wire rope lubricants suppliers free sample

Steel wire ropes are widely used in many applications such as crane, tower crane, surface and underground mining, excavation,logging of any type of terrain, tramway, elevator, oil and gas, drilling, marine and electrical constructions.. The selection of a rope must consider the strength, fatigue and abrasion resistance, crushing resistance, resistance to metal loss and deformation

Wire rope forms an important part of many machines and structures. It is comprised of continuous wire strands wound around a central core. There are many kinds of wire rope designed for different applications. Most of them are steel wires made into strands wound with each other. The core can be made of steel, rope or even plastics.

Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or not it is preformed, by its lay, the number of strands and the number of wires in each strand.

A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small sheaves (pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through abrasives.

There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with a 1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking strength than a fiber core rope and a high resistance to crushing and deformation.

A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope core. WSC ropes are high strength and are mostly used as static or standing ropes.

Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also use plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core ropes are quite flexible and are used in many overhead crane applications.

The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope the strands twist to the right as it winds away from the observer. A left lay twists to the left. A regular lay rope has the wires in the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to have better fatigue resistance due to the flatter exposure of the wires.

Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability and for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used and are described in Table 1.

Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will straighten and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires that are shaped so that they lie naturally in their position in the strand, preventing the wires from protruding and potentially causing injury. Preformed wire ropes also have better fatigue resistance than nonpreformed ropes and are ideal for working over small sheaves and around sharp angles.

Lubricating wire ropes is a difficult proposition, regardless of the construction and composition. Ropes with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials. For this reason, it is important to carefully consider the issue of field relubrication when selecting rope for an application.

There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain a petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants penetrate slightly, sealing the outside of the cable from moisture and reducing wear and fretting corrosion from contact with external bodies.

Both types of wire rope lubricants are used. But because most wire ropes fail from the inside, it is important to make sure that the center core receives sufficient lubricant. A combination approach in which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect the outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease, petroleum oils or vegetable oil-based (Figure 3).

Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection. Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold temperature conditions.

Various types of greases are used for wire rope lubrication. These are the coating types that penetrate partially but usually do not saturate the rope core. Common grease thickeners include sodium, lithium, lithium complex and aluminum complex soaps. Greases used for this application generally have a soft semifluid consistency. They coat and achieve partial penetration if applied with pressure lubricators.

Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil type lubricants helps to wash the rope to remove abrasive external contaminants.

Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and function as a reservoir for prolonged lubrication while in service.

If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of the die that twists the wires into a strand. This allows complete coverage of all wires.

After the cable is put into service, relubrication is required due to loss of the original lubricant from loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect and preserve the rope core and wires, and thus extend the service life of the wire rope.

If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication. The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave where the rope strands have a tendency to separate slightly due to bending to facilitate maximum penetration to the core. If a pressure boot application is used, the lubricant is applied to the rope under slight tension in a straight condition. Excessive lubricant application should be avoided to prevent safety hazards.

Some key performance attributes to look for in a wire rope lubricant are wear resistance and corrosion prevention. Some useful performance benchmarks include high four-ball EP test values, such as a weld point (ASTM D2783) of above 350 kg and a load wear index of above 50. For corrosion protection, look for wire rope lubricants with salt spray (ASTM B117) resistance values above 60 hours and humidity cabinet (ASTM D1748) values of more than 60 days. Most manufacturers provide this type of data on product data sheets.

Cable life cycle and performance are influenced by several factors, including type of operation, care and environment. Cables can be damaged by worn sheaves, improper winding and splicing practices, and improper storage. High stress loading, shock loading, jerking heavy loads or rapid acceleration or deceleration (speed of the cable stopping and starting) will accelerate the wear rate.

Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If a machine is to be shut down for an extended period, the cables should be removed, cleaned, lubricated and properly stored. In service, corrosion and oxidation are caused by fumes, acids, salt brines, sulfur, gases, salt air, humidity and are accelerated by elevated temperatures. Proper and adequate lubricant application in the field can reduce corrosive attack of the cable.

