Correct Fastening Methods and Common Mistakes for Wire Rope Clips

Wire Rope Clips, also known as wire rope clamps, are common fittings used at the end of wire ropes, primarily to form a load-bearing eye loop or to connect two rope ends. Examples include: connecting the ends of crane or winch cables; securing wire rope that passes through eyelet lifting points or shackles; and for perimeter ropes in locations like docks or parking lots.

The U-bolt clip is the most common type of wire rope clip, typically made from forged or malleable steel. It consists of a U-bolt, two nuts, and a metal base (saddle).

1. Clips made from malleable cast iron or cast steel should only be used where loads are relatively light, such as for wire ropes in railings, fences, or guardrails. The base of these clips, made from cast steel, does not possess ideal metallic properties, may fracture if overloaded, and lacks the advantageous grain structure of a forged base.

2. Clips made by drop-forging have a base made from forged steel. This type of clip is heated and hammered into shape, creating a consistent grain structure in the steel. These clips are generally used for critical applications, heavy-duty operations, or sustained overhead work—such as for winch lines, crane hoist ropes, support ropes, guy lines, tow lines, tie-downs, and scaffold cables. They are the ideal choice for the marine and industrial Rigging industries.

Pre-use Checks:
Before use, visually inspect the wire rope clip for damage, corrosion, wear, and cracks. Also, check that the clip is clearly marked with permanent identification, including the size and manufacturer's name. Additionally, inspect the clip to ensure the assembled clip's size, type, and components match the requirements.

1. Ensure the wire rope clip is oriented correctly.

2. When using a wire rope clip, always place the saddle on the live (load-bearing) end of the rope.

3. Ensure the wire rope clip is tightened to the proper specification.

4. Check the torque after use and re-tighten if necessary.

5. Follow the correct procedure when installing wire rope clips.

6. When using multiple clips, arrange them in a straight line with the U-bolts contacting the dead (short, tail) end of the rope, not the live end. If the U-bolt contacts the live end, it can crush the rope, leading to broken wires when under load.

How to Install Wire Rope Clips on an Eye Loop or Thimble:

1. First, place the wire rope into a thimble or form it into a loop to create an eye. Make the number of rope turns back (if applicable) as specified by the manufacturer.

2. Install the first clip one saddle-width from the dead end of the rope. Tighten the nuts on the wire rope clip using a torque wrench.

3. If a second clip is required, place it as close to the eye loop or thimble as possible. Again, always use a torque wrench to tighten the nuts correctly.

4. If more than two clips are needed, space them evenly between the first two installed clips. Again, always use a torque wrench to tighten the nuts correctly.

After installing wire rope clips, it is necessary to periodically cycle the rope under load and re-tighten the clips. The torque on the nuts is critical and must be monitored, as they can loosen with repeated use.

Common Mistakes When Installing Wire Rope Clips:

1. Torque not according to the manufacturer's specification.

2. Using fewer clips than the number recommended by the manufacturer.

3. Incorrect spacing between multiple wire rope clips.

4. Incorrectly placing the clip saddle on the wrong part of the rope assembly.

5. Placing the U-bolt of the clip on the live end of the rope.

6. Alternating the orientation of U-bolts (some on live end, some on dead end) instead of having them all on the dead end.

7. Incorrect number of rope turns when forming an eye loop.

8. Clip type not matching the actual application requirements.

9. Clip size not matching the wire rope size.

10. Failing to cycle the rope and periodically re-tighten the wire rope clips.