HIGH PERFORMANCE

CRANE ROPE
01 | CRANE ROPE
OUR
WORLD
Usha Martin is one of the largest manufacturers of wire ropes in the world. Our journey of more
than six decades has been focused on manufacturing excellence, product innovation, technology
upgradation and customer satisfaction which resulted in establishing Usha Martin crane ropes
as one of the preferred and trusted brands in the world. Our manufacturing architecture
comprises the latest generation of machinery, including an automatic pickling plant, state-of-
the-art patenting furnaces, and high-speed straight-through wire drawing machines to produce
high-quality, high-tensile wires for manufacturing high-performance crane ropes.

Our quality management system is certified in accordance with ISO 9001:2015 standards, along
with manufacturing assessment certifications from ABS, Lloyd’s, DNV, and BV Marine & Offshore,
as well as product certifications from BRIN (Indonesia), Class NK (Japan), and works approval
from CCS (China). Our testing laboratory is accredited in accordance with ISO 17025:2017. We
also hold a certificate of authority for the use of the API monogram. Our products comply with
applicable standards such as IS 2266, EN 12385-4, API 9A, AS 3569, JIS G 3525, ISO 2408, ISO
10425, and others.

Our crane ropes are extensively used in high-capacity cranes installed in renowned ports of the
world and by world-class crane manufacturing companies in non-critical and critical applications.
Our crane ropes are developed to perform smoothly in extreme temperatures as well as in
challenging environmental conditions.

Our desire to excel is manifested through our group dynamics having manufacturing facilities in
India, Thailand, Dubai & United Kingdom, distribution centres spread over all continents, Global
Development Centre in Italy and service centres in India, Netherlands, Scotland, Singapore,
Dubai and Saudi Arabia. Our service module through the Customer Value Management (CVM)
initiative has elevated us from a wire rope supplier to a lifting solution provider and enabled us
to partner the growth process.

CRANE ROPE | 02
GLOBAL
FOOTPRINT

60 + 75 +
PRESENCE ACROSS
YEARS OF
LEADERSHIP
COUNTRIES

06 MANUFACTURING
FACILITIES
02 R&D
CENTRES

250+ GROUP DISTRIBUTION CENTRES

AND CHANNEL PARTNERS

03 | CRANE ROPE
MANUFACTURING
CAPABILITIES
Our state-of-the-art manufacturing facilities have 9000 kN rope breaking load testing machine.
the capability to produce wire ropes ranging upto
160 mm in diameter and are available in various All crane ropes undergo rigorous testing
tensile grades, from 1370 to 2160 N/mm tensile.
2
procedures to meet the technical specifications as
per our customer demand for today’s challenging
Our fully equipped rigging shop allows pressed working conditions.
terminations from 3 mm to 128 mm and wire rope
socketing up to 165 mm. Our technical experts offers on-site installation
services and conduct periodic wire rope
Undergoing all kinds of destructive and non- inspections for customers.
destructive testing.

CRANE ROPE | 04
 EMPOWERING
CUSTOMER
SUCCESS THROUGH
CUTTING-EDGE
SOLUTIONS

Delivering one-stop crane rope solutions

tailored to your unique needs.

Building stronger connections with

an unwavering commitment to
customer satisfaction.

05 | CRANE ROPE
CRANE ROPE | 06
 GUIDE TO APPLICATION &

DOCK-SIDE / DECK CRANES / OFF-SHORE PEDESTAL TOWER CRANES

TYPICAL
APPLICATIONS

MAIN HOIST BOOM HOIST WHIP HOIST MAIN HOIST STAY TROLLEY

HYFLEX 6/6P
POWERFORM® 6/6P

HYFLEX 8/8P
POWERFORM® 8/8P

HYFLEX 4

HYFLEX 18/18P
POWERFORM® 18/18P

HYFLEX 35/35P
POWERFORM® 35/35P

Key: Recommended Allowed Not Recommended

07 | CRANE ROPE
& ROPE SELECTION

MOBILE AND CRAWLER CRANES CONTAINER CRANES / UNLOADERS PILLING LADLE CRANES

MAIN HOIST BOOM HOIST MAIN HOST BOOM HOIST TROLLEY/ HOIST HOIST
RACKING

CRANE ROPE | 08
Non Compacted

Lay direction
LH or RH

Lay Type
Ordinary or Langs

Finish
Bright or Galvanised

09 | CRANE ROPE
HYFLEX

CRANE ROPE | 10
HYFLEX 6 / 6P

MINIMUM BREAKING LOAD

NOMINAL ROPE
APPROX. MASS
DIAMETER
1770 GRADE 1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN kN

