETTING elongation of a spliced rope caused by the adjustment and can cause permanent settling of the strands in the splice elongation PAGE 13 ROP
28. ent 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 Never stand in line with a rope under tension Do not stand in line with a rope under tension The areas marked in orange are considered the danger zone PAGE 21 ROPE HANDLING DANGER TO PERSONNEL SECTION C ROPE HANDLING USAGE 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 PAGE 22 It is highly recommended that the rope manufacturer be consulted if the user has no experience handling and installing high performance synthetic ropes ATTACHING LINE TO A WINCH DRUM There are various methods
29. er PAGE 39 ROPE HANDLING BENDING RADIUS SHEAVE RECOMMENDATIONS SECTION D INSPECTION amp RETIREMENT ROPE INSPECTION amp RETIREMENT One frequently asked question is When should retire my rope The most 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 such as 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 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 inconsistencies in texture and stiffness PAGE 40 Factors such as 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 VISUAL
30. ere strength loss retire rope Hefer to images on Inspection amp Retirement Pocket Guide or Samson app Samson iPhone iPad App This handy app features inspection and retirement criteria internal and external abrasion inspection information plus splice instructions Download it at the Apple Store INSPECTION amp RETIREMENT SINGLE BRAID INSPECTION Request a copy of this handy reference tool from your Samson representative or download the Samson app PAGE 47 SECTION D INSPECTION amp RETIREMENT PAGE 48 DOUBLE BRAIDS Double Braid vs Core Dependent Double braid ropes consist of a cover or jacket braided over a separately braided core Samson produces two types of double braided ropes standard double braids and core dependent double braids The strength of standard double braid ropes is shared between the cover and the core Damage to the cover also usually affects the core and ultimately the strength of the rope In core dependent double braids the core is the strength member and carries the entire load Damage to the cover of a core dependent double braid may not compromise strength of the rope STANDARD CORE DEPENDENT Inspection of both standard double braids and core dependent double braids is essential DOUBLE BRAID DOUBLE BRAID to determining whether the rope can be repaired or if it needs to be retired Load shared between Load carried by the cover and core core only Cut
31. es 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 ROPE SELECTION WORKING LOADS ELONGATION Ropes with higher elastic elongation are typically used to provide a form of energy absorption in a system while ropes with relatively low elongation fiber provide increased position control and less stored energy at a given load PAGE 7 SECTION A ROPE SELECTION PAGE 8 DIAMETER AND LINEAR DENSITY WEIGHT While rope strength is often the critical performance characteristic special attention should be paid to rope diameter and linear density to ensure proper fit for an application and proper service life Rope diameter specifications are generally nominal in nature and during the initial phases of use the diameter will decrease slightly this is a process called bedding in Due to this if specific applications require accurate fit within equipment i e sheaves or passing through parts close attention should be paid to the exact sizes involved as all rope products will behave slightly differently 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
32. etter yet because the durability of the rope increases to rope diameter substantially as the diameter of the surface over which it is worked increases 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 will not be so severe as to cause a parting or tearing action at this point thimbles are normally designed with a 3 1 ratio Minimum 6 Feet Eye splice diameter to the diameter of the object it will be placed over should be 3 1 minimum 5 1 is preferable SHEAVE RECOMMENDATIONS Groove Diameter 6 1 ensure maximum efficiency and safety sheaves for braided ropes should no less than eight times the rope diameter The sheave groove 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 through excessive friction and crushing of the rope fibers Sheave surfaces should be kept smooth and free of a No less than burrs and gouges Bearings should be maintained to ensure smooth rotation 10 greater than rope 8 1 diameter Ratio Twisted Plaited 10 times rope diameter Braided 8 times rope diamet
33. gth degradation Samson designs products with coatings fibers and other attributes to combat such effects However the best way to avoid UV degradation ultraviolet UV radiation is to limit exposure from sunlight causes varying degrees of strength STORAGE degradation 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 on a 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 FIBER STRENGTH RETENTION AFTER recommendations when Every rope is subject to damage by chemicals Consult CHEMICAL IMMERSION the manufacturer for specific chemical exposure such as HMPE strength retention after a rope will be used where solvents acids and alkalis Consult the manufacturer for 6 months of immersion chemical exposure either recommendations when a rope will be used where chemical AGENT HMPE fumes or actual contact exposure either fumes or actual contact can occur can occur Sea Water
34. high load CORRECTIVE ACTION f possible remove affected section and re splice with a standard end for end splice If re splicing is not possible retire the rope Inconsistent Diameter REPAIR OR RETIRE WHAT gt Flat areas gt Lumps and bumps CAUSE gt Shock loading gt Broken internal strands CORRECTIVE ACTION f possible remove affected section and re splice with a Standard end for end splice If re splicing is not possible retire the rope ee A ee 1 lt t EIS gt Ker Ee 2 4 E j A e RO ia tess eS w V 5 lt lt p p 2 NOTES PAGE 51 INSPECTION amp RETIREMENT DOUBLE BRAID INSPECTION D CUT REPA 8 ORANDS Samson App WHAT Two cr For the iPhone and iPad this handy app features T n nspection and retirement criteria E i possis ACTION gt Internal and external abrasion inspection i gt Splice Instructions Download it from the Apple store 4 j REGISTERED TRADEMARK NOTICES AmSteel and DeepCool are registered trademark of Samson Rope Technologies Inc DPX is a trademark of Samson Rope Technologies Inc Dyneema is a registered trademark of Royal DSM N V Dyneema is DSM s high performance polyethylene product Tallman Equipment Innegra i
