what is the difference between strand and wire rope brands

As an operations manager in need of new ropes, your machines require a specific manufacturer of wire ropes. However, when you walk into a supplier’s warehouse, you don’t know how to identify one wire rope manufacturer’s product from another.

With domestic wire rope brands, the way to identify the color strand is by looking at it. This is for general purpose wire rope only, which includes the 6×19 and 6×36 classes.

General purpose wire rope is used in the manufacture of wire rope slings, on overhead cranes, and mobile cranes. It differs from high-performance crane rope. General purpose wire rope isn’t 19-strand or 35×7.

Beginning in the 1980s, U.S. companies used color-coding systems as a form of identification to differentiate from international products. This was done to establish traceability as non-domestic manufacturers became more prominent in the wire rope industry.

The core marker is different than a strand identifier. The core marker is an internal plastic mono filament film that would help identify:Country of origin

Generally, you have to cut into the rope to find the core marker. In the event of a rope failure, the core marker will make it easier to identify the manufacturer. Core markers run throughout the entire wire rope. If you took a cross section of the rope, and deconstructed it, you’d find the film used to identify the manufacturer and country of origin.

Predominantly, domestic wire rope suppliers brought this to market. However, today, most manufacturers, including high quality non-domestic wire rope suppliers, also use internal core markers to identify themselves.

When it comes to the three major domestic wire rope suppliers and the color strand that identifies them, the markings unique to the brand include:Bridon-Bekaert is one blue strand that is going on its general purpose rope

There are no standards from the American Society of Mechanical Engineers (ASME) or Occupational Safety and Health Administration (OSHA) mandating the use of color strand identifiers.

Also, it’s not a hard and fast rule that every run of domestic rope has a color strand. There may be a specific reason that a run of rope doesn’t have a color. Colors are solely based on the manufacturers of the wire rope, and it’s traceability.

This is all about marketing, so customers can identify the manufacturers quickly. The color-coding system was designed so anyone with knowledge of the colors can walk into a warehouse and figure out which suppliers that distributor offers.

By reading this article, you now know the history and reasoning behind the domestic wire rope color-coding system. Also, you understand which colors represent what domestic wire rope manufacturers.

Having this knowledge should clear up confusion the next time you need wire rope. Hopefully, it will make your buying experience more efficient and user-friendly.

Remember, the color strands are simply identifiers. They are not indications of working load limits. For that information, refer to the manufacturer’s standards, or tags required by ASME.

When purchasing wire rope, the many types and designs of cabling can be a bit difficult to understand. What exactly is a wire rope, and what makes it different from other wire ropes, strands, and cables? Understanding the differences between these terms will help you understand what it is that you’re looking for.

To understand ropes and strands, we first need to define these terms. What is a wire rope, what is a wire strand, and what makes them different from each other?

Wire: The basics of wire rope begin with its core component: the solid wire. These lengths of metal, usually steel, are drawn into shape and wrapped around drums for use in manufacturing. The wires are then drawn out and wrapped together to form strands.

Strand: A strand of wire is several lengths of wire wrapped around a single wire that serves as the “core” of the strand. A strand may have multiple layers of wire that wrap around each other, but the constituent parts of a strand are always going to be solid lengths of wire. 1x7 strand is two layers and is made of seven wires; 1x19 is three layers and is made of nineteen wires.

Wire Rope: A wire rope is made up of strands wrapped about a core. The core of a wire rope may be fiber rope, solid polymer, or even another wire strand. When the core is a wire strand, it’s called “strand core” or independent wire rope core (IWRC.) Wire ropes are thick, typically 7/16” diameter up to several inches in diameter. Wire ropes are generally designated based upon the number of strands they contain and the number of wires in each strand (i.e., a 6x19 wire rope is made up of six strands wrapped about a core, with each strand containing 19 individual wires). “Cable,” which is short for“aircraft cable,” is also a term used interchangeably with wire rope, though it is more often applied to wire ropes of ⅜” and smaller diameter. Aircraft cable has a strand core, which is a distinction relative to wire rope.

With a basic understanding of wire ropes and strands, the functional differences, and why would you choose one over the other? When the cable is only or mostly straight or linear then strand is logical. When cable is bending then aircraft cable or wire rope is typical. Here are some other things to consider.

Strength: Tension forces are distributed across a larger number of wires that hold each other together with extreme friction. In addition, wire ropes are more resistant to damage from sheaves and drums due to their ability to absorb more deformation. Learn more about minimum break strength of our wires here.

Flexibility: Flexibility is another major difference between strand and wire rope. As the number of wires increases, so does the flexibility.  Drums must be larger to accommodate a thick wire rope, and pulleys need a much greater diameter to avoid deforming the wire rope. 6x37 class is twice as flexible as 6x19 class, and 6x19 class has roughly the same flexibility as 7x19.

Application: Finally, consider what the aircraft cable or wire rope will be used for. For example, 1x7 is often used for parking lot barrier strands, and 1x19 strand is used for cable railings. Learn more about typical strand constructions below, or by viewing our wire rope specification sheet.

Lay:Strand, aircraft cable, and wire rope can be made left lay or right lay, which describes the stranding direction. 1x7 and 1x19 strands are typically left lay. 7x7 and 7x19 aircraft cable and 6x19 class and 6x37 class wire ropes are typically right lay. Lay length means the distance it takes the wire to make a revolution.

The final step is to choose a vendor for your wire rope or strand, as there are a few key things to keep in mind when choosing your wire rope or wire strand vendor.

Engineering support:Companies that offer engineering support may be better suited to your needs than companies that don’t. Manufacturers with the capability to custom fabricate a wire rope assembly are more likely to have the right product to exactly match your needs.

Testing: Proper testingis vital to ensuring a product performs up to standard, and shops that rigorously test their products in-house can be relied upon to supply consistent quality products.

Lexco Cable is an ISO 9001 certified industry-leading manufacturer of wire rope and cable assemblies, with the engineering capabilities to provide high-quality, reliable wire rope or strand products for nearly any application anywhere in the nation. Our customers can count on us for consistency and we’ll work tirelessly to serve them properly. Contact us to discuss your wire rope project today.

Did you know wire ropes were used as far back as the 1830s for mining hoist applications? Nowadays, we can use steel ropes for many different applications such as lifting and hoisting in elevators and cranes, and for mechanical power transmission. US Cargo Control’s wire rope slings are an excellent choice for heavy-duty jobs as their fabrication offers excellent abrasion resistance and heat resistance for extreme conditions.

Although these slings are beneficial for the lifting and rigging industry, there are a few specifications to know before purchasing them. Continue reading what is wire rope, what are important specifications to look for, and how it’s different from cable rope.

These slings carry different properties that can determine their performance. Wire rope is constructed where a strand consists 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. Once the wires are formed, they all come together to create greater strength and flexibility.

These slings work well for lifting, hoisting, towing, or anchoring loads. They’re manufactured in a variety of configurations, with 6×19 and 6×36 being the most common. When you see 6×19 or 6×36 from our website, these numbers represent the number of wires making up the strand and the number of strands wrapped around the core.

For example, a 6×19 indicates that there are 19 wires making up a strand, and 6 strands wrapping around the core. To learn more about our 6×19 wire ropes, look into our bestselling 1/2″ Galvanized Wire Rope EIPS IWRC, 1/2″ Stainless Steel Wire Rope IWRC T304, and 1/2″ Bright Wire Rope EIPS FC.

The configurations will offer different benefits for certain applications. In general, a smaller number of large outer wires offers better wear and corrosion resistance, while a larger number of small wires provides a better level of flexibility and fatigue resistance. Continue reading to learn which wire rope fits your job.

There are different versions of wire rope slings, ranging from single leg to 4 legs, as well as braided wire rope and domestic wire rope slings (manufactured in the U.S. with Crosby® hardware). When looking at the types of slings we offer at US Cargo Control, be sure to consider how much versatility and capability you need.

For example, a braided wire rope has increased flexibility and friction to grip loads over a regular wire rope. Adding an additional leg to the sling can add additional versatility and strength.

This is the measurement of the rope’s diameter and can be displayed in inches or millimeters. These sizes commonly display different strand patterns where the number of layers, wires per layer, and size of the wires per layer all affect the strand pattern. Wire rope can be constructed using one of the following patterns below or using two or more patterns.

Warrington – this construction has two layers of wires around a center with one diamter of wire in the inner layer, and two diameteres of wire alternating large and small in the outer layer.

The type of lay refers to the way the wires are laid to form a strand. They’re how the strands are laid around the core which can be regular lay, long lay, or alternate lay.

The wires line up with the axis of the rope. This is where the wires are twisting in one direction, and the strands in the opposite direction create the rope. Regular lay is less likely to untwist and less likely to crush.

This is the opposite of regular lay where the wires form an angle with the axis of the rope. The wires and strands spiral in the same direction and run at a diagonal to the centerline of the rope. Lang lay is more flexible and resistant to abrasion than regular lay wire ropes. The only con is this type of lay will be more likely to twist and crush than the regular lay.

Sometimes known as reverse lay, this type of lay consists of alternating regular lay and long lay strands. This unites the best features of both types, and it’s using relatively large outer wires to provide an increase of abrasion resistance.

This refers to the protective coating that’s applied to the wire rope. There are three types of finishes which are galvanized (zinc-coated), stainless steel, and bright (unfinished steel).

The grade of the rope means the grade of steel being used. The plow steel strength calculates the strengths of most steel wire ropes. Some classifications include Improved Plow Steel (IPS), Extra Improved Plow Steel (EIPS), Extra Extra Improved Plow Steel (EEIPS), Galvanized Improved Plowed Steel (GIPS), and Drawn Galvanized Imrpoved Plow Steel (DGEIP).

EIPS is 15% stronger than IPS, and EEIPS is 10% stronger than EIPS. Along with that, GIPS and DGEIP wires can add corrosion resistance to your application, but DGEIP wires have a higher break load than GIPS.

The type of core is what makes up the center of the wire rope. There are three types of core: Fiber Core (FC), Independent Wire Rope Core (IWRC), and Wire Strand Core (WSC).

A fiber core can be made of synthetic polypropylene fibers. The fiber cores offer greater elasticity than a steel core, but are more susceptible to crushing. This isn’t recommended for high heat environments.

A steel core can either be an independent wire rope or individual strand. The steel cores can provide adequate support, or in an operating environment where temperatures can exceed very high heat.

Wire and cable ropes are terms that are often interchangeable but do have one varying difference. Wire rope refers to the diameters that are larger than 3/8 inch. Sizes smaller than this are classified as cable rope or even cords. Regardless of the size difference, cable and wire rope are still classified as a “machine.” Even a group of strands laid around a core would still be called a cable or wire rope.

We know the importance of quality when it comes to lifting supplies. We carry a variety of rigging hardware, as well as lifting beams and spreader bars that are designed to lift heavy loads safely and efficiently. If you’re interested in other lifting slings, check the other types of slings we carry like nylon slings and chain slings.

Contact our sales team at US Cargo Control today at 866-444-9990. Our team of product experts is here to answer any questions about rigging hardware, lifting slings, and more.

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.

In stricter senses, the term wire rope refers to a diameter larger than 9.5 mm (3⁄8 in), with smaller gauges designated cable or cords.wrought iron wires were used, but today steel is the main material used for wire ropes.

Historically, wire rope evolved from wrought iron chains, which had a record of mechanical failure. While flaws in chain links or solid steel bars can lead to catastrophic failure, flaws in the wires making up a steel cable are less critical as the other wires easily take up the load. While friction between the individual wires and strands causes wear over the life of the rope, it also helps to compensate for minor failures in the short run.

