what is the difference between strand and wire rope in stock

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

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

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

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

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

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

Cables designed with 3×7, 7×7 and 7×19 construction provide for increasing degrees of flexibility but decreased abrasion resistance. These designs would be incorporated where continuous flexing is a requirement.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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!

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 complex mechanical device that has many moving parts all working in tandem to help support and move an object or load. In the lifting and rigging industries, wire rope is attached to a crane or hoist and fitted with swivels, shackles or hooks to attach to a load and move it in a controlled matter. It can also be used to lift and lower elevators, or as a means of support for suspension bridges or towers.

Wire rope is a preferred lifting device for many reasons. Its unique design consists of multiple steel wires that form individual strands laid in a helical pattern around a core. This structure provides strength, flexibility, and the ability to handle bending stresses. Different configurations of the material, wire, and strand structure will provide different benefits for the specific lifting application, including:Strength

However, selecting the proper wire rope for your lifting application requires some careful thought. Our goal is to help you understand the components of a wire rope, the construction of wire rope, and the different types of wire rope and what they might be used for. This will allow you to select the best performing and longest-lasting wire rope for the job at hand.

From childhood, many of us have been conditioned to think of a machine as some device with gears, shafts, belts, cams, and assorted whirring parts. Yet, by the rules of physics, an ordinary pry bar is a simple machine, even though it has only one part.

A wire rope is, in reality, a very complicated machine. A typical 6 x 25 rope has 150 wires in its outer strands, all of which move independently and together in a very complicated pattern around the core as the rope bends. Clearances between wires and strands are balanced when a rope is designed so that proper bearing clearances will exist to permit internal movement and adjustment of wires and strands when the rope has to bend. These clearances will vary as bending occurs, but are of the same range as the clearances found in automobile engine bearings.

Understanding and accepting the “machine idea” gives a rope user a greater respect for rope, and enables them to obtain better performance and longer useful life from rope applications. Anyone who uses a rope can use it more efficiently and effectively when they fully understand the machine concept.

Wires are the smallest component of wire rope and they make up the individual strands in the rope. Wires can be made from a variety of metal materials including steel, iron, stainless steel, monel, and bronze. The wires can be manufactured in a variety of grades that relate to the strength, resistance to wear, fatigue resistance, corrosion resistance, and curve of the wire rope.

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.

The core of a wire rope runs through the center of the rope and supports the strands and helps to maintain their relative position under loading and bending stresses. Cores can be made from a number of different materials including natural or synthetic fibers and steel.

Lubrication is applied during the manufacturing process and penetrates all the way to the core. Wire rope lubrication has two primary benefits:Reduces friction as the individual wires and strands move over each other

The number of layers of wires, the number of wires per layer, and the size of the wires per layer all affect the strand pattern type. Wire rope can be constructed using one of the following patterns, or can be constructed using two or more of the patterns below.Single Layer – The most common example is a 7 wire strand with a single-wire center and six wires of the same diameter around it.

Filler Wire – Two layers of uniform-size wire around a center with the inner layer having half the number of wires as the outer layer. Small filler wires, equal to the number in the inner layer, are laid in valleys of the inner wire.

Seale – Two layers of wires around a center with the same number of wires in each layer. All wires in each layer are the same diameter. The large outer wires rest in the valleys between the smaller inner wires.

Warrington – Two layers of wires around a center with one diameter of wire in the inner layer, and two diameters of wire alternating large and small in the outer later. The larger outer-layer wires rest in the valleys, and the smaller ones on the crowns of the inner layer.

On a preformed wire rope, the strands and wires are formed during the manufacturing process to the helical shape that they will take in a finished wire rope.

Preformed rope can be advantageous in certain applications where it needs to spool more uniformly on a drum, needs greater flexibility, or requires more fatigue-resistance when bending.

