wire rope flexibility chart quotation

METRIC WIRE ROPES- 6 x 36 wire rope is a more flexible cable wire than 6 x 19 wire rope since it has a higher number of wires per strand. Some of the most common uses are winch lines, choker and boom lines, and works well in marine environments.

* EIPS (Extra Improved Plowed Steel) wire rope has roughly 10% more strength than regular IPS. Independent wire rope core ( IWRC ) provides added strength, reduces the amount of stretch. IWRC wire rope also is resistance to heat and provides extra corrosion resistance over a typical bright wire finish.

6x37 Classification Wire Ropes have a third layer of wires which makes them more flexible, although less abrasion-resistant, than ropes of the 6x19 classification. Each strand contains numerous, small-diameter wires. As the number of wires in each strand is increased, flexibility is increased… as wires per strand decreases, flexibility is decreased.

Our stainless-steel aircraft cable consists of thin steel wires that are stranded together to give the cable a combination of flexibility and strength. Although the largest diameter of aircraft cable available at Tyler Madison maxes out at a ¼”, it is lightweight and strong enough to meet special airline safety standards.

Commercial quality "aircraft grade" cable is made from galvanized steel wire or stainless steel wire. Galvanized aircraft cable provides high tensile strength and adequate corrosion resistance for most commercial applications. Stainless steel cable provides slightly lower tensile strength, but greater resistance to corrosion. We also offer aircraft cable fitting services.

Cable or wire rope is fabricated from individual wires put together in a uniform helical arrangement to form what is called a strand. A strand typically contains 7 wires (1 x 7) or 19 wires (1 x 19), although others are available. Cable or wire rope contains a varying number of these strands such as 7 x 7 and 7 x 19 (number of strands x wire per strand). The more strands and more wires per strand, the more flexible the cable and the higher the cost. The greater the cable diameter, the greater the diameter of each wire and the greater the breaking strength.

Airplane cable is used for more than just aircraft applications. It’s strength and flexibility make aircraft braided steel cable perfect for numerous commercial and industrial uses. Stainless steel aircraft cable is typically used in areas where the components are exposed to oxidative chemicals such as salt, and the ability to resist corrosion is crucial. Galvanized aircraft cable is a more affordable solution, but it does not resist corrosion as well.

At Tyler Madison Inc., aircraft cable assemblies are just one of the many quality wire rope products that we manufacture for our industrial and commercial customers . We have the ability to create fully customized cable assemblies with standard or custom aircraft cable fittings. With skilled labor and precise advanced equipment, we are able to manufacture quality wire ropes and high-strength cables at an affordable price. Along the way, we can help you design and engineer aircraft cable fittings for your application. If you have an idea of what kind of aviation cable assembly or wire rope you need, but aren"t sure how to make it a reality, just contact Tyler Madison today and we will be ready to help!

No matter how customized the cable, wire rope or aircraft cable fittings for your application needs to be, we are more than capable of helping you get the job done!

For more information or inquiries about our wire rope or aircraft cable fittings, get in touch with us today. Our team of experts are here to answer any of your questions. We look forward to hearing from you!

6 strands, nominally 19 wires per strand This class is the most widely used and is found in its many variations throughout many industries. With its good combination of flexibility and wear resistance, rope in this class is suited to the specific needs of many kinds of machinery and equipment. The designation 6x19 is only nominal; the number of wires ranges from 15 to 26. The following constructions are included in this class:

6x25 Filler Wire. In this construction, there are 19 main wires in each strand, plus six small filler wires. The filler wires are located between the outer layer of 12 wires and the inner layer of six. They provide support and stability to the strand. This construction is the best combination of flexibility and abrasion resistance found in the 6x19 Class.

6x19 Warrington. Each strand is made up of 19 wires. The outer layer of 12 wires has two different sizes of wire; the inner layer of six is one size of wire. The Warrington construction is somewhat less flexible than 6x25 Filler Wire, but more flexible than 6x21 Filler Wire.

6x21 Filler Wire. Each strand is made up of 21 wires. The rope has an outer layer of 10 large wires, an inner layer of five smaller wires and a still smaller center wire. There are five filler wires, located between the outer layer of ten wires and the inner layer of five. The 6x21 Filler Wire ropes are more wear-resistant but less flexible than Warrington, and less abrasion-resistant but more flexible than 6x19 Seale constructions.

6x26 Warrington Seale. This construction is composed of 26-wire strands. It has the same size outer wires as the 6x21 Filler Wire, with an inner wire configuration similar to the 6x36 Class ropes. Thus, it combines the wear resistance of a 6x19 rope with a flexibility between 6x19 and 6x36 Class ropes.

