6611 LuYOdad 14N

THE PROBLEM

Conduct tests to determine which cables are most suitable
for oceanographic applications.

RESULTS

1. Extensive tests were conducted on 14 cables now in
general use for marine operations, to determine their resistance
to elastic and rotational stretch.

2. The 3 x 19 cable was found to have characteristics that

would favor its use for sensitive oceanographic problems when
compared with the other cables tested.

RECOMMENDATIONS

1. On the basis of the evaluation reported here, consider
the 3 x 19 cable the most suitable of those now available for pre-
cision oceanographic applications.

2. In future procurement of oceanographic cables, conduct
similar tests on sample lengths before adopting any new types.

3. Continue investigation of new cable designs for oceano-
graphic use.

HANAN

0 0301 0040531 e2

ADMINISTRATIVE INFORMATION

Work was performed under SR 004 03 01, Task 0539 (NEL
14-1). The report covers work from March 1952 to September
1963 and was approved for publication 13 November 1963.

CONTENTS

INTRODUCTION... page 5
FACTORS IN CABLE EFFECTIVENESS... 5
HAZARDS TO CABLE IN OCEANOGRAPHIC OPERATIONS... 7
Corrosion. ..7
Abrasion... 8
Stretch. ..9
Rotation... 9
TEST PROCEDURE ...1210
SUMMARY... 722
TABLES
1 Major Characteristics of Principal Cable Materials ... page 13

2-15 Results of Tests for Stretch Characteristics... 25=31

ILLUSTRATIONS

Figure

1-2

Tractor and fittings used for raising and lowering test
cables... page 32, 33

Hanger and weights used for loading cable. . . 34

4000-1b load on 3 X 31 wire rope of 21/64"
diameter... 35

4000-lb load secured to cable test specimen. . . 36

Magnified views of Mohole cable and 3 X 31 wire
TAOS Gg a SPY

INTRODUCTION

Wire rope has important applications in industry for holding,
towing, and lifting, and much has been done to improve its qual-
ity and dependability. It has equal importance in oceanographic
work. Deep mooring by the taut-wire technique, coring and
dredging, under-water photography, and sampling of water, bot-
tom materials, and biological life, are only a few of the oceano-
graphic activities which require the use of cables and which pre-
sent new and rigorous demands upon the strength, flexibility, and
general reliability of the wire used in their construction. These
demands increase as oceanographic investigations continue to in-
volve greater depths and longer periods of submersion. Whereas
in most industrial applications both ends of a cable are firmly se-
cured, oceanographic operations require suspension and subse-
quent maneuvering of a weight on the end of a line which is capable
of stretching and rotating as the load is lowered into the water.
The destructive effect of the ocean environment upon cable mate-
rial adds to the problem of selecting wire rope of optimum char-
acteristics for marine operations.

The investigation reported here was undertaken to determine
which cables, of the many types now available, are most suitable
for oceanographic applications.

FACTORS IN CABLE EFFECTIVENESS

The basic requirements for any cable are strength and flex-
ibility. The cables used in oceanographic operations require spe-
cial characteristics in addition to the basic strength necessary to
handle heavy loads. Corrosion, magnetic properties, conditions
of shock, abrasion, vibration, and extremes of temperature are
all potential sources of damage, premature wear, and unsatisfac-
tory performance. These hazards must be considered in any
choice of marine cable.

Both the materials used and the method by which a cable is
fabricated are factors in its suitability. Table 1 summarizes the
pertinent characteristics of several materials which are in wide
use in the manufacture of wire rope. It will be noted that these
materials vary in effectiveness, depending upon the application
for which they are considered.

The method by which the cable is constructed strongly in-
fluences its ability to meet the rigorous demands of oceanographic
operations. Two common types of construction are the Warring-
ton and the Seale configurations, both consisting of two layers of
wire about a central wire: six wires in the inner layer and twelve ©
in the outer. The Warrington varies from the Seale by using large
and small wires alternately in the outer layer; the Seale construc-
tion uses the same size throughout. The Seale type yields a f
smoother surface which reduces friction and resulting abrasion; | -
and the presence of smaller wires in its outer layer increases |
flexibility and therefore reduces bending stresses, especially |
when the cable is being operated over sheaves of small diameter.

