TALURIT Splicing Instructions

Transcription

1 Rev TALURIT The original mechanical splicing system.

2 Contents 1. GENERAL INFORMATION INTRODUCTION DEFINITIONS GENERAL WARNINGS QUALITY & POLICIES GENERAL GUIDELINES SWAGER WORK ZONE GENERAL OPERATIONAL SAFETY SWAGER DIE SAFETY SWAGER INSPECTION AND MAINTENANCE SAFETY WIRE ROPE BASICS CHECKING THE WIRE ROPE TYPE CHECKING THE FILL FACTOR ENDS OF WIRE ROPES TURNBACK FERRULES T AND TKH FERRULES EUROPEAN STANDARD SYSTEM EN T-LOC (STEEL REINFORCEMENT) TALUKON FERRULE TS FERRULE UM AND K FERRULES TCU AND TCUK FERRULES ST, SLST AND STS FERRULES INOX FERRULES TALUCRIMP FERRULES AND HOURGLASS SLEEVES SWAGING INSTRUCTIONS FOR TURNBACK FERRULES SELECTION OF TURNBACK FERRULES ASSEMBLY OF TURNBACK FERRULES SWAGING THE TURNBACK FERRULES MULTI-STAGE SWAGING TURNBACK FERRULES WITH SHORT DIES MULTI-STAGE SWAGING TURNBACK FERRULES WITH LONG DIES MULTI-STAGE SWAGING TURNBACK FERRULES ABOVE SIZE MULTI-STAGE SWAGING TURNBACK FERRULES ABOVE SIZE 60 TOGETHER WITH T-LOC CHECKING AND MARKING AFTER SWAGING USAGE AND SCRAPPING...65 CAUTIONS! All products manufactured by Talurit AB are sold with the understanding that the purchaser has thorough knowledge with the safe and proper use and application of the product. Responsibility for the use and application of the product rests with the user. Failure of the product can occur due to misapplication, abuse, or improper maintenance. Product failure could allow the load to become out of control, resulting in possible property damage, personal injury or death. There are numerous government and industry standards that cover products made by Talurit AB. This catalogue makes no attempt to reference all of them. We do reference the standards that are most frequently asked about. Load limit ratings indicate the greatest force or load a product can carry under usual environmental conditions. Shock loading and extraordinary conditions must be considered when selecting products for use in a system. The Working Load Limit, or Design Factor, or Efficiency Rating of each TALURIT product may be affected by wear, misuse, overloading, corrosion, deformation, intentional alteration, and other use conditions. Regular inspection must be conducted to determine whether use can be continued at the catalog assigned WLL, a reduced WLL, or whether the product must be withdrawn from service. Products that Talurit intends for swaging are identified in this catalogue. For proper swaging machine training, operations and die selection, refer to specific product section in this manual. To develop other product for swaging requires knowledge of the materials, heat treatment, product design, die design and performance of the final product. Use only new genuine TALURIT parts as replacements when servicing or repairing TALURIT products. All our tables and instructions are based on usage of new wire ropes. 2

3 1. GENERAL INFORMATION i 3

4 1.1 INTRODUCTION BUSINESS IDEA The Talurit Group develop, manufacture, market, and maintain equipment and systems with the highest quality for mechanical splicing of wire and wire rope for wireand wire rope fabricators worldwide. Through our high standards of efficiency, safety, reliability, and quality we create added value for our customers. By offering in-house design, development and manufacture, we possess a unique position in our market area. This is supported by a wide product range and extensive technical knowledge gained through years of experience and trust. Our service activities are reinforced by the in-house know-how. OUR PROFILE The platform picture best describes our commitment to safety and our unswerving dedication in this regard. We aspire to the following values: - No. 1 in our field! - Service-minded system supplier! - Best knowledge of mechanical splicing! - Best quality in the market! When conditions are demanding, it is our company the customers contact first! THE GROUP The parent company is based in Gothenburg, Sweden. There are also subsidiaries in Gottmadingen, Germany, in Barnsley, United Kingdom, in Ningbo, China and in Singapore. We sell our products to a global market and have representation in most industrialised countries. We also have stock of our standard products strategically situated around the world to cut lead times and improve efficiency. 4

5 1.1 INTRODUCTION SAFETY AND LIABILITY Our mechanical splicing systems are 100% reliable and comply with all known requirements and standards. All products are identifiable and fully traceable against material certificates. Approvals from LLOYD S, GERMANISCHER LLOYD, BUREAU VERITAS, DET NORSKE VERITAS, etc and certification of these are available upon request. As an added safeguard, we have a product liability insurance of SEK and a recall-action insurance from the company If, which protects our customers from third-party actions related to product defects. AFTER SALES Technical details and support for our machines are available at least 30 years from the date of purchase. This service is formalized as part of our quality system. The total reliability we offer forms a natural basis for co-operation and is an instrument to meet our customer s quality and business requirements. DECOMMISSIONING, DISMANTLING AND SCRAPPING We are committed to the protection of the environment. We strive to minimize the environmental impact of our products by continuously improving product design and our manufacturing methods. After the working life of the machine the user must have it dismantled and its components removed as per EEC directives or in accordance with current legislation of the country in which the machine is located. The making of Carquinez bridge in USA using TALURIT products 5

6 1.2 DEFINITIONS ANGLE PACKER An assembly placed in a press die holder to enable the press to accommodate dies of smaller section. (See DIE HOLDER.) BUTTON See END STOP. C-HEAD PRESS A press that is designed such that the top and bottom of the Press Head are joined only on a single side. This design permits maximum access to the -Pocket. CEN European standard committee. CHOKER FERRULES Fittings used to form a holding point on a piece of wire rope. Ferrules are also called stops, buttons, knobs or end fittings. Ferrules are designed to fit one part of wire rope and may be applied with zinc, with wedges, or by swaging. CLAMP See FERRULE. COMPETENT PERSON A designated person, suitably qualified by knowledge and experience, and with the necessary instructions to ensure that the required operations are carried out correctly. DESIGN FACTOR An industry term that denotes the theoretical reserve capability of a product, usually computed by dividing the Ultimate Load by the Working Load. Design Factor is generally expressed as a ratio (such as 5 to 1 or 5:1). DIE HOLDER/DIE ADAPTER The part of the press into which the dies are fixed. DIES A tool used to compress ferrule terminals onto a rope. Always used in conjunction with a Swager. A die has two defining characteristics: the ferrule for which it is designed for, and the block size in which it is manufactured. A die for a given ferrule may be manufactured in more than one block size and the different bore format e.g. straight through, rounded, conical. DIN 3093 The former German standard for Aluminium Ferrules. Now expired and replaced by EN DIN 3095 The former German standard for Flemish Eye. Now expired and replaced by EN DUPLEX Refers to swaged ferrules intended for use with double-back, fold back, returned loops, or turnback eyes formed by laying the wire rope back on itself to form a loop. Called FSET (Ferrule Secured Eye Termination). EN The European Standard regarding: Terminations for steel wire ropes - Safety EN The European Standard regarding: Steel wire rope slings - Safety END STOP A type of rope fitting used to terminate wire rope, where the swage shank also directly supports the tension applied to the swaged termination. EYE The loop in a rope formed by the manufacture of an eye-splice. FERRULE MANUFACTURER A person or organization that manufactures ferrules for a ferrule-secured eye termination or ferrule-secured endless loop system. FERRULES or SLEEVES Fittings used to form eyes or loop terminations at the end of a piece of wire rope. They are designed to contain two parts of the wire rope and are swaged onto the wire rope at the base of the eye or loop to hold the eye or loop permanently in place. 6

7 1.2 DEFINITIONS FERRULE-SECURED ENDLESS LOOP A loop secured by ferrules pressed on the overlapping rope ends resulting in an endless rope assembly. FERRULE-SECURED SYSTEM DESIGNER A person or organization that designs the ferrule-secured eye termination or ferrule-secured endless loop and assumes responsibility for type testing. FERRULE-SECURED TERMINATION MANUFACTURER A person or organization that manufactures the FSET and/or ferrule-secured endless loop in accordance to the ferrule-secured termination system designer s instructions. FILL FACTOR (f) The ratio between the sum of the nominal metallic cross-sectional areas of all wires in the rope (A) and the circumscribed area (Au) of the rope based on its nominal diameter (d). This may be expressed as: f = A Au FLEMISH EYE FERRULE-SECURED TERMINATION A Flemish eye formed at a rope end secured by means of a ferrule pressed on the main body of the rope and the tail ends of the strands from the Flemish eye. FLEMISH EYE SPLICE A termination to form an eye whereby the ropes firstly undergo a limited form of hand splice which is then completed by mechanically swaging a steel ferrule over the ends of the rope. HAND TOOL Giant Pliers or Sailor tongs are used to press the smaller ferrules. A hand tool may have more than one cavity. It is not to be used for safety critical applications. According to the standard a hand tool should not be used for Aluminum ferrules above size No. 5. HARD EYE An eye termination containing a Thimble. HEXLOC The trade name used for the TALURIT TM range of hexagonal dies for use with Stainless Steel Terminals among others. It is also used for special swages with hexagonal shapes. Normally used for lower strength applications. ISO 8793 An International Standard Organisation s standard for FSET s. It defines certain manufacturing parameters and type approval requirements. LONG SEVERAL STAGE DIES Long dies/swages designed to press ferrules and fittings with several bites. The dies are moved in the swager to get the correct center line, before doing the second stage. These dies are longer than the ferrule length and have to be displaced during pressing operation. For use only with untapered Aluminium and Copper turnback splices and different types of fittings. See relevant data sheet and instruction. MECHANICAL SPLICE Splice which uses some form of Ferrule or End Stop, which is then swaged onto the rope. Both Turnback and Flemish Eye Splices are Mechanical Splices. METALLIC CROSS-SECTIONAL AREA FACTOR (C) Factor derived from fill factor (f) and used in the calculation to determine the nominal metallic cross-sectional area of a rope. This may be expressed as: C = f x π 4 NOMINAL METALLIC CROSS-SECTIONAL AREA (A) The product of the metallic cross-sectional area factor (C) and the square of the nominal rope diameter (d). This may be expressed as: A = C x d 2 OPEN THROAT PRESS See C-HEAD PRESS. PRESS A machine used to compress ferrules onto a rope. The tooling (swaging dies) is changeable. May be hand operated or powered. The force is applied to the swaging dies via a hydraulic ram held in the Press Head. Defined by maximum ram force in tons or kn. Also called Swager. PRESS HEAD The part of the press, which consists of a cast or fabricated frame containing the hydraulic ram and die holder. 7

8 1.2 DEFINITIONS PRESSURE PLATE A hardened steel plate in the Holder upon which the s/angle Packings are placed. Used to prevent damage to the softer die holder. PRESSURE REGULATING VALVE The valve, which allows to regulate the hydraulic pressure (and thus the pressing tonnage) of the press. PREVENTOR STOP See END STOP. PROOF LOAD The average force applied when performing a proof test. Proof Load is usually twice the working load limit. PROOF LOADER A machine used to test wire rope slings and other rigging equipment by applying a pre-determined load. This load is normally twice the rated Safe Working Load of the sling or fitting and also called non-destructive testing. PROOF LOADER / DESTRUCTION TESTER A combined Proof Load/Destruction Test Machine. The capacity of the machine to proof load is far greater than its capacity to destruction test in terms of rope diameter. PULL TESTER See PROOF LOADER, DESTRUCTION TESTER, PROOF LOADER/ DESTRUCTION TESTER. ROLLER SWAGER The pressing cycle is completed by feeding the assembly between two opposed wheels, shaped as rotating dies. These are forming the outer diameter. Can only be used for terminals or sockets. ROUND FERRULE See END STOP. ROUND STOP See END STOP. ROUND STRAND A strand of the wire rope with a round cross-section, which is approximately the shape of a circle. SERVING WIRE OR STRAND Single wire or strand used for making close-wound helical serving to retain the elements of a rope in their assembled position. SHORT SEVERAL STAGE DIES Short dies/swages designed to press ferrules and fittings with several bites. The dies have roundings at both ends and are used to increase the working range of the splicing press. These dies are shorter than the ferrule length. For use only with untapered Aluminium and Copper turnback splices and different types of fittings. See relevant data sheet. SHOCK LOAD A force that results from a rapid application of a load (such as impacting or jerking) or the rapid movement of a static load. Shock loads add significantly to the static load and should be avoided. SLEEVE American term for fitting used for Flemish Eye Splicing. See FERRULE. SLIMSTEEL A TALURIT TM range of steel turnback ferrules. An optimized profile allows larger diameters to be swaged SOCKETS Sockets are designed to fit one part of wire rope and may be applied with socketing media, wedges, or by swaging. SOFT EYE An Eye termination not containing a Thimble. STANDARD FERRULE A range of ferrules conforming to BS 528, ISO 8793 and EN STEEL CORE (WC) A round strand (WSC) or independent stranded rope (IWRC) construction for stranded rope. STRAIGHT THROUGH DIES A type of die which consists of a cylindrical bore only. 8

