Swagingsleeves for steel cable assemblies is one of the most commonly performed rigging functions for lighter duty applications. Watch our video for everything you need to know to swage sleeves safely and correctly for your next application.
For a text and picture version of this information, keep reading.
We’re often asked whether it is better to make an eye with hour glass sleeves or with wire rope clips.
Swaged hour glass sleeves are stronger, more cost effective, and do not require future maintenance or re-torquing of nuts. They are also more streamlined than wire rope clips.
Where rigging products are concerned, swaging refers to the process of using a tool or machine to apply force to a sleeve or ferrule. Through this process, the sleeve becomes compressed onto and around a portion of cable.
7x19 refers to the cable having six outer strands surrounding the center core strand that counts as the seventh. Each strand is composed of 19 smaller wires.
If you look closely, you can see the V-shaped area between the strands. This is referred to as a “valley.”
The aluminum is soft. When compressed by the swaging tool, it will be forced into the valleys of the cable, locking the aluminum sleeve into place.
Creating a Swaged Cable Assembly
Make an eye by passing the cable through the sleeve and doubling it back.
Before swaging, make sure the “cut end” of the cable sticks out at a length at least 2 cable diameters. This will allow for full contact with the cable when the sleeve expands during swaging.
Place the sleeve into the tool jaws.
Note the proper orientation of the swage tool cavity with the aluminum sleeve.
The sleeve should always be vertically aligned and never horizontal.
With the sleeve in the proper position, make your first swage by squeezing the swage tool handles together until the jaws are completely closed.
For each sleeve size, there is a prescribed number of swage crimps that must be made.
In the case of this ¼” sleeve, it requires 4 swage crimps.
Be sure to leave a small space in between each of the crimps. Your finished assembly should look as shown.
Swages per Sleeve
Different sized sleeves will require a different number of swages.
2 swages are required for sizes 1/16ths" and 3/32nds" sleeves.
3 swages are required for sizes 1/8th" and 5/32nds" sleeves.
4 swages are required for 3/16ths" and ¼ inch sleeves.
5 swages are required for 5/16ths" and 3/8ths" sleeves.
Swaging Sequence
When making multiple swages, it is important to follow the correct sequence for each sized sleeve.
The diagram here can be referenced for the swaging sequences of different sized sleeves.
E-Rigging also carries zinc copper hourglass sleeves which are recommended for stainless steel cable.
It is important to note that aluminum sleeves are NOT recommended for stainless steel cable because of the possibility of the aluminum corroding when in contact with stainless steel. Over time this may cause the contact between the sleeve and cable to weaken and make an unsafe assembly.
Lifting, Overhead Lifting, and Suspending
Properly installed Aluminum and Copper duplex sleeves have been used successfully to suspend overhead equipment in various industries such as stage rigging, agriculture, marine, and construction for many years. It is imperative to follow the manufacturer’s swaging procedures and verify the swage with a Go/No-Go gauge prior to use. For critical lifting applications, it is recommended that a qualified person design, break test, and validate the assembly for the intended use. The fabrication process and margin of safety must be considered for the intended application. Shock loads should especially be avoided with these types of fabricated assemblies, but copper sleeves are more resistant to cable slippage than Aluminum sleeves in shock loading situations.