8 0.273 0.184 43.3 47.9 52.8

9 0.346 0.233 54.8 60.6 66.8

10 0.427 0.287 67.6 74.9 82.5

11 0.517 0.347 81.8 90.6 100

12 0.615 0.413 97.4 108 119

1
/2 0.689 0.463 109 121 133

13 0.722 0.485 114 127 139

14 0.837 0.563 133 147 162

5
/8 1.08 0.726 171 190 209

16 1.10 0.739 174 192 212

17 1.24 0.833 197 218 240

18 1.39 0.934 220 244 269

19 1.55 1.04 246 272 300

20 1.72 1.16 272 301 332

22 2.08 1.40 329 365 402

7
/8 2.12 1.42 336 372 410

24 15
/16 2.48 1.67 392 434 478

25 2.69 1.81 425 471 519

1 2.77 1.86 438 485 535

26 2.91 1.96 460 509 561

28 3.37 2.26 533 591 651

1 1/8 3.51 2.36 556 615 678

30 3.87 2.60 612 678 747

1 1/4 4.33 2.91 686 760 837

32 4.40 2.96 697 771 850

36 5.57 3.74 876 970 1069

40 6.88 4.62 1082 1198 1320

44 8.32 5.59 1270 1406 1549

48 1 /8
7
9.90 6.65 1511 1673 1844

52 11.6 7.81 1773 1964 2164

56 13.5 9.05 2056 2277 2510

60 2 3 /8 15.5 10.4 2361 2614 2881

Excellent shock resistance

Enhanced resistance to fleet angle if plastic impregnated

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

11 | CRANE ROPE
HYFLEX 8 / 8P

MINIMUM BREAKING LOAD

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

10 0.435 0.292 72.9 81.4

11 0.526 0.353 86.1 96.5

12 0.626 0.421 105 117

1
/2 0.702 0.472 123 131

13 0.735 0.494 124 138

14 0.853 0.573 143 160

15 0.979 0.658 164 183

16 5
/8 1.11 0.746 187 208

17 1.26 0.847 211 239

18 1.41 0.947 239 267

19 3
/4 1.57 1.05 269 300

20 1.76 1.18 295 331

22 2.13 1.43 356 400

7
/8 2.17 1.46 360 402

24 2.53 1.70 423 475

25 2.75 1.85 459 506

1 2.84 1.91 470 525

26 2.97 2.00 500 562

28 3.45 2.32 572 642

1 1/8 3.59 2.41 596 665

30 3.96 2.66 656 733

32 1 1/4 4.51 3.03 747 836

34 5.09 3.42 843 945

36 5.70 3.83 935 1053

38 1 /21 6.35 4.27 1043 1172

40 7.04 4.73 1162 1313

42 7.85 5.27 1305 1462

44 8.62 5.79 1412 1577

1 /4
3
8.79 5.91 1441 1613

46 9.42 6.33 1543 1731

48 10.3 6.89 1680 1885

NOTE:
50 11.1 7.48 1833 2065 Rope sizes, Grades, MBL,
2 11.5 7.71 1882 2101 and other configurations
not covered in the table are
52 12.0 8.08 1972 2202
available on demand.

Enhanced resistance to fleet angle if plastic impregnated

Greater surface contact area resulting from the eight strand construction

CRANE ROPE | 12
HYFLEX 35 / 35P

MINIMUM BREAKING LOAD

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

10 0.448 0.301 76.0 86.5

11 0.542 0.364 91.0 104

12 0.645 0.434 107 125

1
/2 0.723 0.486 123 137

13 0.757 0.509 128 146

14 0.878 0.590 148 168

15 1.01 0.677 170 194

5
/8 1.13 0.759 190 218

16 1.15 0.771 194 221

17 1.29 0.870 219 247

18 1.45 0.975 242 277

19 3
/4 1.63 1.09 277 312

20 1.79 1.20 301 337

21 1.98 1.33 335 370

22 2.17 1.46 370 412

7
/8 2.21 1.49 376 418

24 2.58 1.73 441 498

25 2.80 1.88 479 540

1 2.89 1.94 491 546

Excellent non-rotational properties

High flexibility and handling properties
High resistance to side pressure and crushing