9 1.2 DEFINITIONS STRAND An element of a wire rope normally consisting of an assembly of wires of appropriate shape and dimensions laid helically in the same direction in one or more layers around a centre. SWAGE AND SWAGING DIES See DIES. SWAGER A North American term for press. See PRESS. SWAGE SOCKETS Another term for Swage Terminals. SYNCRIMP A limited range of thin wall figure 8 shaped ferrules used with synthetic ropes. It is not for use in safety critical applications. TALURIT Talurit AB is the registered holder of the trademark TALURIT in more than 70 countries worldwide. TAPERED DIES A die with a parallel portion and tapered bore portion at one end only. Also called conical dies. TENSILE STRENGTH Describes the strength of the wires in a wire rope or the wire rope itself. Also called GRADE and designated to be the value according to the lower limit of tensile strength, used when specifying the strength of wires in a wire rope when determining the calculated minimum breaking force of a rope. TURNBACK FERRULE-SECURED EYE TERMINATION (FSET) An eye formed at a rope end secured by means of a ferrule pressed onto the main body of the rope and the tail end. TURNBACK SPLICE A Mechanical Splice whereby the rope is passed through the ferrule and then looped back on itself and back through the ferrule. The ferrule is then swaged onto the rope forming an FSET. ULTIMATE LOAD The average load or force at which the product fails and no longer supports the load. WEDGE GRIP A tool used to clamp directly onto a wire rope and hold it in a Test Machine. WIRE ROPE In the European market a standard has been built up to classify steel wire ropes. See EN All our tables and instructions are based on usage of new wire ropes. WORKING LOAD LIMIT The maximum mass or force, a product, is authorized to support in service when the pull is uniformly applied in line with the centre line of the product. YACHT FITTING A generic term for Stainless Steel terminals used in the yacht leisure industry. TEST MACHINE See PROOF LOADER, DESTRUCTION TESTER, PROOF LOADER/ DESTRUCTION TESTER. THIMBLE A shaped piece of metal held in the eye of a FSET by the rope available in different styles and metals. It is used to protect the wire rope from damage by usage and attached hardware. TOOL See DIES. 9

10 1.3 GENERAL WARNINGS UNDERSTANDING ALL WARNINGS WARNING: Failure to follow warnings and instructions may result in serious injury or death. Make sure purchasers and end users of TALURIT TM products read and understand all warnings, cautions, and instructions. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what has been tested. Please note that we do not take responsibility for results when a specification is outside the splicing system requirements. If in doubt, contact our Technical department for advice and cooperation. NOTE: If the required pressure is higher than indicated in our tables or the length after swaging does not match our given after swage dimensions, then special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. Always contact our technical department for guidance. All TALURIT TM products are sold with the express understanding that the purchaser is thoroughly familiar with the correct application and safe use of the product. Always refer to new and not used products. Responsibility for the use and application of the products rests with the user. Any product will fail if it is abused, misapplied, worn out, or improperly maintained. Failure can cause loads to swing or fall out of control, and may result in personal injury or death, as well as property damage. Never exceed the Working Load Limit for the product. The Working Load Limit (WLL) is the maximum load which should ever be applied to the product. WLL ratings are based on usual environmental conditions in wire rope catalogs. When recommended wire rope sizes are shown in catalogs or instructions, TALURIT TM products are rated for use only with those sizes. Do not exceed the Working Load Limit stated by the rope manufacturer. Extreme environmental conditions of heat, cold, and/or corrosion, or high-risk applications may necessitate a reduction of the WLL. Avoid shock loads. Avoid jerking, impacting, swinging or handling loads in such a manner that the WLL of the rigging can be exceeded. Avoid irregular loading. No rigging fitting should be loaded principally in bending, torsion, or shear. Avoid these conditions by loading only in the normal, straight-line pull for which the fitting is designed. Avoid side loading. Inspect products regularly. No product will last indefinitely. Corrosion, wear, deformation, gouges, misuse, abuse, alteration, and other conditions will occur and will reduce the Working Load Limit of a product. Perform periodic inspection to determine when to replace a product and avoid a rigging hazard. Inspection frequency depends on users specific applications and local conditions. When in doubt, inspect prior to use. If a part is judged defective, destroy the part - do not just discard it! Never permit anyone under a lifted load. Conduct all lifting operations in such a manner that if an equipment failure should occur, no person will be injured. Keep out from under a load and keep out of a load s line of force. Do not weld or modify fittings. TALURIT TM swage fittings are designed to be mechanically attached to the wire rope using TALURIT TM Swage s, Swaging machines and Procedures. Do not weld or otherwise modify TALURIT TM swage fittings. 10

11 1.3 GENERAL WARNINGS Proper training is important. Riggers should be properly trained in the design and use of rigging assemblies. Follow the Manual and the Swaging instruction. Follow TALURIT TM Swage Instruction Manual for proper wire rope selection, die selection and swaging techniques when using TALURIT TM swage fittings. The manual contains detailed instructions for swaging all TALURIT TM wire rope fittings with illustrations and captions on how to assemble and swage each type of fitting. Don t swage without it. Correct rope length. Do not use too short lengths of rope between swage fittings as this reduces the strength of the assembly. Performance is adversely affected when there are less than 20 rope diameters or a minimum of 3 feet of free rope between swaged fittings. If assemblies less than 3 feet must be used, testing should be performed to ensure adequate strength. Swage fitting performance. TALURIT TM swage fittings are designed to perform satisfactorily when new and when they are applied to the proper size new wire rope using the procedures described in the TALURIT TM Swaging Instructions Manual. Wear and normal use will reduce the Working Load Limit of any assembly. If you have any doubts about a new or used assembly, appropriate inspection and testing should be conducted to ensure adequate performance. Do not use end stops (Round ferrules) for suspending loads. They are not intended for use in applications where loads are fully suspended overhead except in some log harvesting systems where adequate precautions are taken. Other fittings, such as sleeves and sockets, should be used for overhead work. Use drumline ferrules only in winchline-drum applications. Drumline ferrules are intended only for use in holding the winchline in the winch drum pocket. Drumline ferrules must not be used as choker ferrules or for any other purpose than intended. When using drumline ferrules, at least 3 windings of the winchline must remain on the winch drum to avoid direct strain on the drumline ferrules. The distance between ferrule and thimble has to be more than 1xD from pointed end after pressing. If the thimble has no pointed end the missing distance has to be added, so that the distance to the simulated point is min. 1xD. Regarding wire rope outside the general standard EN and 5 you need to have contact with our technical department for advice. WARNING! All terminations on non-standard ropes need to be tested and verified according to valid standard requirements.! CAUTION!! WARNING!! DANGER! 11

12 1.4 QUALITY & POLICIES CERTIFICATION: Satisfying the EC Machinery Directive regarding environmental, safety and quality assurance requirements, our factories in Sweden, Germany and UK have all been awarded ISO 9000 certification. We are with this offering quality assured products to our customers, assuring full technical backup and after sales service. APPROVALS: To verify our test result on ferrules, documents from Lloyd s Register of Shipping - London, Det Norske Veritas - Oslo, Germanischer Lloyd - Hamburg, Bureau Veritas - Paris, Board of Labour Protection - Stockholm and others are available. TRACEABILITY: All aluminium ferrules from sizes no 8 and upwards are marked with size, type and manufacturing batch number. Key products like swaging machines and press dies are also covered by our traceability through unique production id numbers. Taking use of our internal files, all delivered items are fully traceable. Traceability means that we internally can use a well documented method to find and recall items learned to have a fault in material or production, should this happen. LIABILITY: Besides the quality of our products thereis an extra safeguard involved with the use of our products, protecting our customers from economical third-party actions. This is related to defects on fabricated items where our machines, tools and ferrules have been occupied. TALURIT TM Ferrule Securing Instruction and applicable machine instructions must have been followed. Our product liability insurance covers claims up to SEK and is offered in cooperation with the Swedish insurance company If. CORE VALUES All our work regarding Engineering, Quality, Manufacturing, and Customer Service are related to our core values: Safety, Reliability, Efficiency and Quality. Our mission is to be the industry leader of our core products in Mechanical Splicing Systems. QUALITY POLICY Talurit develop, manufacture and market mechanical splicing systems for wire and wire rope fabricators. It is with the responsibility and commitment of all employees of the Talurit Group to maintain and strengthen the competitiveness in the market. Our target is to strive to get 100% satisfied customers and act with consideration regarding the customers needs, requirements and wishes. This is done by providing complete solutions that stands for maximum efficiency, safety, reliability and quality within our industry. To do it right from the beginning and deliver on time applies for all work in the company. The daily work must be characterized by consideration and an orderly manner. Order and method are fundamental for correct quality. It is also the basis for a pleasant and good working environment. The group shall always strive to have qualified and well-educated personnel. We shall continuously improve our working methods, processes and products. Thereby we can improve the starting position in the competition and strengthen our position on the market. Talurit shall actively act on improving environmentally effecting factors in the company s operation. By continuously improving our working methods, processes and products we shall improve our quality and environmental performance. We shall actively reduce our impact on the external environment with consideration taken to known technology and reasonable economy. Our concern for the external environment shall supersede applicable laws and regulations. 12

13 Splicing System Instructions 1.5 GENERAL GUIDELINES GUIDELINES AND RECOMMENDATIONS FOR SAFE OPERATION OF SWAGING MACHINES 13

14 1.6 SWAGER WORK ZONE MARK THE WORK ZONE There must be a clearly marked work zone around your swager. This marked zone is to keep unauthorized and untrained people clear of an operating swager. These boundaries must be maintained so they can be easily seen. As the operator it is your responsibility to: Know the boundaries of the work zone. This zone s limits must be clearly marked and maintained. Boundaries can be marked by a wall, a fence, a rail, or a painted area on the floor which has been posted in writing. The swager work zone needs to be adapted for each swager size, i.e. a larger work zone for larger swagers. Before you begin swaging, make certain only trained swager operators or helpers are inside the zone. If unauthorized employees enter the zone while you are operating the swager, warn them to stay away. Do not allow other workers to take your attention away from the swaging operation. 14

15 1.7 GENERAL OPERATIONAL SAFETY THE FOLLOWING GUIDELINES ARE IMPORTANT TO AVOID ANY PERSONAL INJURIES WHILE OPERATING A SWAGER: The original mechanical splicing system. Rev Operating a swager safely and properly begins before the dies even start to close. Make sure you are familiar with the manufacturer s instruction manual before operating the swager. If you are in doubt about a particular job, ask your supervisor or competent person. General Instruction Small Swagers Models: P 0130T 1P/1S and P 0250T 1S E Copyright 2017, Talurit AB Since 1948 Personal protective equipment could help you avoid a serious accident. Wear safety glasses, safety shoes and helmet when operating the swager. Keep hands and fingers clear of die faces. Never place hands or fingers between die faces. Never use a swager to press out the core of a spelter socket. When swaging multi-leg bridles, take care to keep oblong links and other end fittings clear of die rails and die lockup pins. To avoid pinching of fingers you must always hold the wire rope. Both hands should hold the wire rope with safe distance from the dies when operating the machine with foot pedal. Never use a swaging machine to straighten a bent tool or rod or any other object. Use the correct size of die for the sleeve or ferrule to be swaged. If you do not have the correct size die for the sleeve or ferrule, never attempt to swage the sleeve or ferrule by using multiple passes and a die that almost fits. Deadly explosion of the die can be the result! Follow the manufacturer s recommendations for the type of fitting in use. Fittings may be single-swage, two-swage, or multi-swage. s may be multi-swage and may require partial length swaging. 15

16 1.7 GENERAL OPERATIONAL SAFETY If a thimble is assembled in an eye termination, make sure distance between ferrule and simulated top of thimble is minimum 1xD after swaging. If not followed, severe failure can occur. If special solid thimbles or very short thimbles are used, contact our Technical department for advice. Critical and heavy-duty applications should be protected with extra safety. Our T-LOC system is one solution in some applications. Contact our Technical department. Verify after-swage dimensions by measuring or with gauges. This applies to both diameter and length. PAY ATTENTION! Min. 1xD after swaging Simulated point If the required pressure is higher than indicated in our tables or the length after swaging does not match our given after swage dimensions, then special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. Always contact our technical department for guidance. Use proper size and type fittings for the rope construction. Use only wire rope constructions recommended for the fittings being swaged. Do not swage on used/second hand wire ropes. Make sure dies are properly mounted. Do not allow flashing with steel fittings. Give consideration when swaging metric versus imperial rope sizes. Do not swage oversized fittings. Do not swage mis-matched components. Do not swage other objects, such as rebar, pipe, tubing, etc. Make sure dies and fittings are well lubricated. Ensure the dies are clean and free of debris. 16

