what is the difference between strand and wire rope quotation

Wire rope and cable, is there a difference? The terms are often used interchangeably, but are they different? Each is considered a machine. Wire ropes are usually ⅜” in diameter or larger, while cables or cords are smaller. Though this little distinction exists in aircraft and marine cables, wire ropes and cables are synonymous in most other ways.

A strand is made up of two or more wires twisted around a center wire. Each strand is made up of 7, 19, or 37 wires. Cable or wire rope is made when a group of strands is twisted around a center wire or rope. They are named for the numbers of wires and strands. A 7×7 cable has 7 strands with 7 wires in each strand wrapped around a central core. A 7×19 cable would include 7 strands with 19 wires in each cable.

Different wire rope applications require different demands for abrasion, strength, and corrosion resistance. Different materials are used to meet different needs. Sizes under ⅜ “ are considered aircraft cable, sizes over 3/8 “ in diameter are considered wire rope.Stainless Steel – Type 302, made up of 18% chromium and 8% nickel alloy, is the most common grade because of its high strength and resistance to corrosion. When non-magnetic properties are required, type 305 is employed. Other common types used in wire rope are 304, 305, 316, and 321. Each has specific advantages and disadvantages. Stainless steel is the stronger of the two, so its cost is higher but well worth it.

Galvanized Carbon Steel – To protect from the elements, a coating of zinc is applied to wire ropes used in the making of this wire rope. It is the wire rope of choice when strength is necessary, but corrosion resistance is not significant enough to warrant the use of stainless steel. Galvanized carbon steel is the go-to for cost-effectiveness.

If you require flexibility, you need wires that have more strands, more strands equal more flexibility. Look for 3×7, 7×7, and 7×19; these will give you more flexibility. However, as the degrees of flexibility increase, the abrasion resistance decreases. These cables are most useful where you require continuous flexing. Basic cable construction:

1×19 cable – This cable is still reasonably flexible, yet it resists compressive forces. It is smooth on the outside, and sizes above 3/32” diameter are the strongest.

It is essential to correctly estimate the qualities necessary for the work the wire rope will be doing. To decide the importance of the essential attributes to do the job, you need to look for quality and figure out whether it can withstand how it will be used and the length of time it can be used in this capacity. In choosing a wire rope for the job at hand, these four things must be considered:Sufficient strength to lift the load and then some, keeping safety in mind. Always overestimate.

Whether it is a crane, a pulley, or some other machine, be sure to choose the proper size, construction, and grade of wire rope appropriate for the job.

To find the wire rope or cable you need for the job, contact us atSilver State Wire Ropefor all of your wire rope and rigging needs. We have all sizes of cable and wire rope; whether you need it for aircraft, marine, or land use, we have it all!

Have you ever wondered why aircraft cable is called aircraft cable instead of aircraft strand? Do you use the words cable and wire rope interchangeably when you’re not sure which is correct? The world of manufacturing is chock-full of words to describe wire products, and while it may seem confusing to keep track of them at first, having some background knowledge about cable construction will help you understand each component. Let’s take a moment to differentiate our terms by starting small.

Wire: In its simplest form, wire is a single, flexible, string-like rod. It begins life as a metal such as stainless steel or carbon steel that becomes narrower in diameter as it is drawn through a series of small holes called dies. Used in everything from electrical equipment and coat hangers to art projects and nails, wire is the foundation of many wide and varied items.

Strand: Strand is made of two or more wires laid around a single center wire. In general, “1 by…” products are considered strand, like 1x7 and 1x19, which are two common configurations.

Notice how this 1x7 strand is a unit comprised of individual wires. It is 1 strand of 7 wires.1x19, as another example, is 1 strand of 19 wires. Like wire,strand can exist as its own product, or it can be laid around a core in multiples to become cable or wire rope.

Cable:Cables are made by concentrically wrapping groups of strands. A 7x7 cable, for example, is comprised of seven strands, each made of 7 wires. 7x19 cable, as another example, has seven strands with 19 wires in each one. Wire rope is technically also a group of strands wrapped around a core, which is why the terms cableand wire rope are often used interchangeably. Professions will argue that wire rope is designated for products with a diameter larger than 3/8 inch while cableis designated for all smaller diameters, but in practical application, the terms are somewhat interchageable.

Looking for wire, strand, or cable for your application? Make sure that you specify the size, construction, and material of a product when building your quote on www.strandcore.com. Luckily, Strand Core provides comprehensive data sheets for all our aircraft cable and general purpose wire rope products to help make your selection easier. Visit https://strandcore.com/products/general-purpose-wire-rope/ to start browsing our wire rope products, today.

When buying wire rope, cable, and strandproducts, specification numbers are often listed in the description. While these numbers are significant resources, they have little meaning without knowing the requirements and details of each number. Strand Core offers products that conform to nine different specifications. By understanding the various specs, you will be able to shop for the exact requirements you need. We hope this brief guide makes getting the perfect product just a little bit easier.

This specification explains the requirements for flexible wire rope designed for aircraft control. MIL-DTL-83420 covers the requirements of carbon steel and corrosion-resistant steel for the wire rope. There are two different types of MIL-DTL-83420 Wire Rope, Type I (Non-jacketed Wire Rope) and Type II (Jacketed Wire Rope). Both Types must perform to specified levels for characteristics such as breaking strength and stretch limits.

This specification explains the requirements of non-flexible wire rope used in aircraft applications. MIL-DTL-87161 covers the requirements for carbon steel and corrosion-resistant steel for the wire strand used in aircraft application other than over sheaves. The two types of wire rope are Type I (non-flexible, 1x7 class) and Type II (non-flexible, 1x19 class). Both Types have two Constructions, one for Right Lay and the second for Left Lay. There are two composition types of the wire rope. Composition A is made of carbon steel that is zinc coated. Composition B is made of corrosion-resistant steel.

MIL-DTL-18375 covers the requirements for corrosion-resistant, nonmagnetic steel wire rope used in aircraft flight controls. The wire rope can operate within a -65 Degree F to +250 Degree F temperature range in dust, fuel, wind, and oil spills, in wash-down and other environmental stresses and aircraft experiences. All MIL-DTL-18375 wire rope must meet the breaking strength, endurance, stretch limits, ductility of steel, test load, magnetic permeability, and operating temperature range.

