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rope
Specification for
BRITISH STANDARD
Co-operating organizations
© BSI 04-1999
Amd. No. Date Comments
Contents
Page
Co-operating organizations Inside front cover
Foreword ii
1 Scope 1
2 Definitions 1
3 Factor of safety 1
4 Wire rope 3
5 Materials 3
6 Block shell 3
7 Head fittings 4
8 Becket 6
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9 Axle pin 6
10 Sheaves 6
11 Lubrication 7
12 Locking nuts 7
13 Proof load 7
14 Examination after proof loading 7
15 Marking 7
16 Certificate of test and examination 8
Appendix A Typical head fittings 9
Appendix B Formulae for round section eyes 10
Appendix C Proof load in relation to safe working load 11
Appendix D Recommendations relating to contracts 12
Appendix E Details which should be agreed between
the purchaser and the supplier 12
Figure 1 — Nomenclature of block components 2
Figure 2 — Plain bearing 5
Figure 3 — Ball bearing 6
Table 1 — Permissible loading on shanks of head fittings 4
© BSI 04-1999 i
BS 4536:1970
Foreword
1) Information on frictional resistance in pulley blocks, and the resulting rope tensions when
hoisting and lowering, is given in BS Handbook No. 4, “Lifting tackle”, Part 1, “Ropes and
fittings”.
ii © BSI 04-1999
BS 4536:1970
Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 12, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on
the inside front cover.
iv
blank
BS 4536:1970
1 Scope
This British Standard specifies requirements for heavy duty pulley blocks for use with wire rope, with
sheave diameter (measured at the bottom of the rope groove) not less than 15 times the rope diameter.
For the purposes of this standard, single blocks are regarded only as lead blocks.
2 Definitions
For the purposes of this British Standard, the following definitions apply (see also Figure 1):
1) pulley block
a block with sheave(s) for use with steel wire rope and forming a wire rope purchase
3) lead block
a single block changing the direction of the haulage part of the rope
4) head fitting
the means by which the block is attached to its anchorage or to the load being lifted (Typical head fittings
are shown in Appendix A)
5) becket
the fitting on the block to which the rope used in the rig may be anchored. (See Figure 1.)
7) proof load
the load (on the head fitting) to which every block is tested.
8) resultant load
the load imposed on the head fitting of the block by application of the safe working load when the block is
rigged as follows:
Single block rigged as a lead block.
Double block rigged as top block of a 2/2 combination.
Treble block rigged as top block of a 3/3 combination.
n-fold block rigged as top block of an n/n combination.
9) ultimate strength
the load at which the block fails by releasing the load
10) inspector
the representative of the purchaser or of a certifying body
3 Factor of safety
For the purposes of this British Standard, the factor of safety is the ratio between the ultimate strength of
the block as a unit, and the load imposed on the block, neglecting frictional resistance and acceleration of
the load.
© BSI 04-1999 1
Licensed Copy: hydrocarbon user ., Hydrocarbon Resources Ltd, 09 June 2005, Uncontrolled Copy, (c) BSI
2
BS 4536:1970
© BSI 04-1999
BS 4536:1970
The factor of safety as so defined shall not be less than 5 for safe working loads up to and
including 100 t (tonnes)3), nor less than 4 for safe working loads over 100 t.
It is further required that the permissible working stresses specified in Clauses 6, 7, 8 and 9, which make
due allowance for friction and acceleration, shall not be exceeded in the design of the block.
4 Wire rope
The design of the block shall be based on the minimum breaking load of the following wire rope:
Round strand equal lay 6 × 26 to 6 × 41 series, independent wire rope core, complying with BS 3024).
5 Materials
5.1 Specifications. The following materials are suitable for the construction of engineering blocks to this
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standard.
If other materials are used, their suitability is the responsibility of the block manufacturer. Wrought steels
shall be selected from BS 970-15) or BS 970-26) and stress-bearing components shall be marked with the
grade.
1) Forgings
a) Mild steel: Grade 070M20a. (For the large sizes when higher tensile steel is not
obtainable.)
b) Higher tensile steel: 080M27a, 080A30a, 080A32a, “30” carbon steel.
150M19a, 150M28a carbon-manganese steel.
c) Alloy steel: 605M36b manganese-molybdenum steel.