17 1.8 SWAGER DIE SAFETY DIFFERENT TYPES OF SWAGER DIES ROUND-TO-ROUND DIES SWAGE: ROUND FITTINGS INTO ROUND FINISHED SHAPES Typically used with steel fittings for flemish eye sleeves or swage sockets. OVAL-TO-ROUND DIES SWAGE: OVAL FITTINGS INTO ROUND FINISHED SHAPES Typically used with aluminium oval ferrules s must be aligned exactly and must not float in swager. Use only in swagers designed for this type of swage. ROUND-TO-HEX, HEX-TO-HEX: THESE TYPE OF DIES SWAGE FITTINGS INTO HEXAGON FINISHED SHAPES Typically used with some proprietary swage designs. s must be aligned exactly and must not float in swager. 17

18 1.8 SWAGER DIE SAFETY CHECKING THE DIES The parts subject to the greatest force during the swaging operation are the dies and the die holders. Take special care to check these areas prior to operating the swager: KEEP A CLEAR VIEW OF THE WORK An unobstructed view of the swager dies is crucial to the production of a wire rope assembly which will perform to its specifications in the field. Some areas to watch include:! Damaged dies can be dangerous! Inspect your dies and never use any dies that are cracked, worn or abraded (galled).! Allow nothing to obstruct or block your view, or your co-worker s view, of the die closing area.! Only use the proper size die. You, the operator, are responsible for making sure the dies, the rope and the fittings match.! You may be moving the assembly several times during the operation. Allow sufficient rope handling room around the swager area.! Always, use a matched set of dies.! If your swager uses foot controls, make certain they are unobstructed and guarded.! Always make certain that the dies are clear of any foreign matter before you begin swaging. This will keep foreign matter from being ejected during the swaging operation.! When manipulating wire rope assemblies in and out of the swaging area, be careful not to damage hydraulic hoses, gauges, guide bushings or tie rods.! Always wear personal safety gear such as glasses, shoes, helmet and gloves. 18

19 1.9 SWAGER INSPECTION AND MAINTENANCE SAFETY THE FOLLOWING IS IMPORTANT TO CONSIDER IN TERMS OF SWAGER INSPECTION AND MAINTE- NANCE SAFETY: Safe swaging depends on regular and careful inspection of the swager. If early signs of wear are found, take immediate steps to determine if maintenance is required. Maintenance assure that the swager continues to run smoothly. Only a well-maintained swager will produce quality assemblies which perform to specification in the field. To safely inspect or maintain any swager, follow any lockout/tagout procedures your shop uses. This prevents accidental and unexpected machine startup. AFTER YOU HAVE DISABLED THE SWAGER, CHECK THE FOLLOWING: Make sure all bolts and nuts are in place and tightened to proper torque. Make sure the die holder is not damaged. surfaces should be smooth and free of cracks. holder side rails should be straight and tight. Keep dies and die holder surfaces clean and free of metal shavings, slag, grit, and sand. REDUCING FRICTION WHEN THE SWAGER OPERATES IS ESSENTIAL! Lubricate all guide bushings daily with light oil. Inspect hydraulic rods for corrosion. Use emery cloth or steel wool to maintain a high polish on rod surfaces. Lubricate dies and fittings before beginning each swaging operation. 19

20 2. WIRE ROPE BASICS 20

21 2.1 CHECKING THE WIRE ROPE TYPE DIAMETER OF THE WIRE ROPE: Before swaging always begin by checking the diameter of the wire rope. The largest measured diameter is applicable. Tables and instructions are based on new wire ropes. ROPE TYPE, GRADE, CORE, LAY AND FILL FACTOR: Check rope type, core, rope grade, type of rope lay and fill factor (f) or metallic cross-sectional area factor (C). Make sure the wire rope corresponds to requirements in the tables for each ferrule type. Note! Most of the selection tables refer to 1960 rope grade. Single layer round strand rope with a fibre core Single layer round strand rope with a metallic core BASIC ROPE TYPES: Single layer round strand rope Cable laid rope Rotation-resistant round strand rope Parallel-closed round strand rope Spiral strand rope (see pictures to the right) Cable laid single layer round strand rope with a metallic core Rotation-resistant round strand rope with a metallic core (always more than one layer) Parallel-closed round strand rope with a metallic core APPLICABLE ROPE TYPES AND GRADE FOR THE TALURIT TM SPLICING SYSTEMS INSTRUCTIONS: Single layer, rotation-resistant and parallel-closed stranded ropes conforming to EN Stranded ropes conforming to EN Spiral strand ropes conforming to EN Cable-laid ropes as specified in EN Spiral strand rope with a metallic core The rope grade is normally to be maximum The types of rope lay shall be Ordinary or Lang lay. Note! Some designs of FC ropes are made very rigid and might need different selection of ferrule. Indication of this is that the ferrule becomes longer after swaging and higher required load. 21

22 2.2 CHECKING THE FILL FACTOR CHECKING THE FILL FACTOR: The fill factor (f) is the ratio between the sum of the nominal metallic cross-sectional areas of all the wires in the rope (A) and the circumscribed area (Au) of the rope based on its nominal diameter (D). The fill factor is important when selecting the ferrule or fitting size. The general guideline is: The higher the fill factor, the larger the ferrule. f = A A u = C = f π ENDS OF WIRE ROPES SERVED WIRE ROPE ENDS: Always ensure that the cut ends of the pre-formed wire rope will not unlay. If a served rope end is to be swaged within the ferrule the serving shall consist only of a strand or wire. The serving material shall be of aluminium or annealed steel and shall have a tensile strength no greater than 400 N/mm 2. The diameter of the serving shall be no greater than 5% of the nominal rope diameter. Any serving within the ferrule before swaging shall be no longer than 0,5 x nominal rope diameter and the overall length of serving shall extend no further than 1 x rope diameter from the rope end. ANNEALED WIRE ROPE ENDS: Annealed ends must not be swaged inside the ferrule and annealed ends are recommended not to be longer than 0,5 x the wire rope diameter. Please also see our separate instructions for annealing machines type AV. Please note that our ferrules should only be used on new wire ropes. Served rope end to prevent unlay approx. 0,5xD Annealed rope end Annealed ends are not to be cooled in water due to hardening risk of the wires. 22

23 TALURIT SPLICING CALCULATOR - AVAILABLE FOR BOTH ANDROID AND IOS TALURIT TM SPLICING CALCULATOR The TALURIT Splicing Calculator is now available for both Android and IOS. This app is an excellent tool for those who need help selecting the correct ferrule for different types of wire ropes. The calculator can be used to calculate the right size of ferrules, as well as providing guidance for choosing the right die sizes. The app contains tables for selections of various types of ferrules. The tables are based on European standards and TALURIT specifications. IMPORTANT! This app is only compatible with TALURIT mechanical splicing systems. Download the app for Android here Download the app for IOS here 23

24 3. TURNBACK FERRULES SELECTING THE RIGHT TALURIT SWAGING PRODUCT T ferrule TK ferrule TKH ferrule T-LOC ferrule TKON ferrule TS ferrule UM ferrule K ferrule ST ferrule SLST ferrule STS ferrule INOX ferrule TCU ferrule 24

25 TURNBACK FERRULES T ferrule TKH ferrule 3.1 T AND TKH FERRULES EUROPEAN STANDARD SYSTEM EN GENERAL DESCRIPTION The aluminium ferrules, type T and type TKH correspond to the European standard for turnback ferrules (also known as ferrule secured eye terminations, FSET). The standard is EN The ferrule system is specified in Appendix 1. The ferrules are extruded seamlessly over mandrel and the aluminium alloy is EN AW-5051A according to EN APPLICATIONS The aluminium ferrules are the most commonly used ferrules on the market today. They have a vast variety of applications, especially in the lifting gear industry. The T ferrules and TKH ferrules are thoroughly specified and very well defined for many different wire rope applications. Four different cases are tested and verified according to the standard, EN The ferrules can be used for fibre core single layer wire ropes, steel core single layer wire ropes, rotation resistant wire ropes and spiral strand ropes. Always use new wire ropes. THE CORRECT SIZE OF THE SLING EYE If a thimble is not used, the distance from the unswaged ferrule to the bearing point of the soft eye must be at least 15 x the wire rope diameter (D), as per the figure. When using a pin or a hook, you should calculate max. 3 x pin diameter, or the hook width to verify 15 x D or more. The width of the eye without load shall be approximately half its length. Pin diameter max h/3 Dimensions for eye and pin D D= Nominal rope diameter TO BE NOTED h The turnback ferrule system is easy to use. It is quick, safe and has proved itself to be totally reliable. It is also more efficient than most other swaging methods on the market and has been tested and verified according to type testing requirements. Only valid for up to 1960 grade wire rope. TK ferrules do not correspond to standard mentioned above but have been tested and verified by Talurit (please follow our swaging instructions as per the technical data sheet. 25

26 EUROPEAN STANDARD SYSTEM EN Table of sizes for T and TKH ferrules (cylindrical part only) The measurements of the standard ferrule are given from the table A.1 in the standard EN Ferrule Internal size Wall thickness size number a tolerance b tolerance s Nominal Deviation of average wall thickness from nominal thickness s s Tolerable wall thickness difference Length u l tolerance kg 2,5 2,7 + 0,2 5,4 + 0,2 1,05 ± 0,04 0, ,2 0, ,3 0 6,6 0 1,25 ± 0,04 0, ,5 0,843 3,5 3,8 7,6 1,5 ± 0,05 0, ,32 4 4,4 + 0,2 8,8 + 0,2 1,7 ± 0,05 0, ,2 1,81 4,5 4,9 0 9,8 0 1,9 ± 0,06 0, ,5 2,61 5 5,5 11,0 2,1 ± 0,06 0, ,57 6 6,6 13,2 2,5 ± 0,08 0, ,2 5,86 6,5 7,2 ± 0,15 14,4 ± 0,15 2,7 ± 0,08 0, ,5 7,55 7 7,8 15,6 2,9 ± 0,09 0, ,53 8 8,8 17,6 3,3 ± 0,10 0, ,5 13,7 9 9,9 ± 0,2 19,8 ± 0,2 3,7 ± 0,11 0, , ,9 21,8 4,1 ± 0,12 0, , ,1 24,2 4,5 ± 0,13 0, ,5 35, ,2 ± 0,3 26,4 ± 0,3 4,9 ± 0,15 0, , ,2 28,4 5,4 ± 0,16 0, , ,3 30,6 5,8 ± 0,17 0, ,5 73, ,5 ± 0,3 35 ± 0,3 6,7 ± 0,20 0, ,6 39,2 7,6 ± 0,23 0, ,7 ± 0,3 43,4 ± 0,3 8,4 ± 0,25 0, , ,3 48,6 9,2 ± 0,28 0, , ,4 ± 0,4 52,8 ± 0,4 10 ± 0,30 0, , ,9 ± 0,32 0, , ± 0,4 62 ± 0,4 11,7 ± 0,33 0, , ,1 66,2 12,5 ± 0,35 0, ,2 70,4 13,4 ± 0,37 0, , ,8 ± 0,4 75,6 ± 0,4 14,2 ± 0,38 0, , ,8 79,6 15 ± 0,40 0, ,9 83,8 ± 0,4 15,8 ± 0,41 1, , ± 0, ,6 ± 0,43 1, , ,4 96,8 ± 0,5 18,3 ± 0,46 1, ,8 ± 0,4 105,6 ± 0,5 20,0 ± 0,5 1, , ,2 114,4 21,6 ± 0,54 1, , ,6 ± 0,5 123,2 ± 0,6 23,3 ± 0,58 1, ± 0,5 132 ± 0,6 25 ± 0,63 1, , ) Cylindrical ferrules, informative only -1,5 Nominal weight of 1000 pieces 1) 26

27 FERRULE SELECTION ACCORDING TO EN T ferrule (T) (aluminium) T Konit with inspection hole (TKH) (aluminium) Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! f = Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = Nominal metallic cross-sectional area factor of the rope C = f π 4 MATCHING WIRE ROPE TO FERRULE Selection of the correct ferrule is to take account of: -The measured rope diameter -The rope type (and core) -The nominal fill factor, f (or metallic cross-sectional area factor, C) of the rope. Very important for fibre core ropes! Case 1 For single layer round strand ropes with fibre core and cable-laid ropes having a fill factor of at least 0,36 (C 0,283) and max 0,45 (C 0,353), a ferrule having a size / Code number equivalent to the measured rope diameter is to be selected from the table on next page. Case 2 For single layer round strand ropes with fibre core and cable laid ropes having a filling factor greater than 0,45 (C>0,353) and for single layer round strand ropes with metallic core and for rotation-resistant round strand ropes having a fill factor up to 0,62 (C 0,487), a ferrule having the next larger size / Code number than the measured rope diameter is to be selected from table on next page. Case 3 For single layer round strand ropes with metallic core and for rotation-resistant round strand ropes and parallel-closed round strand ropes having a fill factor greater than 0,62 and up to 0,78 (0,487<C 0,613) the ferrule is to be selected from table on next page. Case 4 For spiral strand rope having a fill factor not greater than 0,78 (C 0,613), ferrules are to be selected having two size / Code numbers larger than the actual rope diameter from table on next page. Two ferrules spaced two rope diameters apart are to be used per termination. After pressing a space is to be maintained between the ferrules. Applicable rope types and grade Single layer, rotation resistant and parallel-closed stranded ropes confirming to EN , stranded ropes conforming to EN , spiral strand ropes conforming to EN and cable-laid ropes as specified in EN The maximum rope grade is to be The types of rope lay shall be Ordinary or Lang lay. For tensile grade up to and including 2160 we have an approved system called T-LOC. For higher and lower filling factor, please contact our Technical Department. 27

