[TowerTalk] Phillystran Cable Question

Wed Feb 26 11:14:08 EST 2014

I talked to the factory this month about old (pre 1991) Phylli. I've 
also taken some of the 5/8" dia apart since I have about 1800 feet of it 
and would like to use it on a Rohn 65G project.  The factory no longer 
sells the epoxy or terminals (spelter sockets), but will pot ends if you 
send the PS to them.  They claim is the process is too tricky.

I purchased a Crosby spelter socket for wire rope to see if it might 
work.  There are quite specific instructions for cleaning and splaying 
wires into the socket before potting.  A review of epoxies and ways to 
clean kevlar causes me to believe this is doable with old PS.  Some test 
lab data also indicates that the grip strength is developed in the first 
inch or so in the taper of the socket which is important since the 
Crosby socket taper is much shorter than the PS one I removed.  Load 
testing will be needed to find out if this is so.  Kevlar seems to be 
friendly to a variety of epoxies and solvents (MEK was recommended by 
one poster).  However, how to splay the very fine Kevlar fibers and 
wetting them with epoxy with no air entrapment in the socket feels 
challenging.

I think there is no way to use grips on the old PS.  Simple bends cause 
the fibers to retract in the sheath, there is no grip by the sheath on 
the fiber bundle which is all parallel laid and continuously tied with 
what appears to be a lacing cord.  I'm in process of  building a test 
stand to see if saddle clamps will work (loads to 24,000lbs).  Any 
experiences with saddle clamps on larger diameter PS would be appreciated.

Grant KZ1W

On 2/26/2014 5:00 AM, Cqtestk4xs at aol.com wrote:
> The old style (1970's and 1980's) was meant to be used with potted  ends.
> The newer stuff is made to be used with the specially made PLP  grips.
>   
> People don't always follow the instructions from the factory on  many
> things relating to towers....reusing guy grips, going higher than they  should
> with a tower, etc.  Many times these experiments work, until  they don't one
> day  Check my info with the manufacturer, Phlly Rope Works  for the scoop on
> the old style stuff.
>   
> Bill K4XS
>   
>   
> In a message dated 2/26/2014 5:50:19 A.M. Coordinated Universal Time,
> K8RI-on-TowerTalk at tm.net writes:
>
> On  2/25/2014 10:15 PM, Cqtestk4xs at aol.com wrote:
>> I had a chance to pick  up some of the old style Philly without ends.
> This
>> stuff  needs to have "potted" ends.  Plan on spending at least $35 for
> each
>> "empty" end and at least $70 for the resin potting  compound.  You will
>> find the cost is prohibitive unless you are  pouring a dozen or so ends,
> since
>> the potting mix has to mixed all at  once.
> With out ends?  All the Phillystran I have which is all the  guys, use
> only a plastic cap, RTVd in place.  14 years and no  problems. For the
> smaller stuff (less than 1/4" use the cable clamps with  the "U" bolt on
> the dead side. Do not over tighten. Typical is 4 cable  clamps and 1 end
> cap  Because it's the jacket that compresses, not  much strength is lost
> compared to cable clamps on wire.  For anything  other than small loads,
> I'd use 1/4" and larger with big grips and cap the  ends by RTVing the
> caps. Don't forget to use the proper size thimble and  guy brackets.
> Don't just wrap it around a tower leg.  The guy bracket  removes the side
> stress from the tower legs.
>
> I've not seen any,  including the older phillystran that couldn't be used
> with big grips and  capping the ends. Big grips should be installed with
> the Phillystran under  working tension. IE 1/4" at 440# and 5/16ths at 600#
>
> Kevlar does not  stand up well to moisture, so if the cable is old and
> the ends were not  capped, I'd cut at least several feet off each end.
> Hopefully it hasn't  been stored outside and uncapped. In that case you
> might need to cut back  quite a bit and I don't know how to tell.  The
> Kevlar core is made up  of many very fine strands. If they are still
> flexible and strong, I'd  think they are good.
>
> On the 45G the bottom two tier I use HTPG40001 ant  the top tier is
> HTPG67001.  Texas towers has end caps for all sizes  and I'd assume Davis
> does as well.
>
> 73
>
> Roger  (K8RI)
>
>>    
>> The factory can give you the  details.
>>    
>> Bill K4XS/KH7XS
>>     
>>    
>> In a message dated 2/26/2014 2:38:46 A.M.  Coordinated Universal Time,
>> Gunsrus1942 at Comcast.net  writes:
>>
>> I'm  going to be using Phillystran Cable .22 size  and am not able to use
>> the  "Big Grip" on a couple of the ends  & was wondering if a standard
>> "guy  wire clamp" can be used  and what is the recommended configuration?
>> It  appears that DX  Engr. recommends that guy wire clamps only be used on
>> .17  and  smaller.
>>
>> Thanks for your input.
>>
>> 73, Tom   W1ALZ
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