“PEDAGOGS”
international research journal ISSN:
2181-3027
_SJIF:
5.449
https://scientific-jl.com/ped
Volume-82, Issue-2, May -2025
76
METHODS OF INSTALLATION OF WIRE ROPE AND
BINDER WHEN SECURING LOADS
Bozorov R.Sh.
1
, Boboev D.Sh.
2
1,2
– Tashkent State transport University (Tashkent, Uzbekistan).
Keywords:
Tensioner, tie, flat wire tie, installation methods, deformation,
reinforcement, elastic vibration, fastening tool, Cable clamps.
Abstract:
The article shows the suitability of fastening tools in the process of
securing cargo in railway transport and the methods of their installation. Fastening
tools for safe transportation of cargo are studied, measures and proposals for their
selection are developed. In addition, the technical characteristics of the main models
of fastening elements are analyzed, and proposals are made for the installation of
tensioners and fasteners to eliminate the shortcomings of the existing system.
Introduction.
When securing cargo, wire (metal cables) tensioners and ties are widely used to
prevent cargo movement, keep it stable, and ensure the safety of the vehicle.
The function of wire tensioners and ties: to prevent the cargo from sliding, tipping,
or falling; to stabilize the center of gravity of the cargo; to counteract the inertial forces
that arise when the vehicle is moving [1].
Types of wire ropes and ties: flat wire tie (filler) - for light and medium loads;
steel cable - for heavy loads and containers; adjustable tensioner (tensioner) - allows
you to regulate the tension; clip (karabiner) tie - for quick fastening and loosening.
Installation methods: direct lashing - the wire lashing is passed through the middle
of the load and attached to the platform rings or crane hooks; the two ends of the wire
are secured with a hose clamp; X-shaped (diagonal) lashing - the wires are passed
through the four corners of the load in a cross (X) diagonal direction, this method
provides greater protection against lateral movement of the load; loop lashing - the wire
lashing is passed around the load in a loop and attached to the clamp at both ends, often
used for drum or rolled loads; multi-point lashing - a separate wire lashing is pulled on
each side of the load [2].
Each tie is tightened to a predetermined force (this force is controlled by a
tensioner). Wire ties must be made of rustproof material. Ties must have a load-bearing
capacity appropriate to the weight of the load. Soft protective pads are used to prevent
damage to the surface during fastening. Wire ties are constantly checked - there must
be no rust, cracks, deformation. Each fastening point must comply with standards.
The main part.
“PEDAGOGS”
international research journal ISSN:
2181-3027
_SJIF:
5.449
https://scientific-jl.com/ped
Volume-82, Issue-2, May -2025
77
Method 1. The tensioner and the tie are made of a continuous wire rope. One end
of the wire (Figure 1) is wound 2 times around the wagon (cargo) coupling device and
is tightened by twisting it at least 2 times around the rope. The other end of the wire is
passed sequentially through the cargo and wagon coupling devices, forming the
required amount of rope in the tensioner or tie. The last end of the rope is tightened in
the wagon or cargo coupling device in the above manner, that is, it is wrapped around
one or more tensioner ropes. The length of the wire ends left for tightening must be at
least 500 mm. When tightening, the direction of the wire ends should be chosen so that
the fastening force does not weaken during the subsequent turning of the tensioner. The
tensioner or tie ropes are tightened by pulling and twisting using a metal beam or other
device [3].
Figure 1. Installing the tensioner and fasteners according to method 1
Method 2. The tensioner and the tie are made of a continuous wire rope. The wire
rope is passed through the wagon (load) tie, folded over it and formed into two equal
lengths of rope (Figure 2). Then it is sequentially passed through the tie of this load
and wagon, forming the required amount of rope on the tensioner or tie. The last wagon
(load) tie is turned around 2 times, then the wire ends are individually wrapped around
one or more tensioner (tie) ropes. The length of the wire ends left for reinforcement
must be at least 500 mm. The requirements for reinforcing the wire ends and tightening
the tensioner or tie by twisting are the same as in Method 1 [4].
Figure 2. Installing the tensioner and fasteners according to method 2
“PEDAGOGS”
international research journal ISSN:
2181-3027
_SJIF:
5.449
https://scientific-jl.com/ped
Volume-82, Issue-2, May -2025
78
Method 3. The tensioner and the tie are made using two continuous wire strands
(Figure 3). They are passed through the tie, folded, and one end of at least 500 mm in
length is left for reinforcement. Each strand is wound 2 times around the wagon (load)
tie and secured by twisting it at least 2 times. After the required amount of strand is
formed on the tensioner or tie, the end is wound 2 more times around the wagon (load)
tie. Then each wire end is individually wrapped around one or more tensioner (tie)
strands. The length of the wire ends left for reinforcement must be at least 500 mm.