MIL-DTL-83140 covers the requirements for rotation-resistant preformed stainless steel wire rope intended for aircraft rescue hoists, utility, retrieval hoists or winching applications. The preformed stainless steel wire rope is available in two types. Type I is a rotation-resistant 19x7 construction that is used for hoisting (vertical) operations. Type II is a rotation-resistant 10x7 construction (7x19 IWRC) used for winching (vertical, horizontal, or at-angle) operations.

RR-W-410 covers wire ropes and wire seizing strands. The specification does not include all types of wire ropes and seizing strands but covers the most common classes, types, constructions, and sizes best suited for federal government use.

This specification covers stranded carbon steel wire ropes used for general purposes. ASTM A1023/A1023M covers various grades, constructions, and performance requirements.

All nine specifications are important to keep in mind when shopping for wire rope, cable, and strand products. Knowing the various specs means you can shop for the exact requirements you need. Strand Core recommends buying wire rope, cable, and strand that meets specific specifications, to ensure you buy a high-quality product that is thoroughly tested and capable of performing at top levels.

To find out more about each of these specifications, please visit our Specifications page here. Or check out our products page to find the wire rope, cable, or strand product for you at strandcore.com. If you have any questions, our team is happy to help! Reach out to us by email through sales@strandcore.com, or by phone at 800-983-9926.

Understand that most of the people out from the industry always face the problem of having no idea with the terms of wire rope when receiving quotation. In this update, we will explain in the most simple way and hopefully it is applicable to anyone.

6X36 = Construction of wire rope (There are quite a lot different constructions available for different application for example like, 6X25, 6X29, 6X31, 4X39, 19X7, 8X26 etc.)

RHOL = Right hand ordinary lay, it is the wire lay direction and very important to select the right direction of wire when dealing with multi-reeving, crane and hoist application.

EIPS (1960) = Extra improved plow steel and 1960 stands for the tensile strength 1960N/mm2. The figure is telling you the grade of wire rope, lower or higher tensile strength will result in different breaking strength.

UNGALVD = Ungalvanized, the surface finishing of wire rope. Galvanized and Ungalvanized are the basic surface finishing selection with different grade of lubrication.

G411 THIMBLE EYE = Thimble eye model. Soft eye will be stated with the effective working length and the size of soft eye is based on nominal diameter x 15times according to EN131411 standard.

MECH SPLICED = Mechanical splicing is the process of using hydraulic pressure to press the aluminum sleeve or metal sleeve and a loop is formed. This phrase is always telling you the terminal of both end wire rope. It can be plain, socketed, fuse tapered or eye formed.

Wire rope could have a lot of variation upon the application which I will cover in the next update. The essay above is good enough to tell the basic and hope it helps for procurement department while dealing with steel wire rope. Last but not least, selecting the right wire rope is crucial to your company"s long term expenditure and safety purposes. Do not take the risk because of cheap.

Ropes and wire strands are metallic components used to carry and move objects and loads and to convey, lift, tension and hold elements in different applications, from elevators to suspension bridges. Ropes and strands can also be used to transmit force and mechanical power.

Wire rope properties include a high load-carrying capacity combined with flexibility and elasticity as well as high durability and wear resistance and favorable permanent bending cycle properties. Steel wire ropes ensure a reliable function and long useful life at temperatures between -40° C and +250° C. The selection of steel wire ropes for end-use applications depends upon the load bearing capacity as well the lifespan. With increasing number of wires, the strength of the rope and its flexibility are growing.

Depending on the area of ​​application, also ropes made of certain non-ferrous metals and other materials such as synthetic fibers are used. Furthermore, combinations of different materials, metal wires with natural or synthetic fibers are possible. For certain applications ropes are sheathed with plastic coatings.

Hemp ropes, however, were expensive and could only be applied in dry pits. The iron chains, on the other side, were highly stressed by the continuous winch up and down processes and failed totally when the proverbially weakest link broke – very often with catastrophic consequences. Therefore, Wilhelm August Julius Albert, an official of the German Board of Mines and adviser for the mining, was looking for a replacement for the conveyor chains.

Albrecht, who became also the founder of wire rope research, developed a steel wire rope which consisted of three strands. Each strand was built up by four wires, each 3.5 mm in diameter. The wire rope had a diameter of approximately 18 mm.

The Albert Rope had six times the load capacity of a hemp rope of the same diameter and four times the load capacity of a chain eight times as heavy. The wire rope was successfully tested on July 23, 1834 in a 484 m mine shaft at Clausthal, Germany [Roland Verreet: „A short history of steel wire ropes“].

Wire ropes are used in many technical areas. According to the main uses and the acting forces, wire ropes can be divided into four main groups: wire rope slings, track wire ropes, running wire ropes, and stationary or structural wire ropes.

Wire rope slings are used to harness goods. These slings are stressed by the tensile forces and by bending stresses when they are bent over the edges of the goods.

Track wire ropes are full-locked ropes with a plastic coating which act as rails for the rollers of cabins or other loads in aerial ropeways. While track wire ropes carry the loads, haulage (or traction) ropes pull them. These ropes are used dynamically and thus belong to the group of running wire ropes. As they are running above sheaves, drums or traction sheaves, they are mainly stressed by bending and secondly by tension. Further well-known application examples are elevator ropes which lift and lower elevators and haulage ropes used in lifting and conveying systems such as cranes.

Thin steel wire ropes (also called “cables”) are often used to transmit force in mechanisms and initiate switching and safety functions in technical components. One example are the pull ropes used under the name “Bowden cables” which are applied on two-wheelers for switching or braking processes. Such ropes are also used in airplanes where they connect the cockpit levers and pedals with the movable parts of the wings and other components. Furthermore, the function of sun protection awnings and photocopiers is based on fine wire ropes. Wire ropes are also used as saw strands, for example in medical technology, or as diamond wire ropes in quarries. Finally, conveyor belts, V-belts and the tires of vehicles are reinforced by inserted wire ropes.