28 STANDARD SYSTEM BASED ON EN Selection table for T and TKH ferrules f = fill factor C= Nominal metalic cross-sectional area factor of the wire rope Ferrule size / Code No. Measured Wire Rope Diameter Range (mm) Case 1 Fill factor 0,36 f 0,45 0,283 C 0,353 Case 2 Fill factor f 0,62 C 0,487 Case 3 Fill factor 0,62<f 0,78 0,487<C 0,613 Case 4 Fill factor f 0,78 C 0,613 Identification s marked Diameter after pressing Straight length, L, after pressing approx. T TKH Min Max Min Max Min Max Min Max mm Tol mm kn 1* 0,9 1,1 0,8 1, ,2 6,5 5 1,5* 1,2 1,6 1,1 1,4 1,5 3, * 1,7 2,1 1,5 1, ,5 2,5 2,7 2,0 2,4 2, ,8 3,2 2,5 2, ,5 3,3 3,7 2,8 3,2 3, ,8 4,3 3,3 3, ,5 4,4 4,8 3,8 4,3 4, ,9 5,4 4,4 4,8 3,8 4, ,5 6,4 4,9 5,4 4,4 4, , ,5 6,5 6,9 5,5 6,4 4,9 5,4 6, ,0 7,4 6,5 6,9 6,0 6,4 5,5 6, ,5 8,4 7,0 7,4 6,5 6,9 6,5 6, ,5 9,5 7,5 8,4 7,0 7,9 7,0 7, ,6 10,5 8,5 9,5 8,0 8,9 7,5 8, , ,6 11,6 9,6 10,5 9,0 9,9 8,5 9, ,7 12,6 10,6 11,6 10,0 10,9 9,6 10, ,7 13,7 11,7 12,6 11,0 11,9 10,6 11, ,8 14,7 12,7 13,7 12,0 12,9 11,7 12, , ,8 16,8 13,8 14,7 13,0 13,9 12,7 13, ,9 18,9 14,8 16,8 14,0 15,9 13,8 14, , ,0 21,0 16,9 18,9 16,0 17,9 14,8 16, ,1 23,1 19,0 21,0 18,0 19,9 16,9 18, ,2 25,2 21,1 23,1 20,0 21,9 19,0 21, ,3 27,3 23,2 25,2 22,0 23,9 21,1 23, ,4 29,4 25,3 27,3 24,0 25,9 23,2 25, ,5 31,5 27,4 29,4 26,0 27,9 25,3 27, , ,6 33,6 29,5 31,5 28,0 29,9 27,4 29, ,7 35,7 31,6 33,6 30,0 31,9 29,5 31, ,8 37,8 33,7 35,7 32,0 33,9 31,6 33, , ,9 39,9 35,8 37,8 34,0 35,9 33,7 35, ,0 42,0 37,9 39,9 36,0 37,9 35,8 37, Required pressure approx. valid for T * These sizes are not included in the EN Table corresponds to EN : A1:

29 STANDARD SYSTEM BASED ON EN Selection table for T and TKH ferrules Ferrule size / Code No. Measured Wire Rope Diameter Range (mm) Case 1 Fill factor 0,36 f 045 0,283 C 0,353 Case 2 Fill factor f 0,62 C 0,487 Case 3 Fill factor 0,62<f 0,78 0,487<C 0,613 * These sizes are not included in the EN Table corresponds to EN : A1: 2008 Case 4 Fill factor f 0,78 C 0,613 Identification s marked Diameter after pressing Straight length, L, after pressing approx. Required pressure approx. valid for T T TKH Min Max Min Max Min Max Min Max mm Tol mm kn 42* 42* 42,1 44,1 38,4 40,3 37,0 38,9 36,8 38, , ,1 46,2 40,0 42,0 38,0 39,9 37,9 39, * 46* 46,3 48,3 42,1 44,1 39,0 40,9 39,0 40, ,3 50,4 42,1 46,2 40,0 43,9 40,0 43, * 50* 48,4 52,5 44,2 47,9 42,0 45,9 42,0 45, ,5 54,6 46,3 50,4 44,0 47,9 44,0 47, * 54* 52,6 56,7 48,0 51,7 46,0 49,9 46,0 48, ,7 58,8 50,5 54,6 48,0 51,9 48,0 50, * 58* 56,8 60,9 51,8 55,6 50,0 52,9 49,0 52, ,9 63,0 54,7 58,8 52,0 54,6 50,5 54, L Ferrules: T and TKH have been validated according to EN regarding Ferrule Secured Eye Terminations and Ferrule Secured Endless slings. Wire rope: Above table applies to new bright or galvanized single layer steel wire ropes with round strands and rope grade Wire ropes shall conform to EN , 5 and 10. The types of rope shall be Ordinary or Lang lay. For higher tensile grade we have an approved system called T-LOC. For higher and lower filling factor, please contact our Technical Department. Note! Please refer to the TALURIT Ferrule Securing Instructions for further information. TKH ferrule (aluminium) Note! If the required pressure is higher than indicated in our tables or the length after swaging does not match our given after swage dimensions, then special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what has been tested. Always contact our technical department for guidance. 29

30 Rev TALURIT SPLICING SYSTEM Selection table for larger T ferrules Ferrule No. 62* * 78* 82* * 152* Wire rope Capacity Diameter (mm) Fill factor (f=0,40-0,45) Fibre Core (C= 0,314-0,353) Fill factor (f=0,45-0,60) Fibre Core and Steel Core (C=0,353-0,471) s marked identification Diameter after pressing Length after pressing approx. Required pressure approx. T Min Max Min Max T mm / Tol mm kn 61,0 65,2 69,4 73,6 77,8 82,0 85,1 93, * Available on request. T ferrules: Wire rope: Swaging: 65,1 69,3 73,5 77,7 81,9 86,1 90,3 98, ,7 59,5 63,3 67,2 71,0 74,8 77,7 82,5 88,9 95,2 101,6 106,9 114,1 120,1 127,0 139,5 152,0 59,4 63,2 67,1 70,9 74,7 78,6 82,4 88,8 95,1 101,5 106,8 114,0 120,0 126,0 133,5 147,0 160, DAP DAP DAP DAP DAP DAP DAP DAP DAP DAP ,8 0 +2,0 0 +2, , T ferrules above size 60 have been tested and validated according to TALURIT splicing system requirements. Please read our TALURIT carefully to secure a safe and correct swaging operation. For more information, please contact our technical department. Above table applies to new bright or galvanized single layer steel wire ropes with round strands and rope grade Wire ropes shall conform to EN and 5. The types of rope shall be Ordinary or Lang lay. For higher tensile grade, there is a system called T-LOC. For higher and lower filling factor, please contact our Technical Department. Note! Please read our TALURIT carefully to secure a safe and correct swaging operation. IMPORTANT! For T ferrules larger than size 60 there is a special method for multi-stage swaging! Always swage according to accurate instructions! When swaging an assembly with a thimble, we recommend a larger distance between the ferrule and the top of the thimble, than specified in the standard. Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! T ferrule (T) (aluminium) f = Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter.. C = f π 4 C = Nominal metallic crosssectional area factor of the rope Note! If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what is proven. Always contact our technical department for guidance.! IMPORTANT! For ferrules larger than size 60 there is a special method for multi-stage swaging! Always swage according to accurate instructions! 30

31 TURNBACK FERRULES T-LOC (steel reinforcement) T ferrule (aluminium) T-LOC before swaging Patent pending: Splitting ing risk on 2160 grade wire rope without T-LOC 3.2 T-LOC (STEEL REINFORCEMENT) TALURIT SYSTEM Application no. PCT/SE2010/ Reinforced aluminium termination. T-LOC after swaging GENERAL DESCRIPTION T-LOC is produced from carbon steel and designed for rotation resistant wire rope of grade 2160 together with T ferrules, especially in combination with solid thimble eyes. The system is tested with rotation resistant wire ropes in class 35(W) x 7 and has been validated according to EN The tested constructions are 34(W) x K7 and 39(W) x K7-WSC, fill factor: APPLICATIONS When using high tensile wire rope of grade 2160, T-LOC will secure the special sling eye which has a higher splitting force than normal. Since T-LOC is produced from carbon steel and has a better tensile strength than aluminium. Solid thimbles according to DIN 3091 as well as high rope grades will apply strain on the ferrule side nearest the sling eye. T-LOC prevents the aluminium ferrule from splitting due to pressure from the wider angle of the sling eye. TO BE NOTED No new dies are necessary, T-LOC is swaged in your existing dies along with the aluminium ferrule. During the swaging operation they re joined together seamlessly. Only aluminium T ferrules may be used together with T-LOC. Due to the variety of steel wire ropes, it is difficult to approve all of them. If other wire rope constructions and fill factors are to be used, tests must be done in order to verify the strength of application. T-LOC is available from stock for wire rope diameter range 8 to 55 mm. The distance from the T-LOC to the solid thimbles after swaging must be at least 1xD from the simulated point of the nominal wire rope diameter. 1 D Simulated point 31

32 Rev TALURIT SPLICING SYSTEM Selection chart for T-LOC ferrules Measured wire rope (grade 2160) (mm) 35(W) x 7 Fill factor: 0,74 f 0,75 T-LOC No. Min Max 10 8,0 9,0 11 9,0 9, ,0 10, ,0 11, ,0 12, ,0 13, ,0 15, ,0 17, ,0 19, ,0 21, ,0 23, ,0 25, ,0 27, ,0 29, ,0 31, ,0 33, ,0 35, ,0 37, ,0 39, ,0 43, ,0 47, ,0 51, ,0 54, ,7 59,9 Larger sizes available on request. Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! T-LOC ferrule, Steel reinforcement used together with a T ferrule f = Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = Nominal metallic crosssectional area factor of the rope. C = f π 4 T-LOC ferrules: The T-LOC system is tested and validated according to EN The tested constructions are 34(W) x K7 and 39(W) x K7-WSC, fill factor: Selection of the correct ferrule is to take account of: 1) the measured rope diameter 2) the rope type (and core) and 3) the nominal fill factor, f (or metallic cross-sectional area factor, C) of the rope. Wire Rope: Applicable wire rope is new rotation resistant wire ropes in class 35(W) x 7 as specified in EN The maximum rope grade is to be The types of rope lay shall be Ordinary or Lang lay. Swaging: Note! See separate swaging instructions for T-LOC on the following page. Please read our TALURIT carefully to secure a safe and correct swaging operation. 32

33 T-LOC SPLICING SYSTEM Swaging instructions Note! Use personal safety gear Matching wire rope to ferrule Selection of the correct ferrule is to take account of: 1) the measured rope diameter 2) the rope type (and core) and 3) the nominal fill factor, f (or metallic cross-sectional area factor, C) of the rope. f = Fill factor, is the ratio between the sum of the nominal metallic cross-sectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = Nominal metallic cross-sectional. area factor of the rope C = f π 4 Applicable rope types and grade Rotation resistant wire ropes in class 35(W) x 7 as specified in EN The maximum rope grade is to be The types of rope lay shall be Ordinary or Lang lay. Assembly (T-LOC is marked black) Thread ferrule and T-LOC on wire rope. Make the eye Incorporate thimble, if used. Further adjustment while swaging. Mount in lubricated dies. T-LOC must be positioned next to T ferrule. Use the swager s hold position and swage until T-LOC and ferrule are clamped. STOP. Measure. Distance T-LOC and solid thimble before swaging must be at least times the nominal diameter. For pointed thimbles the distance can be reduced.??? Swage T-LOC and ferrule (or first part of the ferrule, if the assembly is too long for the dies). Close dies. Make sure that T-LOC remains next to the T ferrule. If a second swaging is required, open dies and swage the second part of the ferrule. Close dies. 1xD Distance between thimble and T-LOC after swaging 1xD Simulated point Thimble with point 33

34 TALURIT THE ORIGINAL MECHANICAL SPLICING SYSTEMS Quality! 34

35 TURNBACK FERRULES TALUKON is a patented solution: Application no Condition for usage of TALUKON ferrules is a signed license agreement with Talurit AB. 3.3 TALUKON FERRULE TALURIT SYSTEM Design with square end; type TK and TKH Streamlined design, type TALUKON GENERAL DESCRIPTION The aluminium TALUKON ferrule has been developed to have a very tight streamlined fit around the wire rope after pressing. TALUKON splicing system is validated and fulfills the requirements of EN The aluminium ferrule is tapered in a milling machine to obtain the special design and inspection hole. TALUKON is available in sizes 18-44, art no: TKON. The ferrules are marked with a batch number and type number. APPLICATIONS TALUKON is tailor made for the lifting gear industry. TALUKON has the tightest fit around the wire rope than any other conical ferrule system. The taper has been designed so it will not get caught when lifting but should slide off, minimizing the risk of accidents. TO BE NOTED The inspection hole has been designed so that the exact insertion length can be achieved and verified after the swaging operation. Check after swaging that the wire rope has not slipped while swaging. TALUKON is a patented solution: Application no Conical ferrule for sling application. Condition for usage of TALUKON ferrules is a signed license agreement with Talurit AB. 35 KL 35

