Wire rope is a vital component in industries where heavy lifting, rigging, and securing loads are essential. From construction to marine applications, it is known for its strength and versatility. However, ensuring the safety and effectiveness of wire rope starts with proper handling, including cutting and attaching it correctly.

1. Understanding Wire Rope Structure

Before diving into the cutting and attachment process, it’s essential to understand the anatomy of wire rope. Wire rope consists of several strands of wire twisted together around a central core. The core could be a fibre core (FC), a wire strand core (WSC), or an independent wire rope core (IWRC). Different applications will require different types of wire rope based on their strength, flexibility, and durability.

2. Tools You’ll Need to Cut Wire Rope

Cutting wire rope requires the right tools to prevent fraying and ensure a clean, safe cut. Here’s what you need:

• Wire rope cutters: Specifically designed to cut through the strands without crushing or fraying them. Standard bolt cutters are not recommended.
• Tape or electrical tape: To wrap the wire rope before cutting to prevent unwrapping.
• Marking tool: A marker or chalk to indicate where you’ll make the cut.
• Safety gear: Gloves, eye protection, and possibly hearing protection if using powered cutting tools.

3. How to Cut Wire Rope

Now that you have your tools ready, follow these steps for a clean cut:

• Mark the rope: Use a marker or chalk to mark the spot where the cut will be made.
• Wrap the tape: Before cutting, wrap the area to be cut tightly with electrical tape. This prevents the strands from fraying or unravelling.
• Position the cutters: Place the wire rope cutters at the mark and apply steady, even pressure until the rope is cut cleaning through. For thicker ropes, consider using powered cutters. For rotational resistant ropes wire seizing is required for securing either side of the cut.
• Inspect the gear: Once the rope is cut, inspect the ends to ensure there are no frayed wires. If needed, trim any frayed ends with pliers.

4. Attach Wire Rope Fittings

After cutting the wire rope, the next critical step is attaching the appropriate fittings. Fittings such as thimbles, wire rope grips, and swage sleeves are commonly used to form secure loops or terminations. Note: all wire ropes with a end terminations are required to be tested before use. Here’s how to attach some of the fittings properly:

1. Using wire rope grips: Wire rope grips are U-bolt style clamps used to secure the ends of wire rope. When used correctly, they provide a strong, reliable connection. Here’s the correct way to attach wire rope grips:
   • Form a loop: Begin by forming the desired loop size at the end of the wire rope.
   • Attach the first clip: Place the U-bolt of the grip over the dead end (the shorter cut end) of the rope, and the saddle on the live end (the longer, continuous rope). Tighten the nuts evenly.
   • Attach additional clips: Depending on the diameter of the wire rope, you may need more than one grip. As a rule of thumb, use at least three grips for small diameters and more for larger diameters. Space them evenly along the dead end, tightening each one securely. Note: Please refer to Australian Standard AS 2076 for the number of wire rope grips to include.
   • Recheck tension: After the grips are attached, recheck their tension after the first load is applied. Tighten if necessary.
   • Using Ferrules: Ferrules are often used for a more permanent attachment. These sleeves compress around the wire rope, forming a tight, immovable grip. You will need a swaging tool for this process:
     • Slide the ferrule on: Slide the swage sleeve onto the wire rope before forming a loop.
     • Create the loop: pull the wire rope through the fitting or around the object it needs to be secured to, then slide the end back through the swage sleeve.
     • Compress the ferrule: Use the swaging tool to compress the sleeve according to the manufacturer’s specifications. This creates a permanent, secure connection.
     • Check the connection: After swaging, double-check the compression points for any gaps or inconsistencies to ensure the rope is securely attached.