Abrasive wear occurs on the inside and outside of wire ropes. Individual strands inside the rope move and rub against one another during normal operation, creating internal two-body abrasive wear. The outside of the cable accumulates dirt and contaminants from sheaves and drums. This causes three-body abrasive wear, which erodes the outer wires and strands. Abrasive wear usually reduces rope diameter and can result in core failure and internal wire breakage. Penetrating wire rope lubricants reduce abrasive wear inside the rope and also wash off the external surfaces to remove contaminants and dirt.

Many types of machines and structures use wire ropes, including draglines, cranes, elevators, shovels, drilling rigs, suspension bridges and cable-stayed towers. Each application has specific needs for the type and size of wire rope required. All wire ropes, regardless of the application, will perform at a higher level, last longer and provide greater user benefits when properly maintained.

Lubrication Engineers, Inc. has found through years of field experience, that longer wire rope life can be obtained through the use of penetrating lubricants, either alone or when used in conjunction with a coating lubricant. Practical experience at a South African mine suggests that life cycles may be doubled with this approach. At one mine site, the replacement rate for four 44-mm ropes was extended from an average 18.5 months to 43 months. At another mine, life cycles of four 43-mm x 2073 meter ropes were extended from an average 8 months to 12 months.

In another study involving 5-ton and 10-ton overhead cranes in the United States that used 3/8-inch and 5/8-inch diameter ropes, the average life of the ropes was doubled. The authors attribute this increased performance to the ability of the penetrating lubricant to displace water and contaminants while replacing them with oil, which reduces the wear and corrosion occurring throughout the rope. A good spray with penetrating wire rope lubricant effectively acts as an oil change for wire ropes.

In these examples, the savings in wire rope replacement costs (downtime, labor and capital costs) were substantial and dwarfed the cost of the lubricants. Companies who have realized the importance of proper wire rope lubrication have gained a huge advantage over those who purchase the lowest priced lubricant, or no lubricant at all, while replacing ropes on a much more frequent basis.

Proper lubrication of your wire rope, chain and cable can safely extend its operational life regardless of application. Cranes, elevators, shovels, drilling rigs, suspension bridges and draglines are some of the many applications that use wire rope, chain or cable to perform work such as pulling, dragging or hoisting. These applications often are exposed to harsh environmental conditions, including extreme weather. Lubrication Engineers can help your wire rope, chain and cable last longer and operate safely by implementing a lubricant reliability program and recommending the right lubricants for the job.

Most wire ropes are lubricated during the manufacturing process, but this lubricant will not last the entire life of the rope. When looking for a lubricant to relubricate your wire rope, choose one that contains no acids or alkalis, possesses the adhesive strength to stay on the rope, can penetrate between wires and strands, has high fluid film strength, resists oxidation and remains pliable. It is important to remember that most wire ropes fail from the inside out. Corroded rope can be a safety hazard, as there is no way to determine its remaining strength and life. Proper lubrication will help prevent deterioration of wire rope due to rust and corrosion.

Because most wire ropes fail from the inside, it is critical to ensure the center core receives sufficient lubricant. LE recommends a combined regimen in which a penetrating lubricant is used to saturate the core, followed by a coating lubricant to seal and protect the outer surface. LE offers several penetrating and coating type wire rope lubricants to suit your specific needs.

Penetrating lubricants contain an evaporative solvent that facilitates migration of the lubricant into the core of the wire rope, then evaporates, leaving behind a heavy lubricating film that protects and lubricates each strand.

Wirelife Almasol Coating Grease (451-453) is a soft, semifluid calcium-based grease designed to coat wire rope as well as moving chain and cable parts to ensure long life and smooth, quiet operation. Its tacky, water-resistant characteristics enable it to adhere strongly to rapidly moving parts, seal out damaging moisture, protect against premature wear and shield metal against corrosive attack.

