wire rope conduit factory

Wire rope manufacturers produce their products in order to provide a high load capacity, versatile alternative to weaker ropes like manila rope or hemp rope. Wire rope products are used for a wide variety of motion transmission applications, among them: lifting, baling, tie down, hoisting, hauling, towing, mooring, anchoring, rigging, cargo control, guidance and counterbalance. They can also be used as railing, fencing and guardrailing.

Wire rope is a must-have for many heavy duty industrial applications. From mining to forestry to marine and beyond, there’s wire rope for almost every job. Some of the many industries in which wire rope is popular include: construction, agriculture, marine, industrial manufacturing, fitness, sports and recreation (plastic coated cables for outdoor playground equipment and sports equipment), electronics, theater (black powder coated cables for stage rigging), mining, gas and oil, transportation, security, healthcare and consumer goods.

Wire rope as we know it was invented just under 200 years ago, between 1831 and 1834. At that time, the goal was to create a rope strong enough to support work in the mines of the Harz Mountains. Invented by Wilhelm Albert, a German mining engineer, this wire rope consisted on four three-stranded wires. It was much stronger than older rope varieties, such as manila rope, hemp rope and metal chain rope.

While studying at Freiburg School of Mines, a man named L.D.B. Gordon visited the mines in the Harz Mountains, where he met Albert. After he left, Gordon wrote to his friend Robert Stirling Newall, urging him to create a machine for manufacturing wire ropes. Newall, of Dundee, Scotland, did just that, designing a wire rope machine that made wire ropes with four strands, consisting of four wires each. After Gordon returned to Dundee, he and Newall, along with Charles Liddell, formed R.S. Newall and Company. In 1840, Newall received a patent for “certain improvements in wire rope and the machinery for making such rope.”

In 1841, an American manufacturer named John A. Roebling began producing wire rope for suspension bridges. Soon after, another set of Americans, Josiah White and Erskine Hazard, started incorporating wire rope into coal mining and railroad projects, forming Lehigh Coal & Navigation Company (LC&N Co.). In 1848, wire rope from their wire rope factory in Mauch Chunk, Pennsylvania provided the lift cables needed to complete the Ashley Planes Project. This project sought to improve the performance and appearance of the freight railroad that ran through Ashley, Pennsylvania, by adding lift cables. This increased tourism and increased the railroad’s coal capacity. Before, cars took almost four hours to return; after, they took less than 20 minutes.

Wire rope likewise changed the landscape (again) in Germany, in 1874, when an engineering firm called Adolf Bleichert & Co. used wire rope to build Bi-cable aerial tramways. These allowed them to mine the Ruhr Valley. Several years later, they also used wire rope to build tramways for the German Imperial Army and the Wehrmacht. These tramways were wildly successful, opening up roads in Germany and all over Europe and the USA.

Since the 1800s, manufacturers and engineers have found ways to improve wire rope, through stronger materials and material treatments, such as galvanization, and different rope configurations. Today, wire rope makes possible many heavy industrial processes. It has become a necessity of the modern world.

Strands are made by tightly twisting or braiding individual wire together. One strand could have anywhere between two and several dozen wire filaments depending on the necessary strength, flexibility, and weight capacity.

One of the most dynamic elements of wire cables is the inner core. The strands are wrapped around the core, and it can be made of different metals, fibers, or even impregnated fiber materials. For heavy applications, cores are often made of a different strand of wire called an independent wire rope core (IWRC). An IWRC has a considerable amount of flexibility and it is still very strong. In fact, at least 7.5% of the strength increase in a wire rope can be attributed to an IWRC.

While they sometimes use other metals, like aluminum, nickel, copper, titanium, and even bronze for some applications, manufacturers primarily produce wire rope from steel. This is because steel is very strong and stretchable. Among the most common types they use are: galvanized wire, bright wire, stainless steel and cold drawn steel.

Of the wire rope steels, cold drawn carbon steel wire is most popular, although stainless steel wire rope is sometimes employed as well. Stainless steel rope is most popular for its anti-corrosive properties. Bright wire rope, a type of ungalvanized steel wire rope, is also popular. For added strength and durability, galvanized steel wire rope/galvanized steel cables are a very popular choice. Galvanized aircraft cable, for example, is always a must in aerospace.