Stationary or structural wire ropes are anchored at two fixed points and have to carry static and fluctuating tensile forces. Such ropes, mostly full-locked, are used to support structures such as suspension bridges or stadium roofs.

Friction between the individual wires and strands of a steel wire rope helps to compensate minor failures in the short run but causes wear over the life of the rope. Therefore, wire ropes must be inspected at regular intervals and at the latest be replaced when their discarding time is reached.

Wire ropes are several strands of metal wire that are twisted into a helix to form a composite rope, known as a laid rope. Large diameter wire rope consists of several strands of rope laid in what is known as cabling. Wire ropes are complex mechanical devices consisting of several moving parts that work together to help support & move an object or load.

In the lifting & rigging industries, wire rope is attached to a crane or hoist & fitted with a swivel, shackle, or hook to attach to a load and move it into a controlled case. It can also be used for lifting and lowering elevators or as a means of support for suspension bridges or towers. Wire rope is a preferred lifting tool for many reasons.

Its unique design consists of several steel wires that form separate strands placed in a helical pattern around a core. These structures provide strength, flexibility, & the ability to handle bending stresses. In the strictest sense, the term wire rope refers to a diameter larger than 3/8 inch (9.52 mm), with a smaller gauge specified cable or cord.

Initially, iron wires were used, but today the main material used for wire ropes is steel. Wire rope is made from cold-drawn wires to increase strength & durability. It may be noted that as its size decreases, the strength of the wire ropes increases.

The various materials used for wire ropes are iron, cast steel, extra strong cast steel, steel, and alloy steel, in order of increasing strength. For some purposes, wire rope can also be made from copper, bronze, aluminum alloys, and stainless steel. Wire ropes were developed in the 1830s with mining hoist applications.

Wire ropes are used in cranes and elevators for dynamic lifting and lifting and for transmission of mechanical power. It is also used to transmit forces to mechanisms, such as Bowden cables or the control surface of an airplane connected to levers and pedals in the cockpit.

Wire rope is made of threads of metal wire that are braided together to form a helix. Due to its heavy, flexible and tough characteristics, as well as being weather- and corrosion-resistant, it is commonly used in the building and construction, engineering, agriculture, aircraft, and marine industries.

Each wire strand bringing equal pressure to the bundle contributes to its strength and flexibility, making it an ideal material for pulleys. In Australia, wire rope was made of iron; Today, the materials used are mainly steel. Different industries use different types of wire ropes.

This is because the suitability of a specific wire rope for an application depends on the design, size, type of braids, and other characteristics. For example, marine-grade 316 wire rope is suitable for a variety of marine applications and settings.

Stainless steel is the standard alloy used in rope and cable. Its resistance to corrosions is much higher than that of galvanized & coated ropes, although there are no differences in strength. Therefore, it is the preferred material uses in marines and water-based salt industries.

It does not readily react to chemicals from food processing, textiles, and photographic settings. Its high resistance to corrosion, heat & cold, and pulp & paper chemicals makes stainless steel wire rope a much-needed material for manufacturing precision instruments, automobiles, fishing vessels, petrochemical equipment, & other fields.

Galvanized wire ropes are also steel wire materials that have undergone a galvanizing process to increase their corrosion resistance. The finished wire is immersed in a zinc bath to coat the product completely, i.e., it is galvanized.

Zinc is used in this process because cathode protection increases the life expectancy of the wire. Although the coating will degrade over time, it is still resistant to rust, corrosion, and other harsh chemicals. Galvanized wire can be found in the industrial and construction sectors as well as in agricultural and DIY projects.

Stainless steel and galvanized wire can be PVC coated with poly-vinyl-chloride or vinyl. Coated wire rope comes in various colors such as clear, black, white, or any other color that is required in various industries. PVC coated wire is flexible, weather-resistant, and very cost-effective.

Nylon-coated wire, although not as flexible as PVC, is abrasion-resistant and ideal for businesses in extremely cold regions. Wire ropes can be assembled to suit specific applications. If you have a project requiring a specific type of wire rope, send us an inquiry, and we’ll send you a special quote.

The wire is the smallest component of wire rope, and they form the individual strands in the rope. Wire can be made from a variety of metal materials, including steel, iron, stainless steel, Monel, and bronze. Wires can be manufactured in varieties of grades that are related to wire rope strength, wear resistance, fatigue resistance, corrosion resistance, and curve.

These strings symbolize the smallest component of a wire rope and are tied together around a core to form complete wire ropes. The wire themselves can be coated but are usually available in “bright” or uncoated finishes.

Wire rope strings form two or more wires wrapped around an axial member in a geometric pattern or in combination with steel wires and other materials. These individual strands are then placed around the core in a helical pattern. Strands represent the major part that serves as the primary load-bearing unit.

A typical strand can form any number of strands, and the same goes for a rope that can have an ‘n’ number of strands. Wires made from larger diameter wires are more resistant to abrasion, while wires made of smaller diameter wires are more flexible.

The core of a wire rope runs through the center of the rope & supports the wires and helps them maintain their relative position under loading and bending stress. Cores can be made from many different materials, including natural or synthetic fibers and steel. It supports the strands and helps maintain their relative position under loading and bending stress.

Wire ropes are made from the various grades of steel wires with tensile strengths ranging from 1200 to 2400 MPa. The wires are first given special heat treatment & then cold drawn for the high strength and durability of the rope. Steel wire ropes are manufactured by special machines.

First, strands of wire such as 7, 19, or 37 are routed into a single strand, and then several strands, usually 6 or 8, are twisted around the core or center to form a rope. The core may be made of loops of hemp, jute, mica, or soft steel wire.

The core must be continuously saturated with lubricants for the long lives of the core as well as the entire rope. Asbestos or soft wire core is used when a rope is subjected to radiant heat, such as cranes working near furnaces.

However, a wire core reduces the rope’s flexibility, and such ropes are only used where they are subject to high compression, as in the case of multiple layers being injured on a rope drum.