36 Rev TALURIT SPLICING SYSTEM Selection table for TALUKON ferrules Ferrule No. Wire rope Capacity Diameter (mm) Fill factor (f=0,40-0,45) Fibre Core C= 0,314-0,353 Fill factor (f=0,45-0,60) Steel Core C=0,353-0,471 s marked identification Diameter after pressing Straight length, L, after pressing approx. Required pressure approx. TKON Min Max Min Max TKON mm / Tol mm kn 18 16,9 18,9 15,4 17, , ,0 21,0 17,4 19, ,1 23,1 19,3 21, ,2 25,2 21,2 23, , ,3 27,3 23,1 24, ,4 29,4 25,0 26, ,5 31,5 26,9 28, , ,6 33,6 28,9 30, ,7 35,7 30,8 32, ,8 37,8 32,7 34, , ,9 39,9 34,6 36, ,0 42,0 36,5 38, ,1 44,1 38,4 40, , ,2 46,2 40,4 42, Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! L f = C = Fill factor, is the ratio between the sum of the nominal metallic cross-sectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = f π Nominal metallic cross-sectional area factor of the rope. 4 TKON ferrule (aluminium) TALUKON ferrules: Wire rope: Swaging: Note! TALUKON splicing system with ferrules type TKON has been validated according to TALURIT splicing system regarding Ferrule Secured Eye terminations. TALURIT splicing system is tested and approved according to EN TKON has a streamlined fit around the wire rope compared to other conical ferrules on the market. Above table applies to new bright or galvanized single layer steel wire ropes with round strands and rope grade Wire ropes shall conform to EN and 5. The types of rope shall be Ordinary or Lang lay. For higher tensile grade as well as higher and lower filling factor, please contact our Technical Department. See separate swaging instruction for TALUKON Ferrules on the following page. Please read our TALURIT carefully to secure a safe and correct swaging operation. TKON with tight fit Note!! If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what is proven. Always contact our technical department for guidance. IMPORTANT! Lubricate only the conical part in the dies before swaging. 36 KL 36

37 Rev TALUKON SPLICING SYSTEM SWAGING INSTRUCTIONS Use personal safety gear such as gloves, glasses and shoes! Clean the dies from grease and oil. Lubricate the conical part of the ferrule and the inspection hole. Note! It s important that the rest of the ferrule is not greased! Mount the steel wire rope inside the ferrule and place the ferrule in the correct position between the dies. Note! it s important that the dead end of the steel wire rope merely passes the inspection hole of the ferrule and nothing more Measure the distance between the dies when the ferrule is locked in position. Start swaging, but stop swaging when 2/3 of the ferrule is swaged. Remove the ferrule Lubricate the conical part of the ferrule once more and make sure there is no grease on the rest of the ferrule or on the cylindrical part of the dies. If the dies are greasy in the cylindrical part, remove this before continuing. Start swaging again and this time swage all the way until the dies meet. 10 Remove the flash material. 11 Make sure the dead end of the wire rope is visible in the inspection hole. The swaging procedure is now complete. 37 KL 37

38 TALURIT The original mechanical splicing systems 38

39 TURNBACK FERRULES TS ferrule Swaged TS ferrule 3.4 TS FERRULE TALURIT SYSTEM GENERAL DESCRIPTION The TS ferrule is the shorter version of the standard T ferrule. APPLICATIONS TS-ferrules corresponded to the old British standard, BS But due to the shorter length of the TS-ferrule, there is a limitation in strength. It is now used less commonly due to the limitations in performance for certain wire rope grades and applications. TO BE NOTED In low-grade wire rope applications, the TS ferrule can be an alternative to the T ferrule as the cost is lower. The TS ferrule is only tested and verified on strength on wire ropes up to grade KL 39

40 Rev TALURIT SPLICING SYSTEM Selection table for TS ferrules Ferrule No. Wire Rope Capacity Diameter (mm) Fill factor (f=0,40-0,45) Fibre Core C=0,314-0,353 Fill factor (f=0,45-0,60) Steel Core C=0,353-0,471 s marked Identification Diameter after pressing Length after pressing approx. Required pressure approx. TS Min Max Min Max T (mm) / Tol. mm (kn) 8 7,5 8,4 6,8 7, , ,5 9,5 7,8 8, ,6 10,5 8,7 9, , ,6 11,6 9,7 10, ,7 12,6 10,6 11, ,7 13,7 11,6 12, ,8 14,7 12,6 13, , ,8 16,8 13,5 15, ,9 18,9 15,4 17, , ,0 21,0 17,4 19, ,1 23,1 19,3 21, ,2 25,2 21,2 23, , ,3 27,3 23,1 24, ,4 29,4 25,0 26, ,5 31,5 26,9 28, , ,6 33,6 28,9 30, ,7 35,7 30,8 32, ,8 37,8 32,7 34, , ,9 39,9 34,6 36, ,0 42,0 36,5 38, * 42,1 44,1 38,4 40, , ,2 46,2 40,4 42, * 46,3 48,3 42,3 44, ,0 50,4 44,0 46, * 48,4 52,5 44,2 47, , ,0 54,6 46,3 47, * 52,6 56,7 48,0 51, ,0 58,8 50,5 51, , * 56,8 60,9 51,8 55, ,6 63,0 54,7 55, * These sizes are not included in the EN f = C = Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! TS ferrule (TS) Short aluminium ferrule Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. Nominal metallic crosssectional area factor of the rope. C = f π 4 TS ferrules: The TS ferrules have been validated according to TALURIT splicing system requirements. Since it is shorter than ordinary T ferrule, it only fulfills the requirements in the European standard EN up to grade Please read our TALURIT carefully to secure a safe and correct swaging operation. Wire rope: Above table applies to new bright or galvanized steel wire ropes with round strands and rope grade Wire ropes shall conform to EN and 5. The types of rope shall be Ordinary or Lang lay. Swaging: Note! The TS ferrules are swaged according to our specified swaging method for turnback ferrules. Please read the swaging instructions for turnback ferrules. If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what is proven. Always contact our technical department for guidance. KL 40

41 TURNBACK FERRULES UM ferrule (Ultragrip TM ) 3.5 UM AND K FERRULES TALURIT SYSTEM K ferrule (Konit TM ) GENERAL DESCRIPTION The aluminium ferrules UM (Ultragrip ) and K (Konit ) are made from a special designed profile. The UM ferrule corresponds to EN , the European standard and also to the Japanese standard for turnback ferrule or ferrule secured eye termination (FSET). The K ferrule has been validated according to TALURIT splicing system requirements. The ferrules are produced from seamfree extrusions which are extruded seamlessly over mandrel and the aluminium alloy is EN AW-5051A according to EN APPLICATIONS The UM ferrule and the K ferrule can be used in basic applications, with bright or galvanized single layer steel wire ropes with round strands up to fill factor 0,60 and grade The types of rope lay shall be Ordinary or Lang lay. For fibre core wire ropes larger than 60 mm the maximum rope grade is Wire ropes shall conform to EN and 5. THE CORRECT SIZE OF THE SLING EYE If a thimble is not used, the distance from the unswaged ferrule to the bearing point of the soft eye must be at least 15 x the wire rope diameter (D), as per the figure. Using a pin or a hook calculate max. 3 x pin diameter or the hook width to verify 15 x D or more. The width of the eye without load shall be approximately half its length. Pin diameter max h/3 Dimensions for eye and pin D D= Nominal rope diameter h TO BE NOTED The UM ferrule and the K ferrule become smaller in diameter after pressing than the T ferrule. The UM ferrule can be used as an alternative to the T ferrule at wire rope grades up to and including The UM ferrule and the K ferrule are available from stock in sizes from

42 Rev TALURIT TM SPLICING SYSTEM Selection table for UM and K ferrules Ferrule No. Wire Rope Capacity Diameter (mm) Fill factor (f=0,40-0,45) Fibre Core C=0,314-0,353 Fill factor (f=0,45-0,60) Steel Core C=0,353-0,471 Identification s marked Diameter after pressing Straight length, L, after pressing approx. Required pressure approx. Valid only for UM Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! UM K Min Max Min Max UM, K (mm) / Tol mm (kn) 9 9 8,3 9,0 7,6 8, , ,1 10,1 8,3 9, ,2 11,2 9,3 10, , ,3 12,3 10,3 11, ,4 13,4 11,3 12, ,5 14,5 12,3 13, ,6 16,1 13,3 14, , ,2 18,2 14,8 16, ,3 20,2 16,7 18, , ,3 22,4 18,5 20, ,5 24,6 20,5 22, ,7 26,9 22,6 24, , ,0 28,6 24,7 26, ,7 30,8 26,2 28, ,9 32,7 28,2 29, , ,8 34,9 30,0 31, ,0 37,1 32,0 33, ,2 39,2 33,9 35, , ,3 41,4 35,8 37, ,5 43,6 37,9 39, ,7 45,7 39,9 41, , ,8 48,0 41,8 43, ,1 50,6 43,9 46, ,7 55,0 46,3 50, , ,1 59,4 50,3 54, ,5 63,8 54,3 58, , ,9 67,6 58,3 61, , ,7 71,9 61,8 65, ,0 76,3 65,7 69, , ,4 80,7 69,8 73, ,8 85,0 73,7 77, ,5 93,7 81,7 85, , f = Ultragrip (UM) (aluminium) Konit TM (K) (aluminium) Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = Nominal Metallic crosssectional area factor of the rope. C = f π 4 L UM/K ferrules : The UM ferrules have been validated according to EN regarding Ferrule Secured Eye terminations and Ferrule Secured Endless slings. The K ferrules have been validated according to TALURIT splicing system requirements. Please read our TALURIT carefully to secure a safe and correct swaging operation. Wire rope: The table applies to new bright or galvanized single layer steel wire ropes with round strands. Maximum rope grade is Wire ropes shall conform to EN and 5. The types of rope shall be Ordinary or Lang lay. For higher tensile grade and higher fill factor, please contact our Technical Department. Swaging: Note! The UM ferrules and the K ferrules are swaged according to our specified swaging method for turnback ferrules. Please read the swaging instructions for turnback ferrules. If the required pressure is higher than indicated in our tables or the length after swaging does not match our given after swage dimensions, then special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what has been tested. Always contact our technical department for guidance. 42

43 TURNBACK FERRULES TCU ferrule TCUK ferrule 3.6 TCU AND TCUK FERRULES TALURIT SYSTEM GENERAL DESCRIPTION TCU and TCUK ferrules are made from Copper. These ferrules have been validated according to TALURIT splicing system, which is within the framework of EN The Copper material is not accepted in this standard. APPLICATIONS Copper is used together with stainless steel wire ropes to avoid galvanic corrosion in a saltwater environment. The same dies as in aluminium turnback ferrules can be used. The material is high grade copper in soft condition. The ferrules are seamlessly extruded over mandrel. TO BE NOTED We do not guarantee the strength of slings for lifting activities made of Copper turnback ferrules. A termination performed according to our instructions will normally withstand a tensile strength of 90% of minimum breaking load (MBL) of the wire rope. Verifying tests must be done to secure the strength of the termination. 43