Direction and type of lay refer to the way the wires are laid to form a strand (either right or left) and how the strands are laid around the core (regular lay, lang lay, or alternate lay).Regular Lay – The wires line up with the axis of the rope. The direction of the wire lay in the strand is opposite to the direction of the strand lay. Regular lay ropes are more resistant to crushing forces, are more naturally rotation-resistant, and also spool better in a drum than lang lay ropes.

Lang Lay– The wires form an angle with the axis of the rope. The wire lay and strand lay around the core in the same direction. Lang Lay ropes have a greater fatigue-resistance and are more resistant to abrasion.

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. Steel cores are best suited for applications where a fiber core may not provide adequate support, or in an operating environment where temperatures could exceed 180° F.

The classifications of wire rope provide the total number of strands, as well as a nominal or exact number of wires in each strand. These are general classifications and may or may not reflect the actual construction of the strands. However, all wire ropes of the same size and wire grade in each classification will have the SAME strength and weight ratings and usually the same pricing.

Besides the general classifications of wire rope, there are other types of wire rope that are special construction and designed for special lifting applications.

Some types of wire rope, especially lang lay wire rope, are more susceptible to rotation when under load. Rotation resistant wire rope is designed to resist twisting, spinning, or rotating and can be used in a single line or multi-part system.

Special care must be taken when handling, unreeling, and installing rotation resistant wire rope. Improper handling or spooling can introduce twist into the rope which can cause uncontrolled rotation.

Compacted strand wire rope is manufactured using strands that have been compacted, reducing the outer diameter of the entire strand, by means of passing through a die or rollers. This process occurs prior to closing of the rope.

This process flattens the surface of the outer wires in the strand, but also increases the density of the strand. This results in a smoother outer surface and increases the strength compared to comparable round wire rope (comparing same diameter and classification), while also helping to extend the surface life due to increased wear resistance.

A swaged wire rope differs from a compacted strand wire rope, in that a swaged wire rope’s diameter is compacted, or reduced, by a rotary swager machine after the wire rope has been closed. A swaged wire rope can be manufactured using round or compacted strands.

The advantages of a swaged wire rope are that they are more resistant to wear, have better crushing resistance, and high strength compared to a round strand wire rope of equal diameter and classification. However, a swaged wire rope may have less bending fatigue resistance.

A plastic coating can be applied to the exterior surface of a wire rope to provide protection against abrasion, wear, and other environmental factors that may cause corrosion. However, because you can’t see the individual strands and wires underneath the plastic coating, they can be difficult to inspect.

Plastic filled wire ropes are impregnated with a matrix of plastic where the internal spaces between the strands and wires are filled. Plastic filling helps to improve bending fatigue by reducing the wear internally and externally. Plastic filled wire ropes are used for demanding lifting applications.

This type of wire rope uses an Independent Wire Rope Core (IWRC) that is either filled with plastic or coated in plastic to reduce internal wear and increase bending fatigue life.

Remember, wire rope is a complex piece of mechanical machinery. There are a number of different specifications and properties that can affect the performance and service life of wire rope. Consider the following when specifying the best type of wire rope for your lifting application:Strength

When you select a piece of rope that is resistant to one property, you will most likely have a trade-off that affects another property. For example, a fiber core rope will be more flexible, but may have less crushing resistance. A rope with larger diameter wires will be more abrasion resistant, but will offer less fatigue resistance.

At Mazzella Companies, we offer all different kinds of wire rope from all of the leading manufacturers. We sell the highest-quality domestic and non-domestic rigging products because product quality and operating safety go hand-in-hand. We have one of the largest and most complete inventories of both domestic and non-domestic rigging and lifting products to suit your lifting needs.

If you’re looking for a standard or custom specified wire rope for your lifting project, contact a Lifting Specialist at a Mazzella Companies location near you.

We stock well over 2,000,000 feet of wire rope in our various locations … ready for immediate delivery! We provide wire rope assemblies, and manufacture bridge cables, crane cables, steel mill cables, and thousands of OEM assemblies.

We can also manufacture assemblies with standard or custom end fittings. Special testing and tolerance requirements are also available.In sizes from 1/4″ to 3″ diameter and 9 mm to 52 mm diameter

The difference between wire rope and industrial cable is important to understand. Both are renowned for their incredible strength and durability. While smaller cables and wires are used in everything from swing sets and exercise equipment, more robust models are used in suspension bridges and skyscrapers.

While wire ropes and cables are used all the time in today’s world, they have only been around for less than 200 years. Thewas created in Germany by a mining engineer with wrought iron. However, today’s cables and wire ropes are made nearly exclusively from steel.

But this is not the only detail that both wire ropes and industrial cables share. This is often why these pieces of hardware are confused and their terms are used interchangeably. So, what is the difference between wire rope and industrial cable?

As the name implies, a wire rope is constructed similarly to ropes made from fabric like hemp, but in this case, it is made with thin metal strands. These are woven together to form a strong yet flexible material that is used for support, overhead lifting, and securement. Wire ropes are used in industrial applications commonly with cranes, hoists, swivels, shackles, or hooks for attachments.

The demand for durable wire ropes has been steadily increasing since it is extensively used in massive industries like oil and gas, construction, marine fishing, and mining. While COVID-19 slowed down production in 2020 and 2021, the market size isthrough 2026 and will exceed $17.5 billion.

There are various mechanics which attribute to the strength and recommended use of wire ropes. For instance, a wire rope constructed with more strands will be more flexible than one with fewer. The diameter of the wires also contributes to flexibility and strength.

Wire ropes come in bright, galvanized, or stainless-steel finishes. Bright wire ropes may only be used for applications where the rope will not come into contact with moisture, as the material will corrode. Galvanized and stainless-steel ropes are corrosion resistant, and stainless steel is the strongest material available.

Other factors to be aware of when purchasing wire ropes are the core and pattern or lay. Wire ropes may have a fiber, independent wire, or wire strand core to support either flexibility or strength. The lay or direction in which the wires are woven also impacts the rotation resistance.

Although cable shares many of the same properties as wire rope, it is most easily classified based on size. The key difference between industrial cable and wire rope is the diameter of the strands. The smallest diameter of strands for a wire rope is typically 3/8”, while cables can have wires.

Since industrial cable wires are smaller, they are far more flexible and a bit more versatile. Like wire ropes, cables are used in construction, engineering, and machinery. But industrial cable is also commonly used in

Another slight difference between industrial cables and wire ropes. Industrial cable is not offered in a bright finish, only galvanized and stainless steel. This is because the increased flexibility naturally decreases abrasion resistance. Galvanized and stainless steel are better at resisting fatigue and abrasion than bright steel.

Industrial cables do have the same core offerings as wire rope: fiber, independent wire, or wire strand. However, another difference is the strand groupings. Industrial cables are most commonly offered in either 7×7 or 7×19 construction, while wire ropes have far more groupings.

While the differences between industrial cable and wire ropes may appear subtle, it is critical to select the correct hardware depending on the application. Weight load limits are generally the first indication of whether a wire rope or industrial cable will be used. Since wire ropes have a larger wire diameter, they can withstand heavier loads.

The required range of flexibility is also an important factor. For applications such as pulley systems, industrial cables are often recommended. Their construction is more flexible and abrasion-resistant, and it even offers a bit of stretch to combat cable fatigue.

No matter what, safety and overall construction quality need to be of top priority when selecting this type of hardware. If you are unsure of which to use, consult a knowledgeable wire rope and industrial cable wholesaler for assistance.

If you have further questions regarding the construction and use of either wire ropes or industrial cable, you can. We’ve built a reputation as a trustworthy and experienced wire rope and industrial cable supplier – and our team is here to help you out.