35. idelines to Enhance Durability and the Safer Use of Rope 2004 INSPECTION amp RETIREMENT VISUAL INSPECTION Inspection and Retirement Cur OF TIME Samson iPhone iPad App This handy app features inspection and retirement criteria internal and external abrasion inspection information plus splice instructions Download it from the Apple store Pocket Guide Request a copy of this handy reference tool from your Samson representative PAGE 43 SECTION D INSPECTION amp RETIREMENT PAGE 44 SINGLE BRAIDS Cut Strands REPAIR OR RETIRE WHAT gt Two or more cut strands in proximity CAUSE gt Abrasion gt Sharp edges and surfaces gt Cyclic tension wear CORRECTIVE ACTION f possible remove affected section and re splice with a Standard end for end splice If re splicing is not possible retire the rope Compression REPAIR WHAT gt Visible sheen gt Stiffness reduced by flexing the rope gt Not to be confused with melting gt Often seen on winch drums CAUSE gt Fiber molding itself to the contact surface under a radial load CORRECTIVE ACTION Flex the rope to remove compression Pulled Strand REPAIR WHAT gt Strand pulled away from the rest of the rope gt Is not cut or otherwise damaged CAUSE gt Snagging on equipment or surfaces CORRECTIVE ACTION Work back into the rope Melted or Glazed REPAIR OR RETIRE WHAT gt Fused fibers gt Visibly charred
36. n suffer greater strength reduction if equal amounts of twist are in fact induced 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 2 Generally speaking extremely cold temperatures commonly will 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 2 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 TABLE 2 THE CRITICAL AND MELTING TEMPERATURES FOR SYNTHETIC FIBERS FIBER TYPE CRITICAL TEMP MELTING TEMP _ 150 F 65 C 300 150 C Polypropylene 250 F 120 330 F 165 C Nyon 325 162 425 F 218 C Polyester 350 F 176 C 480 F 250 C 520
37. ng 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 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 PAGE 25 D PAGE 26 SECTION C ROPE HANDLING USAGE 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 for
38. of attaching a line to a winch drum using a wedge or plug and set screw in the main body of the drum or using a U bolt through the side of the flange Another method involves welding a round plug to the winch drum with the soft eye at the end of the line placed over the plug and held in place with a flat keeper The preferred method will depend on the user s ability to install a pre spliced eye If the rope connection is outside the drum flange oftentimes a plain end is needed to ensure fit In these cases the rope manufacturer should be consulted to identify the proper splice or termination methods that complement the drum termination Attach the end of the rope Keeper to the winch drum using the fittings and instructions supplied by the manufacturer In all cases the attachment method should not have a sharp edge that will cut the line under load If possible it is advisable to have an eye splice in both ends of the line so that it can be reversed in the event of damage to one end However this is not always possible depending upon the method of attachment to the winch drum and whether not a closed thimble is spliced into the eye eee Capacity PAGE 23 ROPE HANDLING INSTALLING ON A WINCH SECTION C ROPE HANDLING USAGE PAGE 24 INSTALLING TENSIONING WINCH LINES Installing synthetic rope onto winches requires several specific considerations Improper installation may prevent the rope from
39. rface 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 EUN UE 8 strand braided construction 12 strand braided construction For applications that require durability when exposed to mechanical abrasion and regular wear and tear a firmer rope usually provides longer service life ROPE CLASS Samson categorizes its ropes as a Class or Class construction for splicing and testing purposes Rope class 15 a determining Class ropes are produced with traditional fibers such as olefins polypropylene or factor when selecting th polyethylene nylon or polyester These fibers impart the strength and stretch characteristics Hum nU MIR to the rope which have tenacities of 15 grams per denier g den or less and a total stretch proper splice method at break of 696 or greater Class Il ropes are produced with high 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 Il ropes are produced with HMPE Dyneema Innegra S aramid Technora LCP Vectran or PBO Zylon Both Class and Class ropes can be produced in various rope constructions such as 3 strand 8 strand 8x3 strand 12 strand double braids or core dependent braids 11 ROPE SELECTION CONSTRUCTION
40. s a registered trademark of Innegrity LLC Technora is a registered trademark of Teijin Ltd ie 2 Vectran is registered trademark of Co Ltd ax J 5 Sales TallmanEquipment com Zylon PBO is a registered trademark of Toyobo Co Ltd 2015 Samson Rope Technologies Inc All rights reserved www TallmanEquipment com
41. 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 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 ROPE SELECTION STRENGTH 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 When comparing our data to that of other rope manufacturers please be sure that spliced strengths are used PAGE 5 SECTION A ROPE SELECTION PAGE 6 WORKING LOADS amp SAFETY
42. t 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 it is also true that a knot is a convenient way to terminate a rope for attachment to other hardware equipment The strength 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 oplice 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 PAGE 32 Splicing and lock stitching instructions are available for download at SamsonRope com 4
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