44 Rev TALURIT TM SPLICING SYSTEM Selection table for TCU and TCUK ferrules Ferrule No. Wire Rope Capacity Diameter (mm) Fill factor (f=0,40-0,50) Fibre Core C=0,314-0,393 Fill factor (f=0,50-0,60) Steel Core C=0,393-0,471 Identification s marked Diameter after pressing Straight length, L, after pressing approx. Required pressure approx. Valid for TCU TCU TCUK Min Max Min Max T (mm) / Tol. mm (kn) 1 0,9 1,0 0,8 0, ,2 6,5 10 1,5 1,1 1,5 1,0 1,4 1,5 3, ,6 2,0 1,5 1, ,5 2,1 2,6 2,0 2,4 2, ,7 3,1 2,5 2, ,5 3,2 3,6 2,9 3,3 3, ,7 4,1 3,4 3, ,5 4,2 4,6 3,9 4,2 4, ,7 5,1 4,3 4, ,2 6,1 4,8 5, , ,5 6,2 6,6 5,7 6,1 6, ,7 7,1 6,2 6, ,2 8,2 6,7 7, ,3 9,0 7,6 8, ,1 10,1 8,3 9, , ,2 11,2 9,3 10, ,3 12,3 10,3 11, ,4 13,4 11,3 12, ,5 14,5 12,3 13, , ,6 16,1 13,3 14, ,2 18,2 14,8 16, , ,3 20,2 16,7 18, ,3 22,4 18,5 20, ,5 24,6 20,5 22, , ,7 26,9 22,6 24, ,0 28,6 24,7 26, ,7 30,8 26,2 28, , f = Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! Copper ferrule (TCU) (copper) L Copper ferrule (TCUK) (copper) Fill factor, is the ratio between the sum of the nominal metallic cross-sectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = Nominal metallic cross-sectional area factor of the rope. C = f π 4 TCU and TCUK ferrules: Wire rope: Swaging: Note! The TCU and TCUK ferrules have been validated according to TALURIT splicing system, which is within the frames of EN Copper as material is not accepted in this standard. We do not guarantee strength of slings for lifting activi ties made of Copper turnback ferrules. A termination performed according to our instructions will normally withstand a tensile strength of 90% of minimum breaking load (MBL) of the wire rope. Verifying tests must be done in order to find out the strength. Please read our TALURIT carefully to secure a safe and correct swaging operation. Above table applies to new stainless steel wire ropes as well as bright or galvanized wire ropes. It applies to single layer wire ropes with round strands and rope grade Wire ropes shall conform to EN and -5. The types of rope shall be Ordinary or Lang lay. For higher tensile grade and higher Fill factor, please contact our Technical Department. Note! Stainless steel as a material is not included in the EN standard for wire ropes. The TCU and TCUK ferrules are swaged according to our specified swaging method for turnback ferrules. Please read the swaging instructions for turnback ferrules. If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and has to be seen as guidelines. There will always be cases where some specifications are different from what is proven. Always contact our technical department for guidance. 44

45 TURNBACK FERRULES ST, SLST (carbon steel turnback ferrules) STS (carbon steel turnback ferrules) 3.7 ST, SLST AND STS FERRULES TALURIT SYSTEM GENERAL DESCRIPTION ST, SLST and STS turnback ferrules are made from carbon steel. These ferrules are typically more resistant to mechanical wear and have been validated according to EN The material used is in compliance with the standard. This carbon steel ferrule system is available in sizes APPLICATIONS Typically carbon steel ferrules are used when corrosion, higher temperature and special dragging applications are used. This system is also an alternative to the flemish eye, this is due to the fact that you have all the benefits as above but the simplicity of a straight turnback system. TO BE NOTED The turnback ferrule system is easy to use. It is quick, safe and has proved itself to be totally reliable. It is far more efficient than all other swaging methods on the market. 45

46 Rev TALURIT SPLICING SYSTEM Selection table for carbon steel turnback ferrules ST and SLST Ferrule No. Wire Rope Capacity Diameter (mm) Fill factor (f=0,45-0,52) Fibre Core C=0,353-0,41 Fill factor (f=0,58-0,60) Steel Core C=0,456-0,471 s marked Identification Diameter after pressing Straight length after pressing approx. Required pressure approx. Min Max Min Max ST/SLST (mm) / Tol. (kn) 17 16,0 16,8 15,5 16,3 ST/SLST 16 28,7 +0, ,8 18,3 16,3 17,8 ST/SLST 17 29, ,3 19,3 17,8 18,7 ST/SLST 18 32, ,3 20,2 18,7 19,6 ST/SLST 19 33,3 +0, ,2 20,9 19,6 20,3 ST/SLST 20 34, ,9 21,8 20,3 21,1 ST/SLST 21 35, ,1 23,2 ST/SLST 22 39, ,5 24,3 ST/SLST 23 40, ,6 24,5 ST/SLST 24 42, ,5 25,5 ST/SLST 25 43, ,5 27,5 ST/SLST 26 45, ,7 28,5 ST/SLST 27 46, ,9 28,8 ST/SLST 28 49,0 +0, ,9 29,8 ST/SLST 29 50, ,9 30,8 ST/SLST 30 53,0 +1, ,9 31,8 ST/SLST 31 54, ,9 32,8 ST/SLST 32 55, ,9 33,8 ST/SLST 33 56, ,9 34,8 ST/SLST 34 58, ) 35 34,9 35,8 ST/SLST 35 59, ) 39 37,9 38,8 ST/SLST 38 65, ) 39 38,9 39,9 ST/SLST 39 66, ) * Not applicable 1) Special request only 2) According to the table, kn is required to swage for instance ferrule no. 35. By using a multi stage swaging method a 600-ton swager is sufficient for larger ferrules. See page 2 for instructions on how to perform multi stage swaging. ST and SLST Ferrules: Wire Rope: Swaging: The ST and SLST ferrules have been validated according to the requirements in the standard EN regarding ferrule secured eye terminations. These carbon steel ferrules applies to new single layer round strand ropes with metallic core. Wire ropes shall conform to EN and 5, class 6 x 36, maximum rope grade is to be 1960, fill factor 0,58-0,60. For other classes, rope grades and fill factor verifying test must be performed. Steel wire rope with a fiber core has not been tested. Contact our Technical Department for more advice. The ST and SLST ferrules are swaged according to specific instructions for ST, SLST and STS ferrules on the page following the STS selection table. Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! ST, SLST ST and SLST ferrules have been validated according to EN regarding Turnback Eye Ferrule Secured Termination. ST and SLST Ferrule (carbon steel) f = Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter.. C = f π 4 C = Nominal metallic crosssectional area factor of the rope Note! Note! Please read our TALURIT carefully to secure a safe and correct swaging operation. If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. Always contact our technical department for guidance. 46

47 Rev TALURIT SPLICING SYSTEM Selection table for carbon steel turnback ferrules STS Ferrule No. Wire Rope Capacity Diameter (mm) Fill factor (f=0,45-0,52) Fibre Core C=0,353-0,41 Fill factor (f=0,58-0,60) Steel Core C=0,456-0,471 s marked Identification Diameter after pressing Straight length after pressing approx. Required pressure approx. Min Max Min Max STS (mm) / Tol. mm (kn) 5 4,3 5,2 4,0 4,9 5 10,0 +0, ,3 6,2 5,0 5,9 6* 12,3 ±0, ,3 7,2 6,0 6,9 7* 14,0 +0, ,3 8,2 7,0 7,9 8* 16,4 ±0, ,3 9,2 8,0 8,8 9* 18, ,3 10,2 8,9 9,8 10* 20, ) 10,3 11,2 9,9 10,9 11 1) 22,0 +0, ,3 12,2 11,0 11,8 12* 24, ) 12,3 13,2 11,9 12,8 13 1) * 26, ,3 14,2 12,9 13,8 14* 28,0 +0, ,3 16,2 13,9 15,7 16* 32, ,7 17, , , , , , , ,6 +0, , , ,8 29, ,0 +0, , , , ,0 39, ,0 +1, ,0 41, , ,0 43, , ,0 45, , ,0 47, , ,0 50, , ,8 54, , ,7 58, , ,9 63, , ,1 67, ,5 +1, ,3 70, , ,0 75, , ,0 79, , ,0 83, , ,0 88, , ,0 95, , IMPORTANT! Measure the wire rope and use the actual, not the nominal, diameter to find corresponding ferrule in this table! STS ferrules from size 42 are galvanized for better corrosion protection. * s suitable for swaging INOX ferrules in the corresponding size. s marked STS/INOX. STS ferrules have been validated according to EN regarding Turnback Eye Ferrule Secured Termination. Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! 1) Available on request. f = Fill factor, is the ratio between the sum of the nominal metallic crosssectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter.. C = f π 4 C = Nominal metallic crosssectional area factor of the rope STS Ferrules: The STS ferrules have been validated according to the requirements in the standard EN regarding ferrule secured eye terminations. The STS ferrules between size 5-16 differ in material compared to the larger sizes, but the entire STS system fulfills the requirements according to the standard. Please read our TALURIT carefully to secure a safe and correct swaging operation. STS sizes between 5-16 was previously called STD. Wire Rope: These carbon steel ferrules applies to new single layer round strand ropes with metallic core. Wire ropes shall conform to EN and 5, class 6 x 36, maximum rope grade is to be 1960, fill factor 0,58-0,60. For other classes, rope grades and fill factor verifying test must be performed. Steel wire rope with a fiber core has not been verified. Contact our Technical Department for more advice. Swaging: Note! The STS ferrules are swaged according to specific instructions for ST, SLST and STS ferrules on the following page. If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what is proven. Always contact our technical department for guidance. 47

48 TURNBACK FERRULES INOX ferrule 3.8 INOX FERRULES TALURIT SYSTEM GENERAL DESCRIPTION INOX turnback ferrules are made from stainless steel. The material is AISI 316 and the ferrules are validated according to the TALURIT splicing system. Available in sizes from Special sizes on request. APPLICATIONS The ferrules are commonly used in applications within the food processing industry and the nuclear industry. They have common uses in marine applications and they are widely used in architectural designs e.g. balustrades and fencing. TO BE NOTED These ferrules are normally used on stainless steel wire ropes to achieve the best possible resistance against corrosion. 48

49 Rev TALURIT SPLICING SYSTEM Selection table for INOX turnback ferrules Ferrule No. Wire Rope Capacity Diameter (mm) Fill factor (f=0,42-0,52) Fibre Core C=0,353-0,41 Fill factor (f=0,53-0,58) Steel Core C=0,416-0,455 s marked Identification Diameter after pressing Required pressure approx. INOX Min Max Min Max INOX (mm) / Tol. (kn) ,1 0,8 1,0 1 3,4 +0, ,5 1,2 1,6 1,1 1,4 1,5 3,9 +0, ,7 2,2 1,5 2,0 2 4, ,5 2,3 2,7 2,1 2,6 2, ,8 3,2 2,7 3, ,5 3,3 3,7 3,1 3,5 3,5 7, ,8 4,2 3,6 4, ,5 4,3 4,7 4,1 4,5 4,5 9, ,8 5,4 4,6 5,0 5 10,8 +0, ,5 6,4 5,1 6,1 6* 12,3 ±0, ,5 7,4 6,2 7,1 7* 14 +0, ,5 8,4 7,2 8,1 8* 16,4 ±0, ,5 9,5 8,2 9,1 9* 18, ,6 10,5 9,2 10,1 10* 20, ,6 11,5 10,2 11, , ,6 12,6 11,2 12,2 12* 24 +0, ,7 13,6 12,3 13,2 13* ,7 14,6 13,3 14,2 14* 28 +0, ,7 16,7 14,3 16,2 16* ,8 19,0 16,3 18, , ,1 21,0 18,3 20, ,1 23,1 20,3 22, ,2 25,2 22,3 24, , ,3 27,3 24,3 26, ,4 29,4 26,5 28, ,5 31,5 28,5 30, Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! f = INOX ferrule (Stainless steel) *s suitable for swaging STS ferrules in the corresponding size. s marked STS/INOX. Fill factor, is the ratio between the sum of the nominal metallic cross-sectional areas of all the wires in the rope and the circumscribed area of the rope based on its nominal diameter. C = Nominal metallic crosssectional area factor of the rope. C = f π 4 INOX ferrules: The INOX ferrules have been validated according to TALURIT splicing system. Wire rope: Above table applies to new stainless steel single layer wire ropes with round strands and rope grade For higher tensile grade and higher Fill factor, please contact our Technical Department. Swaging: Note! Note! The INOX ferrules are swaged according to our specified swaging method for turnback ferrules. Please read the swaging instructions for turnback ferrules in chapter 4. We do not guarantee strength of slings for lifting activities made of INOX-ferrules. A termination performed according to our instructions will normally withstand a tensile strength of 90% of the minimum-breaking load (MBL) of the wire rope. Verifying tests must be done to find out the strength. Please read our TALURIT carefully to secure a safe and correct swaging operation. If the required pressure is higher than indicated in our tables or that the length after swaging does not match our given after swage dimensions, special care must be taken! This is an indication that something is wrong or not matching the parameters in our tables. All selection tables are recommendations built on test results, standard requirements and experience and must be seen as guidelines. There will always be cases where some specifications are different from what is proven. Always contact our technical department for guidance. 49

50 TURNBACK FERRULES TALUCRIMP ferrule HOURGLASS sleeve 3.9 TALUCRIMP FERRULES AND HOURGLASS SLEEVES TALURIT SYSTEM GENERAL DESCRIPTION TALUCRIMP is a mechanical splicing system that is used on steel wire rope from 8 to 12 mm diameter (fibre and steel core). The ferrules are swaged onto the rope using light weight hand tools weighing less than 8 kgs. These tools provide an efficient turnback connection. HOURGLASS sleeves for eye, lap and stop splicing are available in aluminum. These sleeves are not made from seamless tubes! Do not use for lifting or other critical application. APPLICATIONS TALUCRIMP is a tested connection for steel wire rope in 7x19 Seale construction. This rope is used in the construction of ropes courses but also in forrestry applications. The HOURGLASS sleeves are used on farms for fences and also to make anti-theft protection on for example bicycle locks. TO BE NOTED TALUCRIMP ferrules and HOURGLASS sleeves are not approved for lifting purposes or other critical applications. Use our TALURIT swagers and follow our Ferrule Securing Instruction for these type of rope slings. 50

