How do you pull test a wire rope cable assembly?
A pull test loads a cable assembly in tension to confirm the termination holds the required strength. At Tyler Madison, before each production run begins, we destructively pull-test a representative assembly on a 50-ton swage setup to confirm it meets the required minimum breaking strength. Every finished assembly then receives a functional check before it ships.
What’s the difference between a destructive pull test, a proof test, and a functional check?
| Test | What it does | Does the part survive? | What it proves |
|---|---|---|---|
| Destructive pull test | Loads a sample assembly until it reaches the required strength or fails | No, the sample is destroyed or retired | The cable, fitting, and swage setup together meet the strength requirement |
| Proof test | Loads an assembly to a specified load below its breaking strength | Yes | That individual assembly held the specified load |
| Functional check | Confirms the assembly works as designed | Yes | The finished part performs the way the application needs |
Why pull test a representative cable assembly instead of every one?
A destructive test destroys the part, so it can’t be run on every assembly that ships. Testing a representative assembly at the start of each production run confirms that the cable, the fitting, and the swage setup for that run produce a termination that meets the requirement, before the rest of the run is built.
What does a passing pull test result look like?
The assembly reaches the required minimum breaking strength for its cable size and construction. Those values are on our wire rope breaking strength chart. Where a fitting is rated below 100% of cable strength, the requirement is the fitting’s rated holding strength. See the termination methods guide for those ratings.
Example: commercial fitness equipment cable
Construction: 1/8″ 7×19 galvanized with a ball-shank termination.
Required minimum breaking strength: 1,760 lbs, confirmed by destructive pull test before each production run.
Functional check on every finished assembly: the ball-shank termination rotates smoothly.
What gets checked on every finished cable assembly?
The functional check depends on what the assembly has to do. On a ball-shank fitness cable, it confirms the termination rotates smoothly so the cable doesn’t twist in service. Tell us how your assembly works in the application and we’ll define the check around it.
How else can a swaged fitting be verified without destroying it?
Industry practice adds two non-destructive checks, both described in FAA guidance for aircraft cable (AC 43.13-1B):
- Go/no-go gauge. A gauge confirms the swaged fitting was compressed to the correct diameter.
- Insertion and slippage marks. The cable is marked at the depth it should sit inside the fitting, then checked after swaging to confirm it didn’t slip. Painting the joint afterward lets later inspections spot slippage as a gap in the paint.
When does a new wire rope construction need to be proof-tested?
Whenever a termination’s published strength data doesn’t cover the cable you’re using. FAA guidance notes that its copper sleeve strength data comes from tests on flexible aircraft cable, and that sleeves used on other wire rope constructions should be proof-tested for each cable type first. Rope strengths, grades, constructions, and actual diameters vary, and the test confirms the materials, the pressing procedure, and the safety margin.
What should you ask a cable assembly manufacturer about pull testing?
- When do you pull test: before each run, at setup changes, or only on request?
- Is the test destructive, a proof load, or both?
- What load is the pass threshold, and is it the cable’s breaking strength or the fitting’s rated holding strength?
- What check does every finished assembly get?
- Do you gauge swaged fittings?
If your program requires specific test documentation, include that in your RFQ so it can be quoted with the assemblies.
Cable Assembly Pull Testing FAQs
Does Tyler Madison pull-test every finished cable assembly?
No. Before each production run begins, Tyler Madison destructively pull-tests a representative assembly on a 50-ton swage setup to confirm it meets the required minimum breaking strength. Every finished assembly then receives a separate functional check.
What is the difference between a pull test and a proof test?
A destructive pull test loads a sample until it meets the required strength or fails, and the sample isn’t shipped. A proof test loads an assembly to a specified load below its breaking strength, so the part survives.
What strength should a pull-tested cable assembly reach?
The required minimum breaking strength for the cable size and construction, or the fitting’s rated holding strength if the fitting is rated below 100% of cable strength.
What is a go/no-go gauge for swaged fittings?
A gauge that confirms a swaged fitting was compressed to the correct diameter. FAA guidance calls for checking swaged fittings with one.
Need assemblies with a defined test plan built in?
Tell us your strength requirement and we’ll quote the build and the testing together.
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