When choosing or designing a custom wire rope for your application, suppliers consider factors such as: the environment in which the rope will function, required rust resistance, required flexibility, temperature resistance, required breaking strength and wire rope diameter. To accommodate your needs, manufacturers can do special things like: make your rope rotation resistant, color code your rope, or add a corrosion resistant coating. For instance, sometimes they specially treat and coat a cable with plastic or some other compound for added protection. This is particularly important to prevent fraying if the wire rope is often in motion on a pulley.

Manufacturers and distributors identify the differences in wire cable by listing the number of strands and the amount of wires per strand so that anyone that orders understand the strength of the cable. Sometimes they are also categorized by their length or pitch. Common examples of this include: 6 x 19, 6 x 25, 19 x 7, 7 x 19, 7 x 7, 6 x 26 and 6 x 36.

More complex wire rope identification codes connote information like core type, weight limit and more. Any additional hardware like connectors, fasteners, pulleys and fittings are usually listed in the same area to show varying strengths and degrees of fray prevention.

Cable wire rope is a heavy-duty wire rope. To give it its high strength, manufacturers construct it using several individual filaments that are twisted in strands and helically wrapped around the core. A very common example of cable wire rope is steel cable.

Spiral rope is made up an assemblage of wires with round or curved strands. The assemblage features at least one outer layer cord pointed in the opposite direction of the wire. The big advantage of spiral ropes is the fact that they block moisture, water and pollutants from entering the interior of the rope.

Similarly, stranded rope steel wire is made up of an assemblage of spirally wound strands. Unlike spiral rope, though, its wire patterns have crisscrossing layers. These layers create an exceptionally strong rope. Stranded rope may have one of three core material types: wire rope, wire strand or fiber.

Wire rope chain, like all chains, is made up of a series of links. Because it is not solid, wire rope chain is quite flexible. At the same time, it is prone to mechanical failure.

Wire rope slings are made from improved plow wire steel, a strong steel wire that offers superior return loop slings and better security. The plow wire steel also shields rope at its connection points, which extends its working life. Wire rope slings, in general, provide their applications with increased safety, capacity and performance. Wire rope sling is a rope category that encompasses a wide range of sub-products, such as permaloc rope sling, permaloc bridle slings and endless slings. These and other wire rope slings may be accompanied by a wide variety of sling terminations, such as thimbles, chokers and hooks.

Wire rope offers its user many advantages. First, design of even distribution of weight among strands makes it ideal for lifting extremely heavy loads. Second, wire rope is extremely durable and, when matched properly to the application, can withstand great stress and elements like corrosion and abrasion. In addition, it is very versatile. Its many iterations and the ways in which the rope can treated means that users can get rope custom fit for virtually any application.

Depending on the type of wire rope with which you are working and your application, you may want to invest in different accessories. Among these accessories are: wire rope clips, steel carabiners, fittings, fasteners and connections.

To ensure that your wire rope quality remains high, you must regularly inspect them for wear and degradation. The right wire rope should be selected for a particular use. Watch out for performance-impacting damage like: rust, fraying and kinks. To make sure that they stay in tip-top shape, you should also clean and lubricate them as needed. Check for this need as a part of your regular inspection.

Rope care is about more than inspection. It’s also about making an effort to use and store them properly every time you use them. For example, never exceed your rope’s rated load and breaking strength. Doing so will not only cause the weakening of your cable, but it may even cause immediate breakage. In addition, always store your wire rope cable in a dry and warm area, away from those elements that could cause premature rusting or other damage. Finally, always carefully wind your wire rope when you’re done with it, so as to avoid kinks. If you follow all these tips and treat your wire rope assemblies well, they will reward you with a long and productive service life.

Always make sure that you purchase wire rope that matches your industry and regional standards. Some of the most widely referenced standards organizations for wire rope include: ISO, ASTM International and OSHA. Talk over your specifications and application with your wire rope supplier to figure out what’s best for you.

If you’re in the market for a wire rope or a wire rope assembly, the best way to know you’re getting something that will both perform well and be safe if by working with a vetted professional. Find one among the list we’ve provided on this page. Check out their profiles to get an idea of the services and products they offer. Pick out three or four to whom you’d like to speak, and reach out. Talk to them about your specifications, standard requirements and budget. Ask about lead times and delivery options. Once you’ve spoken with all of them, compare and contrast their answers. You’ll know you’ve found the one when you talk to a wire rope company that is willing to go above and beyond for your satisfaction.

Wire assemblies are also useful in motion control and mechanical automation applications for not only lifting but pulling and support as well. Wire rope assemblies allow for the incorporation of wire cables into machinery or other equipment for use improving connectivity and versatility and to prevent damage, such as fraying, to the rope mechanisms.

The capacity of a given system is determined by the type and placement of wire rope fittings in the assembly. Common fittings include clamps, clips, sleeves, links, hooks, forks, eyes, studs, and pins. The utility and added security afforded by wire rope assemblies allows their use in both commercial and residential arenas in addition to their traditional applications in the industrial sector.

As cables for heavy-duty hoisting vary considerably from those used to support a home shelving unit, it is vital that the intended use be considered when selecting the proper assembly. Wire rope manufacturers often provide a range of wire fitting options in order to accommodate the many different uses for the cables.

While specific fittings and terminations are achieved through various metal stamping, die cutting, or swaging techniques, the process of wire rope making is fairly uniform, though specifics will vary.

Wire ropes comprise the base or body of every assembly, these are the lengths of stranded wire cable that run between two fittings or pieces of equipment. Each rope consists of three main elements. Cold drawn metallic filaments are twisted or braided into strands which are in turn helically wrapped around a core, which may be metal or fiber based. The number of strands per cable and filaments per strand are used to identify wire ropes as are the lay or style in which each component was assembled.

Fittings and wires are commonly made of the same materials; most popular are durable metals. Steel and stainless steel, titanium, nickel alloys, and other metals are selected based on specific properties such as resistance to wear and corrosion, tensile strength, and weight to strength ratios.

Further considerations for wire rope assemblies include diameter, length, flexibility, difficulty of flattening, temperature resistance, and average lifespan.

Flexible conduit is used for push-pull or pull-pull controls.  Our conduit(s) are referred to as Bowden wire conduit(s).  This is the most common type we carry and they can be used in almost any application.  They consist of a bowden spring for structure and are covered and lined with HDPE (high-density polyethylene). This material offers the best abrasion resistance and protection for the cost. Currently we stock conduits for the following sizes and constructions of wire rope or solid wires:  3/64″, 1/16″, 3/32″ and 1/8″.  We also can manufacture other styles of conduits such as flat wire, strand wire and braided.  If you don’t see what you need here, please contact us so we can provide further information to service your needs.  See our complete conduit fittings category for terminations of the conduit and our wire rope fittings sections for end fittings.  The combinations for your assemblies are limitless.

Continental Cable employs 65 people specializing in the manufacture of custom mechanical wire rope cable assemblies. Other product lines include stainless steel and galvanized aircraft cable, a complete line of cable related hardware and tools and plastic coated cable.

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. Wire ropes are attached to a crane or hoist and are fitted with swivels, shackles or hooks. These are suitable for lifting or lowering elevators and are also used for supporting suspension bridges or towers.

In this article, we"ll cover details on the top U.S. providers of wire ropes, along with our featured list of top wire rope suppliers on Thomasnet.com.

Below is a list of featured suppliers of wire rope from our platform. Included with these companies is their location, year established and the number of employees.

Below we have assembled information on the top suppliers of wire rope in the U.S. based on currently available public sales data. The table also includes the company name, location and the number of employees.

With the help of the provided details on the wire rope suppliers in the United States in the above tables and descriptions, we hope you can use this data to further aid your sourcing decisions.