The number of layers of wires, the numbers of wires per layer, & the size of the wire per layer all affect the strand pattern type. Wire ropes can be constructed using any one of the following patterns or can be made using two or more of the pattern below.

The Two-layer of similarly sized wire around a center whose inner layer is half the number of wires as the outer layer. Small fillers wires, equal to the numbers in the inner layer, are placed in the valleys of the inner wire.

Two layers of wires around centers with the same numbers of wires in each layer. All wire in each layer is of the same diameter. The larger outer strings rest in the valleys between the smaller inner strings.

The inner layer consists of two layers of wires around a center with one diameter of the wire, and the latter alternates two diameters of the larger and smaller wire in the outer. The larger wires in the outer layer are placed in the valleys & the smaller ones on the crowns of the inner layer.

On a prefabricated wire rope, the wire and wire are formed during the manufacturing process into the helical shape that they will take into a finished wire rope. Prefabricated rope can be beneficial in some applications where it needs to be spooled more evenly over the drum, more flexibility is required, or greater fatigue resistance is required when bending.

Direction and laying type refer to how the wires are laid to form a strand, either right or left & how the strands are laid around the regular core lay, lang lay, or alternate lay.

The wires are lined up with the axis of the rope. The direction of the wire held in the strand is opposite to the direction in the strand lay. Regular lat ropes are more resistant to crushing forces, are more naturally rotation-resistant, and also have a better spool in the drum than lang lat ropes.

The wires make an angle with the axis of the rope. The wire lay down, and the strand lay around the core in the same direction. Lang le ropes have greater fatigue resistance and are more resistant to abrasion.

A fiber core may be made of natural or synthetic polypropylene fibers. Fiber cores offer greater elasticity than steel cores but are more susceptible to crushing and are not recommended for high heat environments. A steel core can be independent wire ropes or an individual strand.

Steel cores are bests suited for applications where the fiber core cannot provide adequate support or in an operating environment where temperatures may exceed 180 degrees Fahrenheit. Based on what we have learned above, this wire rope description will provide the following information to the user:

Wire rope classifications provide the total number of wires in each strand, as well as the nominal or an exact number of wires. These are general classifications & may or may not reflect the actual constructions of the strands. However, all wires rope of the same size & wires grade in each classification will have similar strength and weight ratings and generally similar pricing.

Some types of wire rope, particularly lang le wire rope, are more susceptible to rotation under load. Rotation-resistant wire rope is designed to resist twisting, spinning, or twisting and can be used in a single-line or multi-part system. Special care should be taken when handling, unrolling, and installing rotation-resistant wire rope. Improper handling or spooling can introduce a twist in the rope, which can lead to uncontrolled twisting.

Compact Strand Wire Rope is manufactured using strands that have been compacted, by means of passing through a die or rollers, reducing the outside diameter of the entire strand. This process occurs before the rope is closed. This process flattens the surfaces of the outer strands in the strand but also increases the density of the strand.

This resulted in a smoother outer surface and increased strength compared to comparable round wire rope compare similar diameters and assortments while also helping to increase surface life due to increased wear resistance.

A swaged wires rope differs from a compacted strand wires rope in that the diameter of a swaged wire rope is compacted or reduced by a rotary swagger machine after the wire rope is closed. A curved wire rope can be manufactured using rounded or narrower wires.

The advantages of a swaged wires rope are that they are more resistant to wear, has better crushing resistance, and has higher strength than a round strand wire rope of similar diameter and assortment. However, a swaged wire rope may have low bending fatigue resistance.

The plastic coating may be applied to the outer surface of a wire rope to provide protection from abrasion, wear, and other environmental factors that can cause corrosion. However, because you can’t see the individuals strand & wires beneath the plastic coating, they can be difficult to inspect.

Plastic-filled wire ropes are fitted with a plastic matrix where the wires and the internal spaces between the wires are filled. Plastic fillings help improve bending fatigue by reducing wear internally and externally. Plastics-filled wire rope is used for demanding lifting applications.

This type of wires rope uses an independent wires rope core (IWRC) that is either filled with plastics or coated in plastic to reduce internal wear & increase bending fatigue life.

Strands of wire rope consist of two or more wires arranged and twisted in a specific arrangement. The individual strands are then laid in a helical pattern around the core of the rope. Strands made of larger diameter wires are more resistant to abrasion, while strands made of smaller diameter wires are more flexible.

The Three Basic Wire Rope Components · Fiber Core (F.C.), usually polypropylene, sometimes hemp (H.C.) and sisal, Independent Wire Rope Core (IWRC), Wire Strand Core (WSC)

The term cable is often used interchangeably with wire rope. However, in general, wire rope refers to diameters larger than 3/8 inch. Sizes smaller than this are designated as cables or cords. Two or more wires concentrically laid around a center wire are called a strand.

The term cable is often used interchangeably with wire rope. However, in general, wire rope refers to diameters larger than 3/8 inch. Sizes smaller than this are designated as cables or cords. Two or more wires concentrically laid around a center wire are called a strand.

A fiber core can be made of natural or synthetic polypropylene fibers. Fiber cores offer greater elasticity than a steel core but are more susceptible to crushing and not recommended for high heat environments. A steel core can be an independent wire rope or an individual strand.

Rotation-resistant wire rope refers to a series of steel ropes that minimizes the tendency to spin or rotate under load. These wire ropes boast a special design – the outer layer is twisted in the reverse direction of the inner layers for counteracting torsional forces generated from multi-layers of strands.

The helix or spiral of the wires and strands in a rope is called the lay. Regular lay denotes rope in which the wires are twisted in one direction and the strands in the opposite direction from the rope. The wires appear to run roughly parallel to the center line of the rope.

Left hand lay or right hand lay describe the manner in which the strands are laid to form the rope. To determine the lay of strands in the rope, a viewer looks at the rope as it points away from them. If the strands appear to turn in a clockwise direction, or like a right-hand thread, as the strands progress away from the viewer, the rope has a right hand lay. The picture of steel wire rope on this page shows a rope with right hand lay. If the strands appear to turn in an anti-clockwise direction, or like a left-hand thread, as the strands progress away from the viewer, the rope has a left hand lay. (The rope in the left hand lay photo shows one left hand lay rope from left to right and top to bottom, with 5 right hand lay strands, and part of a sixth in the upper left. It is not 5 right hand lay ropes adjacent to each other.)

