wire rope 101 supplier

Bergen Cable knows that different applications for wire rope present varying demands for strength, abrasion and corrosion resistance. To meet these requirements, the Fairfield. N.J.-based company produces wire rope in a number of different materials and styles — each with its own ideal applications.

For applications where corrosion is a concern, stainless steel wire rope is the best option. Type 302 (18 per cent chromium and eight per cent nickel alloy) is the most common grade accepted because of its corrosion resistance and high strength. Other frequently used stainless steel types are 304, 305, 316 and 321, each with its own set of pros and cons. Type 305, for example, is used where non-magnetic properties are required; however, there is a slight loss of strength. Users must determine where their priorities lie in the application, and if the compromise is worth it.

For applications where strength is required and corrosion resistance is not great enough to justify the cost of stainless steel, galvanized carbon steel is an option. Wires used in these wire ropes are individually coated with a layer of zinc, which offers some protection from corrosive elements.

In addition to wire rope material, cable construction is also a consideration. The greater the number of wires the strand or cable has, the more flexible it is. A 1×7 or a 1×19 strand, with seven and 19 wires respectively, is used as a fixed member, straight linkage or where flexing is minimal. The 1×7 offers the least stretch, while the 1×19 is fairly flexible and resists compressive forces.

Bergen Cable has the expertise to help its customers select the most appropriate wire rope for their applications. For more information, contact Bergen Cable.

Wire rope and cable are each considered a “machine”. The configuration and method of manufacture combined with the proper selection of material when designed for a specific purpose enables a wire rope or cable to transmit forces, motion and energy in some predetermined manner and to some desired end.

Two or more wires concentrically laid around a center wire is called a strand. It may consist of one or more layers. Typically, the number of wires in a strand is 7, 19 or 37. A group of strands laid around a core would be called a cable or wire rope. In terms of product designation, 7 strands with 19 wires in each strand would be a 7×19 cable: 7 strands with 7 wires in each strand would be a 7×7 cable.

Materials Different applications for wire rope present varying demands for strength, abrasion and corrosion resistance. In order to meet these requirements, wire rope is produced in a number of different materials.

Stainless Steel This is used where corrosion is a prime factor and the cost increase warrants its use. The 18% chromium, 8% nickel alloy known as type 302 is the most common grade accepted due to both corrosion resistance and high strength. Other types frequently used in wire rope are 304, 305, 316 and 321, each having its specific advantage over the other. Type 305 is used where non-magnetic properties are required, however, there is a slight loss of strength.

Galvanized Carbon Steel This is used where strength is a prime factor and corrosion resistance is not great enough to require the use of stainless steel. The lower cost is usually a consideration in the selection of galvanized carbon steel. Wires used in these wire ropes are individually coated with a layer of zinc which offers a good measure of protection from corrosive elements.

Cable Construction The greater the number of wires in a strand or cable of a given diameter, the more flexibility it has. A 1×7 or a 1×19 strand, having 7 and 19 wires respectively, is used principally as a fixed member, as a straight linkage, or where flexing is minimal.

Selecting Wire Rope When selecting a wire rope to give the best service, there are four requirements which should be given consideration. A proper choice is made by correctly estimating the relative importance of these requirements and selecting a rope which has the qualities best suited to withstand the effects of continued use. The rope should possess:Strength sufficient to take care of the maximum load that may be applied, with a proper safety factor.

Strength Wire rope in service is subjected to several kinds of stresses. The stresses most frequently encountered are direct tension, stress due to acceleration, stress due to sudden or shock loads, stress due to bending, and stress resulting from several forces acting at one time. For the most part, these stresses can be converted into terms of simple tension, and a rope of approximately the correct strength can be chosen. As the strength of a wire rope is determined by its, size, grade and construction, these three factors should be considered.

Safety Factors The safety factor is the ratio of the strength of the rope to the working load. A wire rope with a strength of 10,000 pounds and a total working load of 2,000 pounds would be operating with a safety factor of five.

It is not possible to set safety factors for the various types of wire rope using equipment, as this factor can vary with conditions on individual units of equipment.

The proper safety factor depends not only on the loads applied, but also on the speed of operation, shock load applied, the type of fittings used for securing the rope ends, the acceleration and deceleration, the length of rope, the number, size and location of sheaves and drums, the factors causing abrasion and corrosion and the facilities for inspection.

