How to Install Wire Rope Clips: Number, Direction and Spacing
2 min read OSAK
A wire rope clip is the most practical way to form an eye at the end of a steel wire rope. However, an incorrectly installed clip can cut the connection’s capacity by half. Here is what you need to know for correct installation.
The golden rule: saddle on the live end
A clip consists of a U-bolt, a saddle and two nuts. The saddle must always go on the long, load-bearing end (live end), and the U-bolt on the short end that is folded back (dead end). Known as “never saddle a dead horse”, this rule prevents the U-bolt from crushing and weakening the load-bearing rope.
How many clips should I use?
The number of clips depends on the rope diameter. As a general guide, use at least 3 clips on small diameters (Ø 3–12 mm), 4 on medium diameters and 5–6 on large diameters. In lifting applications, always follow the manufacturer’s table and standards such as DIN 1142.
Step-by-step installation
- Fold the rope end back enough to form the required eye size; insert a thimble in the eye if needed.
- Install the first clip about one saddle width from the end of the dead end and tighten the nuts.
- Install the second clip as close to the eye as possible and hand-tighten the nuts.
- Place the remaining clips at equal spacing of about six rope diameters.
- Apply slight tension to the rope and tighten all nuts alternately.
- After the first load, check and retighten the nuts; the rope diameter settles a little as the rope beds in.
Common mistakes
- Installing the clips the wrong way round (saddle on the dead end)
- Using clips larger than the rope diameter
- Using fewer clips than required
- Forgetting to retighten after the first load
- Using light DIN 741 clips for lifting work
The safest approach is to buy the rope and clips in the same order with matching diameters. For systems that need tensioning, combine them with a turnbuckle.
