wire rope construction details in stock

Wire rope is a complex mechanical device that has many moving parts all working in tandem to help support and move an object or load. In the lifting and rigging industries, wire rope is attached to a crane or hoist and fitted with swivels, shackles or hooks to attach to a load and move it in a controlled matter. It can also be used to lift and lower elevators, or as a means of support for suspension bridges or towers.

Wire rope is a preferred lifting device for many reasons. Its unique design consists of multiple steel wires that form individual strands laid in a helical pattern around a core. This structure provides strength, flexibility, and the ability to handle bending stresses. Different configurations of the material, wire, and strand structure will provide different benefits for the specific lifting application, including:Strength

However, selecting the proper wire rope for your lifting application requires some careful thought. Our goal is to help you understand the components of a wire rope, the construction of wire rope, and the different types of wire rope and what they might be used for. This will allow you to select the best performing and longest-lasting wire rope for the job at hand.

A wire rope is, in reality, a very complicated machine. A typical 6 x 25 rope has 150 wires in its outer strands, all of which move independently and together in a very complicated pattern around the core as the rope bends. Clearances between wires and strands are balanced when a rope is designed so that proper bearing clearances will exist to permit internal movement and adjustment of wires and strands when the rope has to bend. These clearances will vary as bending occurs, but are of the same range as the clearances found in automobile engine bearings.

Understanding and accepting the “machine idea” gives a rope user a greater respect for rope, and enables them to obtain better performance and longer useful life from rope applications. Anyone who uses a rope can use it more efficiently and effectively when they fully understand the machine concept.

Wires are the smallest component of wire rope and they make up the individual strands in the rope. Wires can be made from a variety of metal materials including steel, iron, stainless steel, monel, and bronze. The wires can be manufactured in a variety of grades that relate to the strength, resistance to wear, fatigue resistance, corrosion resistance, and curve of the wire rope.

Strands of wire rope consist of two or more wires arranged and twisted in a specific arrangement. The individual strands are then laid in a helical pattern around the core of the rope.

The core of a wire rope runs through the center of the rope and supports the strands and helps to maintain their relative position under loading and bending stresses. Cores can be made from a number of different materials including natural or synthetic fibers and steel.

Lubrication is applied during the manufacturing process and penetrates all the way to the core. Wire rope lubrication has two primary benefits:Reduces friction as the individual wires and strands move over each other

The number of layers of wires, the number of wires per layer, and the size of the wires per layer all affect the strand pattern type. Wire rope can be constructed using one of the following patterns, or can be constructed using two or more of the patterns below.Single Layer – The most common example is a 7 wire strand with a single-wire center and six wires of the same diameter around it.

Filler Wire – Two layers of uniform-size wire around a center with the inner layer having half the number of wires as the outer layer. Small filler wires, equal to the number in the inner layer, are laid in valleys of the inner wire.

Seale – Two layers of wires around a center with the same number of wires in each layer. All wires in each layer are the same diameter. The large outer wires rest in the valleys between the smaller inner wires.

Warrington – Two layers of wires around a center with one diameter of wire in the inner layer, and two diameters of wire alternating large and small in the outer later. The larger outer-layer wires rest in the valleys, and the smaller ones on the crowns of the inner layer.

On a preformed wire rope, the strands and wires are formed during the manufacturing process to the helical shape that they will take in a finished wire rope.

Preformed rope can be advantageous in certain applications where it needs to spool more uniformly on a drum, needs greater flexibility, or requires more fatigue-resistance when bending.

Direction and type of lay refer to the way the wires are laid to form a strand (either right or left) and how the strands are laid around the core (regular lay, lang lay, or alternate lay).Regular Lay – The wires line up with the axis of the rope. The direction of the wire lay in the strand is opposite to the direction of the strand lay. Regular lay ropes are more resistant to crushing forces, are more naturally rotation-resistant, and also spool better in a drum than lang lay ropes.

Lang Lay– The wires form an angle with the axis of the rope. The wire lay and strand lay around the core in the same direction. Lang Lay ropes have a greater fatigue-resistance and are more resistant to abrasion.

