How to Swage a Wire Rope Guardrail

How to Swage a Wire Rope Guardrail

Swaging a wire rope guardrail is a straightforward process that ensures a secure, durable, and aesthetically pleasing handrail. This guide will demonstrate how to replace an old swage fitting with a modern stainless steel 316 wire rope system, ideal for applications such as boat guardrails, handrails, or balustrades.

Materials Required:

  • Stainless steel 316 wire rope (coated with UV-resistant PVC for added protection)

  • Rigging screw turnbuckles (closed-body, with a swage fitting on one end and a fork at the other)

  • Swage forks (for securing the opposite end of the wire rope)

  • Hydraulic swaging tool

  • Swage anvil (appropriate size for wire diameter)

  • Wire rope cutters

  • Measuring tape and marker

  • Adjustable spanners

  • Loctite or anti-seize lubricant

Step-by-Step Guide

1. Remove the Old Guardrail

  • Inspect the existing fittings and wire rope.

  • Cut away any old rope or corroded fittings.

  • If there is any adhesive residue or corrosion on the mounting points, clean and prepare them before installation.

2. Measure and Cut the New Wire Rope

  • Measure the distance between the attachment points.

  • Allow extra length for swaging and fine adjustments.

  • Use wire rope cutters to ensure a clean cut.

3. Prepare the Wire Rope for Swaging

  • Peel back the PVC coating at the end of the wire rope.

  • Ensure the wire rope goes all the way into the swage fitting.

  • Mark the insertion depth with a pen to confirm it moves fully into place.

4. Attach the Swage Fittings

  • Select the appropriate swage anvil for the wire size:

    • Number 10 swage anvil for 4mm wire.

    • Larger anvil for 6mm wire.

    • Smaller anvil for 2mm wire.

  • Place the swage fitting with the wire in it into the swage anvil.

  • Position it towards the end of the swage fitting, about 8-10mm.

5. Swage the Fittings

  • Set the hydraulic swaging tool to the "on" position.

  • Pump the handle to apply pressure and crimp the swage fitting.

  • Do not over-tighten, as excessive pressure can damage the swage tool.

  • Verify that the fitting is firmly attached, with no movement.

6. Install the Guardrail

  • Attach the swage fork to the existing mounting point.

  • Secure the turnbuckle fork to its anchor point.

  • Hand-tighten the turnbuckle to remove slack.

7. Tensioning the System

  • Gradually tighten the turnbuckles using adjustable spanners.

  • Ensure the wire rope is taut but not overstressed.

  • Apply Loctite or anti-seize lubricant to prevent loosening over time.

8. Final Inspection and Adjustments

  • Check that all fittings are securely fastened.

  • Test the tension by applying moderate pressure to the guardrail.

  • Ensure symmetry and alignment for a professional finish.

Alternative Fittings

For added flexibility, an alternative to the standard swage fitting is a Pelican fitting, which allows for easy removal and reattachment of the handrail. This can be particularly useful for boats or other installations where adjustability is needed.

Conclusion

Swaging a wire rope guardrail is a reliable and effective method to create a strong and visually appealing barrier. Whether used on a boat, balcony, or deck, stainless steel 316 wire with UV-resistant PVC coating offers excellent longevity and corrosion resistance. Properly executed swaging ensures a durable installation that withstands environmental conditions and daily use.

By following these steps, you can replace an outdated guardrail with a sleek, modern alternative that provides both safety and style.

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