51 Rev TALURIT SPLICING SYSTEM Selection table for TALUCRIMP ferrules Wire Rope Diameter *(mm) Identification Ferrule No. Fibre core or steel core Tool marked** Approx. after pressing (mm) TALUCRIMP Min Max TC Diameter/Tol. Length (16) Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! (18) (20) (22) (24) * rope class max 1960 ** the number in bracket is marked in the bore of the press die and will be visible on the ferrule after pressing. Please check this number to be sure the correct tool was used for crimping. The number refers to the diameter of the crimped area. TALUCRIMP ferrule Wire rope: Above table applies to new single layer wire ropes with round strands and rope grade max For higher tensile grade and higher Fill factor, please contact our Technical Department. Note! TALUCRIMP splices are not approved for lifting purposes. A termination performed according to our instructions will normally withstand a tensile strength of 90% of the minimum-breaking load (MBL) of the wire rope. Verifying tests must be done in order to find out the strength. Please read our TALURIT carefully to secure a safe and correct swaging operation. Ropes according to EN and 5. Rev TALURIT SPLICING SYSTEM Selection table for HOURGLASS sleeves Article Code kg/1000 UGC inch mm (kg) 01,5 1/16 1,6 0, /64 2 0,6450 Please note that these instructions are only applicable to products produced and supplied by Talurit AB, Sweden and Gerro GmbH, Germany! 02,5 3/32 2,4 1, /8 3,2 2, /32 4 3, ,5 3/16 4,8 7, /32 5,6 10, /4 6,4 11,7600 Hourglass sleeve Note! These sleeves are not made from seamless tubes! Do not use for lifting or other critical application. These sleeves are not conform to European standard for ferrules EN Do not use for lifting or any critical application. To produce standard-compliant terminations, we recommend our T ferrule selection table. 51

52 4. SWAGING INSTRUCTIONS FOR FERRULE SECURED EYE TERMINATIONS Picture is showing a 1000T swager with a rigging device (RBS 75) 52

53 4.1 SELECTION OF TURNBACK FERRULES FOLLOWING TURNBACK FERRULES ARE INTENDED FOR USE ON STEEL WIRE ROPES: T ferrules (T) T Konit -ferrules (TK) T Konit -ferrules with inspection hole (TKH) T-LOC ferrule for reinforcement (T-LOC) TALUKON -ferrules (TKON) T ferrules short version (TS) Ultragrip Metal ferrules (UM) Konit ferrules (K) Steel ferrules (ST) Steel ferrules (SLST) Steel ferrules (STS) FOLLOWING FERRULES ARE INTENDED FOR USE ON STAINLESS STEEL WIRE ROPES: Copper ferrule (TCU) Stainless steel ferrule (INOX) T ferrule T-LOC C ferrule UM ferrule SLST ferrule TK ferrule TKON ferrule K ferrule STS ferrule TKH ferrule TS ferrule ST ferrule INOX ferrule! Only ferrules type T, TKH, UM, T-LOC (together with the T ferrule), ST, SLST, and STS correspond to the European standard EN SELECTING THE CORRECT FERRULE SIZE: The correct size of ferrule is selected from the applicable table for each type of ferrules. Note applicable rope types in each table. All our aluminium ferrules comply with this quality specification and to other material specifications stated in the ruling standards. All our ferrules are seamlessly extruded over mandrel. Ferrule selection is based on the following criteria: The rope grade, the diameter of the wire rope, the fill factor or metallic cross-sectional area factor, the wire rope core i.e. fibre core (FC) or steel core (IWRC= independent wire rope core). TCU ferrule Example of ferrule selection table Wire rope Capacity Diameter (mm) identification Ferrule No. Fill factor Fill factor s Diameter Length after Required (f=0,40-0,50) (f=0,50-0,60) marked after pressing pressure Fibre Core Steel Core pressing approx. approx. T TK TKH Min Max Min Max T/TK/TKH mm / Tol mm kn 1 0,9 1,1 0,8 1, ,1 6,5 5 1,5 1,2 1,6 1,1 1,4 1,5 3, ,7 2,1 1,5 1, , ,5 2,2 2,6 2,0 2,4 2, ,7 3,2 2,5 2, ,5 3,3 3,7 3,0 3,4 3, ,8 4,2 3,5 3, ,5 4,3 4,7 3,9 4,3 4, ,8 5,3 4,4 4, ,4 6,3 4,9 5, , ,5 6,4 6,8 5,9 6,2 6, ,9 7,4 6,3 6, ,5 8,4 6,8 7, ,5 9,5 7,8 8, ,6 10,5 8,7 9, , ,6 11,6 9,7 10, ,7 12,6 10,6 11, ,7 13,7 11,6 12, ,8 14,7 12,6 13, , ,8 16,8 13,5 15, ,9 18,9 15,4 17, , ,0 21,0 17,4 19, ,1 23,1 19,3 21, ,2 25,2 21,2 23, , ,3 27,3 23,1 24, ,4 29,4 25,0 26, ,5 31,5 26,9 28, , ,6 33,6 28,9 30, ,7 35,7 30,8 32, ,8 37,8 32,7 34, , ,9 39,9 34,6 36, ,0 42,0 36,5 38, ,1 44,1 38,4 40, , ,2 46,2 40,4 42, ,3 48,3 42,3 44, ,0 50,4 44,0 46, ,4 52,5 44,2 47, , ,0 54,6 46,3 47, ,6 56,7 48,0 51,

54 4.2 ASSEMBLY OF TURNBACK FERRULES MAKING THE EYE: Enter the wire rope into the ferrule. When the loop is formed the end of the wire rope is returned into the ferrule according to type as indicated in the figures. (D= wire rope diameter.) Note! The free end must always protrude after swaging, but must not protrude more than 0,5xD after swaging. To achieve the correct protrusion several attempts might be needed. In case of ropes severed by heat process, only the annealed portion shall protrude but no more than one rope diameter. EYE ASSEMBLY WITH A THIMBLE: The distance between the point of the thimble and the ferrule should be at least 1,5 x D (D= the nominal diameter of the wire rope) before swaging. When using a thimble without a point the distance should be at least 2 x D. Please note that this distance is measured with a caliper between the ferrule and the top of the thimble. We recommend larger distances than above for assemblies on large wire rope diameters (above 60 mm). 1,5xD before swaging Thimble with simulated point 1,5xD before swaging Thimble with point CONICAL FERRULES WITH INSPECTION HOLE: Before swaging conical ferrules with inspection hole, make sure that the short end of the wire rope is entered all the way to the back edge of the inspection hole! Some variations can occur depending on type of wire rope. THE CORRECT SIZE OF THE SLING EYE: If a thimble is not used, the distance from the unswaged ferrule to the bearing point of the soft eye must be at least 15 x the wire rope diameter (D), as per the figure. In some cases the sling eye should be even larger. Using a pin or a hook calculate maximum 3 x pin diameter or the hook width to verify 15 x D or more. The width of the eye without load shall be approximately half its length. Pin diameter max h/3 h Dimensions for eye and pin D= Nominal rope diameter D FIXING THE WIRE ROPE END IN THE FERRULE: If the end of the wire rope is fixed in the ferrule before swaging then this should be done with care and preferably with controlled pressure, e.g. with our pre-swaging machines. Avoid faulty or unnecessary deformation of the ferrule. Do not clench or hammer in the middle of the long side of the ferrule. See figure. Correct Wrong 54

55 4.3 SWAGING THE TURNBACK FERRULES PERSONAL SAFETY GEAR Always wear protectional safety gear such as gloves, glasses and shoes. CHECKING THE SWAGE DIES: Check that the ferrule type and code number corresponds with the details marked on the die.! Note! Our dies are not marked TCU; for these ferrules use the type markings for T ferrules. Before swaging the dies should be carefully cleaned and the bore of the dies should be lubricated. This will aid material flow and lengthen die life. 1/2 D POSITIONING OF THE FERRULE IN THE DIES BEFORE SWAGING: The figures to the right show how the ferrule should be positioned before swaging when using swage dies with rounding or taper. In straight cylindrical dies the ferrule is placed in the middle of the cylindrical bore. ( with one-sided rounding) Place the ferrule about half a wire rope diameter away from the die rounding. (Conical die) Place the ferrule centered in the straight cylindrical section of the die. See next page for more info (Conical die) Place the ferrule with the short wire rope end downwards and make sure the tap is in the inspection hole. 55

56 4.3 SWAGING THE TURNBACK FERRULES PERSONAL SAFETY GEAR Always wear protectional safety gear such as gloves, glasses and shoes. HOW TO COMPLETE A SWAGING: 1. Make sure the dies are set up correctly and aligned. Align upper and lower die. 2. Lubricate the bore of the dies. Lubricate the bore of the dies 3. Swage the ferrule, holding the wire rope with your two hands in a safe distance from dies, one at each side of the dies. Use both hands when swaging! The closing dies imply a risk of crushing! 4. The major axis of the oval ferrule cross-section must align with the direction of swaging. Use the regulating valve on the swager to find the correct pressure in addition with an oil drop test (see number 5). correct Align the ferrule wrong Align the ferrule Regulating valve 56

57 4.3 SWAGING THE TURNBACK FERRULES 5. On completion of the swaging operation the dies shall meet and the swaging must stop! Note! Talurit turnback ferrules are made for one swaging only. Do not turn and swage again! The upper and lower die shall meet, just slightly. 6. To ensure that the surfaces on the upper die and the lower die in fact meet each other there is a simple solution, we call it The oil drop test : Place an oil drop on the supporting edge of the lower die. Use the regulating valve to close the dies. When the oil drop is pressed out of the closing dies, the accurate pressure is achieved and must not be increased! Place an oil drop on the lower die When oil is pressed out, the correct pressure is achieved! Do not overload the dies! Only swage the ferrule in one direction. Never turn the ferrule! If the dies are overloaded they will be severely damaged 7. Fins or flash material shall be removed by a grinding method without damaging or reducing the round diameter of the ferrule. Flash material! Any flash material shall not be swaged back into the ferrule. Flash material 57

58 4.4 MULTI-STAGE SWAGING TURNBACK FERRULES WITH SHORT DIES All swagers have a capacity limitation for how large ferrules they can swage in one stage. By using the multi-stage technique, it is possible to extend this range of ferrules to larger sizes. The principle is to swage the back and front part of the ferrule in stages in order to close the dies completely. Back Front This method requires approximately half the pressure listed in the tables of Ferrule Securing Instruction. Note! Use the pressure regulating valve to find the correct pressure! Stage 1 LUBRICATE METHOD - SHORT DIES The procedure employing the short type dies involves moving the ferrule with the die remaining static in its fixed position see figures to the right. The pressure must be decreased to almost half the necessary pressure for full-length swaging. D/2 D/2 Ferrule Stage 1 Lubricate the dies! Positioned in the centre of the dies, start swaging the back part of the ferrule nearest to the sling eye (symbolized with green colour). Use the regulating valve to find the correct pressure. Stop swaging when the distance between the dies is approximately half the diameter of the wire rope. Front view Stage 2 Side view LUBRICATE Stage 2 Positioned in the centre of the dies, start swaging the front part of the ferrule closest to the free end rope (symbolized with yellow colour). Use the regulating valve to find the correct pressure to close the dies. Stop swaging when the dies meet. 0 Front view 0 Ferrule Side view! Do not overload the dies! Stop swaging when the dies meet. Stage 3 LUBRICATE Stage 3 Positioned in the centre of the dies, start swaging the back part of the ferrule nearest to the sling eye (symbolized with green colour). Use the same pressure as in stage 2. Stop swaging when the dies meet. Sometimes it is necessary to straighten the swaged ferrule by contact swaging afterwards in the middle of the ferrule. Only very low pressure is needed. Front view 0 Ferrule Side view 58

59 4.5 MULTI-STAGE SWAGING TURNBACK FERRULES WITH LONG DIES All swagers have a capacity limitation for how large ferrules they can swage in one stage. By using the multi-stage technique, it is possible to extend this range of ferrules to larger sizes. The principle is to swage the back and front part of the ferrule in stages in order to close the dies completely. Back Front This method requires approximately half the pressure listed in the tables of Ferrule Securing Instruction. Note! Use the pressure regulating valve to find the correct pressure! METHOD - LONG DIES The procedure employing the short type dies involves moving the ferrule with the die remaining static in its fixed position see figures to the right. The pressure must be decreased to almost half the necessary pressure for full-length swaging. D/2 Stage 1 D/2 LUBRICATE Ferrule Stage 1 The Long dies are installed at the centre line of the piston. Assemble the rope and ferrule and position in the centre line of the piston. Start the swaging as per standard procedure utilizing full pressure if needed. The swaging is completed if the dies meet (steps 2 & 3 are not required). If the dies do not meet, then proceed to steps 2 & 3 detailed below. Front view Stage 2 Side view Centre line of piston LUBRICATE Stage 2 Re-position the dies to their second fixing hole. Before starting to swage ensure the pressure regulating valve is reduced to approx. half of the maximum. pressure. The multi-stage swaging is performed on half the length of the ferrule. Care must be taken to ensure the entire swaging operation is carried out over the centre line of the piston. IMPORTANT! The pressure must be reduced for this and the following operation to ensure no damage is done to the dies. 0 Front view 0 Side view Ferrule Move the long dies so half the length will be in centre line of piston Stage 3 The multi-stage swaging is now completed by swaging the remaining half of the ferrule. The dies remain in the same position as in step 2 but the ferrule is moved in the direction of the arrow. Again, care must be taken to ensure the swaging takes place over the centre line of the piston. NOTE! To ensure that the ferrule is correctly swaged horizontally we suggest the flash is used as a guide. The flash can be broken off and the ferrule ground or filed to produce a smooth finish. Stage 3 Front view 0 Side view LUBRICATE Centre line of piston Ferrule 59