The requirements for reinforcing the wire ends and tightening the tensioner or tie by
twisting are the same as in Method 1 [5].
Figure 3. Installing the tensioner and fasteners according to method 3
The tightening of the towbar and ties must be uniform along their entire length.
The tightening device must be installed at the central point between the wagon and the
load fastening devices (or the wagon fastening device and the bending point on the
load, the bending points on the load).
If the length of the towbar or tie is more than 1.5 meters, it is allowed to tighten it
in 2 places, but it is not allowed to loosen the previously tightened parts.
The ties must be screwed into the opposite webs in at least 2 places.
In towbars and ties where there are folds in the webs on the load, the sections with
a length of more than 300 mm between the folds must be additionally screwed into [6].
Figure 4. Procedure for tightening the fasteners when there is a bend
“PEDAGOGS”
international research journal ISSN:
2181-3027
_SJIF:
5.449
https://scientific-jl.com/ped
Volume-82, Issue-2, May -2025
79
When calculating tensioners, ties, compression devices and fastening elements,
the number of wire strands, the working cross-sectional area and the permissible load
are determined without taking into account the reinforcement ends (Figure 5). The
number of strands in tensioners, ties and compression devices must be even [7].
Figure 5. Determining the number of wire strands in tensioners, binders,
and compression devices
When the wire diameter is 6 mm or more, the number of wire strands of the
tensioner, tie, fastening and clamping devices should not exceed 8. When the wagon is
fastened with a load capable of relatively elastic oscillation (for example, spring-
loaded), contact between the tensioner and fasteners is not allowed. When using wire
fastening devices, it is allowed to replace the specified wire diameter with another
diameter, provided that the strength of the fastening device is ensured in accordance
with Table 1 [8].
Table 1.
Compatibility of wire fasteners with cross-sectional area
The amount of 6 mm
diameter wire ropes
that need to be
replaced
The corresponding number of wire strands of different diameters
4,0
4,5
5,0
5,5
6,3
6,5
7,0
7,5
8,0
2
6
4
4
4
2
2
2
2
2
4
-
8
6
6
4
4
4
4
4
6
-
-
8
8
6
6
6
4
4
8
-
-
-
-
8
8
6
6
6
For the methods of placing and securing cargo provided for in these technical
conditions (TU), as well as in NTU and MTU, it is allowed to replace wire and
combined tensioners, ties and fasteners with cable tensioners, ties and fasteners.
“PEDAGOGS”
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_SJIF:
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Volume-82, Issue-2, May -2025
80
The cable parts of cable pullers, tie-downs and combination pullers are made from
a continuous piece of cable, using cable clamps and tensioning devices – turnbuckles
[9].
For the manufacture of cable tensioners, ties and fasteners, double-stranded steel
cables with a diameter of at least 5 mm and a breaking strength of not less than 1320
kgf are used. The technical characteristics of the cable used must comply with
international or national standards. The diameter of the cable used instead of tensioners,
ties and fasteners made of wire with a diameter of 6 mm is accepted in accordance with
Table 2.
Table 2.
Replacing tensioners, ties and fasteners made of 6 mm diameter wire with
tensioners, ties and fasteners made of steel cables
The amount of 6 mm
diameter wire ropes that need to
be replaced with rope
Minimum wire diameter for
tensioners, ties and fasteners made
of steel wire ropes, mm
2
5
4
6,4
6
8,0
8
9,1
The diameter of the cable (wing) is determined as its largest cross-sectional
dimension. The connection of the cable branches is carried out using cable clamps
(Figure 6). The technical characteristics of the cable clamps must comply with the
requirements of international or national standards.
Figure 6. Cable clamp
“PEDAGOGS”
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_SJIF:
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Volume-82, Issue-2, May -2025
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Table 3.
Choosing the diameter and number of ropes
Wire rope (wing)
diameter, mm
Minimum number of
clamps, pcs.