Ordinary and Ducay"s lay describe the manner in which the wires are laid to form a strand of the wire rope. To determine which has been used, first identify if left or right hand lay has been used to make the rope. Then identify if a right or left hand lay has been used to twist the wires in each strand. (On ordinary lay, the outer wires approximately follow the alignment of the rope: with Lang"s lay they are cross at an angle of about 45�.) Lang"s laid rope is able to flex over sheaves more easily (with less damage) but it has the disadvantage of having a high torque tendency (it tends to untwist when tension load is applied) compared with ordinary laid rope. Untwisting can be dangerous with a steel-cored rope: load is shed from the strands and may cause the core to fail as it becomes higher loaded. For this reason, swivel termination units can be dangerous.

The specification of a wire rope type � including the number of wires per strand, the number of strands, and the lay of the rope � is documented using a commonly accepted coding system, consisting of a number of abbreviations.

Wire rope is the term assigned to diameters greater than ⅜”, although most engineers refer to wire rope as anything ¼” or greater. By comparison, mechanical cable refers to product that is smaller than ⅜” and, as a matter of fact, Sava manufactures what is known as ultrafine cable and it is as small as .004”. For context, miniature or, as mentioned, ultrafine cable that is .004” in diameter is comparable to the thickness of a sheet of paper.

Wire rope (and mechanical cable) is made when a group of stranded metal extrusions are twisted in a helical manner, around a center wire, or another internal helix. Wire rope is typically named for its strand construction, such as a 19x19 wire rope, which consists of 361 individual filaments or wires. An important distinction to make however, is that this same 19x19 wire rope, becomes miniature or ultrafine mechanical cable once it is made in diameters less than ⅜”.

The Brooklyn Bridge is suspended using four, 15.75” wire ropes made from galvanized steel. That’s some huge wire rope. Alternatively, Sava produces ⅜” wire rope used in retractable lighting systems for nighttime road work areas. Said plainly, there are limitless wire rope use cases to pour over.

However, as versatile as wire rope is, there are as many ways to define it. Wire rope can be distinguished from mechanical cable by size, as already covered, but there are also other characteristics that are useful to examine as well.

Wire rope can be coated in Teflon® (FEP), or other extruded materials such as nylon (PA), vinyl (PVC) or polyurethane (PU). This protective coating ensures the wire rope is not exposed to particulates and other undesirable environmental contaminants. Furthermore, wire rope can be made from a vast array of alloys, such as stainless steel, galvanized steel, tungsten and others.

For example, the Brooklyn Bridge required galvanized steel due to its strong resistance to oxidation. Tungsten, used prolifically in surgical robotics, by comparison, is characteristically malleable, and thus allows for the mechanical cable to turn around tight, miniature pulleys with ease. So one’s choice of wire rope material depends entirely on what needs to be achieved.

Construction & Diameter: The size and structure of wire rope can affect its strength in different applications. For example, mechanical cables, with more space or air between the strands, allow greater compression, which works well in a pulley system, but may lack the pull strength needed to hang a heavy load.

Cable Lay: Lay refers to the way wires and strands are twisted, including its direction and lay length, which can inform strength and overall lifecycle.

Malleability — It is important to know if your project requires wire rope that is rigid or flexible. Stainless steel wire rope is extremely strong, but tends to resist bends. Thus, if the application calls for the wire rope to complete tight radii, without the urge to spring back to its original shape, tungsten cable may be the alternative.

Cutting & Resistance — Lifecycle can be shortened by both the presence of corrosion and how the wire rope is terminated. Because of tungsten cable’s meteorological properties, for instance, the cable filaments want to fall away from one another if cut mechanically. It is therefore necessary to electrocut tungsten cable to ensure a small amount of molten material is applied to the cut, simultaneously, to ensure the filaments stay bonded at the ends. Wire rope exposed to seawater, or rain water, is produced with different alloys. Stainless steel does a better job tolerating salt water than a galvanized cable alternative.

Medical — While much of the medical industry"s demand for wire rope has shifted to smaller diameter cables, wire rope is still a vital component in some life sciences applications.

Realistically, budget constraints may affect the material selection. For example, tungsten mechanical cable will generally be more expensive than stainless steel wire rope. And while tungsten is superior in many ways to stainless steel, when all variables are identical, the application may be well served by a more modestly priced stainless wire rope. It is quite common to arrive at a cost-effective wire rope or mechanical cable material that suits application requirements, but does so without undermining the product’s ability to compete in fierce markets. It is therefore critical that product designers collaborate with Sava’s engineers on material type.

At Sava, we have manufactured and supplied wire rope, precision miniature and ultrafine cables and assemblies to satisfied customers across dozens of industries for over 50 years. Contact us today to take advantage of our expertise in selecting wire rope and related products.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire. On shipping docks, rigging, and load bearing equipment, wire rope is attached to swivels, shackles, or hooks to lift a load in a controlled, even, and efficient manner.

The uses for wire rope include adding support to suspension bridges, lifting elevators, and serving as additional reinforcement for towers. The design of wire rope, with its multiple strands wrapped around a stable core, provides strength, flexibility, and ease of handling for applications that have bending stress.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of lifting or supportive applications.

The term wire rope encompasses a wide range of mechanical tools that are made to perform heavy and extreme lifting jobs. Wire rope is a complicated and complex tool with multiple moving parts capable of moving in unison. A 6 by 25 wire rope has 150 outer strands that move as one in an intricate pattern supported by a flexible core.

An essential part of the design of wire rope is the required clearance between the strands to give each stand the freedom to move and adjust when the rope bends. It is this unique feature that differentiates wire rope from solid wire and other forms of cable.