Typical Applications: Wire rope, chain links, pins, bushings, cable sheave bushings, cables, open and closed silent and roller chains, and small, slow-turning gearboxes that require a semifluid lubricant

Wirelife Almasol Coating Lubricant (2002) is a fluid wire rope lubricant that provides a tough outer coating to seal and protect against fretting corrosion, wear and rust – even under extreme load and moisture. It seals and protects better than any product available. When used in conjunction with Wirelife Monolec Penetrating Lubricant, maximum protection and wear reduction is achieved.

Wirelife Almasol Syn Coating Lubricant (2022) is an extremely tacky, nonasphaltic synthetic lubricant with exceptionally high film strength. Perfect for extreme environments and conditions, it is the ultimate outer surface protector for wire rope and cable and comes from the same advanced technology that LE developed to protect large open gears in the mining and quarry industries. It derives its high load-carrying capacity from its synergistic blend of an extreme pressure additive and Almasol, LE’s exclusive wear-reducing additive.

Wirelife Monolec Penetrating Lubricant (2001) has excellent corrosion resistance and high load-carrying (EP) properties. It penetrates to the core of wire ropes, whether they are running or stationary. It is also excellent as a penetrating lubricant for chains of all sizes and works well in a variety of other industrial applications. When used in conjunction with Wirelife Almasol Coating Lubricant, maximum protection and wear reduction is achieved.

It contains a petroleum solvent to enhance its ability to penetrate. The solvent evaporates, leaving behind a film of heavy-bodied lubricant that protects and lubricates each strand and resists leakage from the wire rope core. Available in bulk sizes or in an aerosol version.

Typical Applications: All stationary or moving wire ropes or cables under heavy loads; chains of all sizes; mining and construction applications such as standing and running lines, draglines, cranes and derricks; marine applications such as cranes, hoists and drilling rigs; any other application that requires excellent rust protection for steel parts.

Designed for marine environments and other applications where environmental concerns require the use of a very low toxicity wire rope and chain lubricant, LE’s Wirelife Low Tox Penetrating Lubricant (2011) has excellent load-carrying capability and provides outstanding protection against rust, while having the lowest possible toxic effect on the environment.

Earthwise EAL Wire Rope Grease (3353) is recommended for use in applications on or near the waterways. It is an EAL and meets the specifications required by the EPA’s Vessel General Permit (VGP). It is readily biodegradable, exhibits minimal aquatic toxicity and will not accumulate in the cells of fish and other aquatic life forms. It is a soft, semifluid formulation designed to coat wire rope as well as moving chain and cable parts to ensure long life and smooth, quiet operation. Its semi-tacky, water-resistant characteristics enable it to adhere to the application and seal out damaging moisture and protect against rust formation.

Typical Applications: Applications near or around waterways including: Wire rope; chain links, pins and bushings; cable sheave bushings, bearings and strands; open and closed silent and roller chains. Ideal for use in automatic lubrication systems.

LE is happy to offer industrial lubricant and reliability recommendations for a variety of applications, and to provide product-specific data on all of our items to help you make the right decision. To learn more about our wire rope lubricants, wire rope lubricators as well as our other enhanced lubricants and lubricant reliability products, please

Wire rope forms an important part of many machines and structures. There are many kinds of wire rope designed for different applications. The wire rope’s performance is influenced by several factors, including type of operation and environment which can accelerate corrosion, oxidation, and wear. Hence, proper, and adequate lubricant application in the field is paramount. Essentially, wire rope lubricants have three principal functions, and it is to reduce friction, provide wear protection and corrosion protection.