We believe that purchasinghigh-quality wire ropes and cable is the best way to ensure its strength and performance. That’s why we only offer the best-rated hardware on the market. Get in touch today to place an order.

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.

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.

At Carl Stahl Sava Industries, our steel mechanical cable choices include 304 and 316 stainless steel and galvanized steel cable. Sava is both a wire rope supplier and a wire rope manufacturer that is able to work withexotic steel alternatives upon request, both stainless steel and galvanized steel mechanical cable offer distinct benefits, depending upon the application. Read on to learn the differences between galvanized vs. stainless steel wire ropeand determine which custom wire rope will better serve your application requirements.

One of the greatest benefits of stainless steel wire rope is that it is suitable for nearly any application. While it may have a slightly higher cost than galvanized steel cable, stainless steel cable provides customers with greater ROI and maintains its high-strength qualities over its lifespan under most conditions. While not as strong as tungsten or tolerant of excessive temperatures, stainless steel mechanical wire rope is an incredibly effective cable construction material.

Stainless steel has high corrosion resistance due to it being treated with chromium. This additional element makes stainless steel suitable for use in moist environments, even when harmful salty conditions are present. Specifically in marine environments, for instance, stainless steel wire rope can be used for years without corroding. And in the medical devices field, stainless steel is commonly the metal of choice for many medical device instruments like endoscopes because of its high sanitization level and durability over many cycles makes it ideal.

Galvanized steel is steel that has been dipped in a zinc coating, which gives it good corrosion-resistant qualities. But even with the addition of zinc, galvanized wire rope’s strength is weaker than stainless steel because of the presence of chromium, making the cable stronger and more tolerant of corrosive elements like saltwater. Galvanized cable will rust and corrode if salty wet conditions are present. And like stainless steel, galvanized steel cable ends will also weld together if they make contact with one another.

Galvanized steel cable is often found in industrial applications, since items may brush up against the wire rope in the field, which again, are environmental conditions that galvanized steel tolerates quite well over time. For this and other reasons, Galvanized steel wire rope works exceptionally well in aerospace applications.

Stainless steel wire rope is a cost-effective solution that works across a range of applications, is impervious to salty wetness and is stronger than galvanized steel cable. But galvanized steel wire rope is corrosion-resistant, except when salt is present and tolerates contact with itself far better than stainless steel cable.

It"s important to remember that since each application has unique needs, these comparisons are general guidelines. Contact Sava today to discuss your project, so we can help you determine whether a stainless steel wire rope or galvanized steel wire rope is best for your cable manufacturing needs.

In the past (pre 19th century), most heavy haulage and lifting needs were met by bulky chains or big ropes made of fiber. In the early 1830’s, a mine in Germany dropped a mine conveyance full of ore to the bottom of their mine and it was found that the heavy chains they were using to haul the conveyance to the surface suffered from work hardening and became severely brittle, leading to its failure.

As time progressed, other nations and people began to experiment with the fabrication of wire rope and, initially, each of them were essentially drawing hot steel through some dyes to create wires which were then laid helically together to form the wire rope. The type of steel that was readily available at the time was the same steel used to create ploughs for agriculture; thus the “Plough Steel” designation was used to denote what grade of steel was used to fabricate the rope.

Improvements were made to the ingredients of Plough Steel that allowed for a higher tensile strength of the wire rope. This new grade was aptly named, “Improved Plough Steel” or I.P.S. for short. Improved plough steel became the de facto steel to be used until it was once again improved upon, to the point where it is actually difficult to find Plough Steel grade wire rope in inventory at a sling shop.

Speaking of improvements made to the already Improved Plough Steel, once the recipe was perfected and it was found that wire rope could be made to have some extra strength. What did the powers that be name this new and improved wire rope…You guessed it, “Extra Improved Plough Steel.” EIPS offers approximately 10-15% increases in tensile strength over the old IPS depending on diameter. The higher tensile strength improves the minimum breaking strength of the wire rope. This, of co