Wire ropes were developed starting with mining hoist applications in the 1830s. Wire ropes are used dynamically for lifting and hoisting in cranes and elevators, and for transmission of mechanical power. Wire rope is also used to transmit force in mechanisms, such as a Bowden cable or the control surfaces of an airplane connected to levers and pedals in the cockpit. Only aircraft cables have WSC (wire strand core). Also, aircraft cables are available in smaller diameters than wire rope. For example, aircraft cables are available in 1.2 mm (3⁄64 in) diameter while most wire ropes begin at a 6.4 mm (1⁄4 in) diameter.suspension bridges or as guy wires to support towers. An aerial tramway relies on wire rope to support and move cargo overhead.

Modern wire rope was invented by the German mining engineer Wilhelm Albert in the years between 1831 and 1834 for use in mining in the Harz Mountains in Clausthal, Lower Saxony, Germany.chains, such as had been used before.

Wilhelm Albert"s first ropes consisted of three strands consisting of four wires each. In 1840, Scotsman Robert Stirling Newall improved the process further.John A. Roebling, starting in 1841suspension bridge building. Roebling introduced a number of innovations in the design, materials and manufacture of wire rope. Ever with an ear to technology developments in mining and railroading, Josiah White and Erskine Hazard, principal ownersLehigh Coal & Navigation Company (LC&N Co.) — as they had with the first blast furnaces in the Lehigh Valley — built a Wire Rope factory in Mauch Chunk,Pennsylvania in 1848, which provided lift cables for the Ashley Planes project, then the back track planes of the Summit Hill & Mauch Chunk Railroad, improving its attractiveness as a premier tourism destination, and vastly improving the throughput of the coal capacity since return of cars dropped from nearly four hours to less than 20 minutes. The decades were witness to a burgeoning increase in deep shaft mining in both Europe and North America as surface mineral deposits were exhausted and miners had to chase layers along inclined layers. The era was early in railroad development and steam engines lacked sufficient tractive effort to climb steep slopes, so incline plane railways were common. This pushed development of cable hoists rapidly in the United States as surface deposits in the Anthracite Coal Region north and south dove deeper every year, and even the rich deposits in the Panther Creek Valley required LC&N Co. to drive their first shafts into lower slopes beginning Lansford and its Schuylkill County twin-town Coaldale.

The German engineering firm of Adolf Bleichert & Co. was founded in 1874 and began to build bicable aerial tramways for mining in the Ruhr Valley. With important patents, and dozens of working systems in Europe, Bleichert dominated the global industry, later licensing its designs and manufacturing techniques to Trenton Iron Works, New Jersey, USA which built systems across America. Adolf Bleichert & Co. went on to build hundreds of aerial tramways around the world: from Alaska to Argentina, Australia and Spitsbergen. The Bleichert company also built hundreds of aerial tramways for both the Imperial German Army and the Wehrmacht.

In the last half of the 19th century, wire rope systems were used as a means of transmitting mechanical powercable cars. Wire rope systems cost one-tenth as much and had lower friction losses than line shafts. Because of these advantages, wire rope systems were used to transmit power for a distance of a few miles or kilometers.

Steel wires for wire ropes are normally made of non-alloy carbon steel with a carbon content of 0.4 to 0.95%. The very high strength of the rope wires enables wire ropes to support large tensile forces and to run over sheaves with relatively small diameters.

In the mostly used parallel lay strands, the lay length of all the wire layers is equal and the wires of any two superimposed layers are parallel, resulting in linear contact. The wire of the outer layer is supported by two wires of the inner layer. These wires are neighbors along the whole length of the strand. Parallel lay strands are made in one operation. The endurance of wire ropes with this kind of strand is always much greater than of those (seldom used) with cross lay strands. Parallel lay strands with two wire layers have the construction Filler, Seale or Warrington.