ISO 9001 & AS 9120 certified 8(m)WOSB certified custom manufacturer of corrossion resistant galvanized aircraft stainless steel metal safety cable and wire braid materials include braided cords with wire center for aeronautical, aerospace, halyard, helicopter lead line, sailboat, rigging, hoisting, automotive applications and more. Wire rope products are available in 1x7 strand through 6x36 strand for aircraft cable, non rotating and non flexible applications. Custom coatings and finishes available for aerospace, automotive, safety applications. Also offers custom braids in specialty colors, finishes, and materials such as aramid, ceramic, Dyneema®, fiberglass, Kevlar®, linen, Nomex®, plasma, Spectra®, tarred, marlin, Technora™, Twaron®, and Vectran™. Galvanized aircraft wire ropes and cables available in 302/304, 305, and 316 stainless steel and zinc-coated carbon steel materials. Offers non-flexible types in 1 x 7 and 1 x 19 strand models. Suitable for aeronautical, logging, hoisting, aircraft control, and winching applications.

Tyler Madison has earned its position as a leading custom cable manufacturer of wire rope assemblies through its commitment to quality and customer service. The company always carries an extensive inventory of stock components to meet their customers’ simpler needs. But with an extensive background in wire rope design, the company welcomes the opportunity to design, engineer, and manufacture wire rope solutions to perfectly match its customers’ more specific applications.

At Carl Stahl Sava Industries, manufacturing a comprehensive family of cable, stainless steel wire rope fittings and tools only explain a portion of what makes us so special as a cable assembly manufacturer. In addition to possessing an ISO 9001:2015 certification, Sava is also FDA and ITAR registered, as well as RoHS and REACH certified. Our wire rope manufacturing process leverages almost 50 years of engineering and manufacturing expertise that customers around the world have grown to depend upon every single day. Additionally, Sava’s sales professionals boast over 100 years of combined technical experience helping organizations just like yours meet the most complex and sophisticated application requirements.

PersonalWe are on hand to personally guide you through the entire process, we translate the jargon, we recommend what’s best, and we are always here in person. No nonsense, just straight talking people who always exceed expectations through our extensive wire rope knowledge and superior service.

Edson Pull-Pull Conduit Systems are designed to provide the ability to run steering cables around spaces or structures that otherwise might be difficult or impossible with straight wire runs from sheave to sheave. Pull-Pull System components have been engineered to allow you to use stock parts that will result in a strong, reliable and sensitive steering system. However, you must carefully follow the guidelines at the right to insure a system that is free of friction.

Edson’s 20 foot length - 3/4" Pull/Pull Conduit assembly includes a 20 foot length of #853-250 Conduit and two 854-250 End Fittings. They are cut to length and assembled at the Edson Factory. Two lengths are needed in most steering system installations. The length should be measured from end-to-end including 2-1⁄2”(64mm) for each end fitting.

Edson Pull-Pull Conduit Systems are designed to provide the ability to run steering cables around spaces or structures that otherwise might be difficult or impossible with straight wire runs from sheave to sheave. Pull-Pull System components have been engineered to allow you to use stock parts that will result in a strong, reliable and sensitive steering system. However, you must carefully follow the guidelines at the right to insure a system that is free of friction.

Edson’s 15 foot length - 3/4" Pull/Pull Conduit assembly includes a 15 foot length of #853-250 Conduit and two 854-250 End Fittings. They are cut to length and assembled at the Edson Factory. Two lengths are needed in most steering system installations. The length should be measured from end-to-end including 2-1⁄2”(64mm) for each end fitting.

Lexco® Cable carries a full line of cable turnbuckles for adjusting the tension or length of wire ropes and aircraft cables when they’re attached to structures, supports, or other cables or wire ropes. Turnbuckles are available with various end connectors, including hooks, eyes, and jaws. Threaded studs are also available. We stock both domestic (Made in the USA) turnbuckles and imported models.