Fatigue Fatigue failure of the wires in a wire rope is the result of the propagation of small cracks under repeated applications of bending loads. It occurs when ropes operate over comparatively small sheaves or drums. The repeated bending of the individual wires, as the rope bends when passing over the sheaves or drums, and the straightening of the individual wires, as the rope leaves the sheaves or drums, causing fatigue. The effect of fatigue on wires is illustrated by bending a wire repeatedly back and forth until it breaks.

The best means of preventing early fatigue of wire ropes is to use sheaves and drums of adequate size. To increase the resistance to fatigue, a rope of more flexible construction should be used, as increased flexibility is secured through the use of smaller wires.

Abrasive Wear The ability of a wire rope to withstand abrasion is determined by the size, the carbon and manganese content, the heat treatment of the outer wires and the construction of the rope. The larger outer wires of the less flexible constructions are better able to withstand abrasion than the finer outer wires of the more flexible ropes. The higher carbon and manganese content and the heat treatment used in producing wire for the stronger ropes, make the higher grade ropes better able to withstand abrasive wear than the lower grade ropes.

Effects of Bending All wire ropes, except stationary ropes used as guys or supports, are subjected to bending around sheaves or drums. The service obtained from wire ropes is, to a large extent, dependent upon the proper choice and location of the sheaves and drums about which it operates.

A wire rope may be considered a machine in which the individual elements (wires and strands) slide upon each other when the rope is bent. Therefore, as a prerequisite to the satisfactory operation of wire rope over sheaves and drums, the rope must be properly lubricated.

Loss of strength due to bending is caused by the inability of the individual strands and wires to adjust themselves to their changed position when the rope is bent. Tests made by the National Institute of Standards and Technology show that the rope strength decreases in a marked degree as the sheave diameter grows smaller with respect to the diameter of the rope. The loss of strength due to bending wire ropes over the sheaves found in common use will not exceed 6% and will usually be about 4%.

The bending of a wire rope is accompanied by readjustment in the positions of the strands and wires and results in actual bending of the wires. Repetitive flexing of the wires develops bending loads which, even though well within the elastic limit of the wires, set up points of stress concentration.

The fatigue effect of bending appears in the form of small cracks in the wires at these over-stressed foci. These cracks propagate under repeated stress cycles, until the remaining sound metal is inadequate to withstand the bending load. This results in broken wires showing no apparent contraction of cross section.

Experience has established the fact that from the service view-point, a very definite relationship exists between the size of the individual outer wires of a wire rope and the size of the sheave or drum about which it operates. Sheaves and drums smaller than 200 times the diameter of the outer wires will cause permanent set in a heavily loaded rope. Good practice requires the use of sheaves and drums with diameters 800 times the diameter of the outer wires in the rope for heavily loaded fast-moving ropes.

It is impossible to give a definite minimum size of sheave or drum about which a wire rope will operate with satisfactory results, because of the other factors affecting the useful life of the rope. If the loads are light or the speed slow, smaller sheaves and drums can be used without causing early fatigue of the wires than if the loads are heavy or the speed is fast. Reverse bends, where a rope is bent in one direction and then in the opposite direction, cause excessive fatigue and should be avoided whenever possible. When a reverse bend is necessary larger sheaves are required than would be the case if the rope were bent in one direction only.

Stretch of Wire Rope The stretch of a wire rope under load is the result of two components: the structural stretch and the elastic stretch. Structural stretch of wire rope is caused by the lengthening of the rope lay, compression of the core and adjustment of the wires and strands to the load placed upon the wire rope. The elastic stretch is caused by elongation of the wires.

The structural stretch varies with the size of core, the lengths of lays and the construction of the rope. This stretch also varies with the loads imposed and the amount of bending to which the rope is subjected. For estimating this stretch the value of one-half percent, or .005 times the length of the rope under load, gives an approximate figure. If loads are light, one-quarter percent or .0025 times the rope length may be used. With heavy loads, this stretch may approach one percent, or .01 times the rope length.

The elastic stretch of a wire rope is directly proportional to the load and the length of rope under load, and inversely proportional to the metallic area and modulus of elasticity. This applies only to loads that do not exceed the elastic limit of a wire rope. The elastic limit of stainless steel wire rope is approximately 60% of its breaking strength and for galvanized ropes it is approximately 50%.

Preformed Wire Ropes Preformed ropes differ from the standard, or non-preformed ropes, in that the individual wires in the strands and the strands in the rope are preformed, or pre-shaped to their proper shape before they are assembled in the finished rope.

This, in turn, results in preformed wire ropes having the following characteristics:They can be cut without the seizings necessary to retain the rope structure of non-preformed ropes.