6x19 Seale. This construction has an outer layer of nine large wires, an inner layer of nine smaller wires and a single center wire. The Seale ropes are the least flexible of the 6x19 Class ropes. However, the large outer wires, solidly supported, provide resistance to abrasion and crushing.

The 6x36 Class of wire rope is characterized by the relatively large number of wires in each strand. Ropes of this class are more flexible than the 6x19 Class, but their resistance to abrasion is less than the 6x19 Class ropes.

The designation 6x36 is only nominal, as is the case with 6x19 Class. Ropes in the 6x36 Class may contain 27 to 49 wires per strand. Improvements in wire rope design, as well as changing machine designs, resulted in the use of strands with widely varying numbers of wires and geometry.

Larger wire ropes frequently incorporate a larger number of wires, resulting in a more complex geometry than found in the 6x19 or 6x36 Class wire ropes. WW’s 6x61 Class Bethlehem Mining Ropes generally are designed to comply with ASTM A 1023 geometry, although we added some innovations. WW strands the 6x61 Class Bethlehem Mining Ropes in a single operation, relying on dense, well fitted geometry to provide exceptional rope performance and the flexibility normally associated with 6x61 Class ropes.

The 6x61 Class ropes have a Seale-Filler Wire-Seale design, as shown in the cross sections below, containing from 50 to 77 wires per strand. WW further enhances Bethlehem Mining Rope performance by wire metallurgy and wire properties which are selectively modified to augment the specific rope geometries.

Many wire rope users have observed that heavily loaded ropes fail internally due to the failure of the IWRC. Such conditions illustrate that heavy IWRC stresses exist, which promote fewer fatigue cycles and create short rope life. WW designed Maxi-core to improve rope life under these conditions.

Maxi-core utilizes an IWRC design which features eight strands around a strand center. Maxi-core’s IWRC provides longer life, and, therefore, increases the overall service life of the rope. Because of its specialized IWRC, Maxi-core is resilient and able to accommodate shock loads better than conventional IWRC designs. Maxi-core also adds 33% more core support to the outer strands, thereby reducing internal stresses and promoting longer rope life. As with all Bethlehem Excavator Family Ropes, WW does not publish Maxi-core rope strengths. WW relies on specific rope improvements and specialized features to provide rope designs which give proven, superior field service.

This plastic jacket acts as a cushion or shock absorber between adjacent main strands and at main strand-to-IWRC contact points. The improved internal support is especially significant for ropes subjected to continual bending stresses and fluctuating loads (shock loading). Reduction of wear and damage at internal contact points results in longer and more predictable service life.

Compacted Strands: Beth Pac Beth Pac refers to rope manufactured by compacting each individual strand before closing the rope. In comparison to conventional wire rope, Beth Pac has a higher metallic area, improved crushing resistance and a smoother surface contacting sheaves and drums.

Beth Pac is offered in Excavator and Excavator-AR in diameters 21/4" through 23/4" in 8x36 construction for hoist ropes. Beth Pac can be combined with other Bethlehem Mining Rope features, such as En-core. For more information and help in determining your need for Beth Pac and other available sizes, please contact WW’s Sales and Engineering Departments.

BXL is furnished as right regular or lang lay, Form-set, IWRC wire rope manufactured in the 6x19, 6x36 and 8x36 Classes. Available grades are Excavator and Excavator-AR. For specific information, please refer to the table. For information on smaller diameters for mining applications, please contact our Customer Service Department.

BXL provides the characteristics common to Bethlehem Mining Rope, enhanced by the plastic-infusion. BXL starts with WW’s special wire grades used in the manufacture of mining rope. Excavator grade is designed to provide excellent resistance to bending fatigue, such as those conditions found with hoist ropes. Excavator-AR is intended for those applications where more abrasive operating conditions exist, such as in drag line applications. Enhanced by plastic infusion, BXL offers several improved features.

Improved fatigue resistance is one key feature of BXL. BXL’s polymer cushions each wire and strand, minimizing interstrand and interlayer nicking. BXL also offers improved abrasion resistance. The polymer acts as a barrier between the individual strands, preventing penetration of any adverse material, such as dust, dirt and metal particles. The polymer also distributes and reduces contact stresses between the rope and sheave, reducing the wire rope wear normally associated with uncoated wire rope. Perhaps the most important feature of BXL, however, is the polymer’s ability to maintain the balance of the rope. When a rope is in operation, or simply wound upon a drum, the rope’s components move and adjust accordingly.