Wire rope or cable is used for a wide variety of purposes ranging from stationary service, such as guys or stays and suspension cables, to service involving drawing or hoisting heavy loads. In these various services, all degrees of exposure to environmental conditions are encountered. These range from clean, dry conditions in applications such as elevator cables in office buildings, to full exposure to the elements on outdoor equipment. This could include immersion in water that can be encountered on dredging equipment to exposure to corrosive environments, such as acid water,

found in many mining applications. These and other operating factors require that wire ropes be properly lubricated to provide long rope life and maximum protection against rope failure where the safety of people is involved.

A wire rope consists of several strands laid (helically bent, not twisted) around a core. The core can be a rope made of hemp or other fiber, or may be an independent wire rope or strand. Each strand consists of several wires laid around the core, which usually consists of one or more wires but may be a small fiber rope. The number of wires per strand typically ranges from 7 to 37 or more.

Each wire of a wire rope can be in contact with three or more wires over its entire length. Each contact is theoretically along a line, but this line actually widens to a narrow band because of a deformation under load. As load is applied, and as a rope bends or flexes over rollers, sheaves, or drums, stresses are set up that cause the strands and individual wires to move with respect to each other under high contact pressures. Unless lubricating films are maintained in the contact areas, considerable friction and wear result from these movements.

One of the principal causes of wire rope failures is metal fatigue. Bending and tension stresses, repeated many times, cause fatigue. Eventually, individual wires break and the rope is progressively weakened to the extent that it must be removed from service. If lubrication is inadequate, the stresses are increased by high frictional resistance to the movement of the wires over one another, fatigue failures occur more rapidly, and rope life is shortened.

Another principal cause of rope failure is corrosion. This covers both direct attack by corrosive materials, such as acid water that may be encountered in mines, to various forms of rusting. To protect against corrosion, lubricant films that resist displacement by water must be maintained on all wire surfaces.

Wear, deterioration, or drying out of the core result in reduction of the core diameter and loss of support for the strands. The strands then tend to overlap, and severe cutting or nicking of the wires may occur. The lubricant applied in service must be of a type that will penetrate through the strands to the core to minimize friction and wear at the core surface, seal the core against water, and keep it soft and flexible.

During manufacture, wire rope cores are saturated with lubricant. A second lubricant, designed to provide a very tenacious film, is usually applied to the wires and strands to lubricate and protect the wires and to help keep (seal) the lubricant in the core as they are laid up. These lubricants protect the rope during shipment, storage, and installation.

Much of the core lubricant applied during manufacture is squeezed out when the strands are laid, and additional lubricant is lost from both the core and strands as soon as load is applied to a rope. As a result, in-service lubrication must be started almost immediately after a rope is placed in service.

Proper lubrication of wire ropes in service is not easy to accomplish. Some of the types of lubricants required for wire ropes may not be easy to apply, and often wire ropes are somewhat inaccessible. Various methods of applying lubricants are used, including brushing, spraying, pouring on a running section of the rope, drip or force feed applicators, and running the rope through a trough or bath of lubricant. Generally, the method of application is a function of the type of lubricant required to protect a rope under the conditions to which it is exposed.

These requirements necessitate some compromises. Wire rope lubricants may be formulated with asphaltic or petrolatum-based material and contain rust preventives and materials to promote metal wetting and penetration. Diluent products are used in some cases for ease of application. Grease products containing solid lubricants such as graphite or molybdenum disulfide are also used. The challenges with greases are the ability of the lubricant to penetrate to the inner core strands and its attraction for dust and dirt buildup. Wire ropes are often used in applications operating near or on an ocean, bay, river, lake, or other waterway, and as a result require environmentally acceptable wire rope lubricants to minimize their impact on the environment.

Please contact us for Your application needs and our technical support team will give You the best lubricating solution!Welcome to Lubrita.com International Lubrita Distributors network and World wide Oils & Lubricants online stores.

Crosby’s Vitalife®products are the preferred wire rope lubricants in the industry because of their ability to penetrate into wire rope and displace water and contaminants, thus reducing wear and corrosion throughout the rope.Available in a variety of container sizes.