The strength of a wire rope increases with its size and with
the excellence of the material (especially the core material) of
which itis made. The strength offered by any method of construc-
tion will vary with the metallic area involved and the basic strength
of the wire used. If a cable is made with an independent metallic
core or inner strand it will be somewhat stiffer than a similarly
constructed rope with a fiber core but, when heavy loads and high
radial pressures are involved, may offer greater strength and re-
sistance to bending fatigue. In many applications the fiber-core
wire rope is satisfactory or even preferable, as when it must con-
form to the diameter of a small sheave or drum.

The flexibility of a wire rope is a function of its "lay," or
the manner in which the strands are joined or twisted, and also
depends upon whether or not the wire is preformed. The com-
monly used Lang lay produces a cable with large cover wires and.
the same number of wires in the outside layers as in the inside
layer.

If the helical angle of the wire wrap is kept tight with a
small angle from the normal to the cable, flexibility will decrease.

A long lay will tend to increase the flexibility up to a point where, | 7
if too great a load is placed on the core of a cable, its strength
will be reduced.

The flexibility of a wire rope of fixed diameter also in-
creases with the number of wires or strands used in its con-
struction, with the size of the individual strands decreasing
proportionately.

HAZARDS TO CABLE IN
OCEANOGRAPHIC OPERATIONS

Cable used in oceanographic operations must meet rigorous
demands, imposed both by the ocean environment itself and by the
nature of the work in which the cable is used. The principal haz-
ards to the cable are as noted briefly here.

Corrosion

Constant exposure to sea water has a corrosive effect upon
cable, first appearing as microscopic pitting which cannot be de-
tected without powerful magnification. The pits act like little
keys; as they develop they restrict the action of the cable ele-
ments, creating stress concentration points, rapidly diminishing
the flexibility of the cable, and reducing its ability to withstand
impact loads and shock. Corroded rope creates a serious hazard
not only to the equipment being handled but to the persons using it.
Frequent inspection and regular lubrication are imperative, as by
the time the corrosive effect becomes visible it is too late to take
preventive action.

Generally, corrosion attacks wire rope on the exposed sur-
face of the wire first and, when this is the case, it is readily ap-
parent. However, it is possible for corrosion to develop inside

the wire rope before any evidence is visible on the outside. This
has been found to be the result of a lubricating practice which has
been adequate to keep the outside of the rope coated but has been
insufficient to prevent the loss of the original lubricant from in-
side the cable and has permitted moisture to penetrate it.

Abrasion

Abrasion and other forms of wear generally appear to pro-
gress very rapidly on a new rope, since only a small surface of
the wires is exposed to abrading objects. However, as worn sur-
faces develop on the wire crowns, the wear is distributed over a
larger area of contact and the apparent rate of abrasion decreases.
On regular lay ropes, the wearing action causes a loss of metal
from the crowns of the outside wires and small, elliptical flat
surfaces develop.

A constant contributor to wear is the peening action produced
when the wire rope is subjected to short, sharp blows against sta-
tionary or moving objects such as small track rollers on a ship.
This type of abuse causes some loss of metal from the wires, but
its principal damage is the deformation of their original circular
shape.

The speed with which the wire rope is handled is a very im-
portant factor in its wearing qualities. Any section of rope oper-
ating over a sheave makes two complete bends (one when it con-
forms to the sheave groove and another when straightened). These
changes in curvature require rapid movement of the wires and
strands, and materially influence their bending fatigue.

In general, the safety of a working load is determined by the
same conditions which contribute to abrasion and corrosion: the
weight of the applied load, the speed of operation and of accelera-
tion and deceleration, the length of the wire rope used, and the
number, size, and location of sheaves and drums.

Stretch

Stretching is a propensity of wire rope which must be taken
into account in selecting and using marine cables. When drops to
precise depths are required, a lengthening of the cable could re-
sult in erroneous data. Also, long cables could be weakened to a
point where critical instrumentation could be lost or subsurface
buoys would gradually rise to the surface as the cable unwound.

There are two types of wire rope stretch: (1) elastic stretch,
which is a function of the elastic properties of the material of
which the rope is made, and which is recoverable in accordance
with Hooke's law; and (2) constructional stretch, which is caused
by the progressive adjustment of the individual wires moving to
seat themselves more firmly into the cable structure. Construc-
tional stretch is not recoverable and will manifest itself, during
the first few times the cable is loaded, to a degree depending upon
the severity of the loading.

Corrosion and rope stretch, as discussed above, may be
considered mechanical problems, which depend largely upon the
composition and construction of the wire rope. There are other
aspects of the corrosion and wear problems, such as electrolytic
corrosion and the effects of sheave and drum action, but these all
point mainly to proper selection and maintenance of the cable.

Rotation

A further problem which exists in the use of wire rope in
oceanographic operations is that of rotation. When a weight is
suspended from a ship, the cable supporting it becomes a free
body able to rotate at will. Such rotation causes an unlay of the
wires composing the cable and could, if permitted to proceed far
enough, reduce its strength capability to the breaking point and
cause the loss of both cable and load. The personal hazards in-
volved are obvious. A further undesirable effect of the rotation is
that it opens the cable structure and allows entry of sea water,
thus hastening corrosion of the core and inner wrap wires.

10

Rotation of the wire rope is a function of its helical con-
struction, and the direction in which it rotates depends upon the
direction in which the strands are laid. Length of cable and weight
of loading determine the degree of rotational stretch which will be
produced.

TEST PROCEDURES

Conducting a study at sea to gather the information sought in
this evaluation would require operation of a test vessel with in-
strumentation which would be prohibitively expensive. The manu-
facturers of wire rope and cable were not able to supply directions
for such an investigation, and since no A.S.T.M. standards or
guide lines were available, the test procedure to be described was
developed empirically at NEL.

NEL towers were used to support a length of cable. Gener-
ally 120 feet of cable was used so that one end could be secured in
the tower. The working length was 100 feet, suspended to within
5 or 6 feet of the ground. A drag or brake system was used to
regulate the twist, from unwind to rewind, to the speed at which
it was estimated the cable would be turning in the sea, and to sim-
ulate the drag it would encounter in sea water. Count was made of
rotational turns from unwind to wind. Other tests were made, on
longer lengths of cable, by securing sheaves at different levels in
the tower and, by means of a winch from a tractor, raising and
lowering the weights to distribute a load over the required length
of cable (figs. 1-6). To determine the amount of stretch for any
given load, the cable length was measured before addition of a
weight and again after it was completely ''relaxed" under the addi-
tional load.

Each cable was tested under these conditions to determine
the elastic stretch and rotational effect when known loads were
applied to a given length of cable. The test results are summa-
rized in tables 2-15 which indicate the amount of elongation

produced by suspension with various loads and the amount of "'re-
turn" to original length, both immediately after release of weights
and as measured after the cables were removed from the test lo-

cation, coiled, and allowed to relax for several hours or days.

11

12

SUMMARY

On the basis of the extensive tests reported here, the 3 X 19
cable is considered the most suitable of those now available for
oceanographic applications, from the standpoint of its resistance
to elastic and rotational stretch. In future procurement of marine
cables, any new types under consideration should be similarly
tested before adoption. New cable designs should be investigated
as they are developed.

Material

Blue center steel

Composition

Finest quality im-
proved plow steel

TABLE 1.

Applications

Fabricated into ropes for
uses requiring optimum
strength, toughness and
uniformity

MAJOR CHARACTERISTICS OF PRINCIPAL CABLE MATERIALS

Advantages Disadvantages

Can withstand heavy loads,
severe abrasion, shock, and
vibration

Plow steel

a

Steel ropes

Traction steel

Iron ropes

+—

Designed especially for
elevator cables

High strength; unusual
toughness

High resistance to bending
fatigue; shows minimum
wear over sheaves and
drums

Comments

All cables should be prop-
erly lubricated before
immersion and carefully
rinsed with fresh water
after using in sea water

Advantages exceeded only
by those of blue center
grade

Is of exceptionally high
quality

Low carbon steel

Stainless steel

Phosphor bronze
rope

18 chromium, 8
nickel

Principally used for wire
ropes in marine and air-
craft applications and in
industrial uses where
excessive environments
are to be encountered

Tin-copper alloy

Used mainly when loads
are light

Low in strength compared
to other steel grades

Corrosion resistant when
material is properly chosen
and treated for expected
environment

Inferior to carbon steel in
stress fatigue

Recommended for situa-
tions requiring frequent
submersion and removal
rather than continuous
submersion

Effectively resists certain
types of corrosion; is
nonmagnetic

Has little resistance to
abrasion; low fatigue
life

13

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14

TABLE 2. TEST FOR TOTAL STRETCH OF 0.170" DIA. CABLE (50-FT LENGTH)

Number of Turns
To
Unwind

Load released

To
Wind

Cable removed from tower,
coiled in 2-ft circle, allowed to
relax for 175 hr at 70°F.

Cable measured; it had returned
to original length and was in
good condition.

15

TABLE 3. TEST FOR TOTAL STRETCH OF 0.170" DIA. CABLE (150-FT LENGTH)

Number of Turns Time
Load To To {From Start} Stretch
(lb) | Unwind Wind (hr) in. /50 ft) Notes

1000 Test cable up in the control
tower through three sheaves.

Elastic stretch at loading.

Load raised 50 feet
Load lowered 50 feet Total elongation 26.5"

500 7" relaxation

Load raised 50 feet
Load lowered 50 feet

HL 05
When the final increment of load
was released and the cable re-

laxed for 48 hours, the cable
was back to its original length.

16

TABLE 4. TEST FOR TOTAL STRETCH OF 3 X 19E (0.217"' DIAMETER)
GALVANIZED MONARCH CABLE (150-FT LENGTH)

Number of Turns Time
Load To To |From Start} Stretch
(Ib) | Unwind Wind (hr) in. /50 ft) Notes
1500 0
72
The load was raised for 48
hours then lowered to distribute
the loading equally in all sec-
120 tions of the cable.
This resulted in an additional
elongation of 7.0". When com-
pared to the stretch in 120
hours with the same load, the
effects of sheave resistance are
striking.
1000 192
240 2. 3B}
500 264
336 1.5
408 0.67
456

17

TABLE 5. TEST FOR TOTAL STRETCH OF WIRE CABLE 7 X 19 (150-FT LENGTH)

Number of Turns Time
Load To To |From Start} Stretch
(Ib) | Unwind Wind (hr) (in. /50 ft Notes
1500 0 Data required were limited to
stretch characteristics after
preload; therefore, the prelim-
inary stretch measurement was
not taken.
Load raised 75 feet 48
Load lowered 75 feet
90.5
40.3
11.0
U2
168
1000 23.3
358
1.3 6.12

Load raised 75 feet 192
Load lowered 75 feet 240
21.6
Bod!

312

18

TABLE 5. (Continued)

Number of Turns Time
Load To To |From Start} Stretch
(Ib) | Unwind Wind (hr) (in. /50 ft) Notes
500 42.3
6.3
i, 6
1.3 5. 03
Load raised 75 feet 360 4,95
Load lowered 75 feet 408
3.81
0.8
0.3 4,65
480 4.67
0 504 1.04 Upon release of the last 500 lb,

the wire cable twisted and curled
considerably. There was a per-
manent stretch of 3.13 inches.

19

TABLE 6. TEST FOR STRETCH CHARACTERISTICS OF PRELOADED WIRE
CABLE 3 X 19D, SPECIMEN 474, 3/32" DIAMETER, REEL 34893
(100-FT LENGTH)

Number of Turns Time
Load To To |From Start] Stretch
(Ib) | Unwind Wind (hr) (in. /50 ft) Notes
292 Bio BS! 0 Data required were limited to
Load raised 50 feet 48 stretch characteristics after
Load lowered 50 feet 72 preload; therefore, the prelimi-
67.5 nary stretch measurement was
20.0 not taken.
To®
4.5 144
196 As the load was lightened, the
10.5 reduction in elongation extended
Load raised 50 feet 192 negatively from the initial
Load lowered 50 feet 288 measurement.
312
100
Load raised 50 feet 336
Load lowered 50 feet 360
115), ©
6.0 384 -2.12
0 0.00 No permanent stretch.