60 4.6 MULTI-STAGE SWAGING TURNBACK FERRULES ABOVE SIZE 60 All swagers have a capacity limitation for how large ferrules they can swage in one stage. By using the multi-stage technique, it is possible to extend this range of ferrules to larger sizes. The principle is to swage the back and front part of the ferrule in stages in order to close the dies completely. Back Front This method requires approximately half the pressure listed in the tables of Ferrule Securing Instruction. Note! Use the pressure regulating valve to find the correct pressure! Stage 1 LUBRICATE METHOD - SHORT DIES The procedure employing the short type dies involves moving the ferrule with the die remaining static in its fixed position see figures to the right. The pressure must be decreased to almost half the necessary pressure for full-length swaging. D/2 D/2 Ferrule Front view Side view Stage 1 Lubricate the dies! Positioned in the centre of the dies, start swaging the back part of the ferrule nearest to the sling eye (symbolized with green colour). Use the regulating valve to find the correct pressure. Stop swaging when the distance between the dies is approximately half the diameter of the wire rope. D/2 Stage 2 D/2 LUBRICATE Ferrule Stage 2 Positioned in the centre of the dies, start swaging the front part of the ferrule closest to the free end (symbolized with yellow colour). The pressure is the same as in stage 1 and there is no need to reset the regulating valve. Stop swaging when the distance between the dies is approximately half the diameter of the wire rope. Front view Stage 3 Side view LUBRICATE Stage 3 Positioned in the centre of the dies, start swaging the back part of the ferrule nearest to the sling eye (symbolized with green colour). Use the regulating valve to find the correct pressure. Stop swaging when the distance between the dies is approximately a quarter of the wire rope diameter. D/4 Front view D/4 Side view Ferrule 60

61 4.6 MULTI-STAGE SWAGING TURNBACK FERRULES ABOVE SIZE 60 Stage 4 Positioned in the centre of the dies, start swaging the front part of the ferrule closest to the free end (symbolized with yellow colour). The pressure is the same as in stage 3 and there is no need to reset the regulating valve. Stop swaging when the distance between the dies is approximately a quarter of the wire rope diameter. D/4 Stage 4 D/4 LUBRICATE Ferrule Front view Side view Stage 5 Positioned in the centre of the dies, start swaging the back part of the ferrule nearest to the sling eye (symbolized with green colour). Use the regulating valve to find the correct pressure. 0 Stage 5 0 LUBRICATE Ferrule! Do not overload the dies! Stop swaging when the dies meet. Front view Side view Stage 6 Stage 6 Positioned in the centre of the dies, start swaging the front part of the ferrule closest to the free end rope (symbolized with yellow colour). The pressure is the same as in stage 5 and there is no need to reset the regulating valve. Stop swaging when the dies meet. 0 0 LUBRICATE Ferrule Front view Side view! For other types of multi-stage swaging, please contact our technical department. 61

62 4.7 MULTI-STAGE SWAGING TURNBACK FERRULES ABOVE SIZE 60 TOGETHER WITH T-LOC All swagers have a capacity limitation for how large ferrules they can swage in one stage. By using the multi-stage technique, it is possible to extend this range of ferrules to larger sizes. The principle is to swage the back and front part of the ferrule in stages, this in order to close the dies completely. This method requires approximately half the pressure listed in the tables of the. Note! Use the pressure regulating valve to find the correct pressure! METHOD - SHORT DIES The procedure employing the short type dies involves moving the ferrule with the die remaining static in its fixed position see figures to the right. The pressure must be decreased to almost half the necessary pressure for full-length swaging. T-LOC T-ferrule Stage 1 Lubricate the die cavities! Insert max 40% of the ferrule between the dies in first step. Note! The T-LOC should be swaged together with the 40% of the ferrule in this first step. Start swaging the front part of the ferrule nearest to the sling eye. Use the regulating valve to find the correct pressure. Stop swaging when the distance between the dies is approximately half the diameter of the wire rope. D/2 Stage 1 Front view D/2 0,2xD Side view LUBRICATE Ferrule Stage 2 Insert the rest of the ferrule between the dies in the second step. Positioned in the centre of the dies, start swaging the back part of the ferrule closest to the free end. The pressure is the same as in stage 1 and there is no need to reset the regulating valve. Stop swaging when the distance between the dies is approximately half the diameter of the wire rope. D/2 Stage 2 D/2 LUBRICATE Ferrule Front view Side view Stage 3 Start swaging the front part of the ferrule nearest to the sling eye together with the T-LOC. Use the regulating valve to find the correct pressure. Stop swaging when the distance between the dies is approximately a quarter of the wire rope diameter. D/4 Stage 3 D/4 0,2xD LUBRICATE Ferrule Front view Side view 62

63 4.7 MULTI-STAGE SWAGING TURNBACK FERRULES ABOVE SIZE 60 TOGETHER WITH T-LOC Stage 4 Note! If the whole ferrule can be swaged in two stages, swage the remaining ferrule (see picture 4b). If not possible, devide the remaining part of the ferrule in two equal sections (4a and 4b). D/4 Stage 4a D/4 LUBRICATE Ferrule Stage 4a Start swaging the centre part of the ferrule. Stop swaging when the distance between the dies is approximately a quarter of the wire rope diameter. Front view Side view Stage 4b Note! This step is only required if the ferrule is too long to be swaged in two steps. Positioned in the centre of the dies, start swaging the back part of the ferrule. Stop swaging when the distance between the dies is approximately a quarter of the wire rope diameter. Stage 4b D/4 Front view D/4 Side view LUBRICATE Ferrule! Do not overload the dies! Stop swaging when the dies meet. Stage 5 0,3xD LUBRICATE Stage 5 Start swaging the front part of the ferrule nearest to the sling eye together with the T-LOC. Use the regulating valve to find the correct pressure. Stop swaging when the dies meet. 0 Front view 0 Side view Ferrule Stage 6 Positioned in the centre of the dies, start swaging the centre part of the ferrule. The pressure is the same as in stage 5 and there is no need to reset the regulating valve. Stop swaging when the dies meet. 0 Stage 6 Stage 7 Positioned in the centre of the dies, start swaging the back part of the ferrule closest to the free end rope. The pressure is the same as in stage 6 and there is no need to reset the regulating valve. Stop swaging when the dies meet. Stage LUBRICATE Ferrule Front view Side view LUBRICATE Ferrule! For other types of multi-stage swaging, please contact our technical department. Front view Side view 63

64 4.8 CHECKING AND MARKING AFTER SWAGING CHECK THE CONDITION OF THE SWAGED FERRULE Check that the ferrule has been properly swaged and the wire rope is correct in alignment. Each ferrule shall be visually examined, free from flaws and defects. Any flash produced on the ferrules should be removed without damage to the ferrule or the rope. CHECK THE DIAMETER AND LENGTH AFTER SWAGING At each set-up the swaged ferrule shall be dimensionally checked to verify that it is within the diameter and when applicable length limits specified in the tables for ferrules. Each swaged ferrule after the set-up shall be checked for diameter to verify that it is within the diameter limits. SWAGING WITH A THIMBLE If a thimble is incorporated the point of the thimble should be at least 1 x D (the diameter of the wire rope) away from the ferrule after swaging. See figure. When using a thimble without point, the point has to be simulated and the distance from the simulated point must be minimum 1 x D after swaging. Thimbles are recommended to follow applicable standard. Note! The distance is measured with a caliper between the ferrule and the top of the thimble. WARNING! If the ferrule is swaged too close to the thimble there is a severe risk of splitting the ferrule. Correct! The wire rope is alligned and the ferrule is round. Wrong! The top and the bottom half of the ferrule are displaced. Always check the diameter after swaging Min. 1xD after swaging Thimble with point Min. 1xD after swaging Wrong! The ferrule has cracked during swaging CHECK THE SIZE OF THE DEAD END Make sure the dead end of the wire rope protrudes from the ferrule after swaging. Our recommendation is less than 0,5 x D (the diameter of the wire rope), to exceed this can cause injury. In case of conical ferrule make sure the dead end is visible in the inspection hole. Thimble with simulated point Max. D/2 MARKING OF FERRULES AFTER SWAGING Marking of swaged ferrules should be carried out according to ruling standards. Use a steel stamp or our marking machines. The following maximum letter sizes and maximum depth of impression are valid: For ferrule No. Max. letter Size Max. impression depth mm 0,5 mm mm 1,0 mm 64

65 Splicing System Instructions 4.9 USAGE AND SCRAPPING NON SUITABLE ENVIRONMENTS Ferrule secured eye terminations of aluminium, copper, steel and INOX shall not be exposed to temperatures outside the range: -40 C to 150 C (IWRC) -40 C to 100 C (FC) See table below! Nor should they be exposed to long-term submersion in seawater. DE-RATED WORKING LOAD LIMIT OF SLINGS DUE TO TEMPERATURE (according to EN ) Sleeve material Rope core De-rated working load limit expressed as % of WLL of the sling Temperature, T, C -40<T <T <T <T <T <T Aluminum Fibre 100 Do not use Do not use Do not use Do not use Do not use Aluminum Steel Do not use Do not use Do not use Do not use Copper Fibre 100 Do not use Do not use Do not use Do not use Do not use Copper Steel Do not use Do not use Do not use Do not use Steel Fibre 100 Do not use Do not use Do not use Do not use Do not use Steel Steel do not use INOX Fibre 100 Do not use Do not use Do not use Do not use Do not use INOX Steel Do not use Do not use Do not use Do not use CHECK FOR DEFORMATION AND CHECK DIAMETER AND LENGTH Slings shall be taken out of use if their ferrules have been exposed to deformation or when the outer diameter has been reduced to less than 95% of the original diameter. The TKH ferrule has an inspection hole to ensure the short end of the wire rope is correctly positioned after swaging. The ferrule is swaged in a die with a spigot to ensure that the inspection hole remains open after swaging. This check could also be used during service. 65

66 Splicing System Instructions 4.9 USAGE AND SCRAPPING DECOMMISSIONING, DISMANTLING AND SCRAPPING We are committed to the protection of the environment. We strive to minimize the environmental impact of our products by continuously improving product design and our manufacturing methods. After the working life of the machine the user must have it dismantled and its components removed as per EEC directives or in accordance with current legislation of the country in which the machine is located, taking particular care over the dismantling of the following materials of environmental impact:» plastic and rubber parts» coated electric wiring and electric motor» metal parts and press body» fluids Drainage and collection of used oils and coolants must be handled with care. Appropriate waste separation, collection, environmentally compatible treatment and disposal is intended to reduce harmful environmental effects and promote the reuse and recycling of materials contained in the equipment. We recommend to follow local authorities regulations about recycling and disposal. Talurit AB is available for advise in all in all questions regarding decommissioning, dismantling, disposal and scrapping. Unlawful disposal of such equipment will be subject to the application of administrative sanctions provided by current legislation. Talurit AB are prepared to take care of your unit after its working life and are able to recycle the material in a correct way. TYPE OF DISPOSAL PRODUCT Plastic and rubber parts Coated electric wiring and electric motor Metal parts and press body Fluids HOW TO HANDLE? Recycling according to local authorities directive Recycling according to local authorities directive Metal scrap at recycling station or recycling according to local authorities directive Destruction, disposal or recycling according to local authorities directive 66

67 The original mechanical splicing systems 67

68 Talurit AB Amalia Jönssons gata Västra Frölunda SWEDEN Phone: Service: Fax: Website: Talurit (UK) Ltd R-Eevolution Gateway 36 Unit 3 Kestrel Way Birdwell, Barnsley South Yorkshire ENGLAND S70 5SZ Phone: info@talurit.co.uk Website: Gerro GmbH Carl-Benz-Strasse Gottmadingen GERMANY Phone: Fax: info@gerro.de Website: Talurit Pte Ltd 151 Chin Swee Road #03-30 Manhattan House SINGAPORE Phone: Fax: info@talurit.sg Website: Talurit Machinery (Ningbo) Co., Ltd No. 982 Mingzhou Road, Beilun Ningbo , Zhejiang CHINA Phone: +86 (574) Fax: +86 (574) info@talurit.cn Website: