How can I calculate and manage pulling tension to prevent cable damage?

2025-08-15

Effective tension management is a critical safety and quality control measure. The maximum pulling tension is determined by the cable manufacturer and should never be exceeded. To manage this, follow these best practices:

  • Pre-Pull Calculation: Use the cable's weight, the coefficient of friction, and the number of bends to estimate the required pulling force. This helps you select a winch with the appropriate capacity.

  • Tension Monitoring: Use a tension meter or dynamometer on the pulling winch. This device provides a real-time display of the pulling force, allowing the operator to adjust speed and lubrication to stay within safe limits.

  • Lubrication: Applying a compatible, high-quality cable pulling lubricant is the single most effective way to reduce pulling tension. It can reduce friction by over 50%, making the pull smoother and safer.

  • Proper Sheaves and Rollers: Ensure all rollers and sheaves have a diameter that respects the cable's minimum bending radius. This prevents excessive sidewall pressure, which can cause internal cable damage.

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