20

TABLE 7. TEST FOR STRETCH CHARACTERISTICS OF PRELOADED WIRE
CABLE 7 X 7D, SPECIMEN 475, 3/32" DIAMETER, REEL 34894
(100-FT LENGTH)

Number of Turns Time
Load To To |From Start] Stretch
(Ib) | Unwind Wind (hr) (in. /50 ft Notes
292 0 Data required were limited to
10.0 stretch characteristics after
1.0 preload; therefore, the prelimi-
Load raised 50 feet 48 nary stretch measurement was
Load lowered 50 feet 72 not taken.
37.0
168
196 As the load was lightened, the
Load raised 50 feet 192 reduction in elongation indicated
Load lowered 50 feet 216 a zero elongation at 100 lb.
18.75
2.9 240
100
Load raised 50 feet 264
Load lowered 50 feet 336
360 -1.66
0 0.12 Permanent stretch.

21

TABLE 8. TEST FOR STRETCH CHARACTERISTICS OF PRELOADED STANDARD
B.T. CABLE SPECIMEN 476, WIRE CABLE, 3/32" DIAMETER
(100-FT LENGTH)

Number of Turns Time
Load To To |From Start} Stretch
(Ib) | Unwind Wind (hr) in. /50 ft) Notes
292 0 Data required were limited to
stretch characteristics after
preload; therefore, the prelimi-
nary stretch measurement was
not taken.
0), 75 2.47
Load raised 50 feet 48
Load lowered 50 feet 120
4.0 4.00
14.25
196 42.25
4.0
Load raised 50 feet 144
Load lowered 50 feet
Bo ZNO)
168
100 39.0 As the load was lightened, the
6.5 reduction in elongation indicated
2.0 0.35 a zero elongation at 100 pounds.
Load raised 50 feet 240 0.35
Load lowered 50 feet
9.0 264
3.0 0)
0 288 iL, OS} Permanent stretch.

22

TABLE 9. TEST FOR TOTAL STRETCH OF H.I. WIRE CABLE (100-FT LENGTH)

Number of Turns Time
Load To To | From Start} Stretch
(lb) | Unwind Wind (hr) (in. /50 ft Notes
(Hanger)
39
230 0 0.78
Lo 8}
1.0
1.0
0.9
1.0
0.8
1.0 0.65
No rotation 72
423 1.53
4,29
3.79
3.50
3.90
3.33
3.25
3.25
3.00
3.00
2.86
2.76
2.62
2.50 1.55
No rotation 144 5

23

TABLE 9. (Continued)

Number of Turns Time
Load To To |From Start] Stretch
(Ib) | Unwind Wind (hr) (in. /50 ft) Notes
616 as PAON
7c BH0)
216 Pag yy
809 2.90
4.25 Bio A)
No rotation 312 Bia Za
1004 35 18
7.00
5.30
5) 2B)
5.00
4,88
4,795
4,50
4.50 3. 94
No rotation 384 4.10
No rotation 480 4,42

24

TABLE 9. (Continued)

Number of Turns Time
Load To To | From Start} Stretch
(lb) | Unwind Wind (hr) (in. /50 ft
809 576 3.68
5 LS
88 3.62
rotation 648
615
63
.38
rotation 744
423 i BS
0.30
5.00
5.00
4,75
4.63
4.50 2.47
No rotation 816 Ph, BND)

Notes

25

TABLE 9.

Number of Turns

Load To
(tb) | Unwind
230
5.00
4.50
AL 25)
No rotation
(Hanger)
39 | No rotation
(Hanger)

26

(Continued)

Time
To |From Start] Stretch
Wind (hr) (in. /50 ft)

1.35
5.63
4.75
4.38

1.75

912 1.53

1.06

1296 0.94

Notes

Permanent stretch. The cable
shows excellent characteristics
in resisting rotation under vari-
ous loads. The elastic stretch
reached 8.44 inches with a
1000-lb load.