In principle, spiral ropes are round strands as they have an assembly of layers of wires laid helically over a centre with at least one layer of wires being laid in the opposite direction to that of the outer layer. Spiral ropes can be dimensioned in such a way that they are non-rotating which means that under tension the rope torque is nearly zero. The open spiral rope consists only of round wires. The half-locked coil rope and the full-locked coil rope always have a centre made of round wires. The locked coil ropes have one or more outer layers of profile wires. They have the advantage that their construction prevents the penetration of dirt and water to a greater extent and it also protects them from loss of lubricant. In addition, they have one further very important advantage as the ends of a broken outer wire cannot leave the rope if it has the proper dimensions.

Stranded ropes are an assembly of several strands laid helically in one or more layers around a core. This core can be one of three types. The first is a fiber core, made up of synthetic material or natural fibers like sisal. Synthetic fibers are stronger and more uniform but cannot absorb much lubricant. Natural fibers can absorb up to 15% of their weight in lubricant and so protect the inner wires much better from corrosion than synthetic fibers do. Fiber cores are the most flexible and elastic, but have the downside of getting crushed easily. The second type, wire strand core, is made up of one additional strand of wire, and is typically used for suspension. The third type is independent wire rope core (IWRC), which is the most durable in all types of environments.ordinary lay rope if the lay direction of the wires in the outer strands is in the opposite direction to the lay of the outer strands themselves. If both the wires in the outer strands and the outer strands themselves have the same lay direction, the rope is called a lang lay rope (from Dutch langslag contrary to kruisslag,Regular lay means the individual wires were wrapped around the centers in one direction and the strands were wrapped around the core in the opposite direction.

Multi-strand ropes are all more or less resistant to rotation and have at least two layers of strands laid helically around a centre. The direction of the outer strands is opposite to that of the underlying strand layers. Ropes with three strand layers can be nearly non-rotating. Ropes with two strand layers are mostly only low-rotating.

Stationary ropes, stay ropes (spiral ropes, mostly full-locked) have to carry tensile forces and are therefore mainly loaded by static and fluctuating tensile stresses. Ropes used for suspension are often called cables.

Track ropes (full locked ropes) have to act as rails for the rollers of cabins or other loads in aerial ropeways and cable cranes. In contrast to running ropes, track ropes do not take on the curvature of the rollers. Under the roller force, a so-called free bending radius of the rope occurs. This radius increases (and the bending stresses decrease) with the tensile force and decreases with the roller force.

Wire rope slings (stranded ropes) are used to harness various kinds of goods. These slings are stressed by the tensile forces but first of all by bending stresses when bent over the more or less sharp edges of the goods.

Technical regulations apply to the design of rope drives for cranes, elevators, rope ways and mining installations. Factors that are considered in design include:

Donandt force (yielding tensile force for a given bending diameter ratio D/d) - strict limit. The nominal rope tensile force S must be smaller than the Donandt force SD1.

The wire ropes are stressed by fluctuating forces, by wear, by corrosion and in seldom cases by extreme forces. The rope life is finite and the safety is only ensured by inspection for the detection of wire breaks on a reference rope length, of cross-section loss, as well as other failures so that the wire rope can be replaced before a dangerous situation occurs. Installations should be designed to facilitate the inspection of the wire ropes.

Lifting installations for passenger transportation require that a combination of several methods should be used to prevent a car from plunging downwards. Elevators must have redundant bearing ropes and a safety gear. Ropeways and mine hoistings must be permanently supervised by a responsible manager and the rope must be inspected by a magnetic method capable of detecting inner wire breaks.

The end of a wire rope tends to fray readily, and cannot be easily connected to plant and equipment. There are different ways of securing the ends of wire ropes to prevent fraying. The common and useful type of end fitting for a wire rope is to turn the end back to form a loop. The loose end is then fixed back on the wire rope. Termination efficiencies vary from about 70% for a Flemish eye alone; to nearly 90% for a Flemish eye and splice; to 100% for potted ends and swagings.

When the wire rope is terminated with a loop, there is a risk that it will bend too tightly, especially when the loop is connected to a device that concentrates the load on a relatively small area. A thimble can be installed inside the loop to preserve the natural shape of the loop, and protect the cable from pinching and abrading on the inside of the loop. The use of thimbles in loops is industry best practice. The thimble prevents the load from coming into direct contact with the wires.