Whitmore’s Wire Rope Lubricant products also coat these strands to prevent friction and wear. This results in longer wire rope life, less downtime for rope changes and more production.

Whitmore’s Wire Rope Lubricant is easily pumpable at temperatures down to -25°F (-35°C). Its nondrying film remains flexible in the most extreme weather conditions, which eliminates flaking and peeling.Whitmore’s Wire Rope Lubricant can be used to lubricate all sizes of wire rope, as well as chains, leaf springs and other applications where penetrating oil is needed. It may be applied by hand or automatic lube system.

We manufacture wire rope lubricants in our technologically advanced, highly efficient manufacturing facility. This highly flexible plant produces products for stranding and closing operations for supply into many applications such as elevators, surface mining, mining, drilling, fishing GP-engineering, construction, cranes and offshore.

Wire rope lubricants are used to reduce the friction and corrosion between the wires. Wire ropes are initially lubricated during the manufacturing. but remanufacturing is good to improve the life span. And the bending and stretching will get easier.

We understand the critical importance of lubricants within the wire manufacturing industry, which is why our research and development team are constantly striving to produce high performance, innovative lubricants.

Wire Rope Grease penetrates between the strands to the core of the rope providing complete rope lubrication.Wire Rope is a critical component in so many industrial applications across the world. Wire ropes simply comprise of continuous wire strands wound around a central core & are commonly used in crane, tower crane, surface and underground mining, excavation, logging of any type of terrain, tramway, elevator, oil and gas, drilling, marine, and electrical constructions, etc.Wire rope lubricants have two principle functions:

In static and dynamic work situations, wire ropes, also known as cables in gauges less than 3/8 in. dia., are connective elements that serve industry and infrastructure needs. Static wire-rope uses include primary suspension bridge support systems and tensioned cable used to support tall, free-standing structures like microwave cell towers. Mining-cage hoists, elevator hoists, draglines, and cranes are examples of dynamic uses in which the wire rope moves under tension and weight to lift, hoist, and transfer motion and power.Wire rope is still made in a similar manner from multiple strands of metal wire laid (wound) in a helical pattern around a center core, as it was originally developed in early 19th century Germany for the mining industry as a better alternative to existing metal chains and hemp rope—regular failure always proved catastrophic—wire rope is still made in a similar manner from multiple strands of metal wire laid (wound) in a helical pattern around a center core. Hemp rope, plastic, fiber, or steel can be used for the center core (specific to aircraft cable). The multi-strand construction process gives considerable tensile strength (100,000 to 350,000 psi, depending on wire steel grade) for lifting and hoisting while also allowing for traction and movement recovery across pulley or drum surfaces.

This is the first of three articles dealing with this very important subject. In this part, the intention is to convince the reader, if he should need any convincing, of the vital necessity for correct wire rope lubrication. Part Two will deal with the duties and properties of wire rope lubricants. Part Three will cover the methods of application of wire rope lubricant and should be of interest to every large user of wire ropes.

A distinction is made between the nominal rope diameter and the effective rope diameter. The nominal wire rope diameter is an agreed theoretical value for the diameter of the smallest circle circumscribing the outer strands.

The effective rope diameter, also called actual rope diameter, is the diameter of the smallest circle enclosing all outer strands, as measured on the rope itself. The tolerance range for the effective rope diameter is specified in related national and international standards. According to EN 12385-4 it is between -0{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} and +5{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} (for nominal rope diameters ≥ 8mm)

This means that the effective rope diameter upon delivery must neither be smaller nor bigger than 5{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} than the nominal rope diameter. The tolerance range is often higher for smaller ropes like 3mm to 7mm nominal diameter. In the Oil and Gas industry, which is firmly based on US regulations, a tolerance range from -1{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} to 4{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} is applied. The effective rope diameter changes depending on the load applied. Therefore the effective rope diameter should in critical cases be measured on a rope that is loaded with 5{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} of the calculated breaking strength. verope® produces standard tolerances of +2{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} to +4{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} and special tolerances upon request.