Due to the nature of wire rope, this movement may cause accelerated wear, and in uncoated rope, may also produce a flattening or ovaling of the rope. The polymer in BXL minimizes this movement by locking the individual wires and strands in place. With the rope’s holding its intended shape during operation, operating stresses such as vibration are evenly distributed to all wires and strands, thereby reducing fatigue breaks and increasing service life.

This rope is particularly suitable where severe crushing and abrasion on a drum occur, or where a higher strength design is required than can be obtained with a similar round strand rope. The triangular strand shape not only provides better resistance to crushing, but also offers a greater exposed surface area for contact with sheaves, drums or underlying areas of spooled rope.

This feature, combined with Lang lay, distributes the abrasive wear over a greater number and longer length of wires. The broad, smooth surface of the rope also helps to minimize wear on drums and sheaves.

We make a full line of tail ropes customized to meet your requirements of strength and weight to balance your friction hoist system. Please contact your salesman or customer service with your specifications and we will supply a quotation to meet your needs.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire. On shipping docks, rigging, and load bearing equipment, wire rope is attached to swivels, shackles, or hooks to lift a load in a controlled, even, and efficient manner.

The uses for wire rope include adding support to suspension bridges, lifting elevators, and serving as additional reinforcement for towers. The design of wire rope, with its multiple strands wrapped around a stable core, provides strength, flexibility, and ease of handling for applications that have bending stress.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of lifting or supportive applications.

The term wire rope encompasses a wide range of mechanical tools that are made to perform heavy and extreme lifting jobs. Wire rope is a complicated and complex tool with multiple moving parts capable of moving in unison. A 6 by 25 wire rope has 150 outer strands that move as one in an intricate pattern supported by a flexible core.

An essential part of the design of wire rope is the required clearance between the strands to give each stand the freedom to move and adjust when the rope bends. It is this unique feature that differentiates wire rope from solid wire and other forms of cable.

The basic element of wire rope is wire that is used to configure, shape, and form the rope. Typically, steel, stainless steel, and galvanized wires are the first choice with aluminum, nickel alloy, bronze, copper, and titanium being second possibilities. The choice of wire is dependent on the type of work the wire is going to be used to perform with strength, flexibility, and abrasion resistance being the major determining factors.

Stainless steel wire rope has all of the basic qualities of galvanized and general wire rope with the added benefits of corrosion and rust resistance; this makes it the ideal choice for harsh and stressful conditions.

Steel wire rope is classified as general purpose wire rope and comes in a wide variety of sizes, diameters, and strengths. It is the most common type of wire rope and is used for several industrial, manufacturing, and construction applications.

Before going further into the discussion of how wire rope is made, it is important to understand the numbers used to describe each type. All wire ropes have a core around which wires are wound. The various styles of cores vary according to the construction and design of the requirements of the wire rope that is being produced.

Wire rope is classified by the number of strands it has as well as the number of wires in each strand. The most common classification is a seven wire rope that has one strand in the center and six around its circumference. This type of wire rope is lightweight with a very simple construction. The majority of wire ropes are more complex and intricate with multiple intertwining strands and wires.

What must be understood about wire rope is that it has a complicated configuration. It is actually wires wrapped around wires to form bundles that are wrapped around other bundles. In the case of a seven wire wire rope, the core has bundles of wires wound around it; this can be seen in the image below.

The first step in wire rope creation is the production of wire strands where wires are wound around a single core wire. The number of wires included in the strand is dependent on the specified strength, flexibility, and size requirements of the rope. Once the strand is completed, it is straightened before being moved to wire rope construction.

Like wire ropes, strands have different patterns; patterns are the arrangements of the wires and their diameters. Though most strands have a core, there are strand patterns that have three or four wires without a core that are referred to as centerless strands. The design of each strand pattern is meant to enhance the strength of the wire rope and improve its performance.

For a multiple layer strand, the layers of wire are placed over one another in successive order. The placement of the wires on top of each other must be such that they fit smoothly and evenly.

The Warrington pattern is like the multiple layer pattern with one variation. Like the multiple layer pattern, the inner wires and the core are the same and have the same diameter. The difference is in the outer layer, which has wires of alternating sizes of large and small with larger diameter wires laying in the valleys of the inner wires.

All of the wires of a filler pattern are the same size. What makes this pattern unique is the insertion of small wires in the valleys of the inner wires to fill the gap between the inner and outer layer.