Sanlo Inc. is a leading manufacturer of custom cable assemblies in a wide variety of bare and coated cable configurations. Coatings include nylon, vinyl, and other thermoplastic and/or specialized coatings. A full line of cable end fittings is available to meet your specific application. Wire rope and mechanical cable assemblies provide a simple, reliable, and cost-effective solution to an ever-increasing diversity of applications. We manufacture and sell cable assemblies for industrial, commercial, and consumer end-uses which includes aircraft cable. Sanlo offers on-site engineering services to assist with your custom designs and can often prototype your assemblies. Sanlo is a member of the Central Wire Industries (CWI) group of companies.

Conduit provides a secure barrier between electrical wiring and exterior conditions that could damage or corrode it over time. A wide variety of conduit is available for both interior and exterior applications, including flexible conduit that allows wires to curve around obstacles. However, rewiring these conduits during repairs and renovations can be challenging. With conduit sometimes running hundreds of feet long, it can be difficult to ensure that wiring runs all the way through without getting caught. Fortunately, there are several methods to pull wire through conduit, and some of the best are covered here.

In ideal situations, you’ll work with a conduit that still has old wire running through it. In these cases, you can simply attach the end of the old wire to the end of the new wire and use it as a pull wire, pulling the new line through the conduit. However, this is not always an option, especially when working with new conduit or severely damaged old wiring.

If you find yourself needing to pull wire through conduit, you can choose from multiple methods. Some of the best methods for pulling wire through electrical conduit are listed below, along with their advantages and limitations.

The string method is the simplest technique for pulling wire through conduit and relies on a strong string called a pull string. The method works as follows:

This method works best on pieces of conduit that are short and straight. Longer pieces of conduit or lengths with more curvature will require an alternative method.

The mouse method is a variation of the string method that uses a tool called a conduit mouse or conduit piston instead of a rod. This tool is a small foam cylinder that is slightly smaller in diameter than the interior of the conduit. It is used in tandem with a shop vacuum. The method for using this tool is detailed below:

Insert the mouse: Place the mouse into the conduit opposite from the side you plan to pull from. Fit the mouse so that it fills the conduit space and so that the string follows behind it.

Apply the vacuum: Take the shop vacuum and apply it to the opposite end of the conduit. Make sure that the vacuum hose is fitted to the conduit so that it creates the best suction.

Pull the wire: Pull the opposite end of the string to pull the wire into the conduit. For longer conduits, have a partner feed the wire into the conduit.

Tie the weight: Tie a heavy fishing weight to the end of the wires using string or fishing wire to give the weight a 2- to 3-inch lead in front of the wiring. Be sure to choose a fishing weight that is thin enough to run through the conduit but heavy enough to pull lubricated wire.

Drop the weight: Drop the fishing weight into the conduit. If you are working with a free-moving length of conduit, lift the end of the conduit higher than the weight so that gravity can pull the weight along. When necessary, adjust the conduit orientation to get the weight around curves in the conduit. Continue this process until all the wire has been pulled through the conduit.

This method is somewhat limited in its applicability. It works best for straight, vertically-run conduit, though it can be applied to almost any conduit that is free to move around. It is not ideal for a conduit that is fixed in a horizontal position or has excessive curves.

The above methods are excellent for straight conduits but are much more difficult for pulling through conduits with more curvature. So how do you pull wire through flexible conduit with multiple turns? The fish tape method is the most common solution. This technique uses fish tape, a tool commonly used by electricians for pulling wire. Fish tape is a long, flat metal wire wound inside a spool with a hook at the end. To use fish tape, you’ll also need wire strippers and linesman pliers. The fish tape method works as follows:

Feed the tape: Feed the end of the tape into the end of the conduit you wish to pull from. Continue pushing the tape through the conduit and unwind the spool as you go. When the end of the fish tape emerges from the end of the conduit, stop feeding the tape.

Strip insulation: Strip insulation from the end of the wire using wire strippers. If you are feeding multiple wires, strip each wire a different amount, leaving one wire longer than the others.

Attach the wires: Hold the wires together so that the insulation is aligned and twist them together with pliers. Bend the longest wire so that it forms a hook and attach it to the hook on the end of the fish tape. Once these are attached, wrap the attachment point with electrical tape to ensure that they don’t detach during the pull process.