13 | CRANE ROPE
HYFLEX 35 / 35P

MINIMUM BREAKING LOAD

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

26 3.03 2.04 517 581

28 3.51 2.36 599 681

1 1/8 3.66 2.46 621 704

30 4.03 2.71 679 775

1 /4
1
4.52 3.03 761 786

32 4.59 3.08 769 865

35 1 3 /8 5.47 3.67 945 1044

36 5.81 3.90 983 1085

38 1 /2
1
6.50 4.37 1078 1205

40 7.17 4.82 1202 1335

42 7.90 5.31 1227 1352

44 8.67 5.83 1347 1484

1 3 /4 8.85 5.95 1375 1515

46 9.48 6.37 1472 1622

48 10.3 6.94 1603 1766

50 11.2 7.53 1740 1917

2 11.6 7.77 1796 1979

52 12.1 8.14 1881 2072

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

CRANE ROPE | 14
HYFLEX 4

MINIMUM BREAKING LOAD

NOMINAL ROPE APPROX. MASS
DIAMETER
1770 GRADE 1960 GRADE

mm kg/m Ib/ft kN kN

16 1.09 0.731 160 177

18 1.38 0.925 203 225

20 1.70 1.14 250 277

22 2.06 1.38 303 335

24 2.45 1.64 360 399

25 2.66 1.78 391 433

26 2.87 1.93 423 468

28 3.33 2.24 490 543

30 3.83 2.57 564 624

32 4.35 2.92 641 710

33.5 4.77 3.20 703 778

34 4.91 3.30 723 801

35.5 5.36 3.60 788 873

36 5.51 3.70 811 898

38 6.14 4.12 904 1001

Torque balanced rope

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the
table are available on demand.

15 | CRANE ROPE
HYFLEX 18

MINIMUM BREAKING LOAD

NOMINAL ROPE APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m lb/ft kN kN

6 0.157 0.105 25.0 27.0

7 0.213 0.143 34.0 37.0

8 0.278 0.187 45.0 49.0

9 0.352 0.237 57.0 61.0

10 0.435 0.292 70.0 76.0

11 0.526 0.354 84.0 91.0

12 0.626 0.421 101 109

1
/2 0.702 0.471 113 121

13 0.735 0.494 118 127

14 0.853 0.573 137 148

15 0.979 0.658 157 169

16 5
/8 1.11 0.748 180 194

17 1.26 0.845 203 219

18 1.41 0.947 226 244

3
/4 1.58 1.06 253 273

20 1.74 1.17 279 301

22 2.11 1.41 339 366

7
/8 2.15 1.44 346 374

Good resistance to rotation

High flexibility and handling properties

CRANE ROPE | 16
Compacted

Lay direction
LH or RH

Lay Type
Ordinary or Langs

Finish
Bright or Galvanised

17 | CRANE ROPE
POWERFORM ®

CRANE ROPE | 18
POWERFORM®
COMPACTED ROPE

A Powerform® compacted rope is

a steel wire rope which has been
manufactured using individually
compacted strands.

Conventional Strand Conventional Rope 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.

Compacted Strand Compacted Rope

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 Compacted Inter strand contact and contact

between adjacent laps of rope on
the winch drum is also improved.

19 | CRANE ROPE
POWERFORM®
SELECTION

Optimised crane design

The 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.

Longer Life
Laboratory fatigue testing indicates that it is
possible to achieve a significant increase in 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 “side crushing”

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.

CRANE ROPE | 20
POWERFORM® 6 / 6P

MINIMUM BREAKING FORCE

NOMINAL ROPE
DIAMETER APPROX. MASS
1770 GRADE 1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN kN

10 0.460 0.309 75.4 83.5 92.0

11 0.557 0.374 91.0 101 111

12 0.662 0.445 108 120 132

1
/2 0.742 0.499 121 134 148

13 0.777 0.522 127 141 155

14 0.902 0.606 148 163 180

15 1.04 0.699 170 188 207

5
/8 1.16 0.779 190 211 232

16 1.18 0.793 193 214 236

17 1.33 0.894 218 241 266

18 1.49 1.00 244 270 298

19 3
/4 1.66 1.12 272 301 332

20 1.84 1.24 302 334 368

22 2.23 1.50 365 404 445

7
/8 2.27 1.53 388 412 454

24 2.65 1.78 434 481 530

25 2.88 1.94 484 522 575

1 2.97 2.00 487 539 594

21 | CRANE ROPE
POWERFORM® 6 / 6P

MINIMUM BREAKING FORCE

NOMINAL ROPE
APPROX. MASS
DIAMETER
1770 GRADE 1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN kN