The flattened strand pattern is also known as the triangular strand, which can be triangular or oval. Three round wires form the core. The outer flattened surface has a greater sectional metallic area; this makes this pattern stronger and longer lasting.

The core of a wire rope runs through the center of the rope and can be composed of a variety of materials, which include synthetic fibers, natural fibers, a single strand, or another wire rope. The core supports the wound strands, helps maintain their position, is an effective lubricant carrier, and provides support.

Wire ropes with fiber cores are restricted to light loads and are not used in severe, harsh, or stressful conditions. Polypropylene and nylon are types of synthetic fiber cores and can be used in conditions where there is exposure to chemicals.

Cores made of wire are classified as independent wire cores. The core of a wire rope with a wire core is actually a wire rope with another wire rope serving as the core, as can be seen in the diagram below. These types of wire ropes are used where the rope will be exposed to exceptional resistance and crushing.

A strand, or wire strand core, is exactly like the rest of the strands of the wire rope with wires of the same diameter and size as the other strands.

The choice of core and creation of the strands are the simplest yet most essential parts of wire rope construction. Wire rope lays, the method used to wind the strands, is more complex and involves several choices.

Lay is a term used to describe three of the main characteristics of wire rope: direction, relationship, and linear distance. The strands can be wrapped around the core going right or left. Right or left refers to the direction of the strands wrapped around the core and the wires within the strands. The linear distance is how far a strand moves when it is making a revolution around the core.

In a regular lay, the wires and strands spiral in opposite directions. With a right hand regular lay, the wires spiral to the left and the strands to the right. In the left hand regular lay, the wires spiral to the right and the strands to the left. This type of lay is easy to handle but wears out quickly because the crown wires are in contact with the bearing surface.

In the Lang, or Albert, lay, the wires and strands spiral in the same direction with right hand lay being the most common. The wires in a Lang lay appear to run parallel to the center line of the rope. The difficulty with Lang lay wire ropes is handling since they tend to kink, twist, and crush.

Wire rope is an exceptionally strong tool that has been configured and designed to withstand the stress placed upon it through rigorous and continual use. In most applications, wire rope has to endure extreme stress and strain. It is for these reasons that coatings have been developed to protect wire rope from abrasions, corrosion, UV rays, and harmful and damaging chemicals.

Three main types of coatings are used to protect wire rope: polyvinyl chloride (PVC), polypropylene, and nylon. Of the three types, PVC is the most popular.

In cases where there are severe and hazardous working conditions, polypropylene is the recommended choice since it is capable of protecting wire rope against corrosion and chemical leaching. Additionally, it is resistant to impact damage and abrasion. Polypropylene is a tough, rigid, and crystalline thermoplastic that is made from a propene monomer and is resilient as well as inexpensive.

Braided wires are electrical conductors made up of small wires that are braided together to form a round tubular braid. The braiding and configuration of braided wire makes them very sturdy such that they do not break when flexed or bent. Braided wires are widely used as conductors, are commonly made from copper due to copper"s exceptional conductivity, and can be bare or coated depending on the application.

Braided wire can be round and tubular or flat. Round tubular braids fit in most spaces where flat braided wire will not. Flat braided wire begins as round braided wire which is flattened on a capstan. They are exceptionally strong and designed for medical and aircraft applications.

Metals used to make wire rope are various grades of stainless steel, bright steel, and galvanized steel. Though the majority of wire rope manufacturers use these three metals, other metals such as copper, aluminum, bronze, and monel are also used on a limited basis.

The most important aspect of wire rope is the wire and the metal from which it is made. The strength and resilience of wire rope is highly dependent on the quality of metal used to make it, and these are essential factors to be considered when purchasing it.

Bright steel wire does not have a coating and is rotation resistant, (designed to not rotate when lifting a load). It is drawn from hot rolled rods that are put through a die to match its specific dimensional tolerances, mechanical properties, and finish. Bright wire is used as a single line in conditions that require a rope that will resist cabling.

Galvanized steel has a zinc coating for corrosion resistance and has the same strength and durability as bright steel. Environmental conditions determine the use of galvanized steel. In mildly severe and slightly harsh conditions, galvanized steel wire is an economical replacement for stainless steel.

In the manufacturing process, galvanized wire goes through the process of galvanization, a method of coating steel wire with a protective and rust resistant metal. Galvanized wire is exceptionally strong, rust resistant, and flexible enough to meet the needs of a variety of applications.

Wire rope made from copper is mostly used for electrical applications due to its exceptional electrical characteristics. The benefits of copper wire rope are its durability, flexibility, and resilience compared to standard copper wire. The strength of copper wire rope is seen in its use in applications where there are vibrations and shaking.