945M38b low alloy steel.
2) Machine parts 070M55a “55” carbon steel.
653M31b 3 % nickel-chromium steel.
Any of the steels listed for forgings.
3) Structure (block shell) Any of the steels listed for forgings.
4) Castings (steel) BS 592c, Grade A, B or C.
5) Castings (iron) BS 1452d, minimum grade 12.
BS 2789e, S.G. iron.
a
BS 970, “Wrought steels, Part 1, “Carbon and carbon manganese steels”.
b
BS 970, “Wrought steels”, Part 2, “Direct hardening alloy steels”
c
BS 592. Included in BS 3100, “Steel castings for general engineering purposes”.
d
BS 1452, “Grey iron castings”.
e
BS 2789, “Iron castings with spheroidal or nodular graphite”.
5.2 Heat treatment. Prior to machining operations all forgings, e.g. head fittings and forged beckets and
pins, shall be either normalized or hardened and tempered in the temperature range appropriate to the
material.
6 Block shell
6.1 Design. The side and partition plates shall project beyond the sheaves to provide adequate protection
for the rope, and the design of the block shall be such that there is no possibility of the rope jamming
between the side plates and the sheaves.
3)
1 t = 1 000 kg
4)
BS 302, “Wire ropes for cranes, excavators and general engineering purposes”.
5)
BS 970, “Wrought steels”, Part 1, “Carbon and carbon manganese steels”
6)
BS 970, “Wrought steels”, Part 2, “Direct hardening alloy steels”.
NOTE Until publication of the revision of BS 970 the following references apply.
070M20 = En3A 080A32 = En5C 945M38 = En100
080M27 = En5A 150M19 or 150M28 = En14A 070M55 = En9
080A30 = En5B 605M36 = En16 653M31 = En23
© BSI 04-1999 3
BS 4536:1970
6.2 Shearing stress in through bolts. The shearing stress shall not exceed 6.2 hbar (hectobar)7) for mild
steel, nor 7.7 hbar for higher tensile steel.
6.3 Workmanship. The plates shall be free from distortion and all edges shall be smoothly finished. All
through holes in side and partition plates shall be in true alignment.
7 Head fittings
7.1 Form and design
7.1.1 Hooks. Hooks shall be designed for the proof load and shall comply with an appropriate British
Standard8), and the screw threads shall comply with 7.2.3.
7.1.2 Forged bow head fittings. Head fittings of the bow or dee shackle form shall be designed for the proof
load in accordance with the requirements of the appropriate British Standard for shackles9).
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It may be assumed that any stress relief due to “end fixing” is offset by the possible effects of unequal
loading due to slight lack of alignment when hoisting and lowering as a result of rope friction, etc.
7.1.3 Forged eye head fittings. Head fittings in the form of round or elongated eyes of circular cross section
shall be designed for the proof load in accordance with the appropriate formula in Appendix B.
7.1.4 Plate crossheads, etc. Plate crossheads, etc. shall be designed for the proof load and may be
manufactured by one of the following methods:
1) Wholly forged to finished dimensions.
2) Rough forged and profiled to shape and dimensions by machining. Machine gas-cutting may be used
provided that an adequate excess of material remains for removal of surface defects by machining,
chipping or flame dressing.
All holes shall be accurately drilled or bored at right angles to the axis of the head fitting.
7.1.5 Other head fittings. Head fittings other than the above are permissible to suit particular applications.
Typical head fittings are shown in Appendix A.
7.2 Shanks
7.2.1 Production. The shanks of head fittings shall be machined from solid forgings, and when threaded
shall be fitted with screwed collars or nuts, the depth of either being not less than the full diameter of the
screwed shank.
7.2.2 Tensile stress. The average tensile stress in the shanks of head fittings shall be based on the minimum
core area (;/4 × square of minimum core diameter).
The average tensile stress due to the resultant load on the shank shall not exceed the values given in
Table 1.
Table 1 — Permissible loading on shanks of head fittings
Resultant load W due to Higher tensile steel hook Higher tensile steel eye
the safe working load and mild steel eye and alloy steel
t hbara hbara
Up to 50 6.2
55 6.5
60 6.8 8.5
(all sizes)
65 7.1
70 7.4
75 and over 7.7
a
1 hbar = 107 N/m2 / 1 kgf/mm2 / 0.65 tonf/in2
4 © BSI 04-1999
BS 4536:1970
7.2.3 Screw threads. The screw threads on the shanks of head fittings shall conform to an appropriate
British Standard.