The basic element of wire rope is wire that is used to configure, shape, and form the rope. Typically, steel, stainless steel, and galvanized wires are the first choice with aluminum, nickel alloy, bronze, copper, and titanium being second possibilities. The choice of wire is dependent on the type of work the wire is going to be used to perform with strength, flexibility, and abrasion resistance being the major determining factors.

Stainless steel wire rope has all of the basic qualities of galvanized and general wire rope with the added benefits of corrosion and rust resistance; this makes it the ideal choice for harsh and stressful conditions.

Steel wire rope is classified as general purpose wire rope and comes in a wide variety of sizes, diameters, and strengths. It is the most common type of wire rope and is used for several industrial, manufacturing, and construction applications.

Before going further into the discussion of how wire rope is made, it is important to understand the numbers used to describe each type. All wire ropes have a core around which wires are wound. The various styles of cores vary according to the construction and design of the requirements of the wire rope that is being produced.

Wire rope is classified by the number of strands it has as well as the number of wires in each strand. The most common classification is a seven wire rope that has one strand in the center and six around its circumference. This type of wire rope is lightweight with a very simple construction. The majority of wire ropes are more complex and intricate with multiple intertwining strands and wires.

What must be understood about wire rope is that it has a complicated configuration. It is actually wires wrapped around wires to form bundles that are wrapped around other bundles. In the case of a seven wire wire rope, the core has bundles of wires wound around it; this can be seen in the image below.

The first step in wire rope creation is the production of wire strands where wires are wound around a single core wire. The number of wires included in the strand is dependent on the specified strength, flexibility, and size requirements of the rope. Once the strand is completed, it is straightened before being moved to wire rope construction.

Like wire ropes, strands have different patterns; patterns are the arrangements of the wires and their diameters. Though most strands have a core, there are strand patterns that have three or four wires without a core that are referred to as centerless strands. The design of each strand pattern is meant to enhance the strength of the wire rope and improve its performance.

For a multiple layer strand, the layers of wire are placed over one another in successive order. The placement of the wires on top of each other must be such that they fit smoothly and evenly.

The Warrington pattern is like the multiple layer pattern with one variation. Like the multiple layer pattern, the inner wires and the core are the same and have the same diameter. The difference is in the outer layer, which has wires of alternating sizes of large and small with larger diameter wires laying in the valleys of the inner wires.

All of the wires of a filler pattern are the same size. What makes this pattern unique is the insertion of small wires in the valleys of the inner wires to fill the gap between the inner and outer layer.

The flattened strand pattern is also known as the triangular strand, which can be triangular or oval. Three round wires form the core. The outer flattened surface has a greater sectional metallic area; this makes this pattern stronger and longer lasting.

The core of a wire rope runs through the center of the rope and can be composed of a variety of materials, which include synthetic fibers, natural fibers, a single strand, or another wire rope. The core supports the wound strands, helps maintain their position, is an effective lubricant carrier, and provides support.

Wire ropes with fiber cores are restricted to light loads and are not used in severe, harsh, or stressful conditions. Polypropylene and nylon are types of synthetic fiber cores and can be used in conditions where there is exposure to chemicals.

Cores made of wire are classified as independent wire cores. The core of a wire rope with a wire core is actually a wire rope with another wire rope serving as the core, as can be seen in the diagram below. These types of wire ropes are used where the rope will be exposed to exceptional resistance and crushing.

A strand, or wire strand core, is exactly like the rest of the strands of the wire rope with wires of the same diameter and size as the other strands.

The choice of core and creation of the strands are the simplest yet most essential parts of wire rope construction. Wire rope lays, the method used to wind the strands, is more complex and involves several choices.

Lay is a term used to describe three of the main characteristics of wire rope: direction, relationship, and linear distance. The strands can be wrapped around the core going right or left. Right or left refers to the direction of the strands wrapped around the core and the wires within the strands. The linear distance is how far a strand moves when it is making a revolution around the core.

In a regular lay, the wires and strands spiral in opposite directions. With a right hand regular lay, the wires spiral to the left and the strands to the right. In the left hand regular lay, the wires spiral to the right and the strands to the left. This type of lay is easy to handle but wears out quickly because the crown wires are in contact with the bearing surface.

In the Lang, or Albert, lay, the wires and strands spiral in the same direction with right hand lay being the most common. The wires in a Lang lay appear to run parallel to the center line of the rope. The difficulty with Lang lay wire ropes is handling since they tend to kink, twist, and crush.

Wire rope is an exceptionally strong tool that has been configured and designed to withstand the stress placed upon it through rigorous and continual use. In most applications, wire rope has to endure extreme stress and strain. It is for these reasons that coatings have been developed to protect wire rope from abrasions, corrosion, UV rays, and harmful and damaging chemicals.

Three main types of coatings are used to protect wire rope: polyvinyl chloride (PVC), polypropylene, and nylon. Of the three types, PVC is the most popular.

PVC is popular because it is multifunctional, extremely flexible, and general purpose as well as low cost. It has an operating temperature between -30° F (-35° C) and 180° F (80° C) with a hardness of 90 on the durometer.

In cases where there are severe and hazardous working conditions, polypropylene is the recommended choice since it is capable of protecting wire rope against corrosion and chemical leaching. Additionally, it is resistant to impact damage and abrasion. Polypropylene is a tough, rigid, and crystalline thermoplastic that is made from a propene monomer and is resilient as well as inexpensive.

Nylon is exceptionally abrasion resistant, which makes it ideal for use in cold environments. It is not as flexible as PVC but has excellent protection against corrosion and impact. It has excellent chemical resistance at temperatures between -65° F (-54° C) and 230° F (110° C) and is available in a wide assortment of colors, or it can be transparent.

Braided wires are electrical conductors made up of small wires that are braided together to form a round tubular braid. The braiding and configuration of braided wire makes them very sturdy such that they do not break when flexed or bent. Braided wires are widely used as conductors, are commonly made from copper due to copper"s exceptional conductivity, and can be bare or coated depending on the application.

Braided wire can be round and tubular or flat. Round tubular braids fit in most spaces where flat braided wire will not. Flat braided wire begins as round braided wire which is flattened on a capstan. They are exceptionally strong and designed for medical and aircraft applications.

Metals used to make wire rope are various grades of stainless steel, bright steel, and galvanized steel. Though the majority of wire rope manufacturers use these three metals, other metals such as copper, aluminum, bronze, and monel are also used on a limited basis.

The most important aspect of wire rope is the wire and the metal from which it is made. The strength and resilience of wire rope is highly dependent on the quality of metal used to make it, and these are essential factors to be considered when purchasing it.

Bright steel wire does not have a coating and is rotation resistant, (designed to not rotate when lifting a load). It is drawn from hot rolled rods that are put through a die to match its specific dimensional tolerances, mechanical properties, and finish. Bright wire is used as a single line in conditions that require a rope that will resist cabling.

Galvanized steel has a zinc coating for corrosion resistance and has the same strength and durability as bright steel. Environmental conditions determine the use of galvanized steel. In mildly severe and slightly harsh conditions, galvanized steel wire is an economical replacement for stainless steel.

In the manufacturing process, galvanized wire goes through the process of galvanization, a method of coating steel wire with a protective and rust resistant metal. Galvanized wire is exceptionally strong, rust resistant, and flexible enough to meet the needs of a variety of applications.

Stainless steel does not have the same strength and endurance as bright steel or galvanized steel but has the many benefits commonly associated with stainless steel, such as resistance to stains, wear, rust, and corrosion. More expensive than the other two metals, stainless steel has the added benefit of lasting longer and providing exceptional performance.

Wire rope made from copper is mostly used for electrical applications due to its exceptional electrical characteristics. The benefits of copper wire rope are its durability, flexibility, and resilience compared to standard copper wire. The strength of copper wire rope is seen in its use in applications where there are vibrations and shaking.

The wire rope lubrication process begins during its fabrication and continues during its use. Lubrication of wire rope is designed to lower the amount of friction it endures and provide corrosion protection. Continued lubrication increases the lifespan of wire rope by preventing it from drying up, rusting, and breaking.

The types of lubricants for wire rope are penetrating or coating with coatings covering and sealing the outside of the rope. Penetrating lubricants go deep into the rope and seep into the core where they evaporate to form a thick coating or film.

The application of the lubricant is dependent on the type of core. Fiber cores absorb the lubricant and serve as a reservoir that retains the lubricant for an extended period of time. With metal cores, the lubricant is applied as the wire is twisted into strands to give complete saturation and coverage of the wires.

Petrolatum compounds are translucent and provide excellent corrosion and water resistance. They tend to drip off at high temperatures but keep their consistency in cold conditions. Petrolatum is a mixture of hydrocarbons from the distillation of petroleum that belong to the methane family of hydrocarbons. It can be used in semi-solid or liquid form and forms a jelly in its semi-solid form.

Asphaltic compounds are a mineral based oil combined with bitumen to create a tacky, high viscosity lubricant with an undiluted viscosity. As a lubricant, asphaltic compounds create an oil film that separates the mating surfaces and are applied as a spray. Once applied, the meshing of surfaces causes the solvent to flash; this leaves a viscous coating of lubricant.

There are several types of greases that are used as wire rope lubricating agents and are made up of oil, a thickener, and additives. The essential components are the base oil and additives, which influence the behavior of the grease. The thickener holds the base oil and additives together. The amount of base oil in a grease is between 70% and 95% with an additive of 10%.

The additive in grease enhances the positive properties of the oil and suppresses the negative properties. Common additives are oxidation and rust inhibitors as well as pressure, wear, and friction reducing agents.

Of the many choices for lubricants, vegetable oil is the easiest to use and penetrates the deepest. The design of the additives for vegetable oils gives them the necessary qualities required to penetrate deep into a wire rope. The exceptional penetration provides protection against wear and corrosion. Since vegetable oil is a fluid, it helps in washing the wire rope to remove external abrasive contaminants.

Wire rope is widely used in machines, structures, and varied lifting applications. Its type, size, and requirements are determined by how it will be used. Regardless of its use, wire rope guarantees exceptional strength and provides high quality and excellent performance.

The lifting of heavy loads for centuries involved the use of hemp rope or chains, neither of which was a guaranteed or substantial method. Early in the 18th Century, between 1824 and 1838, Wilhelm Albert, a German mining engineer, combined the twisting of hemp and strength of chains to create today‘s wire rope.

The most common use of wire rope is as a part of a crane hoist wherein it is attached to the hook of the hoist and wrapped around a grooved drum. The tensile strength and durability of wire rope makes an ideal tool for lifting and keeping loads secure. Though it is used in several industries, it is very popular for production environments wherein materials need to be lifted quickly and efficiently.

In addition to its many lifting applications, the strength and stability of wire rope is useful in other applications, especially in the aerospace industry. Pedals, levers, and connectors in the cockpit of an aircraft are connected with wire rope. The wires provide for the passage of power between systems and mechanisms; this allows control of the aircraft. Wire rope is used to control propeller pitch, cowl flaps, and the throttle. It also assists in lowering and minimizing vibrations.

Tires are reinforced with wire rope to increase their durability and strength. All automotive production environments make use of wire ropes for supplying materials, moving heaving loads, and positioning equipment. Wire rope can be found in the production of steering wheels, cables, exhausts, springs, sunroofs, doors, and seating components.

As surprising as it may seem, the place that wire rope has the greatest use is in the home, where its strength, long life, endurance, and resilience provide guaranteed protection and performance. The main reason wire ropes are so popular for home use is cost.

Inexpensive, easy to obtain, easy to install, and easy to maintain, wire ropes provide an additional method for performing home repairs and structural support. Their excellent flexibility and sturdiness combined with their invisibility has made wire rope an ideal solution to several home maintenance issues. It is used to support staircases, fences, decks, and hang plants.

The search and production of crude oil has relied on wire ropes for centuries to lift drill bits, insert shafts, and support oil rigs on land and the water. When equipment, machinery, and tools have to be lowered into the depths of the earth and sea, wire ropes are the tool that the oil industry relies on to do the job.