A steel core can be an independent wire rope or an individual strand. Steel cores are best suited for applications where a fiber core may not provide adequate support, or in an operating environment where temperatures could exceed 180° F.

The classifications of wire rope provide the total number of strands, as well as a nominal or exact number of wires in each strand. These are general classifications and may or may not reflect the actual construction of the strands. However, all wire ropes of the same size and wire grade in each classification will have the SAME strength and weight ratings and usually the same pricing.

Besides the general classifications of wire rope, there are other types of wire rope that are special construction and designed for special lifting applications.

Some types of wire rope, especially lang lay wire rope, are more susceptible to rotation when under load. Rotation resistant wire rope is designed to resist twisting, spinning, or rotating and can be used in a single line or multi-part system.

Special care must be taken when handling, unreeling, and installing rotation resistant wire rope. Improper handling or spooling can introduce twist into the rope which can cause uncontrolled rotation.

Compacted strand wire rope is manufactured using strands that have been compacted, reducing the outer diameter of the entire strand, by means of passing through a die or rollers. This process occurs prior to closing of the rope.

This process flattens the surface of the outer wires in the strand, but also increases the density of the strand. This results in a smoother outer surface and increases the strength compared to comparable round wire rope (comparing same diameter and classification), while also helping to extend the surface life due to increased wear resistance.

A swaged wire rope differs from a compacted strand wire rope, in that a swaged wire rope’s diameter is compacted, or reduced, by a rotary swager machine after the wire rope has been closed. A swaged wire rope can be manufactured using round or compacted strands.

The advantages of a swaged wire rope are that they are more resistant to wear, have better crushing resistance, and high strength compared to a round strand wire rope of equal diameter and classification. However, a swaged wire rope may have less bending fatigue resistance.

A plastic coating can be applied to the exterior surface of a wire rope to provide protection against abrasion, wear, and other environmental factors that may cause corrosion. However, because you can’t see the individual strands and wires underneath the plastic coating, they can be difficult to inspect.

Plastic filled wire ropes are impregnated with a matrix of plastic where the internal spaces between the strands and wires are filled. Plastic filling helps to improve bending fatigue by reducing the wear internally and externally. Plastic filled wire ropes are used for demanding lifting applications.

This type of wire rope uses an Independent Wire Rope Core (IWRC) that is either filled with plastic or coated in plastic to reduce internal wear and increase bending fatigue life.

Remember, wire rope is a complex piece of mechanical machinery. There are a number of different specifications and properties that can affect the performance and service life of wire rope. Consider the following when specifying the best type of wire rope for your lifting application:Strength

When you select a piece of rope that is resistant to one property, you will most likely have a trade-off that affects another property. For example, a fiber core rope will be more flexible, but may have less crushing resistance. A rope with larger diameter wires will be more abrasion resistant, but will offer less fatigue resistance.

At Mazzella Companies, we offer all different kinds of wire rope from all of the leading manufacturers. We sell the highest-quality domestic and non-domestic rigging products because product quality and operating safety go hand-in-hand. We have one of the largest and most complete inventories of both domestic and non-domestic rigging and lifting products to suit your lifting needs.

If you’re looking for a standard or custom specified wire rope for your lifting project, contact a Lifting Specialist at a Mazzella Companies location near you.

We stock well over 2,000,000 feet of wire rope in our various locations … ready for immediate delivery! We provide wire rope assemblies, and manufacture bridge cables, crane cables, steel mill cables, and thousands of OEM assemblies.

In this full length handbook, learn the basics of wire rope including how to choose and measure wire rope. Additionally, you will understand the fundamental mechanics behind our most popular rope constructions and classifications. Finally, you will learn the proper way to care for and use your wire rope, including end treatments, inspection, and removal criteria.

Twisted hoist lines can bring a construction project to a sudden halt, resulting in downtime. But the good news is that you can minimize block rotation through proper installation, handling and corrective measures. In this reference document, you will better understand torque and gain tips on how to reduce block rotation.

Our galvanized strand products meet or exceed ASTM specifications A475 and ASTM A363. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn what the strands are tested for. Additionally, a chart detailing the physical properties of zinc-coated steel wire strand is included.

Our industry has its fair share of terminology and phrases. In this reference document (an excerpt from the Wire Rope Users Handbook), you will be provided a comprehensive glossary of all Wire Rope words. From “Abrasion” to “Warrington”, your questions are answered here.

How long will your rope last? While there is not a simple answer, there are several factors involved. In this reference document (an excerpt from the Wire Rope Users Handbook), you will the factors affecting the longevity of your ropes life. Additionally, information regarding the cleaning and lubrication of your ropes is included.

There is a correct methodology behind measuring of wire rope diameter. Learn this methodology in this reference document (an excerpt from the Wire Rope Users Handbook). Also, the definition of design factor is available. And finally, detailed information regarding metric conversion and equivalents is included.

Yes, there is a RIGHT way to unreel, uncoil and store a wire rope. Learn the proper steps in this reference document (an excerpt from the Wire Rope Users Handbook). Additionally, the three stages of kinking are vividly displayed.

Wires are the basic building blocks of a wire rope. And, a rope core will greatly impact the performance of your rope. Learn how the number of wire strands and construction determine a wire rope classification. In this reference document (an excerpt from the Wire Rope Users Handbook), you will become familiar with the standard rope classifications and special rope constructions.

The types of wire, lay and performing greatly affect wire rope performance and operation. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the basic types of wire used in ropes, the common grades of wire rope and the meaning of “lay”.

In this Product Bulletin, you will learn about the new rope description format that WireCo WorldGroup will follow in all of our product descriptions. This format will adopt symbols and designations that are part of ISO, ASTM, and other industry standards and specifications.

Rotation-resistant ropes can frequently provide the best and most economical service in specific applications, when you choose, handle and use them properly. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the difference between Category 1, Category 2 and Category 3 Rotation-Resistant Rope.

Previously known as “aircraft” cable, and now known as “utility cable, these small diameter specialty ropes are used in a variety of applications, including control cables, window and door closures, different kind of remote control systems and boat riggings. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn how Union specialty small ropes are engineered and fabricated, and the special lubrication and testing they require. Additionally, a minimum breaking force and weights for 7x7, and 7x19 utility cable is included.

Our industry has its fair share of abbreviations. In this reference document (an excerpt from the Wire Rope Users Handbook), you will be provided a comprehensive glossary of all Wire Rope words. From “PRF” (preformed) to “XIP®” (Extra improved plow steel), your questions are answered here.

Swaged ropes and “Double-Swaged” ropes provide excellent strength for some specific applications. In this reference document (an excerpt from the Wire Rope Users Handbook), you will find the definition of swaged and PowerFlex (aka double-swaged) ropes. Minimum breaking force and weights charts for 6x19, 6x36, PowerFlex, 3x19 and 3x36 ropes are included.

Our most popular Tech Report, this Wire Rope Inspection Tech Report explains why periodic inspection of wire ropes are necessary. Learn how to properly inspect wire rope, what tools are necessary for inspection, and how to use inspection forms. Additionally, you will learn how often you should inspect your wire rope, what your ‘critical’ points are, how to inspect your end attachments, how to make an internal rope examination, how to inspect sheaves, and how to evaluate drums. Finally, you will understand how to properly measure rope diameter and rope lay.

In applications where a specific length is critical, the constructional stretch can be minimized by prestretching the rope prior to installation, HOWEVER, learn why WireCo WorldGroup advises against prestretching Tuf-Kote/PFV rope. After reading this product bulletin, you will understand the rationale behind WireCo WorldGroup’s recommendation against prestretching Tuf-Kote/PFV Rope.

Engineering and producing wire rope slings for your application is a highly specialized field - with exacting standards that we gladly live by. In this marketing flier, learn the different Union Wire Rope Sling constructions. Additionally learn more about Union Spelter Sockets (both open and closed). There are capacity and diameter charts associated with each product.

In this Product Bulletin, learn the various definition of "US made wire rope" including references to the Buy American Act and the Buy America Requirement. Additionally, learn how Union wire rope meets these definitions.

Most ropes are shipped with the ends seized as they are prepared for cutting, however, in some cases, the rope requires special end preparations. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the two chosen methods for seizing cut ends of your wire ropes. Illustrations and step-by-step instructions are included.

All wire ropes will wear out eventually and gradually lose work capability throughout their service life. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn why periodic inspections are critical. The purposes for inspection, guidelines around timing and choosing the right person to inspect are included. Additionally, illustrations regarding “what to look for” in a wire rope is available.

There is obvious evidence of wire rope wear and abuse, and specific criteria regarding removal of your wire rope. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the various types of wear and abuse (illustrations included) and the exact removal criteria. A chart on when to replace your wire rope – based on number of broken wires is included.

In this product bulletin, learn why WireCo WorldGroup refers to XLT4 as a low-torque rope and not a rotation-resistant rope. Also included are the definitions of ASTM A1023 and ASME B30.5.

The majority of steel wires used for making wire ropes are usually manufactured from non-alloy carbon steel having a carbon content of between 0.4 and 0.95%. Since rope wires have a very high strength, they are able to offer support to large tensile forces. They can also run over sheaves even if the diameters are relatively small.

Cross lay strands has several layers, with the wires crossing each other. The parallel lay strands are prevalently used. Here, the lay length of practically all the wire layers have equal measurements. The wires of any two layers that are superimposed are also parallel. This makes for the linear contact.

However, two inner layer wires support the outer layer wire. Throughout the entire length of the strand, these wires are neighbors. Parallel lay strands are manufactured in a single operation. They have a greater endurance than cross lay strands. Parallel lay strands having two wire layers feature the construction Filler, Seale or Warrington.

The strands of spiral ropes are round.  They feature an assembly of wire layers, laid helically through a center. At least a single wire layer is laid in the direction opposite to the outer layer. The dimension of spiral ropes can be non-rotating. They have a negligible rope torque under tension.

The open spiral rope is made up of round wires only. The center of the full-locked coil rope and half-locked coil rope is made of round wires, while the locked coil ropes come with at least a single outer layers of profile wires.

The major advantage is that they are constructed in such a way that dirt and water penetration is prevented to a large extent. Hence, protecting them from losing their lubrication. That’s not all, with the proper dimension, the ends of a broken outer wire will be unable to leave the rope.

Stranded ropes are a combination of several strands laid around a core in one or more layers in a helical shape. The core can be a fiber core, wire strand core, or independent wire rope core (IWRC). The fiber core features a synthetic material or natural fibers like Sysal.

Even though synthetic fibers are stronger and more uniform, they are unable to absorb many lubricants. Nonetheless, natural fibers are able to absorb about 15% of their weight in lubricant. This helps in protecting the inner wires against corrosion. Fiber cores are very elastic and flexible. The only problem is that they can easily get crushed.

Wire strand core consists an extra wire strand. It is basically used for suspension. The independent wire rope core (IWRC) is very durable regardless of the type of environments it is used in.

The majority of stranded ropes possess only a single one strand layer on top of the core. It is denoted with symbol Z when the strands in the rope are laid in the right direction, while symbol S represents left direction. Regular lay denotes that individual wires were wrapped around centers in a single direction, with the strands wrapped around the core in opposite direction.

Wire ropes featuring multiple strands are less resistant to rotation. They possess more than one strand layers, laid helically around the center. The outer strands are laid in an opposite direction to the underlying strands layers. Ropes having more than two strand layers can be non-rotating as well, while those with two strand layers are usually low-rotating.

Since they are used for carrying tensile forces, they are usually loaded by fluctuating and static tensile stresses. Wire ropes that are used for suspension are often referred to as cables.

They are used as rails for the cabin rollers or various other loads in cable cranes and aerial ropeways. Dissimilar to running ropes, the curvature of the rollers are not taken on by track ropes. When track ropes are used, the radius and the tensile force increases, as the stresses decrease.

They are used to bind together various kinds of goods. Wire rope slings are stressed by the tensile forces initially by bending stresses. They are bent over the blunt edges of the goods.

Understanding the basics of wire rope will help guide you on how to choose the right wire rope for your job. Application, required strength, and environmental conditions all play a factor in determining the type of wire rope that is best for you.

But when it comes to buying wire rope, the various numbers and abbreviations that describe the different types of wire rope can be confusing. EIPS wire rope, 6X19 IWRC wire rope, and lang lay wire rope are just some of the many variations available. But what does it all mean?

Displayed as inch or fractional inch measurements, the size indicates the diameter of the rope. Industry standards measure the rope at its widest point. A wide range of sizes are available from 1/8” wire rope to 2-1/2” wire rope. Thicker sized wire rope has a higher break strength. For example, our Wire Rope has a 15,100 lb. break strength while our Wire Rope has a 228,000 lb. break strength.

The numbers indicate its construction. For example: in wire rope, as shown above the first number is the number of strands (6); the second number is how many wires make up one strand (19).

When it comes to wire rope basics, regular lay also refers to right lay or ordinary lay. This indicates that the strands pass from left to right across the rope and the wires in the rope lay in opposite direction to the lay of the strands. This type of construction is the most common and offers the widest range of applications for the rope.

This term indicates that the wires twist in the same direction as the strands. These ropes are generally more flexible and have increased wearing surface per wire than right lay ropes. Because the outside wires lie at an angle to the rope’s axis, internal stress is reduced making it more resistant to fatigue from bending. This type of rope is often used in construction, excavating, and mining applications.

Independent wire rope cores offer more support to the outer strands and have a higher resistance to crushing and heat. Independent wire rope core also has less stretch and more strength.

Many of our customers use our rope and our wire rope clips to create rope assemblies. Check out of video blog on Wire Rope Clips to Wire Rope Assemblies to learn more.

For any questions on our wire rope products, call (877) 923-0349 or email customerservice@uscargocontrol.com to speak with one of our product experts.

HSI is a leader in the wire rope manufacturing industry. Since 1930 when founder Ted Hanes began splicing wire rope for local contractors in Buffalo, we have been dedicated to constructing the highest quality wire rope available.

Wire rope is a durable piece of machinery consisting of several multi-wired strands wrapped around a central core. It is ideal for indoor and outdoor environments, as an incredibly strong and durable rope with resistance to environmental hazards like water, sunlight, heat, and chemicals.

Wire rope consists of a core around which a number of multi-wired strands are “laid” or helically bent. There are two types of cores for wire rope: fiber and wire cores. Fiber cores are made of synthetic fibers, while wire cores are either an Independent Wire Rope Core or a Strand Core. The core provides support and maintains the position of the outer strands during operation.

Any number of multi-wired strands can be laid around the core. The most common arrangement is six strands around the core, as this construction gives the best balance of positive attributes. In general, ropes constructed with more wires have increased flexibility, while ropes constructed with fewer wires have superior resistance to abrasion.

The size, grade, and construction of wire rope needed should be considered when choosing a rope for your application. To learn more about selecting the correct wire rope, wire rope design factors, and to see a comprehensive overview of wire rope, see our Wire Rope Information page.

If you have questions about which wire rope is best suited for your job, please call our product experts at 1-888-426-3755 and we will be happy to advise you on a solution.

HSI standard wire ropes come in a full range of sizes, grades, and constructions. The most common classifications for standard wire rope are 6x7, 6x19, and 6x37. They may be ordered in bright or galvanized finishes, IPS and EIPS grades, right or left lay, and regular lay or lang lay.

While all wire ropes are constructed of multi-wired strands wrapped around a core, cable laid wire ropes take this construction a step further, wrapping several wire ropes, each with their own core, around a central wire rope. This results in a rope constructed with very small wires in reference to its finished nominal dimension which will offer greatly improved flexibility and kinking resistance.

Compact wire rope consists of wire rope strands that have been compacted to reduce the diameter of the strand and increase its density. The resulting rope has superior strength and abrasion resistance compared to standard wire rope, as well increased lateral compression strength. Typical applications for compact wire rope include crane lines, as compact rope can more easily fit into a sheave; and logging applications.