The wire rope lubrication process begins during its fabrication and continues during its use. Lubrication of wire rope is designed to lower the amount of friction it endures and provide corrosion protection. Continued lubrication increases the lifespan of wire rope by preventing it from drying up, rusting, and breaking.

The types of lubricants for wire rope are penetrating or coating with coatings covering and sealing the outside of the rope. Penetrating lubricants go deep into the rope and seep into the core where they evaporate to form a thick coating or film.

The application of the lubricant is dependent on the type of core. Fiber cores absorb the lubricant and serve as a reservoir that retains the lubricant for an extended period of time. With metal cores, the lubricant is applied as the wire is twisted into strands to give complete saturation and coverage of the wires.

There are several types of greases that are used as wire rope lubricating agents and are made up of oil, a thickener, and additives. The essential components are the base oil and additives, which influence the behavior of the grease. The thickener holds the base oil and additives together. The amount of base oil in a grease is between 70% and 95% with an additive of 10%.

The additive in grease enhances the positive properties of the oil and suppresses the negative properties. Common additives are oxidation and rust inhibitors as well as pressure, wear, and friction reducing agents.

Of the many choices for lubricants, vegetable oil is the easiest to use and penetrates the deepest. The design of the additives for vegetable oils gives them the necessary qualities required to penetrate deep into a wire rope. The exceptional penetration provides protection against wear and corrosion. Since vegetable oil is a fluid, it helps in washing the wire rope to remove external abrasive contaminants.

Wire rope is widely used in machines, structures, and varied lifting applications. Its type, size, and requirements are determined by how it will be used. Regardless of its use, wire rope guarantees exceptional strength and provides high quality and excellent performance.

The lifting of heavy loads for centuries involved the use of hemp rope or chains, neither of which was a guaranteed or substantial method. Early in the 18th Century, between 1824 and 1838, Wilhelm Albert, a German mining engineer, combined the twisting of hemp and strength of chains to create today‘s wire rope.

The most common use of wire rope is as a part of a crane hoist wherein it is attached to the hook of the hoist and wrapped around a grooved drum. The tensile strength and durability of wire rope makes an ideal tool for lifting and keeping loads secure. Though it is used in several industries, it is very popular for production environments wherein materials need to be lifted quickly and efficiently.

In addition to its many lifting applications, the strength and stability of wire rope is useful in other applications, especially in the aerospace industry. Pedals, levers, and connectors in the cockpit of an aircraft are connected with wire rope. The wires provide for the passage of power between systems and mechanisms; this allows control of the aircraft. Wire rope is used to control propeller pitch, cowl flaps, and the throttle. It also assists in lowering and minimizing vibrations.

Tires are reinforced with wire rope to increase their durability and strength. All automotive production environments make use of wire ropes for supplying materials, moving heaving loads, and positioning equipment. Wire rope can be found in the production of steering wheels, cables, exhausts, springs, sunroofs, doors, and seating components.

As surprising as it may seem, the place that wire rope has the greatest use is in the home, where its strength, long life, endurance, and resilience provide guaranteed protection and performance. The main reason wire ropes are so popular for home use is cost.

Inexpensive, easy to obtain, easy to install, and easy to maintain, wire ropes provide an additional method for performing home repairs and structural support. Their excellent flexibility and sturdiness combined with their invisibility has made wire rope an ideal solution to several home maintenance issues. It is used to support staircases, fences, decks, and hang plants.

The search and production of crude oil has relied on wire ropes for centuries to lift drill bits, insert shafts, and support oil rigs on land and the water. When equipment, machinery, and tools have to be lowered into the depths of the earth and sea, wire ropes are the tool that the oil industry relies on to do the job.

Many of the tasks of oil production require tools that are capable of enduring severe and harsh conditions. Wire ropes have to withstand enormous pressure, extraordinary stress, and a wide range of temperatures. The use of wire rope includes maintaining oil rig stability and moorings for offshore rigs.

Wire rope has long been a standard component for the transportation industry, from the cable cars of San Francisco to the lift chairs for ski resorts. For many years, cable cars have relied on heavy duty cables (wire ropes) to be pulled by a central motor from multiple locations. It is a method of transportation that has existed for centuries.

In Europe, funiculars use cables that hang from a support to move cars up and down a mountain with cables moving in opposite directions. The word funicular is from the French word funiculaire, meaning railway by cable. The terms wire rope and cable are used interchangeably when discussed by professionals. The first part of funicular, or funiculaire, is from the Latin word "funis," meaning rope.