TABLE 10, TEST FOR TOTAL STRETCH OF 0.123" DIA. STRANDED CABLE
(100-FT LENGTH)

Number of Turns

Load To To Stretch
(Ib) Unwind Wind (in. /50 ft) Notes
Test 1.
39.0
134.5 Bo 1 0,35)
6.50
2.00
After rotating to still condition 0.47
Test 2.
39.0
760.0 82.00 Zeit
60.75
93.20
40.00 3.32
Left hanging overnight 3.40
39.75
3on2D
27.90
5 AG)
UY,
.00
. 00
.00 3.88
Test 3.
134.5 291
1195.5} 149.0
70.75
62.25
54.00
47.00
40,25
34.25
28.29
22.75 These tests were made for com-
US parison with those shown in

After rotating to still condition 7.10 |table 11 for 0.250" dia. cable.

27

TABLE 11.

Load
(Ib)

Test 1,
39.0

Test 3.

39.0
1198.5

28

TEST FOR TOTAL STRETCH OF 0.250" DIA. STRANDED CABLE

(100-FT LENGTH)

Number of Turns

To

Unwind

iL
After rotating to still condition

21.
20.
18.
ie
16.
15.
14,

13.

172i.

After rotating to still condition

50

50
75
25
25
25
00
00
29

50

To
Wind

20.25

19.00
17.75
16.75
15.50
14.50
13.75

13.00

12,25

No rotation

30.
20.
24,
22.

20.
After rotating to still condition

50

00

00

25

79

27.00
25.00

23.25

21,50

Stretch
in. /50 ft) Notes

0.25

0.68

1.39

These tests were made for com-
parison with those shown in
PB. IG} table 10 for 0.123" dia. cable.

TABLE 12. TEST FOR TOTAL STRETCH OF BLACK POLYETHYLENE-COVERED
STEEL CABLE (100-FT LENGTH)

Number of Turns Time
Load To To |From Start Stretch

(Ib) Unwind Wind (hr) (in. /50 ft) Notes
39.0
521.0

Special consecutive hourly
measurements were made on
one day to determine the effect
of temperature on the length
measurement. No effect was
noted.

714.5

After rotating to still condition

905.0 2.65
168 2.78
13.75
11,50
10.50
9.50
After rotating to still condition 2.92 |The total stretch was 6 in/100'
of cable; of this, 1-13/16" was
due to unwinding of the cable
under load. This rotational
stretch was approximately 30%
of the total stretch.

No rotation 240 3.00

29

TABLE 13. TEST FOR TOTAL STRETCH OF PACIFIC TEST ROPE 7971A, 3 X 36,
SUPERSTEEL GALVANIZED, REGULAR LAY 3/8" DIAMETER
(100-FT LENGTH)

To
Unwind

The lack of rotation is a unique
characteristic.

TABLE 14. TEST FOR TOTAL STRETCH OF 1 X 19 BETHANIZED FORMSET AIR-
CRAFT STRAND, 7/32" DIAMETER, WIRE ROPE, USED FOR THE
MOHOLE PROJECT (100-FT LENGTH)

Time
From Start} Stretch

Number of Turns
To To
Unwind Wind

Load

gob (ever) Due to the urgency of this

4000 problem no intermediate
42 loading was required. This
cable was tested for a specific
1.5 4 application.

30

TABLE 15. TEST FOR TOTAL STRETCH OF 3 X 31 WARRINGTON SCALE WIRE
ROPE, 21/64" DIAMETER (100-FT LENGTH)

Number of Turns

Load To
(Ib) Unwind
4000

89 (slight braking action)

2.12

1,25

0.33

0.84

No rotation

To

Wind

3

0.33

Time
From Start} Stretch
(hr) (in. /50 ft)

0 LY)
5.81
24 6.25
6.25

48
6.28

72
6.28
96 6.28

168
6.28
336 6.28

Notes

This is considered a prelimi-
nary test. Due to excessive
rotational stretch further test-
ing was deemed unnecessary.

31

—— TEST CABLE

é
(
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Figure 1. Fittings for securing CAMLE «

32

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and lowering test cable.

33

34

Figure 3. Hanger and weights used for
IOGEMEAG CGO -

Wile tases

A ay

4000-1b load on 3 X 31 wire rope of 21/64" diameter.

Figure 4,

390

Figure 5. 4000-1b load secured to cable test specimen.

36

SCALE IN INCHES

Figure 6. Cable used in Mohole project (top) and
specimen of 3 X 31 wire rope 21/64" in diameter.

37

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