Many of the tasks of oil production require tools that are capable of enduring severe and harsh conditions. Wire ropes have to withstand enormous pressure, extraordinary stress, and a wide range of temperatures. The use of wire rope includes maintaining oil rig stability and moorings for offshore rigs.

Wire rope has long been a standard component for the transportation industry, from the cable cars of San Francisco to the lift chairs for ski resorts. For many years, cable cars have relied on heavy duty cables (wire ropes) to be pulled by a central motor from multiple locations. It is a method of transportation that has existed for centuries.

In Europe, funiculars use cables that hang from a support to move cars up and down a mountain with cables moving in opposite directions. The word funicular is from the French word funiculaire, meaning railway by cable. The terms wire rope and cable are used interchangeably when discussed by professionals. The first part of funicular, or funiculaire, is from the Latin word "funis," meaning rope.

The major use for wire ropes in the food and beverage industries is as a means for lifting and moving heavy loads. Wine barrels and containers full of ingredients are lifted and placed through use of cranes and wire ropes. They are also part of conveyor systems that move products from one station to another.

From the beginnings of amusement rides up to the present, wire ropes have been an essential part of attraction construction and safety. They pull cars on roller coasters, hold cabins that swing, and move carriages through haunted houses. The main concern of amusement parks is safety. The strength, stability, and guaranteed performance of wire ropes ensures that people who attend amusement parks will have a good time and stay safe.

The rigging used to complete the stunts in modern movies depends on wire rope for safety. Much like in amusement rides, wire ropes protect performers from injury and harm as they hang above a scene or carry out an impossible move.

The live theater industry uses wire ropes to raise and lower curtains, support overhead rigging, and hold backdrops and scenery pieces. During a production, rapid and efficient movement is a necessity that is facilitated by the use of wire ropes.

Wire rope is a tool that we tend to envision as indestructible, unable to succumb to any form of damage. Though it is exceptionally sturdy and strong as well as capable of enduring constant use, it is just as susceptible to breakdown as any other tool.

To avoid serious harm and damage, wire ropes should be scheduled for regular inspections. There are situations that can damage or break a wire rope; these should be understood prior to the problem arising.

Guide rollers have the potential to damage and cause abrasions on wire rope if they become rough and uneven. Of the various elements of a crane and lift, guide rollers have the greatest contact with the mechanism‘s wire rope. Regular inspection of guide rollers will ensure they are not damaging the rope or causing abrasions.

Bending is normally a regular part of wire rope usage; this occurs repetitively as the rope passes through a sheave. As a wire rope traverses the sheave, it is continually bent and develops cracks or breaks. The cracking and breaking are exacerbated by movement on and off the groove of the drum. Normally, the breakage happens on the surface and is visible. Once it appears, it accelerates to the core of the rope.

A bird cage is caused by a sudden release of tension and a rebound of the rope. This type of break requires that the rope be replaced since the place of the break will not return to its normal condition.

Wire ropes are multi-layered; this makes them flexible and torque balanced. The layering inside and outside creates flexibility and wear resistance. Relative motion between the wires causes wear over time, which leads to internal breakage. The detection of these breaks can be indicated by an electromagnetic inspection that calculates the diameter of the rope.

Kinked wire rope is caused by pulling a loop on a slack line during installation or operation; this causes a distortion in the strands and wires. This is a serious condition that necessitates rope replacement.

Corrosion damage is the most difficult cause of wire rope damage to identify, which makes it the most dangerous. The main reason for corrosion is poor lubrication that can be seen in the pitted surface of the rope.

The types of damage and problems listed here are only a small portion of the problems that can be caused if a wire rope is not regularly lubricated and inspected. Various regulatory agencies require that wire ropes be inspected weekly or monthly and provide a list of factors to examine.

As with any type of heavy duty equipment, wire rope is required to adhere to a set of regulations or standards that monitor and control its use for safety and quality reasons. The two organizations that provide guidelines for wire rope use are the American Society of Mechanical Engineers (ASME) and the Occupational Safety and Health Administration (OSHA).

ASME is a professional association that provides guidelines to promote the engineering profession. OSHA is a government agency whose purpose is to protect workers and ensure their safety.

All wire rope manufacturers and users closely follow the standards and guidelines established by OSHA and ASME. In the majority of cases, they will identify the specific standards they are following in regard to their products.

OSHA‘s regulations regarding wire rope fall under sections 1910, 1915, and 1926, with the majority of the stipulations listed in 1926 under material handling, storage, use, and disposal.

"Running rope in service shall be visually inspected daily, unless a qualified person determines it should be performed more frequently. The visual inspection shall consist of observation of all rope that can reasonably be expected to be in use during the day‘s operations. The inspector should focus on discovering gross damage that may be an immediate hazard."

"The inspection frequency shall be based on such factors as rope life on the particular installation or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. Close visual inspection of the entire rope length shall be made to evaluate inspection and removal criteria."

ASTM A1023 covers the requirements for steel wire ropes with specifications for various grades and constructions from ¼ in. (6 mm) to 31/2 in. (89 mm) manufactured from uncoated or metallic coated wire. Included are cord products from 1/32 in. (0.8 mm) to 3/8 in. (10 mm) made from metallic coated wire.

United States Federal Spec RR W 410 covers wire ropes and wire seizing strands but does not include all types, classes, constructions, and sizes of wire rope and strands that are available. The purpose of Spec RR W 410 is to cover more common types, classes, constructions, and sizes suitable for federal government use.

Wire rope and wire seizing strand covered by United States Federal Spec RR W 410 are intended for use in general hauling, hoisting, lifting, transporting, well drilling, in passenger and freight elevators, and for marine mooring, towing, trawling, and similar work, none of which are for use with aircraft.

API 9A lists the minimum standards required for use of wire rope for the petroleum and natural gas industries. The types of applications include tubing lines, rod hanger lines, sand lines, cable-tool drilling and clean out lines, cable tool casing lines, rotary drilling lines, winch lines, horse head pumping unit lines, torpedo lines, mast-raising lines, guideline tensioner lines, riser tensioner lines, and mooring and anchor lines. Well serving wire ropes such as lifting slings and well measuring are also included in API 9A.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of a lifting or supportive task.