Extra high strength and corrosion resistant galvanized guy strand cable is an extremely sturdy wire rope used to hold structures in place in the construction and transmission industries, as well as a safety barrier cable and guard rail strand. Typical applications include telephone poles and other positioning applications where a sturdy and non-flexible rope is needed.

Commercial grade galvanized aircraft cable is a general purpose wire rope that is used in many industries for its increased corrosion resistance and strength. The galvanized coating on this wire rope provides lubrication while adding a protective layer against abrasive environments. Contrary to its common name, aircraft control cable, commercial grade GAC cannot be used in aircraft control applications.

Rotation resistant wire ropes are constructed with outer strands twisted in the opposite direction of the inner strands, causing the layers to counteract each other’s twist. This prevents rotation of the load during applications where precise lifting or positioning is required. Rotation resistant ropes are available in a full range of sizes, grades and constructions. Swivels are not recommended for use with rotation resistant wire rope.

6x36 is a flexible general engineering wire rope readily available in galvanised, ungalvanised and marine grade stainless steel. The wire rope has an equal lay construction (warrington seale) and achieves a superior breaking load to the 6x19 construction range. The construction has been designed to give a flexible rope with a good fatigue life. A 6x36 wire rope is available with either FC (fibre core) or IWRC (independent wire rope core) and is used for a wide range of applications, examples of which are shown below:

This compacted wire rope construction is available in both galvanised and ungalvanised finish with either ordinary or langs lay. The construction family includes 32X7, 35X7 and 37X7.

Depending upon your requirement for higher breaking load or better wear characteristics, these wire ropes are available in different finishes and lubrications as well as being available with plastic impregnated or in compacted constructions.

Wire rope is technically defined as multi-wire strands laid geometrically around a core while also used more generally as a term to classify multiple product families including aircraft cable, coated aircraft cable, general purpose wire rope, strand, rotation resistant wire rope, compacted/swaged wire rope, and cable laid wire rope.

Aircraft cable does not fit the definition of wire rope in the strictest sense as it does not have an independent core, but rather a strand core, in which the center is one of the strands that is laid with the outside strand layers. Aircraft cable is available in diameters 3/8" or less with breaking strengths similar to that of equal diameter independent wire rope core (IWRC) and is available in stainless steel and galvanized steel.

Wire rope can be galvanized via three processes. Listed from least corrosion-resistant to the most corrosion-resistant, they are electro-galvanizing, hot-dip galvanizing, and drawn-galvanizing. In addition to being the most corrosion-resistant types of galvanized wire rope, drawn-galvanized has another added benefit which is a breaking strength that is the same as bright wire rope does. Electro-galvanized and hot-dip galvanized wire rope have breaking strengths that are approximately 10% lower.

Wire rope is specified by the number of strands in the rope, the number of wires in each strand, and a description of the core’s material of construction. For example, the notation “6x7 FC” means that the rope has six strands with seven wires in each strand and a fiber core. Commonly used core designations include FC (fiber core), independent wire rope core (IWRC), wire strand core (WSC), and poly core (PC).

There are two elements to wire rope lubrication, the core, and outer strands. IWRC wire rope always has a lubricated core (unless specially ordered as otherwise). Bright wire rope always has lubricated outer strands.  Galvanized wire rope can be manufactured in either dry finish or lubricated with respect to the outer strands.  Typically stainless steel wire rope is manufactured with a lubricated IWRC and dry finish outer strands.

Main difference between both types are the number of outer strands: 19x7 has 12 while 18x7 has just 11. In pactice this difference is neglectable; European ropes tend to be of the 18x7 type having 11 outer strands.

Using the rope to it’s maximum fatigue life will cause the rope to deteriorate from the inside out. Sudden rope failures may be the result. There have been fatal and catastrophic accidents involving this rope construction because of undetected inner rope fatigue.

It is much critical to inspect these rope on a regular basis. Immediately remove such ropes if you detect a difference in diameter between the working section and the the part in front of the wedge socket or safety drum wraps.