They are substantially free from liveliness and twisting tendencies. This makes installation and handling easier, and lessens the likelihood of damage to the rope from kinking or fouling. Preforming permits the more general use of Lang lay and wire core constructions.

Removal of internal stresses increase resistance to fatigue from bending. This results in increased service where ability to withstand bending is the important requirement. It also permits the use of ropes with larger outer wires, when increased wear resistance is desired.

Outer wires will wear thinner before breaking, and broken wire ends will not protrude from the rope to injure worker’s hands, to nick and distort adjacent wires, or to wear sheaves and drums. Because of the fact that broken wire ends do not porcupine, they are not as noticeable as they are in non-preformed ropes. This necessitates the use of greater care when inspecting worn preformed ropes, to determine their true condition.

You might be surprised to learn that industrial cable has been around for thousands of years. Metal wires are mentioned in ancient textsdating back to 4000 BC, and archeologists have found industrial cables made of bronze used in Pompei!

The construction of industrial cable may have changed a bit over the past few millennia, but many of the properties of these steel wires has remained. Over the years, we have discovered ways to create more sturdy cables by adding iron alloys like Chromium to create stainless steel cables. Cables now also come in a range of sizes, lengths, and diameters to optimize their use for specific applications.

First and foremost, we need toexplain the differencesbetween wire ropes and industrial cable. While both of these pieces of hardware share many similar properties, they should not be used interchangeably. Yes, industrial cables are made of wires, but they are not the same as wire ropes.

Wire ropes are constructed from wires that are woven together similarly to a fabricated rope. This creates a flexible but strong material that can be used to add support to an object. This is why wire ropes are primarily used for overhead lifting or securement and tie-downs.

Industrial cables on the other hand tend to be much thinner than wire ropes and much more flexible. They can be wrapped around or threaded through hooks and loops to hold items in place and are used for more permanent fixtures.

Just like wire ropes, industrial cables are constructed from strands made of a number of wires wrapped together. The general rule of thumb here is that the more wires in a strand or the more strands in the cable, the more flexible it will be.

Most steel cables are available in either a 7×7 or 7×19 construction. The first number communicates the number of strands used in the cable, while the second demonstrates the number of wires per strand. A 7×7 cable has 7 strands of 7 wires, while a 7×19 is 7 strands made of 19 wires each.

The interior strand of an industrial cable creates a supportive structure for the strands to wrap around. This core may be made of fibers, like hemp or polypropylene, wire strand, or an independent wire rope core (IWRC). Fiber cores are quite flexible, but not very durable and not recommended for heavy-duty applications. Wire ropes or IWRC add strength and crush resistance, making them ideal for construction use.

Another key categorization for cables is the material used to construct the wires. While industrial cables are always made from steel, there are different grades and finishes offered.

This is a ratio that compares the strength of the cable or wire rope to the working load. This helps to create a safety net for additional factors that can place stress on the cable, such as the speed of movement, friction, and types of fittings.

Frequent movement and abrasion on the wires of a cable will eventually damage the cable, compromising its strength. Be sure to consider the load and stress factors placed on the cable, such as load shock, friction, and constant bending.

Industrial wire rope is an incredibly important piece of equipment. It is used to secure or lift thousands of pounds, so you’ve got to make sure that you are only buying the highest-quality product from your industrial wire rope supplier.

There are lots of distributors and wholesalers offering a variety of wire ropes – but you shouldn’t trust all of them. Sadly, some suppliers will cut corners with their inventory to increase their profits. This could mean that you get a shoddy product, which could be quite dangerous depending on how you intend to use it.

Apart from the quality, you also have to consider the experience that your industrial wire rope supplier provides. You want a distributor who is helpful and trustworthy, not one that just views you as another source of income.

Although most wire ropes are made from stainless steel, there are many types and sizes of these industrial cables. Several categories differentiate the types of wire ropes, which include:

You want to make sure that your wire rope supplier has a good, so you can find the exact one you need, depending on its application. You should look for a wholesaler who offers lots of options for bright, galvanized, and stainless-steel styles with varying diameters, construction, and core options.

Most wire ropes are used in conjunction with other hardware. For instance, wire rope used for overhead lifting requireslike hooks, shackles, swivels, and hoists. You may also need sleeves or clips to hold the wire rope in place, or links to connect two strands together.

