wire rope break brands

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.

A wire rope is a type of cable that includes several wire strands laced together to form a single wire. Generally, both the terms “wire” and “rope” are used interchangeably with “wire rope”; however, according to the technical definition, to be labeled a wire rope, the cable must have a thickness of at least 9.52 mm. As a versatile, high load capacity alternative to natural fiber ropes such as hemp and manila, wire rope provides motion transmission through nearly all angles, tie down, counterbalance, guidance, control, or lift.

Modern wire rope was invented by Wilhelm Albert, a German mining engineer, between 1831 and 1834. He developed them in order for work in the mines in the Harz Mountains. This rope replaced weaker natural fiber ropes, like hemp rope and manila rope, and weaker metal ropes, like chain rope.

Albert’s rope was constructed of four three-stranded wires. In 1840, a Scot named Robert Stirling Newall improved upon this model. A year later in the United States, American manufacturer John A. Roebling started producing wire rope, aimed at his vision of suspension bridges. From there, other interested Americans, such as Erskine Hazard and Josiah White, used wire rope in railroad and coal mining applications. They also applied their wire rope techniques to provide lift ropes for something called the Ashley Planes project, which allowed for better transportation and increased tourism in the area.

Approximately twenty-five years later, back in Germany in 1874, the engineering firm Adolf Bleichert & Co. was founded. They used wire rope to build bicable aerial tramways for mining the Ruhr Valley. Years later they built tramways for both the Wehrmacht and the German Imperial Army. Their wire rope systems spread all across Europe, and then migrated to the USA, concentrating at Trenton Iron Works in New Jersey.

Over the years, engineers and manufacturers have created materials of all kinds to make wire rope stronger. Such materials include stainless steel, plow steel, bright wire, galvanized steel, wire rope steel, electric wire, and more. Today, wire rope is a staple in most heavy industrial processes. Wherever heavy duty lifting is required, wire rope is there to facilitate.

Wire rope is strong, durable, and versatile. Even the heaviest industrial loads may be lifted with a well-made wire rope because the weight is distributed evenly among constituent strands.

There are three basic elements of which wire ropes are composed: wire filaments, strands, and cores. Manufacturers make wire rope by taking the filaments, twisting or braiding them together into strands, and then helically winding them around a core. Because of this multiple strand configuration, wire rope is also often referred to as stranded wire.

The first component, the filaments, are cold drawn rods of metal materials of varying, but relatively small diameter. The second component, the strands, can individually consist of as few as two or as many as several dozen filaments. The last component, the core, is the central element around which strands are wrapped; wire rope cores maintain a considerable amount of flexibility, while increasing strength by at least 7.5% over the strength of fiber core wire ropes.

The helical winding of the strands around the core is known as the lay. Ropes may be right hand lay, twisting strands clockwise, or they may be left hand lay, twisting strands counter-clockwise. In an ordinary lay, the individual strands are twisted in the opposite direction of the lay of the entire rope of strands to increase tension and to prevent the rope from coming unwound. Though this is most common Lang"s lay has both the strands and the rope twisted in the same direction while alternate lays, as the name suggests alternate between ordinary and Lang style lays. While alternative rope designs are available, the helical core design is often favored, as it allows a wire cable to hold a lot of weight while remaining ductile.

There are many design aspects that wire rope manufacturers consider when they are creating custom wire rope assemblies. These include: strand gauge (varies based on application strength, flexibility, and wear resistance requirements), wire rope fittings (for connecting other cables), lay, splices, and special coatings. Specially treated steel cable and plastic coated cables, for instance, are common to many application specific variations of wire rope such as push pull cable assemblies used in transferring motion between two points.

Suppliers typically identify wire cable by listing both the number of strands and the amount of wires per strand respectively, though stranded cable may alternatively be measured by their lay and length or pitch. For example, a door-retaining lanyard wire rope is identified by its 7 x 7 construction, and wire rope used for guying purposes is identified by its 1 x 19 construction. The most common types are 6 x 19, 6 x 25, 19 x 7, 7 x 7, 7 x 19, 6 x 26, and 6 x 36.

An ungalvanized steel wire rope variety. This uncoated wire rope can also be designed to resist spinning or rotating while holding a load; this is known as rotation resistant bright wire rope.

Also called a coiled wire rope, a coiled cable is a rope made from bundles of small metal wires, which are then twisted into a coil. Wire rope and cable can come in a huge variety of forms, but coiled cables specifically provide the benefits of easy storage and tidiness. Unlike other wire ropes, coiled cables do not require a spool for storage. Because it has been coiled, the cable will automatically retract into its spring-like shape when it is not in use, making it incredibly easy to handle.

A type of high strength rope, made of several individual filaments. These filaments are twisted into strands and helically wrapped around a core. One of the most common types of wire rope cable is steel cable.

Wire rope made not as one solid piece, but as a piece made up of a series of metal links. Wire rope chain is flexible and strong, but it is more prone to mechanical failure than wire rope.

Push pull cables and controls are a particular type of control cable designed for the positive and precise transmission of mechanical motion within a given system. Unlike their counterpart pull-pull cables, these wire rope assemblies offer multidirectional control. Additionally, their flexibility allows for easy routing, making them popular in a number of industrial and commercial applications.

Iron and steel are the two most common materials used in producing wire ropes. A steel wire is normally made from non-alloy carbon steel that offers a very high strength and can support extreme stretchable forces. For even more strength and durability, manufacturers can make stainless steel wire rope or galvanized steel wire rope. The latter two are good for applications like rigging and hoisting.

Technically, spiral ropes are curved or round strands with an assemblage of wires. This gathering of wires has at least one cord situated in the opposite direction of the wire in the outer layer of the rope. The most important trait of this rope is that all the wires included are round. The biggest benefit of this category of rope is that it does not allow the entrance of pollutants, water, or moisture.

Contain an assemblage of strands placed spirally around a core. Stranded rope steel wire patterns have different layers that cross each other to form an even stronger cable or rope. Stranded ropes contain one of three types of core: a fiber core, a wire strand core, or a wire rope core.

Provide an added level of security to a manufacturing production application. Wire rope slings are made from improved plow steel wire ropes that, apart from offering added security, also provide superior return loop slings. Plow steel wire ropes improve the life of a mechanism by shielding the rope at its connection points. The key objective of wire rope slings is to enhance the safety of an application while increasing its capacity and performance. Rope slings are also available in various sling termination options, such as hook type, chokers, and thimbles.

The eye in this rope sling is made using the Flemish Splice method. Just like a typical sling, a Permaloc rope sling improves safety and provides reverse strength meaning that the uprightness of the eye does not depend on the sleeves of the metal or alloy. Additionally, permaloc rope slings offer an abrasion resistance feature that makes them long lasting.

These slings have all the features that most other slings offer. However, compared to their counterparts, Permaloc bridle slings provide better load control, wire rope resistant crushing, robust hooks and links that work for a longer duration, and help save on maintenance requirements.

Manufacturers produce wire rope for many different reasons; from cranes to playground swings, wire ropes have something for everyone. Among the many applications of wire rope are hoisting, hauling, tie down, cargo control, baling, rigging, anchoring, mooring, and towing. They can also serve as fencing, guardrails, and cable railing, among other products.

Some of the industries that make use of wire rope include industrial manufacturing, construction, marine, gas and oil, mining, healthcare, consumer goods, and transportation. Others include the fitness industry, which uses plastic coated cable products in weight machines, the theater industry, which uses black powder coated cables for stage rigging, the recreation industry, which uses plastic coated cables for outdoor playground equipment, and the electronics industry, which uses miniature wire rope for many types of electronic equipment and communications devices.

Wire ropes are typically made from cold drawn steel wire, stainless steel wire, or galvanized wire. They may also be made from a wide variety of less popular metals, including aluminum, nickel alloy, bronze, copper, and titanium. However, nearly all wire ropes, including control cables, are made from strands of cold drawn carbon steel wires. Stainless steel rope and cables are subbed in for highly corrosive environments. Galvanized cables and galvanized wire rope are popular for their increased strength and durability; these qualities are important to specialized ropes like galvanized aircraft cable.

A core may be composed of metal, fiber or impregnated fiber materials depending on the intended application. Cores may also be another strand of wire called an independent wire rope core (IWRC).

Wire rope, depending on its application, is subject to many standard requirements. Among the most common of these are the standards detailed by OSHA, ASTM International, and ISO. Per your application and industry, you’ll likely have others you need to consider. To get a full list, talk to your service provider.

To determine the safety factor, which is a margin of security against risks, the first step involves knowing the type of load that the rope will be subjected to. The load must consider the shock loads and blowing wind effects. The safety factor is characterized in ratios; typical are 4:1 and 5:1. If a ratio is 5:1, then the tensile strength of a wire rope must be five times of the load it will be subjected to. In some applications, the ratios can go up to 10:1.

By weighing all these factors carefully, the wire rope that you will buy will be safe to use and last considerably. For the best advice and guidance, though, don’t go it alone! Find a great wire rope supplier that you can trust. You’ll know you’ve found the right supplier for you when you talk to one that can not only fulfill your requirements, but shows that they are excited to go the extra mile for you. For a company like this, browse the list near the top of the page.

As the cables play an integral role in the safety of many operations and structures, careful analysis of a wire rope and all of its capabilities and features is vital. Important qualities and physical specifications you must consider include wire rope diameter, breaking strength, resistance to corrosion, difficulty of flattening or crushing, bendability, and average lifespan.

Each of the aforementioned considerations should be compatible with the specific application for which the rope is intended as well as the environment in which such operations are undertaken. Temperature and corrosive environments often require specially coated wire ropes with increased durability.

When you use your industrial wire rope, the first thing to remember is to not exceed your rope’s rated load and breaking strength. If you do not stay within these parameters, you risk causing your rope to weaken or even break.

Rust, kinks, fraying and even carefully performed splicing will all have an impact on the performance of wire ropes. To maintain the integrity of your wire rope assembly, you need to inspect them regularly and clean and lubricate them as needed. In addition, you need to store them out of the wet and cold as much as possible. Also wrap them up properly, so they are not kinked.

A high-carbon steel having a tensile strength of approximately 260,000 psi that is roughly fifteen percent stronger than Plow Steel. Most commercial wires are made from IPS.

A low carbon steel wire of approximately 10,000 psi, which is pliable and capable of repeated stresses from bending around small sheaves. This grade is effective for tillers, guys and sash ropes.

The manner in which the wires are helically wound to form rope. Lay refers specifically to the direction of the helical path of the strands in a wire rope; for example, if the helix of the strands are like the threads of a right-hand screw, the lay is known as a right lay, or right-hand, but if the strands go to the left, it is a left lay, or left-hand.

A classification of wire rope according to its breaking strength. The rank of grades according to increasing breaking strengths is as follows: Iron, Traction, Mild Plow Steel, Plow Steel, Improved Steel, Extra Improved Steel.

Classification of strands according to breaking strength. The ranking of increasing breaking strengths is as follows: Common, Siemens Martin, High Strength and Extra-High Strength; a utility"s grade strand is available for certain requirements.

The act of fastening a termination to a wire rope through physical deformation of the termination about the rope via a hydraulic press or hammering. The strength is one hundred percent of the wire rope rating.

A grade of rope material that has a tensile strength range of 180,000 to 190,000 psi. Traction steel has great resistance to bending fatigue with a minimum of abrasive force on sheaves and drums, which contributes to its long use in elevators, from which the steel gets its name.

It is composed of wire strands that are braided together. Wire braid is similar to stranded wire. The difference between the two is the fact that stranded wire features strands that are bundled together, rather than braided.

Essential parts of cable assemblies, wire rope assemblies and wire rope slings that assist spliced or swaged rope ends in connecting to other cables and keeping cables and rope from unraveling.

A wire rope cable assembly is a metallic rope consisting of bundles of twisted, spiraled, or bonded wires. While the terms wire rope and cable are often used interchangeably, cables are typically designated as smaller diameter wire ropes, specifically wire ropes with a diameter less than 3/8 inch. Therefore, wire rope cable assemblies are typically utilized for lighter duty applications.

Or cable assemblies, are cables which are composed of many spiraled bundles of wire. These cables are used to support hanging objects, connect objects, pull or lift objects, secure items, and much more.

Wire rope wholesalers can sell an extensive range of wire rope and wire rope accessories at a very affordable rate as well as in bulk. Many of the additional wire rope equipment that wire rope wholesalers provide include: swivel eye pulleys, eye nuts, eye bolts, slip hooks, spring hooks, heavy duty clips, clevis hooks, turnbuckle hooks, anchor shackle pins, s hooks, rigging blocks, and much more. Wire rope fittings will generally improve the versatility of the wire and also prevent fraying.

The 6 x 19 classification of wire ropes includes standard 6 strand, round strand ropes with 16 through 26 wires per strand. The 6 x 36 classification of wire ropes includes standard 6 strand, round strand ropes with 27 through 49 wires per strand. Although their operating characteristics vary, all have the same weight per foot and the same nominal strength, size for size.

While the 6 x 19 ropes give primary emphasis to abrasion resistance in varying degrees, the 6 x 36 ropes are important for their fatigue resistance. This fatigue resistance is made possible by the greater number of small wires per strand.

Although there are exceptions for special applications, the constructions in 6 x 36 classification are primarily designed to be the most efficient for each rope diameter. As the rope size increases, for instance, a large number of wires can be used to achieve required fatigue resistance, and still those wires will be large enough to offer adequate resistance to abrasion.

In this construction, each strand has nine outer wires over nine smaller inner wires over one large center wire. A comparison of cross-sections shows that these outside wires are larger than those of the 6 x 25FW or 6 x 26WS. Therefore, its resistance to abrasion is increased, but its fatigue resistance is decreased. This is a good rope to withstand abrasion or crushing on the drum.

To most wire rope users, 6 x 19 means 6 x 25 filler wire. It is the most common rope in the 6 x 19 classification. This rope has a good balance between both abrasion resistance and fatigue resistance in relation to other ropes.

This construction has better resistance to abrasion than a 6 x 25FW. It also features a compact construction with solid support for the wires; hence, it has a high resistance to crushing. Its number and relative size of the inner wires add to the stability of the strand and gives it a fatigue resistance comparable to a 6 x 25FW.

A standard 6 x 26WS construction provides the best rope for a wide range of applications. In general, we recommend the use of a 6 x 26WS in any application where a 6 x 25FW is used.

In most rope sizes, only one 6 x 36 classification rope is made. These constructions were selected to provide fatigue resistance without having wires that are too small.

The greater number of wires in the 6 x 36 classification makes these ropes more susceptible to crushing. This can be minimized, however, by specifying an Independent Wire Rope Core (IWRC) and by using well-designed sheaves, grooved drums and proper operating techniques.

Rotation-resistant ropes can frequently provide the best and most economical service in specific applications when you choose, handle and use them properly.

Contra-helically laid, rotation-resistant ropes are different from standard ropes because they"re designed to reduce rope torque. Modes of failure and wear for rotation-resistant ropes can differ from those for standard rope constructions. The very nature of these ropes requires special handling, selection and usage not encountered with standard constructions. They are susceptible to kinking, crushing and unbalancing in the form of "core pops" and "birdcages" Use extreme care to avoid operational practices that can possibly lead to these conditions.

Rotation-resistant ropes should not be used with swivels that allow rope rotation -- or in single part lifts where the load can rotate. Rotation will cause a reduction in strength, unequal loading in the rope and possible rope unbalance. If any significant change in diameter is found in a short length of a rotation-resistant rope, the rope needs to be replaced.

These ropes should be replaced when you see two randomly distributed crown wire breaks in six rope diameters -- or four randomly distributed crown wire breaks in 30 rope diameters.

Because rotation-resistant ropes are special, there are separate design, maintenance, inspection and removal criteria established for them by applicable industry regulations and standards.

In an application where a single-part hoist rope is used to lift a free load -- or where rotation-resistant properties are essential for rope performance -- the 19 x 7 can be used. Its rotation-resistant characteristic is achieved by laying six strands around a core strand in one direction, then laying 12 strands around the first operation in the opposite direction. Thus, when the rope is in tension, opposing rotational forces are created between the inner and outer layers.

In addition, frequent and regular inspection for broken wires is critical when using this rope. Due to its design, the 19 x 7 construction has a relatively low reserve strength. This can result in short service life between the point in time when the broken wire removal criteria are met and when actual rope failure occurs.

In a multi-part wire rope system where the blocks have a tendency to twist -- or for a single-part hoist line that doesn"t require the degree of rotation-resistant properties found in a 19 x 7 rope -- the 8 x 25 Resistwist rope has found successful application. The rotation-resistant characteristic is achieved by laying the eight outer strands around an independent wire rope core so these strands are in the opposite direction to the lay of the core. Thus, when the rope is in tension, opposing rotational forces are created between the core and the outer strands.

Though not as rotation-resistant, the 8 x 25 Rotation Resistant rope is more stable than a 19 x 7 rope. It also has increased resistance to bending fatigue and crushing. This is achieved through the use of eight-strand construction with an independent wire rope core.

Like any application where an installation"s rope type is changed, the 8 x 25 Rotation Resistant rope should be substituted only after carefully comparing specifications and strength requirements.

For customers who require peak rope performance levels in mission critical applications, Casar manufactures and supplies highly-engineered ropes that exceed industry standards while providing record-setting service life.

Our proprietary and innovative German-engineered rope designs deliver the highest levels of performance and safety, superior breaking strength values, the highest bending fatigue resistance, superior crushing resistance, and the best rotational resistance characteristics for high lifts.We have decades of global experience and on-site engineering support in the crane, OEM and underground mining sectors.

CASAR has an extensive range of products available and we can customize to your application.Our wire rope specialists will assist customers in design, selection, installation and operation to improve rope performance and maximize service life.

Manufacturing companies choose to use Dyneema rope over steel wire rope for heavy lifting applications such as heavy lift slings, crane rope, and other rigging operations because Dyneema rope:

Dyneema fiber rope is made from Ultra-High Molecular Weight Polyethylene (UHMWPE) fiber. Dyneema 12 strand rope is a common Dyneema fibered rope used for heavy-duty rigging applications. USA Rope & Recovery manufactures several different types of Dyneema fiber rope including the popular 12 Strand, and 24 Strand ropes, as well as others. No matter the application, USA Rope provides strong, durable, and efficient rope for the marine, arborist, nautical, off-roading, and other manufacturing industries.

More times than not, Dyneema fiber rope and steel wire rope are compared by most manufacturing companies–likeThe Rigging Company–for certain maritime, mooring, and towing rope applications. Pound for pound, Dyneema fiber rope is up to 15 times stronger than steel and up to 40% stronger than aramid fibers–otherwise known as Kevlar rope. The high-performance strength and low weight of Dyneema rope ensures that it is safer to use than steel wire rope. Ideally, Manufacturing companies want a rope that can withstand tremendous weight while being light enough to move, use, and work with when needed. Traditionally, steel wire rope is used for heavy-duty maritime, rigging, and mooring rope applications. Although steel wire rope is known for being used for heavy-duty rigging, the disadvantage is the serious risks that come from its heavy-weight and uneven breakage behavior. When a steel wire rope breaks, the combination of the enormous energy and incredible force causes unpredictable recoil. This unpredictable recoil comes from how wire rope is coiled. Essentially, wire rope is several strands of metal wire twisted into a helix, forming a composite rope. When breakage occurs, the helix formed rope unravels, creating a snaking behavior which can cause sharp edges of the broken strands to release at a dangerous force. The lack of strength compared to Dyneema rope shows that steel wire rope is more susceptible to breaking. This can increase risk factors for manufacturing companies that use steel wire rope for rigging, mooring, and heavy duty lifting.

For example, when comparing a ⅜ inch 12 Strand Dyneema rope to a ⅜ inch steel wire rope, the 12 strand Dyneema rope is significantly stronger and presents safer breaking characteristics. The ⅜ inch steel wire rope withstands a load of 14,478 pounds. As the video shows, even in the event of a partial rupture, the steel wire ropes higher mass and recoil provides a greater risk over 12 Strand Dyneema rope. With a ⅜ inch 12 Strand Dyneema rope, it can withstand 18,857 pounds. With the Dyneema fibers low mass and recoil, it reduces the risks for manufacturing companies using rigging rope for heavy-duty lifting applications.

Dyneema is 7 times lighter than steel wire rope at the same strength. In the event of a break, the recoil force is considerably less. Furthermore, the different construction of a Dyneema rope shows a linear recoil without any snaking behavior. This is due to the fact that Dyneema rope is manufactured from UHMWPE, which is comprised of extremely long chains of polyethylene oriented in the same direction, resulting in an overlapping effect. The overlapping of the UHMWPE increases the bond of the chains and thereby strengthens the Dyneema fiber. Dyneema rope offers durable characteristics that can withstand an immense amount of strength while having very little weight to the rope. Because Dyneema fiber is lighter and has a lesser impact when breakage occurs, choosing Dyneema rope over steel wire rope is the safer choice for manufacturing companies working with heavy lifting and below the hook rigging applications for the industrial, nautical, and arborist industries.

When choosing the best rope for any maritime, mooring, towing, or heavy-duty lifting application, choose a rope that can withstand extremely heavy loads and has a long enough lifetime to handle external factors in the nautical, industrial, or arborist industry. In order to decide which rope is best for the job, there are four main challenges that rigging, heavy-duty lifting, mooring, and towing ropes need to overcome:

Dyneema rope is the only high modulus synthetic fiber that has been scientifically engineered–from Ultra-High Molecular Weight Polyethylene (UHMWPE)–to overcome all four of these challenges. Dyneema is the world’s strongest fiber producing ropes that are 15 times stronger than steel wire ropes of the same weight and has become one the most trusted fiber ropes over generic HMPE ropes and steel cable wire ropes for all rigging, maritime, mooring, and towing rope applications.

Manufacturing companies that work with maritime and mooring applications need a durable rigging rope to withstand the constant pulling that comes from the rope running through fairleads and over capstans. Also, in heavy-duty lifting and towing applications, ropes come in contact with rough surfaces such as chocks and the vessel’s deck. These applications can potentially provide severe abrasions to the ropes and degrade the exposed fibers, eventually breaking them. Choosing a Dyneema fibered rope provides manufacturers with a durable, lightweight rope that carries an abrasion lifetime that is four times longer than steel wire rope and rope made with regular HMPE and polyester. With Dyneema’s extended abrasion lifetime, manufacturers are choosing Dyneema rope over steel wire rope for all mooring, towing, maritime, and heavy-duty lifting applications throughout the nautical, arborist, and industrial industries.

Bending fatigue occurs every time a rope flexes under tension. For heavy-duty lifting applications, rope experiences potential bending-fatigue every time something needs to be moved. For example, when a steel beam manufacturer has completed a 15-ton custom-made beam for a military-grade application, the finished product needs to be moved onto a truck for shipment. Rigging ropes are then attached to a crane to then lift, move and place the steel beam from the warehouse to the truck. This can wear out the rope. Another example is when the rope runs over fairleads and pedestals in maritime and mooring applications. This stresses the fiber both inside and outside of the rope causing bending fatigue and decreases the useful life of the rope. Certain conditions in towing and mooring applications can also lead to compression fatigue. This happens when ropes become slack during services and the fibers compress. Due to the molecular properties (UHMWPE) engineered to make Dyneema fiber– and its extremely long chains of polyethylene oriented in the same direction–threats of compression and bending fatigue are far less over other synthetic fibers and steel wire ropes.

In all rigging applications, synthetic ropes elongate when over a long period of time when loaded in higher temperatures–commonly referred to as creep. Creep is irreversible and when combined with abrasions or other risks, it can lead to rope failure. With regular HMPE rope, in heavy-duty lifting and towing applications where high loads and high temperatures are constantly a factor, the creep process can accelerate. This can be a major risk for ropes made from generic HMPE. In contrast, Dyneema rope has up to four times longer creep lifetime. When comparing Dyneema fiber to Spectra, another synthetic fiber rope, under 122 degrees Fahrenheit and 600 MPa load, Dyneema rope has a significantly longer creep lifetime than Spectra fiber rope.

eAfter comparing Dyneema rope to steel wire rope–a ⅜ inch 12 Strand Dyneema rope to a ⅜ inch steel wire rope–there is a guarantee that Dyneema rope is 15 times stronger and better at dealing with abrasions over steel wire rope. For manufacturing companies, Dyneema rope is also considered to be superior to Nylon rope due to Dyneema fiber having low ability to stretch, is UV resistant, and possesses an immense amount of strength. USA Rope properly manufactures Dyneema fibered ropes that are synthetically engineered to uphold incredible weight while enduring constant friction for application uses involving heavy-duty lifting, crane rope support, and below the hook rigging.

Understanding that Dyneema fiber rope is better used for manufacturing companies over steel wire rope, USA Rope & Recovery works hard to manufacture the highest quality rope by using top-of-the-line supplies from across the USA. Dedicating time and effort to finding the next best and technologically advanced products in the market is our main goal at USA Rope in order to help our customers gain the best competitive advantage in their respective field. USA Rope & Recovery also manufactures additional ropes including Spectra, Nylon, Polyester, Polypro, and Kevlar (Aramid) fiber ropes. No matter the application, USA Rope is a leader in custom rope manufacturing for industries including nautical, industrial, arborist, and marine.

In general, running rigging should be replaced whenever it shows visible signs of damage – core hemorrhaged through the cover, several broken strands close together, “rot” from UV exposure, or green and stiff from disuse. There’s a rule of thumb, but it varies rigger to rigger. The Rule of thumb says to replace all rigging hardware every 5-10 years. However, depending on how much everyday usage, weight, and environmental factors the rigging ropes take on can make the rule of thumb shorter or longer.

Buying new crane ropes is a detailed and thorough process. While it may be time-consuming, wire rope replacement prioritizes safety for your workers, minimizes downtime on a jobsite, maximizes the lifespan of the crane and avoids the costly and time-consuming process of getting correct rope onsite and respooling your crane.

Sometimes, it can seem like the wire rope buying process is overly complicated. This is done on purpose to avoid as many issues as possible when the new rope is installed. The reason for that is so buyers avoid putting the wrong types of ropes on cranes and unnecessarily increasing the risk of injuries to workers or damage to loads being lifted. The processes are to make sure to prevent that added risk and put the correct rope on the correct machine, per Original Equipment Manufacturer (OEM) specifications.

Wire rope specialists ask these questions to understand your circumstances and what your needs are. With this information, they are better prepared to get the absolute correct rope.

Most of the time, the customer should have access to their crane’s operations manual that will show what rope diameter and length is specified. The customer may have to measure or come up with his own calculations on length. The crane manufacturer is going to make a specific drum for that specific type of wire rope.

The rope has to be specific to the lagging of the drum for that machine, which is why there are multiple variations for each size of wire rope because each kind is specific to the type of crane, and it shouldn’t be substituted. Mazzella will only install the rope that is the correct brand and tolerance on a particular crane.

Ordering the correct crane rope will prevent crane rope damage. The wrong rope could cause damage to the equipment, and at worst, boom failure. On the less severe side, you will have bad performance or it might not work at all. You could have twist and/or spooling issues. That could lead to the crane failing altogether, which creates downtime as you wait for the correct wire rope to be ordered/delivered and installed.

Many crane owners are working for somebody else when they’re doing jobs, so if the rope doesn’t work, they’re paying for work that is not getting done and falling behind schedule.

On the more severe side, you could total your crane and/or irreparably damage the load being lifted if you use the wrong wire rope. In the worst-case scenario, using the incorrect rope could result in severe injury and/or the loss of life.

Sometimes, customers assume that there’s a one-size-fits-all replacement, that if it’s a non-rotating rope, it should work on every application. There’s a lot of misinformation on what will work and what won’t work. With our experience and access to all brands of wire rope, Mazzella guarantees we can get you the right rope for your cranes. If Mazzella isn’t comfortable with the project, we won’t supply the wire rope.

If the wrong wire rope is ordered and delivered, it could be hours or days before the correct rope is on location. Especially with a lot of the larger cranes, manufacturers are shipping model-specific ropes all over the country, and depending on location and money, that could cause delays on your jobsite.

With our large inventory of rope, Mazzella can have a new spool of wire on a truck and out for delivery in a matter of hours. Avoid the pitfalls of ordering the wrong crane rope and you’ll have a new spool of wire rope on its way. Once the order process is done, what can your company do to prepare for delivery and installation?

It is a good idea to give management the proper notice of when the installer will be on-site, have the necessary technicians on-site to help the installer with the rope replacement and make sure the installer/technicians have a clear working space.

Also, Mazzella recommends you measure your sheaves with a sheave gauge. A sheave gauge will help you measure the wear of the root, the amount of wear on the groove wall and the diameter of the wire rope.

After ordering the correct rope and having the requisite space and approval for installation, how long will it take to remove and replace the old rope when the technician, assistants and supplies arrive onsite? For some small cranes, the timeframe could be as little as 45 minutes, but for larger cranes, removing the old rope and installing the new one could be a several-hour process.

There’s a lot of factors that go into a successful crane rope installation. The most important thing is the quicker your supplier responds to your order and gets a rope on location, the quicker that rope gets installed properly, saving time and money. Downtime is the key, and it could cost companies tens of thousands of dollars per day if their crane(s) are inoperable.

Once a new crane rope is installed, a break-in period or tension period is recommended to make sure everything is performing correctly, and help you avoid shock-loading the newly installed wire rope. The break-in period is recommended because installation and spooling equipment are not going to put adequate tension on the rope. A break-in period consists of putting a low percentage of the working load limit weight on the rope for several lift cycles, and running the blocks up to the boom length (working height) and back down. For the most specific guidelines on the breaking-in process for your new wire rope, refer to the manufacturer’s recommendations.

If a brand-new wire rope on a crane is not broken in properly before lifting a large load, it potentially could damage the rope and render useless the equipment that was just installed on your machine.

When Mazzella fulfills a crane ropes order, it is not just about the sale and the bottom line. While we’re in the business of selling crane ropes, we’re also in the business of building relationships and trust. We are committed to making sure you get the correct products for the right applications.

Crane rope issues don’t just happen 9-to-5 during the normal work week. They happen Friday nights, holidays, weekends and early mornings. They’re always on the clock, and it is just about being honest with the customer and letting them know, they type of rope that is required. That honesty and trust is of utmost importance for the safety of your workers and the proper maintenance of your cranes.

Mazzella has one of the largest crane ropes inventories in the United States. The company provides wire rope assemblies and manufactures bridge cables, crane cables, steel mill cables and thousands of OEM assemblies in sizes from ¼ to 3-inch diameter and 9 to 52 millimeter diameter, domestic and non-domestic and in stock and ready for same or next-day shipment.

Wire rope strength in the United States is typically shown in tons of 2,000 lbs. The wire rope strength is shown as minimum breaking force (MBF). This is a calculated strength that has been accepted by the wire rope industry. When tested on a tensile machine, a new rope will break at a value equal to- or higher than – the minimum breaking force shown for that rope. The published values apply to new, unused rope. A rope should never operate at – or near- the minimum breaking force. The minimum breaking force of the rope must be divided by the design factor required for the application to determine the maximum load allowed on the rope. During its useful life, a rope loses strength gradually due to natural causes such as surface wear and metal fatigue.

Fatigue resistance involves fatigue of the wire used to make up a rope. To have high fatigue resistance, wires must be capable of bending repeatedly under stress – for example, as a loaded rope passes over a sheave during operation. Increased fatigues resistance is achieved in a rope design by using a large number of wires. It involves both the wire properties and rope construction. In general, a rope made of many wires will have greater fatigue resistance than a same – size rope made of fewer, larger wires because smaller wires have a greater ability to bend as a rope passes over a sheave or around drums. To overcome the effects of fatigue, ropes must never bend over sheaves or drums with a diameter so small as to bend wires excessively. Standard for specific applications contain requirements for minimum sheave and drum sizes. Every rope is subject to metal fatigue from bending stress while in operation, and therefore the rope’s strength gradually diminishes as the rope is used.

Crushing is the effect of external pressure on a rope, which damages it by distorting the cross-section shape of the rope, its strands or core -or all three. Crushing resistance therefore is a rope’s ability to withstand or resist external forces, and is a term generally used to express comparison between ropes. When a rope is damaged by crushing, the wires, strands and core are prevented from moving and adjusting normally during operation. In general, IWRC ropes are more crush

resistant than fiber core ropes. Regular lay ropes are more crush resistant than lang lay ropes. 6-strand ropes have greater crush resistance than 8-strand ropes or 19-strand ropes. Compacted strand ropes are more resistant than standard round-strand ropes.

When a load is placed on a rope, torque is created within the rope as wires and strands try to straighten out. This is normal and the rope is designed to operate with this load-induced torque. However, this torque can cause both single part and multiple part hoisting systems to rotate. Load induced torque can be reduced by specially designed ropes. In standard 6 and 8- strand ropes, the torques produced by the outer strands and the IWRC are in the same direction and add together. In rotation-resistant ropes, the lay of the outer strands is in the opposite direction to the lay of the inner strands, thus the torques produced are in opposite directions and the torques subtract from each other.

As specialist for manufacturing quality steel wire ropes over 20 years, our company can supply strong, durable and reliable ropes that capable to minimize your downtime and maximize cost effectiveness. Decades of experience we owned make us know clearly the work you do and capable to provide professional guidance.

We select the best steel or stainless steel as raw material for wire rope manufacturing. Our products are manufactured under strict quality managements and test before they leave the factory.

Our engineers can provide professional advice about picking up optimal steel wire ropes for their application, installation guidance to ensure maximum return in their wire rope system.

If you are going to pick up steel wire ropes that suit your project perfectly, you must have an ideal about the construction about them. Our company can supply bright wire rope, galvanized wire rope, stainless steel wire rope, compacted wire rope, rotation resistant wire ropes, mining wire rope, elevator wire rope, crane wire rope and gas & oilfield wire ropes. Here are some details to solve the problem that may puzzle you whether you are browsing the web or picking up steel wire ropes.

Bright steel wire ropes mean no surface treatment is applied to the rope. Therefore, they have the lower price among these three wire ropes. Generally, they are fully lubricated to protect the rope from rust and corrosion.

Galvanized steel wire ropes feature compressed zinc coating for providing excellent corrosion resistance. With higher break strength yet lower price than stainless steel, galvanized steel wire ropes are widely used in general engineering applications such as winches and security ropes.

Stainless steel wire ropes, made of quality 304, 305, 316 steels, are the most corrosive type for marine environments and other places subjected to salt water spray. Meanwhile, bright and shiny appearance can be maintained for years rather than dull as galvanized steel wire ropes.

Steel wire ropes are composed of multiple strands of individual wires that surrounding a wire or fiber center to form a combination with excellent fatigue and abrasion resistance. These wires and strands are wound in different directions to from different lay types as follows:

Beside above lay types, alternative lay ropes which combine regular lay and lang lay together and ideal for boom hoist and winch lines, can also be supplied as your request.

Two main methods about seizing steel wire ropes in conjunction with soft or annealing wire or strands to protect cut ends of the ropes form loosening.