By the design of a wire rope, one understands the formation principle according to which the elements of the wire rope (the wires and the strands) are arranged relative to each other. The designation of a fiber core is FC, for an independent steel wire rope core it is IWRC. As an example all round strand ropes of the 6×19 Warrington design with a fiber core have the construction 6 x [1-6-(6-6)] – FC.

The fill factor of a rope is defined as the ratio of the metallic cross section of the rope (or a simplified calculation of the sum of the single wire cross sections) related to the nominal rope diameter. The fill factor specifies which amount of space the wires and strands take in the rope (figure 16).

The fill factors of the most common ropes are between 0,46 and 0,75. This means, that the amount of steel in the rope volume is about 46{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} to 75{a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02}. Wire ropes with a wire rope core have higher fill factors than ropes with a fiber core.

Usually fill factors of wire ropes with a fibre core (FC) decrease with an increasing number of outer strands. A rope of the design 6×25 Filler-FC has a fill factor of 0,50, a rope of the design 8×25 Filler-FC has only a fill factor of 0,445.

Usually fill factors of wire ropes with a wire rope core increase with an increasing number of outer strands. A rope of the design 6×25 Filler-IWRC has a fill factor of 0,58 and a rope of the design 8×25 Filler-IWRC has a fill factor of 0,587.

Two lay types are to be considered: Regular or ordinary lay and lang’s lay. In regular lay ropes, the lay direction of the wires in the strands is opposite to the lay direction of the strands in the rope. We distinguish between right hand ordinary lay RHOL (right hand strand, left hand rope, zS) (figure 17) and left hand ordinary lay LHOL (left hand strand, right hand rope, sZ) (figure 18). In lang’s lay ropes, the lay direction of the wires in the strands is equal to the strands in the rope. We distinguish between left hand lang’s lay LHLL (left hand strand, left hand rope, sS) (figure 19) and right hand lang’s lay RHLL (right hand strand, right hand rope, zZ) (figure 20).

In the stranding process the initially straight wires are forced into a helical or double-helical form. Therefore, the wires in a rope are always under tension, even in an unloaded rope. Such a rope must be sealed very tightly left and right of the joint before cutting the rope because otherwise the free ends of the wires will spring open. By using a “preforming tool”, the wires and strands can be heavily plastically deformed during the stranding, so are laying nearly without tension in the rope, the rope now is preformed. The ropemakers consider such ropes to be “dead”. Preformed ropes can be cut much easier, also secured by seizings of course, than nonpreformed ropes.

Usually wire ropes have either a fiber core (FC) or a steel/wire core. The steel/wire core can be a strand (WC) or a small rope, named as independent wire rope core (IWRC). The IWRC can be made in a separate operation or during the closing operation of the wire rope (PWRC). The wire core can also have a plastic coating (EPIWRC). Cores made of compacted strands have the additional designation (K). An independent wire core made of compacted strands is therefore called IWRC (K). A rope closed in a single operation and made out of compacted strands both in the core and the outer strands is called PWRC (K).

wire ropes and their free rope end rotate to a greater or lesser extent around its longitudinal axis under the influence of tension. Wire ropes having a core lay direction opposite to the lay direction of the outer strands and 3- or 4-strand regular lay wire ropes rotate considerably less than wire ropes with the same lay direction of the wire core and the outer strands and wire ropes with fiber cores. According to VDI 2358, a wire rope is semi rotation-resistant when: “the wire rope which turns around its longitudinal axis when subjected to unguided load and/or hardly transmits a torque to the attachment at the end in the event of guided rope ends.”