A wire rope clip, sometimes called a clamp, is used to fix the loose end of the loop back to the wire rope. It usually consists of a U-bolt, a forged saddle, and two nuts. The two layers of wire rope are placed in the U-bolt. The saddle is then fitted to the bolt over the ropes (the saddle includes two holes to fit to the U-bolt). The nuts secure the arrangement in place. Two or more clips are usually used to terminate a wire rope depending on the diameter. As many as eight may be needed for a 2 in (50.8 mm) diameter rope.

The mnemonic "never saddle a dead horse" means that when installing clips, the saddle portion of the assembly is placed on the load-bearing or "live" side, not on the non-load-bearing or "dead" side of the cable. This is to protect the live or stress-bearing end of the rope against crushing and abuse. The flat bearing seat and extended prongs of the body are designed to protect the rope and are always placed against the live end.

The ends of individual strands of this eye splice used aboard a cargo ship are served with natural fiber cord after splicing to help protect seamens" hands when handling.

An eye splice may be used to terminate the loose end of a wire rope when forming a loop. The strands of the end of a wire rope are unwound a certain distance, then bent around so that the end of the unwrapped length forms an eye. The unwrapped strands are then plaited back into the wire rope, forming the loop, or an eye, called an eye splice.

A Flemish eye, or Dutch Splice, involves unwrapping three strands (the strands need to be next to each other, not alternates) of the wire and keeping them off to one side. The remaining strands are bent around, until the end of the wire meets the "V" where the unwrapping finished, to form the eye. The strands kept to one side are now re-wrapped by wrapping from the end of the wire back to the "V" of the eye. These strands are effectively rewrapped along the wire in the opposite direction to their original lay. When this type of rope splice is used specifically on wire rope, it is called a "Molly Hogan", and, by some, a "Dutch" eye instead of a "Flemish" eye.

Swaging is a method of wire rope termination that refers to the installation technique. The purpose of swaging wire rope fittings is to connect two wire rope ends together, or to otherwise terminate one end of wire rope to something else. A mechanical or hydraulic swager is used to compress and deform the fitting, creating a permanent connection. Threaded studs, ferrules, sockets, and sleeves are examples of different swaged terminations.

A wedge socket termination is useful when the fitting needs to be replaced frequently. For example, if the end of a wire rope is in a high-wear region, the rope may be periodically trimmed, requiring the termination hardware to be removed and reapplied. An example of this is on the ends of the drag ropes on a dragline. The end loop of the wire rope enters a tapered opening in the socket, wrapped around a separate component called the wedge. The arrangement is knocked in place, and load gradually eased onto the rope. As the load increases on the wire rope, the wedge become more secure, gripping the rope tighter.

Poured sockets are used to make a high strength, permanent termination; they are created by inserting the wire rope into the narrow end of a conical cavity which is oriented in-line with the intended direction of strain. The individual wires are splayed out inside the cone or "capel", and the cone is then filled with molten lead-antimony-tin (Pb80Sb15Sn5) solder or "white metal capping",zincpolyester resin compound.

Koetsier,Teun; Ceccarelli, Marc (2012). Explorations in the History of Machines and Mechanisms. Springer Publishing. p. 388. ISBN 9789400741324. Archived from the original on 31 March 2017. Retrieved 9 April 2014.

Donald Sayenga. "Modern History of Wire Rope". History of the Atlantic Cable & Submarine Telegraphy (atlantic-cable.com). Archived from the original on 3 February 2014. Retrieved 9 April 2014.

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!

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

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

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

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

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

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

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

Manufacturing companies that work with maritime and mooring applications need a durable rigging rope to withstand the constant pulling that comes from the rope running through fairleads and over capstans. Also, in heavy-duty lifting and towing applications, ropes come in contact with rough surfaces such as chocks and the vessel’s deck. These applications can potentially provide severe abrasions to the ropes and degrade the exposed fibers, eventual