Rope-making

“ Forming and Laying of Ropes and Cables—Ropewalk Method Before taking up the strictly modern machines so largely used now in the final processes of rope-making—the forming of strands, laying of common ropes and closing of cable-laid goods—we shall describe the ropewalk method of performing these operations as it is practised today.
For making tarred goods in all but the smaller sizes the walk has certain advantages not afforded by more advanced methods. It also provides efficient equipment for turning out the largest ropes, which would otherwise require special machinery. ”

“ Thus rope making may be seen to consist in a series of twisting processes, each twist opposite to the former, the rope growing in size and strength at each operation. Horse power or water power was used when the ropes became too large to be made by hand. ”

“ The features we have here touched on are only a few of the many that have transformed the final stages of rope-making from a laborious task—dependent for its success on the skill of the individual expert—into quick, sure operations where every problem is met with the unfailing accuracy of a perfect machine. Rope nowadays is, generally speaking, made more scientifically, more uniformly than it was in the days of strictly hand processes. ”

“ FITTING THE ROPE TO ITS WORK Of the tricks in making ropes, there is no end. They are fitted for their work like a soldier or a gymnast, and built for it. A tiller rope must be flexible to the last degree, but it must be strong enough so it will stand up under the swift tensions of a storm or in the lightning manœuvers of a race. Therefore, like a few ropes built for other purposes, the composite parts are not mere strands of wire, but little ropes in themselves, complete in all parts. ”

“ The mechanism performs its work so accurately that at first glance the man feeding the fiber into the machine and all the other men, busy about their various duties, would appear to be playing very minor parts in modern rope-making. In reality, expert workmanship and watchfulness are very important factors. Good rope depends no more upon scientific machine processes than upon ceaseless attention to the little details. ”

“ Hair from the manes and tails of horses is also used. Hemp and flax are most common in the United States. The simplest mode of making rope is under long sheds. After the material is spun into yarn, it is doubled or trebled, and twisted. Ropes for the rigging of vessels employ a large number of men. The great variety and amount of cordage used make it an extensive trade. Ropes are now manufactured in some places by steam. A small number of women are employed in rope making. S. & M., Philadelphia, employ about fifty female hands. ”

“ Rope making has been treated as an exact science, because it dealt with materials that were more or less standardized. They are learning now that rope has a large unknown quantity that defies formula past a certain point. For the lack of a better term, they call it “personality.” The labor of today, and many years to come, is to identify these intangible factors and bring them where they can be computed to the end of securing greater endurance and safety. ”

“ So highly perfected is the apparatus that by machine work entirely66 the separate hanks of fiber are combed and elongated into a soft, continuous sliver of any size desired and of convenient length, glossy in appearance, perfectly clean, and with each fiber lying as nearly as possible in the straight position which gives it maximum strength. These operations, in which the entire character of the comparatively short vegetable fiber changes seemingly, are wholly a development of modern rope-making, since in the days of hand spinning no sliver was necessary. ”

“ This “top” thus placed prevents the strands from twisting, except in the direction of the smaller end; while a man stationed immediately behind, compresses the rope by a simple piece of apparatus, and causes the twist to become hard and firm. The “top” as the rope closes behind it is slowly urged on from one end to the other—if small it is managed by a top-man, but if large it is supported on a carriage, as in the engraving. No difference exists in making a larger or smaller rope, so far as the principle is concerned. ”

“ Many different vegetable fibres are used for rope-making, but for the combined qualities of strength, flexibility and durability, none can compete with the common hemp, which is consequently the staple of the rope-maker. Cotton ropes are, however, much more flexible, and in addition are strong and durable; they are, therefore, much preferred for power transmission in textile and other works. Manila hemp is a fibre of remarkable tenacity, of unapproached value for heavy cordage, but too stiff for small cords and twines. ”

“ Preparation of Fiber for Spinning—Formation of “Sliver” The opening room where the fiber is made ready for the preparation machinery is a reminder of the days when all rope-making processes were hand work. The bales are first opened up. In the case of Manila this means cutting away the straw matting put on to protect the fiber in shipment. Then the hanks which are packed in various ways—sometimes doubled, sometimes twisted—are taken out and straightened and the band at the end of each hank removed. ”

“ It might be well also to adopt the plan of the few feet of loose end wound round the waist, to make a foot noose with, if the circumstances and position allow.
When the double rope is worn, the rear man should always carry the spare rope. If the double ropes are then, as is quite possible, twisted and jammed in the snow groove, he has yet a third chance of making free and quick connection with his leader; and unless, as I have said, both men can begin instantly to use their full strength upon distinct ropes, there is small chance that one man can get another out of an undercut crevasse. ”

“ Rope-Making in the Seventeenth, Eighteenth and Early Nineteenth Centuries Coming down to more recent times we find that rope-making had been going on for centuries with probably very little change, up to the time of the introduction of machinery and the establishment of the factory system. ”

“ Fig. 158.—Beginning Mat.
Mats are used on board ship to prevent chafing. In making wrought mats a piece of small cord is stretched tight horizontally at about the height of a man, and fastened at each end. Across this, hanging by their middles, nettles are placed. These are often made of “foxes”—that is, three or more rope-yarns twisted together by hand, and each rubbed down with tarred canvas or a handful of rope-yarn. ”

“ With the continuous-wrap system having the rope from one of the grooves pass over a traveling take-up, the latter has a tendency to produce an unequal strain in the rope. In taking up, or letting out, the rope must either slide around the grooves, or the strands having the greatest pull will wedge themselves deeper into the grooves, producing a smaller pitch diameter than the ones having less pull, making a differential action on the ropes. ”

“ Hemp yarns, especially the finer kinds, are sometimes treated in the same manner, but Manila hemp, New Zealand hemp (Phormium) , and similar fibres, are invariably spun on bobbins by special machinery. The strands for light ropes may then be made on the twisting frames, and the rope finished on what is called a “house machine.” When a large rope is desired, at slightly different method is usually employed. ”

“ The primary object of twisting fibres together in a rope is that by mutual friction they may be held together when a strain is applied to the whole. Hard twisting has the further advantage of compacting the fibres and preventing, to some extent, the penetration of moisture when the ropes are exposed to water; but the yield of rope from a given length of yarn diminishes in proportion to the increase of twist. ”

“ To fasten a rope when it has been sufficiently hauled upon, by twining it several times round a cleat, belaying pin, or kevel, without hitching or seizing; this is chiefly applied to the running rigging, which needs to be so secured that it may be quickly let go in case of a squall or change of wind; there being several other expressions used for securing large ropes, as bitting, making fast, stoppering, &c.—Belay there, stop! that is enough!—Belay that yarn, we have had enough of it. Stand fast, secure all, when a hawser has been sufficiently hauled. ”

“ Each group revolves as the yarns are drawn off the bobbins, and thus the threads are formed into three strands. As the strands emerge from the guides, they converge towards three other guides, are laid together, and finally the finished rope is wound on to the reel.
In principle the vertical machine is the same as the horizontal machine, and the rope is, consequently, made in one operation. Any number of bobbins, from 24 to 128, may be twisted at the same time; the machine in fig. 18, Plate IV., is for making a rope of three strands, each with 12 threads, or 36 threads in all. ”

“ To end up a rope with a crown it is merely necessary to leave the projecting ends long and then by bringing them down tuck under the strands of the standing part, as shown in Fig. 112.
Then halve the strands and tuck again, as in making a short splice, until the result appears as in Fig. 113. This makes a neat, handy, and ship-shape finish to a rope's end and is very useful for painters, halyards, etc. It will never work loose like a seizing and is quickly put on at any time, whereas to make a seizing one must be provided with small stuff of some sort, and this is frequently not at hand. ”

“ Middle it and seize a thimble in the bight, making this fast to a post. Then stretch out both parts together, and mark off the positions [Pg 119] for the rungs with chalk, 12 in. apart. At every chalk mark, and round each part of rope separately, put a seven-turn whipping of tarred nettle stuff (this is sold in hanks) . Now begin at the end nearest the bight or lower end, open the strands with a fid and spike above the seizings or whippings, and push in a rung, taking care to avoid twisting the rope by inserting the spike between the two strands best situated. ”

“ Ancient, Mediæval and Tribal Rope-Making How many people have ever given a thought to the question of where rope comes from and how it is made, or realize what a variety of uses it is put to, and how dependent we are upon it in many of the everyday affairs of life? ”

“ Then the loop drawn up between the two twisted ropes is lowered over the corners of the near side of the pack.
Fig. 91. The final strain is taken on the free end of the rope passing along the neck of the animal and tied at the forward point of the diamond with a packer’s knot. If the animal should fall on either side, [43] the knot is easily reached and untied. The free end of the rope is tucked under some part of the hitch or looped over the pack or otherwise disposed of. In making the Diamond Hitch, at no time is the end of the rope pulled through anywhere. ”

“ The native Peruvians were good rope-makers, using a substance known as “totora,” as well as many other materials. The Island tribes of the South Seas, expert in making rope, are favored with some very good materials for its manufacture, obtained from the leaves of various palms and plantains, from the fiber of the cocoanut, etc.
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As, at the present day, the shipping and fishing industries are among the principal users of cordage, so it has been among all tribes and nations from earliest times. ”

“ As the spinner proceeds down the walk, he throws the spun yarn into one of these partitions, thus relieving himself of the weight and keeping the yarn off the ground. When a sufficient length of yarn has been spun, he breaks off the fibres and fastens the yarn to a convenient peg or hook until he has spun a sufficient number (usually three) to form a small rope or cord. The person at the wheel hangs these three yarns one on each of the three hooks B, C and D, while the spinner attaches the other ends to a revolving hook termed a “looper.” ”

“ All these varieties of cordage are composed of a number of separate yarns, each of which is made from some kind of textile fibre by preparing and spinning machinery. The number of separate yarns which ultimately form the rope or cord depends upon the fineness of the yarn, and also upon the circumference of the finished article. From thread and fine twine upwards the whole art of manufacture is that of twisting together fibres and yarns ”

“ The finished strands are wound in turn upon large bobbins, and mounted in the flyers or disks of the rope closing machine. These machines are similar in design to the stranding machine, but are naturally much heavier in construction, and, therefore revolve at a proportionate speed. The speed of the machines varies according to the weight of material, the size of the strands and the construction of the finished rope. The modern machine, or the type most generally used, makes about fifty revolutions per minute, whilst three times this speed is often obtained when spinning the strands. ”

“ During the hackling process a large quantity of comparatively short fibres are retained in the pins; the longest of these are separated, and the remainder used for tow yarns. The above description refers entirely to hand hackling; machine hackling of hemp is very similar to flax hackling.
The spinning is done in what is termed the “rope-walk,” and from the nature of hand-spinning, and the length of the rope required, it is necessary that this walk should be from 300 to 400 yds. in length. It is sometimes completely covered in with walls and roof; at other times only a roof is built ”