26 3.11 2.09 510 564 622

28 3.61 2.43 591 654 721

1 1/8 3.76 2.53 615 681 751

30 4.14 2.78 707 751 828

1 /4
1
4.54 3.05 760 841 927

32 4.61 3.10 764 846 932

34 5.20 3.49 860 953 1050

35 1 3 /8 5.49 3.69 910 1007 1110

36 5.83 3.92 967 1071 1180

38 1 /2
1
6.50 4.37 1073 1189 1310

40 7.20 4.84 1196 1325 1460

42 7.94 5.34 1319 1461 1610

44 8.71 5.85 1442 1597 1760

1 /4
3
8.89 5.97 1475 1633 1800

46 9.52 6.40 1582 1751 1930

48 1 7 /8 10.4 6.99 1721 1906 2100

50 11.3 7.59 1868 2069 2280

2 11.6 7.79 1926 2132 2350

52 12.2 8.20 2016 2232 2460

54 2 /8
1
13.1 2172 2405 2650
8.80
56 14.1 9.47 2335 2586 2850

58 15.1 10.1 2508 2777 3060

60 2 3 /8 16.4 11.0 2712 3004 3310

Improved MBF
Excellent shock resistance
Good resistance to side pressure and crushing
Enhanced resistance to fleet angle if plastic impregnated

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

CRANE ROPE | 22
POWERFORM® 8 / 8P

MINIMUM BREAKING FORCE

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

10 0.460 0.309 87.8 94.0

11 0.557 0.374 106 114

12 0.662 0.445 126 135

/2
1
0.742 0.499 142 152

13 0.777 0.522 148 159

14 0.902 0.606 172 184

15 1.04 0.695 198 211

16 5
/8 1.18 0.791 225 241

17 1.33 0.893 254 272

18 1.49 1.00 284 304

19 3
/4 1.66 1.12 317 339

20 1.84 1.24 351 376

22 2.23 1.50 425 455

7
/8 2.27 1.53 434 464

24 2.65 1.78 506 541

1 2.97 1.99 567 606

23 | CRANE ROPE
POWERFORM® 8 / 8P

MINIMUM BREAKING FORCE

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

26 3.11 2.09 594 635

28 3.61 2.42 688 737

1 1/8 3.76 2.52 717 767

30 4.14 2.78 790 846

32 1 /4
1
4.71 3.17 899 960

34 5.32 3.57 1013 1083

36 5.96 4.01 1138 1218

38 1 1/2 6.64 4.46 1268 1357

40 7.36 4.95 1405 1503

42 8.11 5.45 1535 1651

44 8.91 5.98 1700 1819

1 3 /4 9.09 6.11 1735 1856

46 9.73 6.54 1858 1985

48 10.6 7.12 2023 2162

50 11.5 7.73 2200 2349

2 11.9 7.98 2266 2425

52 12.4 8.36 2374 2541

High MBF
Enhanced resistance to fleet angle if plastic impregnated
Smoother contact surface in respect to conventional hoist rope

NOTE:
Rope wt. mentioned above is correspondence to the 1960 grade. For 2160 grade, Rope wt. will be approx. 5% higher.
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

CRANE ROPE | 24
POWERFORM® 8 MAX

MINIMUM
NOMINAL ROPE BREAKING FORCE
APPROX. MASS
DIAMETER
2160 GRADE

mm inch kg/m Ib/ft kN

10 0.490 0.329 102

11 0.593 0.398 123

12 0.706 0.474 147

0.790 0.531 165

13 0.828 0.556 172

14 0.960 0.645 200

15 1.10 0.739 230

5
/8 1.23 0.827 257

16 1.25 0.840 261

17 1.42 0.954 295

18 1.59 1.07 331

19 3
/4 1.77 1.19 368

20 1.96 1.32 408

22 2.37 1.59 494

7
/8 2.42 1.63 504

24 2.82 1.89 588

25 3.06 2.06 638

1 3.16 2.12 658

26 3.31 2.22 690

28 3.84 2.58 800

1 1/8 4.00 2.69 833

30 4.41 2.96 918

1 1/2 4.94 3.32 1030

Extremely high MBF

High resistance to side pressure and crushing

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

25 | CRANE ROPE
POWERFORM® 18

MINIMUM
BREAKING FORCE
NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 2160
GRADE GRADE