Again, quality and variety are of the utmost importance here. You want to buy from an industrial hardware supplier that sells top-quality products from good materials,. Be sure that your distributor has the right pieces and sizes on hand so you can get your wire ropes and necessary accessories all from one place.

Unless you are a wire rope expert, chances are that you don’t know what all of the abbreviations and numbers mean on a wire rope description. Terms like ‘FC’, ‘IWRC’, or ‘WSC’ don’t make sense to most people. And trying to find a wire rope that meets all of your specifications for a specific project can be quite confusing if you aren’t given much information.

Another signal that you’ve found a good wire rope supplier is that they provide detailed descriptions and definitions for their products. This will help you narrow down your selection without having to get on the phone with their customer service to ask questions.

Although many wire rope distributors offer shipping, it is generally best to pick a supplier who has distribution centers as close to your location as possible. This will cut down on shipping costs as well as delivery times – which is great if you’ve got last-minute orders or tight project deadlines.

Of course, another consideration to keep in mind is shipping rates and costs. Suppliers have different systems here. Some require a total minimum order for a flat shipping rate, while others adjust it based on weight or size. Make sure you inquire with your wire rope distributor about their rates and see if they have order minimums.

You’ll want to find every indication possible that a wire rope distributor is knowledgeable about the products they offer. A good supplier will offer lots of valuable information and resources to their customers to ensure the products are used safely.

Another sign that the wire rope supplier you’ve chosen is reliable and trustworthy is through any earned affiliations and recognitions. This signals that the company is recognized by other organizations for its product and business standards.

You don’t want to take more time finding a new wire rope supplier after the first one provides terrible service. So, make sure that you test it out ahead of time. First, look for information about customer service experiences in online reviews. You can also test it out yourself by phoning in or sending an email. See how long it takes to get a response and how friendly and helpful they are. This will be a pretty good indication of the level of service you can expect.

Finally, make sure that your wire rope wholesaler actually knows what they’re talking about. You shouldn’t have to do all the research on your own when finding the right type and size of wire rope. Plus, you’ll likely want a second opinion to make sure you’ve got all the right specifications and hardware.

Finding a reliable, trustworthy, and overall fantastic wire rope distributor can be challenging. That’s why here at Elite Sales, we do all that we can to meet and exceed our customer’s expectations.

We offer a vast selection of wire ropes and accessories with lots of information and resources for this equipment. Our team of experts is also just a phone call away to answer questions and help you place an order.

ISO 9001:2000 certified manufacturer & distributor of standard & custom rigging equipment & supplies including non-rotating ropes & wire preformed ropes. Types include stainless steel wire ropes, galvanized carbon steel wire ropes, vinyl coated stainless steel wire ropes, vinyl coated galvanized steel wire ropes, nylon jacket galvanized steel wire ropes & nylon jacket galvanized steel Military Spec. wire ropes. Wire ropes are available in strand configurations including 1 x 19, 7 x 7 & 7 x 19 in different dia. & working load limits. Wire ropes are available in spool lengths ranging from 500 ft. to 5,000 ft. 1 x 19 stainless steel wire ropes are available in wire rope dia. ranging from 3/32 in. to 1/4 in.

Other rope construction and/or end-terminations such as master links, shackles, hooks, etc.. possible on request. In that case, please check our website for more standard wire rope slings. You can also contact us to discuss the possible options or specify it with your request.

Other rope construction and/or end-terminations such as master links, shackles, hooks, etc.. possible on request. In that case, please check our website for more standard wire rope slings. You can also contact us to discuss the possible options or specify it with your request.

Bridon-Bekaert Ropes Group concludes investment and commercial partnership with TFI Marine, Dublin, Ireland, to accelerate the go-to-market of digital-enabled mooring solutions

When wire ropes were first invented, they represented a significant leap forward in technology. Industries needed cords that were long and strong and wouldn’t fatigue under constant strain.

Wire ropes material properties provided an alternative to existing cords and worked better in many applications by allowing the tension to be distributed more evenly over the interior surfaces of the rope. So what are the steps to wire rope construction, and how do they help make rope strong?

Wire rope construction begins with steel wires. Typically, the steel wires range from 0.6 to 8 mm in diameter. The wires are wound together into a strand. Different applications require different types of wire rope strands, depending on strength and flexibility requirements.

Once the number of wires and their thickness has been determined, the wires are loaded onto a stranding machine—a device which rotates the strands, winding them together.

Stranding machines can support up to 62 wires in a strand. Most strands, however, are made from between 19 and 36 wires, suitable for the majority of wire rope classifications.

