There are many common mistakes made when installing wire rope clips. However, one of the most common mistakes is an incorrectly positioned saddle. You can avoid this mistake by understanding how a saddle should be positioned when installing your wire rope clips.
When installing U-Bolt wire rope clips, the saddle should be positioned on the live end of the rope while the U-Bolt is on the dead end of the rope. The phrase “don’t saddle a dead horse” will help remind you that the saddle should never be positioned on the dead end of the rope.
By correctly installing a wire rope clip with the right saddle position, you can maximize the holding power of the clip. Once we’ve explained how to position your saddle during the installation process correctly, we’ll discuss the steps in more detail and outline other common mistakes!
How Should Saddle Be Positioned When Installing Wire Rope Clips?
Overall, there are two main types of wire rope clips used today. While U-Bolt clips are the most widely used type, double saddle wire rope clips are also used by some. This section will discuss how to correctly position the saddle when installing each type of wire rope clip.
U-Bolt Wire Rope Clips
U-Bolt wire rope clips can be tricky to install. It requires careful condition and attention to ensure the saddle is correctly positioned when installing the wire rope clips. These clips consist of a U-bolt, two nuts, and a metal saddle. Typically, the saddle is made from cast iron or forged steel.
Wire rope clips with cast iron saddles are used for light duty uses, such as smaller applied loads. However, wire rope clips with forged steel saddles are intended for heavy-duty uses, such as crane hoist lines and towing lines. When installing U-Bolt wire rope clips, you need to ensure you’re using the correct saddle type for your load – and that it’s correctly positioned.
Regardless of what the saddle is made from with U-Bolt wire rope clips, it needs to be in the same position during installation. When securing the rope eye, the clip’s saddle should rest on the rope’s live end. The clip’s U-Bolt should rest on the dead end of your rope.
The mistake of positioning the saddle on the dead end of the rope is known as “saddling a dead horse.” Basically, this means you’ve incorrectly placed the clip’s saddle on the dead end of your rope. This mistake should be avoided when installing your wire rope clips. You can remember the phrase “never saddle a dead horse” to avoid this mistake.
Double Saddle Wire Rope Clips
Unlike the U-Bolt variant, double saddle wire rope clips are comprised of two saddles and two nuts. Due to this design, these wire rope clips can be used in either direction. Naturally, this makes double saddle wire rope clips much easier to install. With this type of wire rope clip, you’ll never need to worry about incorrectly positioning your saddle during installation.
How To Properly Install Wire Rope Clips With Correct Saddle Position
Now that we’ve discussed the correct saddle position to use when installing wire rope clips, let’s outline the process of installing these clips!
Step One: Gather Your Supplies
To correctly install wire rope clips, you’ll need the following supplies:
- Wire rope clips
- Wire rope
- Torque wrench
- Tape measure
- Seizing tape or wire
Step Two: Prepare For Installation
Start by using the tape to size the end of the wire rope – this ensures the strands stay together. For heavy-duty loads, a thin wire should be used instead of the seizing tape.
Step Three: Measure Wire Rope’s Turnback
Next, you’ll need to measure the turnback portion of your rope, which runs from the base of the eye to the rope’s dead end. The amount of turnback required will vary depending on the type of clips used and their size. After this, you should create the assembly eye. Finally, mark the live end and dead end of the rope with the marker – this will ensure you use the correct saddle position!
Step Four: Apply Your Wire Rope Clips
If you’re using U-Bolt wire rope clips, the U-Bolt should be applied to the wire rope’s dead end. The nuts should then be tightened to the recommended torque. The second should be placed near the loop or thimble when using just two clips. When three or more clips are used, the additional clips should be evenly spaced between the first two clips.
When using U-Bolt wire rope clips, you should ensure the saddle is positioned on the live end of the wire rope. The U-Bolt should be positioned on the dead end. If you’re using double saddle clips, you don’t need to worry about their positioning.
Step Five: Test Assembly By Applying First Load
Finally, you can apply your first load to test the assembly. The test load should weigh more than the loads expected in use. After testing the assembly, you should retighten the nuts with the recommended torque in mind.
Other Common Mistakes Made When Installing Wire Rope Clips
As we explained earlier, an incorrectly positioned saddle – also called “saddling a dead horse” – is one of the most common mistakes when installing wire rope clips. Here are five additional mistakes to avoid during the installation process!
#1: Not Retightening The Wire Rope Clips
Another common mistake is not retightening your wire rope clips. Due to repeated use, these clips will loosen. If these wire rope clips are not retightened, they will inevitably fail and could result in an injury.
#2: Using The Wrong Type Of Wire Rope Clip
Cast iron wire rope clips should be used for light-duty uses, while forged steel wire rope clips should be used for heavy-duty uses.
#3: Using Too Few Clips For Rope Thickness
The minimum number of clips a wire rope needs will depend on the rope’s thickness. The thicker the rope’s diameter is, the more clips you’ll need. Many people use too few clips for thicker ropes.
#4: Incorrect Spacing Between Wire Rope Clips
Incorrect spacing between wire rope clips is another common mistake! When three or more wire rope clips are used, the additional clips should be spaced equally between the first two clips.
#5: Incorrect Torque Levels Used For Wire Clips
The last mistake to avoid when installing wire rope clips is not adhering to the recommended torque. When tightening and retightening nuts, you’ll need to ensure you reach the recommended torque for safe usage.
It is important to place the saddle on the live end of the rope when installing U-Bolt wire rope clips. The U-Bolt should be positioned on the dead end of the rope. To remember the correct saddle position, you can use the “never saddle a head horse” phrase. Essentially, this means the saddle should not be positioned on the rope’s dead end. Double saddle wire rope clips can be used in either position.