The fish tape method can be applied to nearly all types of conduit. Note that fish tape is available in a range of lengths from 25 feet to 100 feet, so be sure to get one appropriate for your application. For shorter lengths or small jobs, nylon tape is an economical option that works just as well.

Pulling wire through conduit with existing wires is difficult because any technique you use may get caught on the existing wires — the conduit mouse and fishing weight method are completely unuseable in these cases for this reason.

Pulling cable through conduit bends can also prove problematic. For most conduit, the more severe the angle, the more difficult it is to get a pull string or fish tape in place. This problem is even more pronounced with PVC conduit, as the angle joints can easily catch fish tape as it works through the conduit.

One method to get around these problems uses two fish tapes run at each end of the conduit. Note that this method does require working with a partner. The method goes as follows:

Feed the tapes: Have you and your partner stand at the two ends of the conduit, each with one of the two modified fish tapes. Begin to feed the tapes at each end. Plan it so that your tapes meet at the problem point in the conduit.

Hook and pull: When the tapes meet, spin the hooked end so that it is more likely to grab one of the loops. Once you think you have caught the other line, tug to test. When the two lines are attached, pull one end of the fish tape to pull the other all the way through the conduit.

Once you’ve caught and pulled one fish tape through the entire conduit, you can continue with the normal fish tape technique for pulling wires through. It’s important to note that conduit with severe turns or existing wires will require thorough lubrication to get the wires all the way through without catching.

Before you pick one of the above techniques for pulling wire through conduit, it is important to analyze your conditions and adequately prepare for the process. Some essential tips include the following:

Look for existing tools: While examining your conduit, check for any existing wires or cables in the conduit, as these can be used as pull strings for the new wiring. Also, check to see if these wires are intact — broken wires can pose obstacles during the wire pulling process.

Check local codes: Sheathed cables are an alternative to insulated wiring and are permitted by the National Electrical Code. However, they aren’t universally allowed to be used in interior conduits and should never be used in outdoor applications. Even if they are allowed, the size of the sheathed cable makes it nearly impossible to run it through anything other than short, straight conduits.  If you are thinking about rewiring with non-metallic cable, be sure to check local laws and codes to make sure this is acceptable and ensure that your application will be compatible.

Lubricate the wiring: Pulling wires is difficult enough when working with straight conduit. However, bends and turns increase friction on the wire, making pulling more difficult. If your conduit has bends and curves, lubricate your wiring with a non-conductive lubricant as you feed it into the conduit. This gel or soap substance coats the wiring, making it slick enough to slide through the conduit more easily. Apply the lubricant directly to the wire before pulling it through, using less toward the end of the pull. As with any lubricant, follow the manufacturer’s instructions for optimal functionality.

Work with a partner: While you can theoretically pull wire yourself, it is best to work with at least one other person, no matter what method you choose. This person can help by pulling the wiring while you add lubricant or vice versa. This is especially recommended for longer and more complicated runs of conduit.

Examine your conduit: By far the most important preparation tip is to inspect the length of your conduit from end to end. Measure the length of the conduit and make note of any curves that may pose problems. Be sure that whatever method you decide to use is appropriate for the length and shape of the conduit in question. Also take note of the type of conduit you are running — conduit with corrugated edges will catch wires more easily across the length of the conduit, while smooth PVC conduit may only catch at joints.

One of the important things to consider when preparing to pull cable is the type of conduit you’ll be working with. The thickness of the conduit, as well as the texture, will help determine the best method for pulling wire through the conduit. Thinner conduits may not allow for the use of fishing weights or conduit mice, while larger conduits may support these methods.

AerosUSA is a leading supplier of high-performance conduit systems for industrial applications. As the exclusive U.S. representative of world-renowned manufacturer Flexa GmbH, we carry an extensive and exclusive inventory of high-quality conduits.

Of particular note are our polyamide conduits and galvanized conduits, made to fit the needs of various industries. Our corrugated polyamide conduits provide excellent impact and UV protection and feature snap-on connectors that are easy to use. Our metallic galvanized conduits, on the other hand, provide corrosion protection and shielding needed for the most demanding industrial environments.