Depth of thread
The ratio of ------------------------------------------------------------------------------ shall not be less than 0.040.
diameter at top of thread
The portion of the shank adjacent to the shoulder shall have an undercut and fillet in accordance with the
recommendations for the undercut Form A, Grade 1, in BS 193610).
It is recommended that the screw threads be gauged with an appropriate gauge made to the relevant
specification in BS 91911).
7.2.4 Nuts or collars. All nuts or collars shall be effectively secured against “slacking back”, and shall be
removable for inspection purposes without damage to themselves or to the shank.
The continuous length of shank engaged by the nut or collar on the load side shall be at least equal to the
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diameter of the shank before being interrupted by drilling for split cotter pin or other fixing.
To prevent excessive bearing pressure between the screwed collar and the crosshead of the block, the
diameter of the collar shall not be less than 1.6D, where D is the diameter of the screwed shank.
Swivel head fittings with shanks shall turn freely by hand when not under load.
7.3 Crossheads. The extreme fibre stress at the centre of the length of the crosshead when housing a
swivel head fitting shall not exceed 7.7 hbar12) for mild steel, nor 9.3 hbar for higher tensile steel. This
stress is related to the resultant load on the crosshead when supporting the safe working load, taking into
account the stress concentration at the cross section at the central hole receiving the shank of the head
fitting.
For the purpose of calculation, the reactions may be assumed to act at the positions shown in Figure 2 and
Figure 3.
© BSI 04-1999 5
BS 4536:1970
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8 Becket
The becket shall be cleanly forged or machined from the solid.
The breaking load of the becket shall be at least equal to the minimum breaking load of the wire rope for
which the block is designed. (See Clause 4.)
The load imposed on the becket when proof loading the block is acceptable as a proof load on the becket.
9 Axle pin
9.1 Workmanship. The surface finish of the axle pin shall be appropriate to the bearings. The axle pin
shall be positively secured against rotation and lateral movement, by a means which permits it to be
withdrawn for inspection.
9.2 Bearing stress in the axle pin. The bearing pressure between any sheave bush and the axle pin shall
not exceed 3.9 hbar13) for single sheave blocks, nor 3.1 hbar for multiple sheave blocks. (These limitations
of pressure are imposed to permit adequate lubrication.)
If proprietary bushes are used the bearing maker’s recommendations shall be followed.
The pressure between the axle pin and the stress-bearing members (i.e. straps and supporting partitions)
of the block shall not exceed 16 hbar.
For the foregoing requirements, the projected area of the axle pin in contact shall be taken,
i.e. area = appropriate length × diameter.
9.3 Shearing stress in the axle pin. The shearing stress shall not exceed 6.2 hbar13) for mild steel,
nor 7.7 hbar for higher tensile steel.
9.4 Bending stress in the axle pin. Adequate support shall be provided for the axle pin to prevent
excessive bending stress, and the design of the axle pin and supports shall be such that there is no visible
permanent set after the removal of the proof load.
10 Sheaves
10.1 Material. Sheaves shall be of steel except that those whose diameter at the bottom of the groove
is 300 mm or less may alternatively be iron castings. (See 5.1.)
10.2 Form and dimensions. The diameter of the sheave, measured at the bottom of the rope groove, shall
not be less than 15D, where D is the diameter of the wire rope for which the sheave is designed.
6 © BSI 04-1999
BS 4536:1970
The overall breadth of any part of the sheave shall be at least 1.5 mm less than the boss (i.e. 0.75 mm at
either side).
10.3 Bearings. Sheaves shall be provided either with ball or roller bearings, or with phosphor bronze or
other anti-friction bushes.
Ball or roller bearings shall be in accordance with an appropriate British Standard and shall conform to
the bearing maker’s recommendations as to duty and fittings. They shall withstand the required proof load
on the block without injury.
Sheaves shall rotate freely by hand.