mm inch kg/m Ib/ft kN kN

6 0.175 0.118 29.4

7 0.238 0.160 38.0

8 0.310 0.208 51.8

9 0.393 0.264 64.6

10 0.485 0.326 80.8

11 0.587 0.394 101 111

12 0.698 0.469 116 127

1
/2 0.782 0.525 135 148

13 0.820 0.551 141 155

14 0.951 0.639 160 177

15 1.09 0.732 182 201

16 5
/8 1.24 0.833 209 232

17 1.40 0.941 237 262

18 1.57 1.05 266 295

3
/4 1.75 1.18 291 322

20 1.94 1.30 320 359

22 2.35 1.58 379 424

24 2.79 1.87 462 523

1 3.13 2.10 517 585

26 3.28 2.20 542 613

28 3.80 2.55 632 710

30 4.37 2.94 721 809

32 1 1/4 4.97 3.34 820 920

Good rotational stability

Good resistance to side pressure and crushing

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

CRANE ROPE | 26
POWERFORM® 35 / 35P

MINIMUM BREAKING FORCE

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

10 0.490 0.329 91.0 100

11 0.593 0.398 111 121

12 0.706 0.474 131 144

1
/2 0.790 0.531 148 161

13 0.828 0.556 155 169

14 0.960 0.645 180 196

15 1.10 0.739 207 225

5
/8 1.23 0.827 234 252

16 1.25 0.840 238 256

17 1.42 0.954 269 289

18 1.59 1.07 301 324

19 3
/4 1.81 1.22 336 361

20 2.00 1.34 372 400

22 2.42 1.63 450 484

7
/8 2.47 1.66 459 494

27 | CRANE ROPE
POWERFORM® 35 / 35P

MINIMUM BREAKING FORCE

NOMINAL ROPE
APPROX. MASS
DIAMETER
1960 GRADE 2160 GRADE

mm inch kg/m Ib/ft kN kN

24 2.88 1.94 536 576

25 3.13 2.10 581 625

1 3.23 2.17 600 645

26 3.38 2.27 629 676

28 3.92 2.63 729 788

1 1/8 4.08 2.74 759 817

30 4.50 3.02 837 904

1 1/4 5.04 3.39 937 1010

32 5.12 3.44 952 1040

34 5.78 3.88 1080 1160

35 1 3 /8 6.10 4.10 1130 1220

36 6.48 4.35 1210 1300

38 1 /2
1
7.22 4.85 1340 1440

40 8.00 5.38 1490 1600

42 8.82 5.93 1643

44 9.68 6.50 1803

1 /4
3
9.90 6.65 1840

46 10.6 7.11 1971

48 11.5 7.74 2146

50 12.5 8.40 2328

2 12.9 8.67 2403

52 13.5 9.09 2518

60 18.0 12.1 3353

64 20.5 13.8 3814

66 21.8 14.6 4057

Extremely high MBF

Excellent non-rotational properties
High fatigue life and increased abrasion
Enhanced resistance to fleet angle if plastic impregnated

NOTE:
Rope sizes, Grades, MBL, and other configurations not covered in the table are available on demand.

CRANE ROPE | 28
STORAGE & PRE-INSTALLATION
PROCEDURE
Crane ropes, like any machine or spares, deteriorate during storage as well as in service. Therefore, the
assurance of safety and economy in use of the equipment, dictates the requirement for a procedure of proper
storage, handling and installation of crane ropes.

STORAGE
Store rope in a clean, dry, well ventilated, dust free Avoid rope exposure to elevated temperatures.
undercover location.
Avoid handling damages to wire ropes.
Cover the rope with water proof material and/or canopy,
if not stored inside. Ensure that tag/marking is intact and follow ‘first in, first
out’ principle.
Storage should be free from steam, chemical fumes or
any other corrosive agent. Inspect rope periodically and apply suitable rope dressing
compatible with manufactured lubricant, whenever
Avoid direct contact of rope with floor. necessary.

Place reels, preferably over a frame or cradle and allow Rotate reel periodically, say after every 3 months,
flow of air under the reel. particularly in warm environment.

BEFORE INSTALLATION
Before re-equipping the appliance, all grooves in drums and Never pull the rope from stationery coil or reel
pulleys should be checked to ensure that they will correctly
accept the replacement rope. Avoid contact with ground while unwinding the rope

Keep the reel on a suitable stand with braking arrangement

Sheave groove diameter should be larger than the nominal
rope diameter by about 5% to 10% and ideally at least 2.5% Avoid formation of kink/ bends in the rope during handling
greater than the actual diameter of the new rope.
Follow ‘top to top’ or ‘bottom to bottom’ practice for rope
The diameter of the new rope shall be measured with the transfer from reel to drum / winch.
rope under no tension and the value recorded. Maintain
fleet angle at minimum during installation

Prior to rope cutting, always follow proper procedure of

rope seizing

RUNNING IN PROCEDURE
Run the newly installed wire rope in and out six times over its maximum working length with a load approx. 25% of safe
working load at reduce speed.

Repeat this procedure with load at 50% of safe working load.

Continue the same procedure with load at 100% of safe working load.