According to ISO 21669 and DIN EN 12385-3: “a rope is considered to be semi rotation resistant if it rotates at least once and at most four times around its axis at a length of 1000 x d under a load of 20 {a889db705b9dbdba2a8d0dbcfc2b631547dc85af52ef75a70f044d2486ae0f02} of the minimum breaking force. In terms of rotation angle, the defined limits are between 360° and 1440°.”

According to the regulation of VDI 2358, a wire rope is rotation-resistant, when: “the wire rope, which hardly turns around its longitudinal axis when subjected to unguided load and/or hardly transmits a torque to the attachment at the end in the event of guided rope ends.”

The wire rope lubricant has two major tasks: it should protect the rope from corrosion and minimize the friction between the rope elements themselves and between the rope and the sheave or the drum. A reduction of the friction reduces the actuating power and minimizes the wear of the rope, the sheaves and the drums. We differentiate between wax-based lubricants and oil-based lubricants. While wax-based lubricants offer a better handling of the ropes, the oil-based lubricants advantage is a better closing of the lubrication film due to the gravitational force of the oil. The quality of the wire rope lubricant has a great impact on the fatigue resistance of a wire rope (figure 22).

YuanBo Engineering Co., Ltd., Dunamis Wire Ropes Mfg. LLP, Tokyo Rope Mfg. Co., Ltd., and Guizhou Wire Rope Incorporated Company, among others, are the top players in the bright steel wire rope market.

The global bright steel wire rope market is supported largely by the steel wire rope industry, which attained a CAGR of 3.4% in the forecast period from 2022 to 2027.

Bright steel wire ropes are general wire ropes without any coating, and free from zinc, copper, and other metallic coatings. Grease is generally used to lubricate these wires, hence preventing their deterioration. The major users of bright steel wire ropes are the oil and gas industry, shipping industry, and mining industry. Ever since the crude oil crisis, bright steel wire rope producers have seen a surge in revenue generation, especially with newer ventures for oil extraction, coal mining, and other mineral and industrial drilling.

Bright steel wire rope consumption and sales have been high in the Asia Pacific region in recent years, particularly in China, Indonesia, and India. North America and Europe are the primary areas for the global market for bright steel wire rope since they are major end-users in the oil and gas industry. During the forecasted period, the Asia Pacific countries of China, India, Indonesia, Thailand, and Malaysia are predicted to have considerable growth in the bright steel wire rope sector. Over the recent decade, China"s demand for bright steel wire rope has increased significantly, possibly because of increased steel output and infrastructure investment in lift and motion applications.

YuanBo Engineering Co., Ltd. Is the biggest bright steel wire rope manufacturer in the world. The company provides technology, solutions, and service support to meet the specific needs of customers in the pharmaceutical, chemical, fire, industrial, and other industries. As the company is located close to the northern Chinese, Tianjin port, it enjoys convenience of transport, and as a result, exports are large. It covers an area of 18000 square meters and employs more than 200 people to manufacture its goods. YuanBo exports to Europe, America, Japan, the Middle East, Africa, South Korea, and Australia.

Dunamis Wire Ropes Mfg. LLP is the largest wire rope producer in India. The various ports of Mumbai offer easy transport to other countries, hence increasing their revenue. The company provides wire ropes for a wide variety of applications such as industrial and construction work, mining, oil and gas, bridges, ski lifts, and fishing and marine.

One of the biggest wire rope manufacturers in Asia, Tokyo Rope Mfg. Co., Ltd. have built a reputation for providing the best quality in their products. The seaside ports and the immense connectivity from Japan allow for exceptional transport facilities. It is engaged in the production and sale of steel cables, steel cords, developed products, and others, the real estate leasing business, as well as logistics related business and other services.

Guizhou Wire Rope Incorporated Company is one of the largest companies specialising in steel wire rope products. The enterprise has more than 5000 employees, as they strive to achieve perfect quality control. The capacity of the company is a massive 4,00,000 metric tons a year, which they export to the United States, United Kingdom, Canada, Australia, Denmark, Netherlands, Singapore, and the Middle East.