The major use for wire ropes in the food and beverage industries is as a means for lifting and moving heavy loads. Wine barrels and containers full of ingredients are lifted and placed through use of cranes and wire ropes. They are also part of conveyor systems that move products from one station to another.

From the beginnings of amusement rides up to the present, wire ropes have been an essential part of attraction construction and safety. They pull cars on roller coasters, hold cabins that swing, and move carriages through haunted houses. The main concern of amusement parks is safety. The strength, stability, and guaranteed performance of wire ropes ensures that people who attend amusement parks will have a good time and stay safe.

The rigging used to complete the stunts in modern movies depends on wire rope for safety. Much like in amusement rides, wire ropes protect performers from injury and harm as they hang above a scene or carry out an impossible move.

The live theater industry uses wire ropes to raise and lower curtains, support overhead rigging, and hold backdrops and scenery pieces. During a production, rapid and efficient movement is a necessity that is facilitated by the use of wire ropes.

Wire rope is a tool that we tend to envision as indestructible, unable to succumb to any form of damage. Though it is exceptionally sturdy and strong as well as capable of enduring constant use, it is just as susceptible to breakdown as any other tool.

To avoid serious harm and damage, wire ropes should be scheduled for regular inspections. There are situations that can damage or break a wire rope; these should be understood prior to the problem arising.

Guide rollers have the potential to damage and cause abrasions on wire rope if they become rough and uneven. Of the various elements of a crane and lift, guide rollers have the greatest contact with the mechanism‘s wire rope. Regular inspection of guide rollers will ensure they are not damaging the rope or causing abrasions.

Bending is normally a regular part of wire rope usage; this occurs repetitively as the rope passes through a sheave. As a wire rope traverses the sheave, it is continually bent and develops cracks or breaks. The cracking and breaking are exacerbated by movement on and off the groove of the drum. Normally, the breakage happens on the surface and is visible. Once it appears, it accelerates to the core of the rope.

A bird cage is caused by a sudden release of tension and a rebound of the rope. This type of break requires that the rope be replaced since the place of the break will not return to its normal condition.

Wire ropes are multi-layered; this makes them flexible and torque balanced. The layering inside and outside creates flexibility and wear resistance. Relative motion between the wires causes wear over time, which leads to internal breakage. The detection of these breaks can be indicated by an electromagnetic inspection that calculates the diameter of the rope.

Kinked wire rope is caused by pulling a loop on a slack line during installation or operation; this causes a distortion in the strands and wires. This is a serious condition that necessitates rope replacement.

Corrosion damage is the most difficult cause of wire rope damage to identify, which makes it the most dangerous. The main reason for corrosion is poor lubrication that can be seen in the pitted surface of the rope.

The types of damage and problems listed here are only a small portion of the problems that can be caused if a wire rope is not regularly lubricated and inspected. Various regulatory agencies require that wire ropes be inspected weekly or monthly and provide a list of factors to examine.

As with any type of heavy duty equipment, wire rope is required to adhere to a set of regulations or standards that monitor and control its use for safety and quality reasons. The two organizations that provide guidelines for wire rope use are the American Society of Mechanical Engineers (ASME) and the Occupational Safety and Health Administration (OSHA).

All wire rope manufacturers and users closely follow the standards and guidelines established by OSHA and ASME. In the majority of cases, they will identify the specific standards they are following in regard to their products.

OSHA‘s regulations regarding wire rope fall under sections 1910, 1915, and 1926, with the majority of the stipulations listed in 1926 under material handling, storage, use, and disposal.

"Running rope in service shall be visually inspected daily, unless a qualified person determines it should be performed more frequently. The visual inspection shall consist of observation of all rope that can reasonably be expected to be in use during the day‘s operations. The inspector should focus on discovering gross damage that may be an immediate hazard."

"The inspection frequency shall be based on such factors as rope life on the particular installation or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. Close visual inspection of the entire rope length shall be made to evaluate inspection and removal criteria."

ASTM A1023 covers the requirements for steel wire ropes with specifications for various grades and constructions from ¼ in. (6 mm) to 31/2 in. (89 mm) manufactured from uncoated or metallic coated wire. Included are cord products from 1/32 in. (0.8 mm) to 3/8 in. (10 mm) made from metallic coated wire.

United States Federal Spec RR W 410 covers wire ropes and wire seizing strands but does not include all types, classes, constructions, and sizes of wire rope and strands that are available. The purpose of Spec RR W 410 is to cover more common types, classes, constructions, and sizes suitable for federal government use.