SEIZING PROCEDURE
The purpose of seizing a rotation resistant wire rope is to prevent relative movement of individual strands of inner core as well as
outer layer and thereby preserving its designed integrity and rotational balance. Therefore, before cutting any rotation resistant
wire rope, tightly double seize with soft steel wire of suitable size, on either side of the intended cut. The length of each seizing
should be at least equal to 2 x drope dia and each of the seizing should be spaced approximately6 x drope dia

Use of adhesive tape in lieu of seizing is strictly discouraged.

Fusing of cut ends in strongly recommended.

POWERFORM® 18/HYFLEX 18 | POWERFORM® 35/HYFLEX 35

For 6.0 mm to 24.0 mm wire rope, use 1.0 mm wire

For 25.0 mm to 36.0 mm wire rope, use 1.6 mm wire
For 37.0 mm to 56.0 mm wire rope, use 2.0 mm wire
Double seizing and end fusing mandatory

29 | CRANE ROPE
HANDLING & INSTALLATION
6/8 STRANDED ROPE

Never pull out rope from stationary coil.

Place rope reel on ground and roll out straight.

If heavy, place coil on turntable and pull the end away from coil.

Prevent contamination with dust, grit, moisture, chemicals and

other harmful material.

Put a shaft of adequate strength through reel bore and place in a

suitable stand.

Allow reel to rotate freely and be braked to avoid overrun.

Provide back tension for multilayer spooling and ensure to wind

tightly, particularly the bottom layer.

Maintain constant tension while reeving and avoid layer cross-

over.

Avoid formation of loops or kinks.

Avoid reverse bending during reeving. Wind/Unwind ‘top to top’

or ‘bottom to bottom’.

Take special care while releasing the outboard end of rope from
supplied reel or coil.

Maintain fleet angle at minimum during installation.

Check that the grooves of all sheaves are as recommended and

sheaves are free to rotate.

Check the diameter and pitch of drum grooves, and ensure that
these are as recommended.

‘Run’ the new rope by running the equipment slowly, with a low
load for a number of cycles.

Inspect that the rope spools correctly on the drum and no

slackness or cross-over occurs.

NOTE:
The user should always refer relevant standard/regulations like EN-12385, ISO 4309 for wire rope care,
maintenance & installation.

CRANE ROPE | 30
HANDLING & INSTALLATION
HANDLING OF MULTI-STRAND ROTATION RESISTANT ROPES:
Since rotation resistance wire ropes have special layering and arrangements of strands that are very sensitive,
therefore they require careful handling and installation in order to avoid deterioration, hoisting problems and pre-
mature removal of wire ropes. The recommendations are given below to be followed in addition to the general
mentioned method.

The rope should be paid off in the correct manner to The rope should be smoothly paid out in a straight line
ensure that the turn is neither put in nor taken out. from the reel, mounted on a stand and supported by a
shaft. If the space available does not permit the same,
A small rope of short length, say up to 100 mtr, may be the reel and stand must be placed to limit the fleet angle
unrolled along the ground but should always be kept of installation to 1° 30, i.e., for 1 mtr width between
under control. Never pull a rope from a stationary coil. flanges to 40 mtr of horizontal distance. If space allows
for a longer run, then it can be used with advantage.
Ropes in larger sizes or longer lengths should always be
procured on reels, and transferring these to coils should Care should be taken to avoid the reel being placed in
be avoided. such a position that will set up a reverse bend during
reeving, i.e., for an under-winding drum, the rope should
A long length of rope on a reel has a high moment of be taken off the bottom of the reel.
inertia. Proper braking arrangements must be made to
prevent overrun, which may lead to loop formation. A Multi-strand ropes are generally supplied with fixed
simple braking mechanism consists of a wooden plank ends, unless otherwise specified. If, for any reason, it is
acting against the reel flange. necessary to cut a rope at the site, at least three tight
servings of soft seizing wire should be applied on either
If, for any reason a loop does form, ensure that this does side before cutting.
not tighten to cause a kink, which may lead to distortion
of the rope, requiring its immediate discard.

L R L R

OVERWIND UNDERWIND
LEFT TO RIGHT RIGHT TO LEFT
USE RIGHT LAY ROPE USE RIGHT LAY ROPE

L R L R

OVERWIND UNDERWIND
RIGHT TO LEFT LEFT TO RIGHT
USE LEFT LAY ROPE USE LEFT LAY ROPE

31 | CRANE ROPE
DISCARD CRITERIA
Crane ropes must be removed from service if the examination reveals that the rope deterioration has exceeded
limits of certain criteria. A general retirement plan states that one of the factors listed below, severe enough, can
cause rope discard. However, rope deterioration and decision to discard, almost always, is the result of cumulative
effect of combination of these factors.