Clamping force, N m / kgf
m
5
3
2,0/0,2
6,5
3
3,5/0,4
8
4
4,4/0,5
10
4
6,6/0,7
12
4
14,8/1,5
13
4
24,3/2,4
14
4
24,3/2,4
16
4
36,0/3,6
19
5
50,0/5,0
22
5
79,0/7,9
Cable clamps are selected according to the diameter of the cable (span) used. The
dimension b₁ should be 1.0 - 1.5 mm larger than the cable diameter. The number of
cable clamps to be installed depends on the cable diameter and is determined in
accordance with Table 3.
The surface of the cable clamps should not have any cracks, lines or cracks. The
clamps should also have clearly visible markings. It is not allowed to change the shape
of the clamps by welding, heating or bending. Cable tensioners (connectors) should be
of the closed type only (Figure 7). ring - ring, clamp - clamp, clamp - clamp, clamp -
ring.
The technical characteristics of the fasteners must comply with the requirements
of international or national standards.
Figure 7. Connection design options
:
a – ring (hole) – ring (hole); b – clamp – clamp; c – clamp – clamp;
d – ring (hole) – clamp
“PEDAGOGS”
international research journal ISSN:
2181-3027
_SJIF:
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Volume-82, Issue-2, May -2025
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The fasteners used must have locknuts that prevent spontaneous loosening.
When installing cable tensioners and ties, the selection of ties is carried out based
on their permissible working load, which should not be less than the breaking strength
of the cable used in this tensioner or tie.
The cables (wings) should not have broken wires. The ends of the cables should
not spread out. To prevent this, before cutting the cable, it is tied with a polymer tape
at least 40 mm long and cut in the middle.
When fastening cable tensioners to the fastening devices of the wagon or to cargo
devices with sharp edges, to prevent the tensioners from fraying, tensioners reinforced
with shoes are used or a thick elastic gasket material is additionally placed between the
tensioner and the sharp edge of the fastening device.
Cable clamps should be installed evenly distributed along the connection section
of the cable branches (Figure 8).
Figure 8. Installing cable clamps
When installing cable clamps, their nuts are initially tightened with a torque 20-
30% lower than the values given in Table 22. The final tightening is carried out after
the tightening and tying process using a tie.
When forming the tie and ties, the ties should initially be maximally loosened.
Cable tie and ties are installed using the following methods (Figure 9).
Figure 9. Cable ties and ties
“PEDAGOGS”
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Straps (Figure 1.20) are formed from a continuous wire strand. The strands of the
strap are twisted to the point of tension using a crowbar or other device. The strength
of the strap should not be less than the strength of the components of the fastening tool
to which it is attached.
Figure 10. Method of fastening wire ends inside the clamp
The lashing is formed from a continuous wire rope. The number of wire ropes in
the lashing is determined by calculation or experiment. The wire ropes in the lashing
should be tightly packed together and arranged in a plane perpendicular to the
longitudinal axis of the bundle. The ends of the wire ropes are twisted together at least
five times and tightened until all the lashing threads are tightened (Figure 11).
Figure 11. Installing the tie
Wooden fasteners. Wooden fasteners are made of wood materials of grade no
lower than the third in accordance with the requirements of GOST 8486 and GOST
2695. Birch, aspen, linden and beech wood are allowed to be used only for the
manufacture of additional supports and pads that work in compression and to which
supports, support beams and other fastening elements are not attached. These types of
wood are prohibited from being used in the manufacture of supports, support beams
and reinforcing beams. In addition, it is not allowed to manufacture supports and
reinforcing beams from any type of dried or rotten wood. The dimensions of wooden
fasteners (additional supports, pads, support and reinforcing beams) are indicated in
these technical specifications (TSh) in the following order: height × width × length or
height × width.
“PEDAGOGS”
international research journal ISSN:
2181-3027
_SJIF:
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Volume-82, Issue-2, May -2025
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Use of additional supports and pads. Additional supports and pads are used for
the following purposes: To increase the load bearing surface on the wagon floor, to
ensure the stability of the load row, to enable mechanized loading and unloading, to
protect the load and wagon bearing surface from damage, to create a basis for installing
reinforcing and supporting beams.
If the above conditions are met without the use of additional supports and pads,
their installation is not mandatory. The height of the additional supports and pads must
be at least 25 mm. Their width must be at least 80 mm, and the width to height ratio
must be at least 1.5.
Conclusion. The length of the additional supports placed transversely on the
wagon should be equal to the width of the wagon div, and the length of the pads
should not be less than the width of the load. The transverse pads used to separate the
load row are placed on top of each other and are placed at a distance of at least 500 mm
from the load end and at least 300 mm from the side supports.
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