General Cautions

1. Measure the Rope Ends to be socketed
The rope should be of sufficient length so that the ends of the unlaid wires from the strands will be at the top of the socket basket. (Fig. 1)

2. Apply Serving at Base of Socket
Apply a tight serving band for length of two rope diameters, at the point where the socket base will be to eliminate any distortion below the band of the wires and strands.

3. Broom Out Strand Wires
Unlay and straighten the individual rope strands and spread them evenly so that they form an included angle of approximately 60 degrees. Unlay the wires of each individual strand for the full length of the rope end-being careful not to disturb or change the lay of the wires and strands under the serving band. Unlay the wires of the independent wire rope core (IWRC) in the same manner. A fiber core should be cut out and removed as close to the serving band as possible. (Fig 2)

4. Clean the Broomed-Out Ends
A suggested cleaning solvent for this step is Bromothane R or equivalent solvent. These are known under n-Propyl Bromide or Normal Propyl Bromide (nPB).

Other proven cleaning methods may be used, such as hot detergents. The continued availability of the current cleaning solvents is uncertain due to the federal regulations concerning ozone depleting substances. For information on available solvents consult the solvent suppliers.

Swish the broomed-out end in the solvent, then brush vigorously to remove all the grease and dirt. Make certain that the wires are clean to the very bottom of the broom up to the serving band (Fig. 3). One of the best and preferred cleaning methods for rope ends prior to socketing is ultrasonic cleaning using a suitable solvent. After this cleaning step, place the broomed-out end pointing downward, allowing it to remain until all solvent has evaporated and the wires are dry.

Solvent should never be permitted to remain on the top or on the serving band since it will run down the wires when the rope is turned upright

5. Dip the Broomed-Out Rope Ends in Flux
Mix a flux comparable to hot zinc-ammonium chloride with 1 gallon of water; maintain a solution temperature of 180 degrees to 200 degrees F. Swish the broomed-out end in the flux solution (Fig, 4), then point the rope end downward until the wires have dried thoroughly.

6. Close Rope Ends and Place Socket
Use clean seizing wire to compress the broomed-out end into a tight bundle which will permit the socket to be slipped easily over the wires (Fig. 5). Before placing the socket on the rope, make certain the socket is clean and no moisture is present inside the bowl of the socket. Heating the socket will dispel any residual moisture and will also prevent the zinc from freezing or cooling prematurely.

Another method of placing the socket onto the rope is to first cover the end of the rope with a wrapping or split tubing; then slide the socket onto this section of the covered rope, this will prevent contamination of the inner surface of the socket by the wire rope lubricant. Once the end of the wire rope is cleaned and broomed, the socket can be slid into position and the wrapping or split tubing can be removed.

CAUTION: Never heat a socket after it has been placed on the rope. This could cause damage to the rope.

After the socket is on the rope, the wires should be distributed evenly in the socket basket so the zinc can surround each wire. Use extreme care in aligning the socket with the rope's center line, and in making certain there is a minimum vertical length of rope extending from the socket equal to about 30 rope diameters. This vertical length is necessary for rope balance. Premature wire breaks at the socket can occur if the rope is not balanced at pouring.

Seal the socket base with fire clay or putty but make certain the material does not penetrate into the socket base. Should this occur, it could prevent the zinc from penetrating the full length of the socket basket thereby creating a void (fig 6).

Insert Lube Tube in middle of basket, if required.

7. Pour the zinc
Pour the zinc at a temperature between 925 degrees and 975 degrees F (Fig. 7).

CAUTION: Do not heat zinc above 1000 degrees F. Overheating of zinc may affect its bonding properties. The zinc temperatures may be measured with a portable pyrometer or thermocouple. Remove all dross from the top of the zinc pool before pouring. Pour the zinc in one continuous stream until it reaches the top of the basket and all wire ends are covered. There should be no "capping" of the socket, unless the customer requires a smooth surface with no shrinkage on the top of the basket. The use of a pinhole in the basket may be employed to allow air and voids within the zinc.

8. Remove Serving
After the zinc and socket have cooled, remove the fire clay or putty and the serving band from the socket base, and check to make certain that the zinc has penetrated to the socket base.

9. Lubricate the Rope
Apply the wire rope lubricant to the rope at the base of the socket and on any rope section where the original lubricant may have been removed.

1. Measure the Rope Ends to be socketed
The rope should be of sufficient length so that the ends of the unlaid wires from the strands will be at the top of the socket basket. (Fig. 8)

2. Apply Serving at Base of Socket
Apply a tight serving band for length of two rope diameters, at the point where the socket base will be to eliminate any distortion below the band of the wires and strands.

3. Broom Out Strand Wires
Unlay and straighten the individual rope strands and spread them evenly so that they form an included angle of each individual strand for the full length of the rope end-being careful not to disturb or change the lay of the wires of the independent wire rope (IWRC) in the same manner. A fiber core should be cut out and removed as close to the serving band as possible. (Fig. 9)

4. Clean the Broomed-Out Ends
A suggested cleaning solvent for this step is Bromothene R or equivalent solvent (Fig. 10). It is also known under the names N-Propyl Bromide or Normal Propyl Bromide (nPB), Perchorthane, and Perchlorethylene. Other proven cleaning methods may be used, such as hot detergents. The continued availability of current cleaning solvents is uncertain due to federal regulations concerning ozone depleting substances. For information on available solvents, consult the solvent supplier.

5. Close Rope Ends and Place Socket
Place rope in a vertical position with the broom end up. Close and compact the broom to permit insertion of the broomed end into the base of the socketing (Fig. 11). Slip the socketing on, removing any temporary banding or seizing as required. Make certain the broomed wires are uniformly spaced in the basket, with the wire ends slightly below the top edge of the basket, and the axis of the rope and the fitting are aligned. For sockets with grooves it is recommended to fill the grooves with clay or putty. Seal the ring-like space between the base of the socket and the rope to prevent leakage of the resin from the basket.

In addition to normal sealing materials, non-hardening butyl rubber-base sealant or latex glazing compounds are satisfactory for this purpose. Make sure the sealant does not enter the base of the socket so the resin will be able to fill the complete depth of the socket basket (Fig. 12).

6. Pouring the Resin
Mix and pour the resin in strict accordance with resin manufacturer's instructions (Fig. 13).

7. Lubrication After Socket Attachment
After the resin has cured, re-lubricate the wire rope at the base of the socket to replace any lubricant that may have been removed during the cleaning operation.

8. Resin Properties
All properties and precautions of resins should be obtained from the resin manufacturers. Take special note of the "shelf life" of the resin being used.