Broken Wires | Diameter Reduction | Corrosion | Deformation

NUMBER & CHARACTERISTICS OF BROKEN WIRES

Crane rope must be considered for discard if number of visible broken wires equals or exceeds the allowable limit.
For 6 and 8 strand wire ropes, occurrence of wire breakages, to a large extent is on the outer surface, whereas for
rotation-resistant wire ropes, majority of wire breakages are expected to occur internally and require specialized
examination techniques to reveal.

The table below specifies the number of visible broken wires, which when equalled or exceeded requires mandatory
discard of ropes working on steel sheaves.

VALLEY WIRE BREAKAGE CROWN WIRE BREAKAGE

Wire breaks in the strand valley, generally, indicate internal rope deterioration and require closer inspection of the rope equal to
6 x d.

Broken wires at, or adjacent to the termination, require the termination to be remade by shortening the rope, otherwise the
rope should be discarded.

Concentrated close group of broken wires in a rope length of 6 x d or in any one strand, requires discard of the rope even if the
number given above are not reached.

Complete fracture of one strand or collapse of core requires immediate discard of the wire rope.

SECTION OF ROPE WORKING IN STEEL SHEAVES AND /

OR SPOOLING ON A SINGLE LAYER DRUM SECTION OF ROPE SPOOLING ON A MULTI-LAYER DRUM

PRODUCT CONSTRUCTION NO. OF VISIBLE BROKEN WIRES IN WIRE ROPE

NO. OF VISIBLE BROKEN WIRES IN WIRE ROPE LENGTH
LENGTH EQUALS

(ORDINARY LAY) (LANGS LAY) (ORDINARY LAY) (LANGS LAY)

6xd 30 x d 6xd 30 x d 6xd 30 x d 6xd 30 x d

HYFLEX 4 4X39 2 4 2 4 4 8 4 8

6X25F 5 10 2 5 10 20 10 20

6X29F 6 11 3 6 12 22 12 22
HYFLEX 6/ 6X26WS 6 13 3 6 12 26 12 26
POWERFORM® 6
6X31WS 8 16 4 8 16 32 16 32
6X36WS 9 18 4 9 18 36 18 36
6X41WS 10 21 5 10 20 42 20 42

8X25F 6 13 3 6 12 26 12 26

8X26WS 9 18 4 9 18 36 18 36
HYFLEX 8/
8X31WS 10 21 5 10 20 42 20 42
POWERFORM® 8
8X36WS 12 24 6 12 24 48 24 48
8X41WS 13 26 6 13 26 52 26 52

18X7 2 4 2 4 4 8 4 8
HYFLEX 18/
18X19S 4 8 4 8 8 16 16
POWERFORM® 18 8
18X26WS 6 12 6 12 12 24 12 24

35X7 3 5 3 5 5 10 5 10
HYFLEX 35/
35X19S 6 12 6 12 12 24 12 24
POWERFORM® 35
35X26WS 6 12 6 12 24 12
12 24

CRANE ROPE | 32
RECOMMENDED DO’S & DON’TS

DO’S
Lubricate ropes with good quality acid free and moisture free lubricant
Regularly inspect the sheaves, rollers or pulleys - the life of a rope largely depends on their conditions
Inspect ropes and fittings/terminations periodically

DON’TS
Do not allow ropes in store to deteriorate
Do not mishandle ropes when uncoiling or unreeling & allow kinks to form
Do not use langs lay with swivel for 6/8 standard rope
Do not use a rope with too large groove diameter on drums and pulleys
Do not cut a rope without seizing
Do not load the rope beyond its safe working load. Reduction of safety factor may jeopardise not only rope, but also
equipment, job and men

METRIC – IMPERIAL DIAMETER CONVERSION

inch mm inch mm inch mm inch mm inch mm inch mm

5 1 15
/32 3.97 /2 12.7 /16 23.8 1 1/2 38.1 2 1/2 63.5 4 1 /4 108.0

3 9 3
/16 4.76 /16 14.3 1 25.4 1 5/16 41.3 2 /4 69.9 4 1/2 114.3

7 5 1 3 3 120.7
/32 5.56 /8 15.9 1 /16 27.0 1 /4 44.5 3 76.2 4 /4

1 1 1 127.0
/4 6.35 11
/16 17.5 1 /8 28.6 7
1 /8 47.6 3 /4 82.6 5
5
/16 7.94 3
/4 19.0 3
1 /16 30.2 2 50.8 3 1/2 88.9