Wire rope and wire seizing strand covered by United States Federal Spec RR W 410 are intended for use in general hauling, hoisting, lifting, transporting, well drilling, in passenger and freight elevators, and for marine mooring, towing, trawling, and similar work, none of which are for use with aircraft.

API 9A lists the minimum standards required for use of wire rope for the petroleum and natural gas industries. The types of applications include tubing lines, rod hanger lines, sand lines, cable-tool drilling and clean out lines, cable tool casing lines, rotary drilling lines, winch lines, horse head pumping unit lines, torpedo lines, mast-raising lines, guideline tensioner lines, riser tensioner lines, and mooring and anchor lines. Well serving wire ropes such as lifting slings and well measuring are also included in API 9A.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of a lifting or supportive task.

The calculated breaking strength of a steel wire rope is defined as the metallic cross section of a steel wire rope (the sum of the individual cross sections of all the wires making up the rope) multiplied by the nominal tensile strength of the steel wire rope. The minimum breaking strength of the steel wire rope is the calculated breaking strength of the rope multiplied by the spin factor.

The actual breaking strength of a steel wire rope is the breaking strength of the rope as determined in a pull test. A new steel wire rope must achieve an actual breaking strength equal to or higher than the minimum breaking strength. The breaking strength of a steel wire rope can be increased by increasing the metallic area of the rope (e.g. by using strands with higher fill factors, by compacting the strands or by swaging the rope), by increasing the tensile strengths of the individual wires or by increasing the spin factor of the rope. This can also be achieved by improving the contact conditions between the rope elements by using a plastic infill.

CONSTRUCTION: Expressed in numbers of strands x number of wires. 6 x 25 indicates that the wire rope consists of 6 strands, which in turn have 25 individual wires.

How to measure (or caliper) a wire rope correctly. Since the "true" diameter (A) lies within the circumscribed circle, always measure the larger dimension (B). Actual diameter can be 5% larger than nominal wire rope diameter.

There are numerous ways to cut wire rope - use only appropriate tools specifically designed to cut wire rope. Safety goggles and work gloves must always be worn. Observe other precautions peculiar to the tools used. Wire rope should be properly seized on both sides of the cut with wire or strand. Seizing wire diameter and the number and length of the seizings will depend on the diameter of the wire rope, and whether or not it is preformed.

Since wire rope is a machine with many moving parts, it requires careful installation and breaking in procedures for maximum safety and long service life. After proper installation, allow the wire rope to run through a cycle of operation at a very low speed. Keep a close watch on the wire rope, its attachments and any working parts such as sheaves, drums, rollers, etc. to make certain that the wire rope runs freely. If no problems appear at this stage, run the wire rope through several cycles of operation under light load at reduced speed. This procedure allows the component parts of the new rope to make a gradual adjustment to the actual operating conditions.

Wire rope will develop 100% efficiency, that is, break at or above minimum acceptance strength (not less than 2 1/2% below nominal breaking strength) under controlled laboratory conditions. Once fittings such as sleeves, clips, sockets, etc. are attached and/or the wire rope passes over a curved surface such as sheaves, pins, etc. its strength is decreased. In the case of wire rope passing over a curved surface this decrease in strength depends on the severity of the bend. In the case of wire rope fittings, the decrease in wire rope strength will depend on the type of fittings used. The wire rope efficiency usually ranges from 70% - 100%. For more detailed information consult the strength efficiency of wire rope table on page 86. Note, that hand spliced wire rope, while not using any fittings, has less efficiency than properly flemished and swaged wire rope. There are other factors, depending on the application of wire rope, that can cause a decrease in nominal wire rope strength. They must be considered when choosing a design factor. Refer to the Wire Rope Users Manual and/or other qualified sources for details.

Wire rope is an elastic member; it stretches or elongates under load. This elongation can be permanent or recoverable. The extent of elongation will depend on the wire rope used and the design factor chosen. While it may be acceptable for many wire rope uses to neglect its elastic properties, they are of critical importance for some uses. When in doubt about the importance of wire rope elongation consult professional help. Pre-stretching wire rope will only remove some of the constructional stretch and will not totally eliminate elongation under load.

Installation of wire rope on a plain or grooved drum requires a great deal of care. Make certain the wire rope is properly attached to the drum. Keep adequate tension on the wire rope as it is wound onto the drum. Guide each wrap as close to the preceding wrap as possible, or follow the groove in case of a grooved drum. No blanket recommendations can be given concerning direction of winding, desirable drum diameter, fleet angle, etc. Consult the Wire Rope Users Manual for this and other important technical information.

