What Is the Difference Between Malleable and Forged Wire Rope Clips?
Wire rope clips, we also called as wire rope clamps, metal rope clamps, bulldog clips for wire rope, or u bolt clips. They are one of the most common WIRE ROPE END FITTINGS, used to form an eye or secure the free end of a wire rope in rigging and tensioning systems.
Wire rope clips are classfied in different standards and sizes. Today i will introduce 2 common type, one is Malleable cast wire rope clip, the other is drop forged wire rope clips. Their manufacturing methods, mechanical performance, and suitable applications are different.
Understanding this difference is essential for choose right wire rope clips when the connection is part of a lifting or load-bearing system.
Table of Contents
Manufacturing Process & Structural Difference
A Malleable cast wire rope clip is produced by casting malleable iron wire rope clip. The saddle is formed through a casting process, which is economical and suitable for mass production. This type of wire rope clamp is widely used for light-duty and general securing purposes.
Drop forged wire rope clips are different, manufactured through hot forging or drop forging. The steel is compressed under high pressure, creating a much denser internal structure and continuous grain flow.
This structural difference directly affects the strength, fatigue resistance, and lifetime of the metal rope clamp.
Material & Mechanical Performance
Malleable clips normally use a malleable cast iron saddle combined with a carbon steel U-bolt. Although malleable iron is more ductile than grey iron, its tensile strength and impact resistance are still limited.
Forged wire rope clips are usually made from forged carbon steel or alloy steel. Both the saddle and the load-bearing parts are forged, which enhance tensile strength, resistance to shock and vibration, imporove fatigue performance in repeated loading.
This is why professional rigging systems and high-end brands of forged clamps, such as the well-known crosby clamps wire rope products from The Crosby Group, are typically based on forged construction rather than cast components.
Typical Standards & Applications
Malleable wire rope clips are commonly produced to light-duty standards such as DIN 741. These clips are mainly intended for static or low-load tensioning,fencing and guy wire systems, temporary securing and general-purpose wire rope end fittings.Malleable cast wire rope clips are suitable for non-critical connections.
Forged wire rope clips are typically manufactured to heavier-duty standards such as DIN 1142. These standards are issued by Deutsches Institut für Normung and define stricter requirements for dimensions, materials, and mechanical performance.Drop forged wire rope clips are widely used in lifting, marine, construction, and industrial rigging.
It is important to note that many specifications clearly indicate that malleable clips should not be used in lifting or safety-critical assemblies.
How to Choose: Malleable or Forged Wire Rope Clips?
When selecting a wire rope clamp, the first step is to evaluate the application and risk level.
Choose a Malleable cast wire rope clip when:
- the connection is non-load-bearing
- the system is mainly static
- cost control is important
- the installation is temporary
Choose drop forged wire rope clips when:
- the wire rope is part of a lifting or load transfer system
- dynamic loading or vibration is expected
- higher safety factors are required
- long-term reliability is critical
From a practical purchasing perspective, size selection is also essential. Common sizes requested in international markets include:
- 3/8 wire rope clip
- 5/16 wire rope clip
- 1/2 wire rope clip
- 1/4 wire rope clip
No matter forged wire rope clips or malleable casting wire rope clips you choose, the clip size should match the nominal wire rope diameter. Also correct installation practices must be followed—especially placing the saddle on the live end and tightening the nuts to the specified torque.
Conclusion
Understanding the difference of how they are made and how they perform under load will help us to choosing right wire rope clips.Malleable casting wire rope clips and forged wire rope clips are different in how they are made and how they perform under load. Malleable cast wire rope clip is an economical solution for light-duty and general securing applications. However, for professional rigging, lifting systems, and demanding industrial environments, drop forged wire rope clips provide superior strength, durability, and operational safety. If you want to know more about malleable casting wire rope clips and forging wire rope clips, please feel free to contact Sail Rigging.
