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Bird caging is a specific type of wire rope distortion that causes a section of rope to appear like a birdcage. It is one of the most distinct types of wire rope deterioration and also one of the most severe. Bird caging calls for the immediate removal of the rope from service.

In this blog, we will cover three common forms of wear and tear that wire can experience out in the field. Though wear does occur naturally, regular inspection, maintenance, and equipment repair can help ensure appropriate cycle life for your cable products while also minimizing risks and failures. Be on the lookout for signs of abrasion, bird caging, and kinking as you inspect and operate your equipment.

Abrasion, peening, and corrosion typically impact the outer surfaces of wire rope. Abrasion is a form of metal loss or erosion, and peening describes metal deformation. Both of these phenomena occur when a wire rope contacts other metallic surfaces, or when it passes over a drum or sheave. Sheaves that are heavily worn or badly corrugated can expedite wear and friction, causing the individual cable wires to break down and press together. Additionally, when sheaves are poorly lubricated, they cause pitting in the cable surface that leaves them vulnerable to corrosion and rust. Even a brand new cable is susceptible to premature wear if they are not maintained correctly, and paired with appropriate pulleys.

Bird caging is a severe form of wire rope distortion that causes the individual outer strands of a cable to unravel and expand, creating a bird cage shape at the damage site. Bird caging is usually caused by sheaves that impart unintentional rotation. When a non-rotation resistant cable experiences torsion caused by excessively tight, or incorrectly positioned sheaves, it triggers the outer cable strands to lift away from their normal position. Bird caging poses a severe hazard. To prevent future issues, the damaged cable should be immediately removed from operation, and the sheaves remedied.

A kink is the permanent deformation of strands in a wire rope caused by unintended bending and twisting. This usually occurs when the rope is twisted into a tight loop and then snapped back to a straight direction, leaving a permanent curve at the bend site. Though kinks often result from improperly handling or installing wire rope, they can also appear during service if a heavy load is released suddenly, or if a wire rope bends around too small of a sheave. While most kinks show obvious signs of catastrophic failure, others may appear insignificant or repairable through re-straightening. However, it is important to note that kinks always result in permanent strand damage, no matter how severe they may seem on the surface. If not addressed in a timely manner, kinks pose a severe safety hazard.

Though cable damage may happen unexpectedly, you can set yourself up for success by employing high quality wire rope from the start. Luckily, Strand Core manufactures high quality domestic aircraft cable and wire rope for military and commercial applications. Start a quote today, or contact us with any questions at https://strandcore.com/contact/.

Wire rope is a key part of numerous applications for construction, aerospace, and the marine industry. However, you severely reduce cable service life by causing damage to your wire products and could jeopardize your whole operation or cause injury. Two of the most common types of wire rope damage are kinking and bird caging. Continue reading to learn about these damage types and how to prevent them from occurring in your applications.

A kink appears is the place where a wire rope where the rope has been bent past what it can take. It is caused by applying a bending force beyond a wire rope"s tolerable level of flexibility. The problem most commonly occurs when the wires in the wire rope are all closed in the same direction. Kinking is often caused by the improper handling and uncoiling of wire rope products. If kinking occurs, your wire rope product can be severely damaged, and failure becomes inevitable.

While kinking can be a serious problem, it can be easily avoided. One way to prevent kinking is by using lifting hooks with swivels. A swivel helps prevent kinking as it takes the pressure off wire rope. Kinking can also be prevented by using correct uncoiling techniques. By properly handling your wire rope products, you will avoid kinking and have a wire rope product that lasts for many years! If your current wire rope is kinked, it is best to replace the item as soon as possible.

Bird caging happens when a wire rope experiences stress and then frays or pulls apart, resembling the appearance of a birdcage. The problem most commonly occurs where the wires in the wire rope are closed in different directions. Bird caging is often caused by improper installation or having too much slack in the wire ropes. Bird caging can also result from a sudden release of tension or forced through a light sheave.

One way to prevent bird caging is to use the right size and strength of sheaves and pulleys with your wire rope. By proper installation and preparation of your wire rope application, you can also reduce the possibility of bird caging. A third way to prevent bird caging is to make sure there is torsional balance in your wire rope. If your current wire rope has occurred any form of bird caging, you should replace the item.

Now that you understand how to prevent kinking and bird caging, you can expect to get the highest level of performance from your wire rope products. If you are searching for a replacement wire rope, choose Loos and Company! Our products are domestically manufactured to the highest of standards and offer extreme strength and durability. You can find out more about our wire products here. Alternatively, if you have any questions, our team is happy to help! Reach out to us by email at sales@loosco.com or by phone at (860) 928-7981.

Lexco® Cable offers a large selection of wire rope and aircraft cable hardware and tools. Our hardware items are made for attaching cable and wire rope to structures, supports, and other cables and wire ropes. Unlike our cable fittings, this hardware is not crimped or swaged to the wire rope or cable but is attached through other means, generally through an eyehole on the hardware itself. Our tools are designed to make working with and attaching aircraft cable, wire rope, and hardware faster, easier, and safer.

All of our aircraft cable and wire rope hardware is available in bulk quantities or as part of a complete cable assembly. We specialize in cable assembly fabrication to save you time and money in additional production costs.

Request a quote for the aircraft cable or wire rope hardware items or tools you need, or contact Lexco® for more information. If you cannot find the hardware items or tools that you need in our online inventory, please contact your Lexco® Cable sales representative. We’ll be happy to help you find the ideal product for your application.

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.

Introducing our brand new Performance Wire Ropes Catalog. Included in this catalog is our crane usage table, our high performance compacted strand ropes, category 1 and 2 ropes, and end fittings and connections. Call 215-721-9333 to get a physical copy, or click below to download a PDF version.

As a typical zoo mesh for aviary, the stainless steel wire rope mesh is eco-friendly and has good elasticity. According to birds types, the bird aviary mesh can be arbitrarily designed. And with uniform opening, it provides a cozy and free sight.