The winding process depends on a lubricated die, a kind of opening at the end of the strand winding machine which collects all the wires and determines the thickness of the strand.

The lubrication plays anessential role. Not only does it prevent friction damage to the strand as it spins in the die, but it also gets in between the individual fibers, providing lubrication while the wire rope is in operation.

Once the wound wire strand comes out of the stranding machine, it is fed through a skimmer. The skimmer removes excess oil, preparing the wire for the next step in the manufacturing process.

Individual wires have a “material memory”—they know that they began life in an unwound state. To convince the material that it should stay in the wound state, manufacturers feed it through straighteners, large concrete or steel wheels, which press the wire into place. Straighteners prevent the wires from unraveling once it exits the stranding machine.

Manufacturers collect the newly minted wire strands in a large spool. The purpose of this is to protect the wire rope during transit and to ensure that it does not bend more than tolerances allow.

Some applications require cords with substantial tensile strength, such as in agriculture and shipping. Strands can be wound together to make a thicker, stronger wire rope, capable of supporting more weight in a machine called a closer.

Wire rope, like wire strands, may not have uniform thickness and consistency. Calibration rollers pressure the rope into the desired shape as it comes out of the closer. Rope is then fed into a reel, ready for shipping.

Companies ensure that their cables meet the requirements of their customers by subjecting them to pulling tests. They use a machine that pulls on the wire until it snaps, measuring the tensile strength. Ropes must be able to support loads more than their claimed tolerances. In some applications such as mining, ropes are covered in protective plastic to reduce wear and tear.

Silver State Wire Rope and Rigging has provided the highest quality or well-constructed wire rope for over 20 years! We know the all the steps of the process and how to check for quality assurance to make sure your rope is the safest it can be. We providewire rope servicesfocused on entertainment, mining, and utility. If you’re interested in our expertise,contact us todayto get an estimate!

Our services include stocking and manufacturing of wire rope slings, chain slings, swing and escape ropes, and now nylon slings. We stock a large variety of rigging gear and hardware. Our inhouse services include inspection, test, and certifying of slings and rigging gear. We also offer on-site inspection of rigging, of rolex replica slings and rigging gear. We also offer on-site inspection of rigging, and pickup and delivery.

Wire Rope Clips can have lots of helpful uses – they are a simple fitting that can be easily used in the field or shop.  Sometimes called a u-bolt or u-bolt clip, they can be used to join two wire rope ends together, make an eye for a pulling application, or to secure the loose end of a wire rope after a wedge socket (or other appropriate device) has been used to terminate a crane’s hook.

But using clips to create wire rope slings for overhead lifting is NOT one of their many uses. Did you know that not only is it a poor rigging practice to fabricate slings in this manner, in the U.S. it is against the law?

ASME B30.9 states that wire rope clips shall not be used to fabricate wire rope slings, except where the application of slings prevents the use of prefabricated slings.

ASME B30.9 states wire rope clips shall be drop-forged steel of single saddle (u-bolt) or double saddle clip. Malleable cast iron clips shall not be used.

Why these restrictions? Wire rope clips diminish the working load limit of the wire rope to generally about 70-75% of its original strength.There are better and more efficient ways to fabricate slings for overhead lifting.

For situations where use of wire rope clips are approved, it’s important to remember the proper way to install the clips. Incorrect installation can reduce the working load limit by 40% or more. The easiest thing is to remember, “never saddle a dead horse.”

The saddle of the clip is the piece that the U bolt fits into. The dead end of a wire rope is the end of the eye that contains the cut side. The U bolt should always be in contact with the dead end, while the saddle should be on the live end.

In addition, for clips to work properly and gain their design efficiency, the proper number of clips is required and the nuts must be torqued as prescribed by the manufacturer. For more information on proper installation, check out this video from the Crosby Group.

If you have more questions on wire rope clips, comment below. Remember that Safety through Education is more than just our motto, it is our guiding principle. If you need training on proper application on any other rigging hardware, reach out to us. We are here for you.

6x7 construction general purpose wire rope is available with either FC (fibre core) or WSC (wire strand core). When supplied with a WSC the rope is more commonly referred to as 7x7. The rope is very popular in smaller diameters from 0.5mm to 2mm where the cable remains very flexible. 6x7 ropes become quite rigid in the larger diameters and are often considered stiff in diameters 6mm and above. In these diameters they tend to be used for applications where the rope is omit/not working. A typical example being a mast stay. 7x7 construction is readily available in both galvanised and marine grade stainless steel.