Wire rope can be seen everywhere around us, it is made of strands or bundles of individual wires constructed around an independent core, suitable for hoisting, towing, and anchoring heavy loads.

Wire rope is specified by the number of strands in the rope, the number of wires in each strand, and the strands are then twisted to form a rope construction.

The wire rope core is in the center of the rope and provide the rope stability, it is the foundation for the wire rope. Cores can be supplied with natural or synthetic fibers and steel core. For example, the 6×19 FC wire rope means that the rope has 6 strands, and there are 19 wires in each strand, the numbers 6×19 is followed by a letter combination, it means the core of the wire rope, FC means fiber core.

IWRC is commonly manufactured from 7 strands, while the WSC is manufactured from either 7 or 9 wires. Steel cores have a higher resistance to drum crushing and where less stretch and more strength is required.

The 6×19 FC wire rope means that the rope has 6 strands, and there are 19 wires in each strand, however, 6 x 19 wire rope may not reflect the actual construction, for 6 x 21 wire rope, and 6 x 26 are designated as being in the 6 x 19 classification, despite none of their constructions contain 19 wires.

There are many different wire rope grades, the higher grade, the higher min breaking strength, commonly the grades of wire rope are available include Improved Plow Steel (IPS), Extra Improved Plow Steel (EIPS), Extra Extra Improved Plow Steel (EEIPS), and metric wire rope grades can be designated as 1770n/mm²(Improved Plow Steel), 1960n/mm²(Extra Improved Plow Steel) and 2160n/mm²(Extra Extra Improved Plow Steel).

There are main three protective coatings on the wire rope, zinc-coated (galvanized) wire rope for harsh environment, uncoated steel (bright) wire rope for most running supplied, and stainless steel wire rope for marine and architectural applications.

The type and direction of lay wire rope mean the wires are laid around the strands(regular lay or lang lay) and the direction in which the strands are laid around the core(a right or left hand).

Regular lay is also referred to as ordinary lay. The strands are twisted in one direction, either left or right across the core and the wires are laid in opposite direction to the lay of the strands, which causes the finished product to appear like the wires are running parallel to the axis of the rope.

The regular lay wire rope is more flexible and carries better resistance to crushing forces and is more naturally rotation-resistant and spool better on a drum than lang lay wire rope.

The lang lay wire rope indicates that the wire lay and strand lay around the core in the same direction, either right or left and causes the finished product to appear with the wires to form an angle with the axis of the rope. Thes lang lay ropes are generally more flexible and have increased abrasion resistance leading to a longer lifespan than regular lay ropes, which can be used in construction, excavating, and mining applications.

Crane wire ropes play an important role in ensuring a smooth conduct of work processes in harbors, off-shore platforms or various other applications where cranes are needed. Whether you need tower crane ropes or offshore crane ropes, galvanized or stainless steel ropes, you will find the optimal solution in our company.

When you are picking up crane wire ropes, make sure that the breaking strength of new wire ropes is five times the sizes of the largest load for lifting applications and three times for pulling applications.

“Tough-Lock™” and “Cable-Flex™” slings are uniquely constructed unlike various return wire loop types. Note that our five step manufacturing process, commonly

All “Tough-Lock™” slings adhere and comply with current specifications of OSHA, ASME B30.9c-2000 Wire Rope Technical, and Associated Wire Rope Fabricators.

Wire ropes were primarily used for mining applications in the 19th century. These cables were much stronger than the traditional steel chains, and now are used to hoist and lift large objects. Many structures are affixed to support towers with static wire rope.

The invention of wire rope can be attributed to a German mining engineer named Wilhelm Albert. Albert designed a wire rope with the mining industry in mind. This metallic option was much safer than the rope made of hemp and chain, and it quickly revolutionized the mining industry. Towards the beginning of the 20th century, wire ropes were used as a means of transmitting mechanical power, and were developed by John. A. Roebling, as the primary suspension force in bridges.

Steel wire rope is made from non-alloy carbon steel. Although the carbon only makes up for 0.5% of the content, the wire retains a high strength and tensile forces. There are several different types of wire rope that are all manufactured differently.

Spiral Ropes: Spiral ropes are tasked with handling strong tensile forces and are loaded by static and fluctuating tensile stressors. These ropes are commonly found in suspension bridges and are referred to as cables.

Track Ropes: Track ropes function as the rails for rollers and cabins. Track ropes do not take on the curvature of the rollers and can support a great amount of weight.