10.4 Boss. The face of the boss shall be machined.
10.5 Groove. The sheave groove shall be machined to a depth of not less than the diameter of the rope for
which the sheave is designed, and not more than 1" times this diameter. It shall be smoothly finished and
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free from rough surface defects liable to injure the rope. The edges of the groove shall be radiused. The
angle of flare of the sides of the groove shall be 52°. (See Figure 1.)
The contour at the bottom of the groove shall be circular over an angle of 128°, and the radius of the groove
shall be larger than the nominal radius of the wire rope by the following amounts:
For rope diameters up to and including 30 mm: 1.5 mm minimum
For rope diameters over 30 mm: 2.5 mm minimum
11 Lubrication
Provision shall be made for lubricating all bearings and swivel head fittings. Unprotected oil holes are not
permitted. Plain bearings or their shafts shall have oil or grease grooves to distribute the lubricant over
the bearing surfaces. Ball and roller bearings shall be packed with grease during the initial assembly.
All lubrication nipples shall be readily accessible. BS 148614), Type II nipples are suitable for lubrication.
The shanks of head fittings shall be provided with efficient means of lubrication.
12 Locking nuts
All nuts shall be securely locked by a means which permits removal for the purpose of examination or
repair of the block.
13 Proof load
The completed block shall be subjected to its proof load (see Appendix C).
The testing machine shall be verified in accordance with the requirements of BS 161015) and maintained
within Grade B. Its full load shall not be more than 10 times the proof load.
The testing machine shall be balanced in the presence of the Inspector before the tests are made.
15 Marking
Each block shall be permanently and legibly marked with an individual distinguishing number or mark,
and with the safe working load of the rig for which it is intended, which is governed by the ratios to proof
load given in Appendix C.
Single sheave blocks shall be marked with half of the working load on the head fitting indicated in
Appendix C, since the load is assumed to be attached to the rope.
14) BS 1486, “Lubricating nipples”, Part 1, “Lubricating nipples and adaptors for use on machinery and vehicles”.
15) BS 1610, “Methods for the load verification of testing machines”.
© BSI 04-1999 7
BS 4536:1970
8 © BSI 04-1999
BS 4536:1970
NOTE Safety catches, which are required in some circumstances, are not shown in the above hook illustrations.
© BSI 04-1999 9
BS 4536:1970
When L is less than 2.55d, multiply the formula for P by the reduction factor 0.22 (2 + L/d).
a
1 hbar = 107 N/m2
When D is less than 2.55d, multiply the formula for P by the reduction factor 0.22 (2 + D/d).
NOTE In the above formulae, the effect of the collar has been assumed to add 7" % to the strength of an equivalent link, and 20 %
to the strength of an equivalent ring.
10 © BSI 04-1999
BS 4536:1970
45 30 75 0.75
50 65 35 85 0.85
55 35 90 0.90
60 60 35 95 0.95
65 35 100 1.00
70 55 40 110 1.10
75 40 115 1.15
80 50 40 120 1.20
85 40 125 1.25
90 46 40 130 1.30
95 40 135 1.35
100 43 45 145 1.45
110 41 45 155 1.55
120 38 45 165 1.65
130 36 45 175 1.75
140 35 50 190 1.90
150 34 50 200 2.00
160 33 55 215 2.15
170 33 60 230 2.30
180 33 60 240 2.40
Over 180 33 — — —
a The proof load is quoted in tonnes for application by weights, and in meganewtons (MN) for application by testing machine, and
also for design purposes (see Appendix B).
b 1 MN = 106 N
© BSI 04-1999 11
BS 4536:1970
Appendix E Details which should be agreed between the purchaser and the
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supplier
The following details should be agreed between the purchaser and the supplier:
1) Type of block (single, double, treble, etc.) (Clause 2)
2) Details of rig and position of block (if pre-determined)
3) Diameter of wire rope (Clause 4)
4) Type of head fitting (Appendix A)
5) Type of bearing (10.3)
6) With or without becket
12 © BSI 04-1999
BS 4536:1970
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© BSI 04-1999
BS 4536:1970
Revisions
It is the constant aim of BSI to improve the quality of our products and services.
We would be grateful if anyone finding an inaccuracy or ambiguity while using
this British Standard would inform the Secretary of the technical committee
responsible, the identity of which can be found on the inside front cover.
Tel: 020 8996 9000. Fax: 020 8996 7400.
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