3
/8 9.53
13
/16 20.6 1 1/4 31.8 2 1/8 54.0 3 3 /4 95.3

7 7 3
/16 11.1 /8 22.2 1 /8 34.9 2 1/4 57.2 4 101.6

CONVERSION TABLE

Length 1m = 1000mm = 3.281ft = 39.37 inch

Force 1kN = 101.97kp = 0.10197 t metric-f = 224lbs-f

Tensile Strength 1N/mm² = 0.10197 kp/mm2 = 145.04 p.s.i. = 10 bar

Cross Section 1 mm² = 0.00155 [Link]

Weight 1 metric t = 1000kg = 1.102 short t = 0.9842 long t = 2204.6 lbs

Weight per 1 kg/m = 0.672 lbs/ft

Length Unit

33 | CRANE ROPE
CRANE ROPE | 34
CORPORATE OFFICE

USHA MARTIN LIMITED

2A, Shakespeare Sarani ‘Mangal Kalash’
Kolkata-700 071
Phone: +91 33 71006300 / +91 33 71006492
Email: contact@[Link]

INDIA OFFICES

NORTH REGIONAL OFFICE SOUTH REGIONAL OFFICE

USHA MARTIN LIMITED USHA MARTIN LIMITED

825 & 826, 8th Floor, VKR Tower, No. 14, First Avenue, Ground Floor,
World Trade Tower Ashok Nagar, Chennai - 600083
Plot-1, Block- B, Sector-16, Noida, U.P. - 201301 Phone: +91 44 47885020
Phone: +91 120 6286129 Email: marketing-south@[Link]
Email: marketing-north@[Link]

EAST REGIONAL OFFICE WEST REGIONAL OFFICE

USHA MARTIN LIMITED USHA MARTIN LIMITED

2A, Shakespeare Sarani ‘Mangal Kalash’ Office No. 1001/1002, Chandak Chambers,
Kolkata - 700071 Near WEH Metro Station, Andheri Kurla Road,
Phone: +91 33 71006492 Andheri (E), Mumbai - 400 069
Email: marketing-east@[Link] Phone: +91 22 6239 0290
Email: marketing-west@[Link]

INTERNATIONAL OFFICES

USHA MARTIN AMERICAS, INC EMM CORP SAUDI ARABIA USHA MARTIN VIETNAM CO. LTD
1301 Hays Street Brunton Wire Ropes Industrial Company Limited 18A, D2 Street, Ward 25,
Houston, TX 77009 P3511 Al Ameer Sultan - Al Jawharah Dist. Binh Thanh District, Ho Chi Minh City,
Phone: +1 713 676 1800 Unit No. 15, Al Khobar 34434-9497, S.R Vietnam
Email: sales@[Link] Kingdom of Saudi Arabia Phone: +84 28 3512 2209
Phone: +966 138126266 Email: qui@[Link]
EMM CORP Email: rahat@[Link]
Howe Moss Place, PT. USHA MARTIN INDONESIA
Kirkhill Industrial Estate Dyce, USHA SIAM STEEL INDUSTRIES Konica Building 3A Floor Jl.
Aberdeen AB 21 OGS, Scotland, UK PUBLIC COMPANY LIMITED
Gunung Sahari Raya 78 Jakarta 10610,
Phone: +44 1224 77 5151 66 Q House Asoke Building, Indonesia
Email: info@[Link] 12th Floor, Unit 1207 Sukhumvit 21 road, Phone: +62 21 42870794
North Klongtoey, Wattana, Bangkok 10110 Email: marketing-indonesia@[Link]
BRUNTON SHAW UK Phone: +662 261 7361- 4
Sandy Lane, Worksop, S80 3ES, UK E-mail: info@[Link] USHA MARTIN ITALIA S.R.L
Phone: + 44 1909 537 600 Via Antonio Segni 6
Email: info@[Link] USHA MARTIN SINGAPORE PTE LIMITED
25062 Concesio (BS), Italy.
91 Tuas Bay Drive, Usha Martin Building, Phone: +39 030 7741330
DE RUITER STAALKABEL B.V. Singapore - 637307 Email: info@[Link]
Kerkeplaat 10, 3313 LC Dordrecht Phone: +65 6265 7756
The Netherlands Email: sales@[Link]
Phone: +31 (0) 78 - 8200600
Email: info@[Link] USHA MARTIN AUSTRALIA PTY LTD
Sydney Office: Unit 2, 7 Tarlington Pl,
BRUNTON WIRE ROPES FZCO. Smithfield NSW 2164
P.O. Box 17491, M00301 Phone: +61 411 095 983
Jebel Ali Free Zone, Dubai U.A.E Perth Office: 31 Colin Jamieson Drive,
Phone: + 971 50 4503717 Welshpool WA 6106 Phone: +61 419 939 567
Email: sm@[Link] Email: marketing-australia@[Link]

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