using wire rope in stock

Steel wire rope has been utilized for centuries. Since steel wire rope’s experimental use in the 1800s in Europe, it has become absolutely vital for many industries. Steel wire rope is used in the marine industry, construction, farming, and automotive sector, just to name a few.

A piece of steel wire rope is constructed of fine individual wires woven together around a solid fiber core or steel wire core. It’s this durable design that allows stainless steel wire rope to be heat and impact-resistant. However, regardless of its durability, there are some tips you should know about using wire ropes correctly.

Steel wire rope is meant to last a long time, many years if cared for properly. Keep in mind that you get what you pay for so don’t gyp yourself when it comes to quality. Shop around to check out the different varieties of thicknesses and construction of wire ropes.

Buying online is a good way to save some money if you’re strapped for cash. However, if you buy second-hand, be sure to thoroughly check the wire rope for any damage, such as corrosion, knicks, kinks, and scratches.

It’s imperative that you break in your steel wire rope as soon as you buy it. Breaking in a steel wire rope simply means utilizing it for what you intended minus the load. Remember that wire rope is prone to stretching, so allow a stretch of about half a percent of the rope length.

Towards the end of the rope’s lifespan, it’s good practice to check for stretch. It’s time to replace that rope once the diameter of the rope has been significantly reduced.

Seizing your rope simply means binding the ends of a rope. While a simple step, it is absolutely critical. A good way to learn the proper methods of seizing wire rope is to simply watch tutorials on how it’s done by professionals.

You can extend your wire rope’s lifespan by practicing good coiling and storage habits. This will greatly reduce the kinks and twists that can damage wire rope as time passes. These processes can also be seen done on Youtube tutorials. While it’s not a difficult process, it’s important to pay attention to detail.

As previously mentioned, steel wire rope is manufactured with multiple strands of wire. This allows dust, dirt, and moisture to build up in the tiny gaps. Simply utilize a wire brush and petroleum solvent to scrub away any debris.

While you’re cleaning, use this time to look for any damage to your wire rope. If you see any serious distortion on the rope, it should be replaced immediately.

It’s also important to lubricate your wire rope after you clean it. In addition to the rope itself, you should also lubricate any machinery the rope runs through. Doing so will reduce damaging friction on the cable. This friction can lead to fraying, tears, or even snaps.

When installing wire ropes to machinery or for rigging purposes, it’s absolutely imperative to have this work done by professionals. If you aren’t adequately trained when it comes to installing steel wire ropes, it’s a good idea to hire someone who is. Remember that OSHA regulates the safety of wire rope. AtSilver State Wire Rope and Rigging, our staff has the correct training necessary to provide you and your company with the wire rope and rigging solutions you need.Contact ustoday to get the job done right.

Wire rope is often used in slings because of its strength, durability, abrasion resistance and ability to conform to the shape of the loads on which it is used. In addition, wire rope slings are able to lift hot materials.

Wire rope used in slings can be made of ropes with either Independent Wire Rope Core (IWRC) or a fiber-core. It should be noted that a sling manufactured with a fiber-core is usually more flexible but is less resistant to environmental damage. Conversely, a core that is made of a wire rope strand tends to have greater strength and is more resistant to heat damage.

Wire rope may be manufactured using different rope lays. The lay of a wire rope describes the direction the wires and strands are twisted during the construction of the rope. Most wire rope is right lay, regular lay. This type of rope has the widest range of applications. Wire rope slings may be made of other wire rope lays at the recommendation of the sling manufacturer or a qualified person.

Wire rope slings are made from various grades of wire rope, but the most common grades in use are Extra Improved Plow Steel (EIPS) and Extra Extra Improved Plow Steel (EEIPS). These wire ropes are manufactured and tested in accordance with ASTM guidelines. If other grades of wire rope are used, use them in accordance with the manufacturer"s recommendations and guidance.

When selecting a wire rope sling to give the best service, consider four characteristics: strength, ability to bend without distortion, ability to withstand abrasive wear, and ability to withstand abuse.

Rated loads (capacities) for single-leg vertical, choker, basket hitches, and two-, three-, and four-leg bridle slings for specific grades of wire rope slings are as shown in Tables 7 through 15.

Ensure that slings made of rope with 6×19 and 6x37 classifications and cable slings have a minimum clear length of rope 10 times the component rope diameter between splices, sleeves, or end fittings unless approved by a qualified person,

Ensure that braided slings have a minimum clear length of rope 40 times the component rope diameter between the loops or end fittings unless approved by a qualified person,

Do not use wire rope clips to fabricate wire rope slings, except where the application precludes the use of prefabricated slings and where the sling is designed for the specific application by a qualified person,

Use damaged slings only after they are repaired, reconditioned, and proof tested by the sling manufacturer or a qualified person using the following criteria:

Ensure that wire rope slings have suitable characteristics for the type of load, hitch, and environment in which they will be used and that they are not used with loads in excess of the rated load capacities described in the appropriate tables. When D/d ratios (Fig. 4) are smaller than those listed in the tables, consult the sling manufacturer. Follow other safe operating practices, including:

When D/d ratios (see Fig. 6) smaller than those cited in the tables are necessary, ensure that the rated load of the sling is decreased. Consult the sling manufacturer for specific data or refer to the WRTB (Wire Rope Technical Board) Wire Rope Sling Users Manual, and

When using a basket hitch, ensure that the legs of the sling contain or support the load from the sides, above the center of gravity, so that the load remains under control,

Before initial use, ensure that all new swaged-socket, poured-socket, turnback-eye, mechanical joint grommets, and endless wire rope slings are proof tested by the sling manufacturer or a qualified person.

Permanently remove from service fiber-core wire rope slings of any grade if they are exposed to temperatures in excess of 180 degrees F (82 degrees C).

Follow the recommendations of the sling manufacturer when you use metallic-core wire rope slings of any grade at temperatures above 400 degrees F (204 degrees C) or below minus 40 degrees F (minus 40 degrees C).

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.

Small diameter 7×7 and 7×19 construction wire rope is commonly referred to as “aircraft cable”. IT IS NOT INTENDED FOR AIRCRAFT USE but designed for industrial and marine applications. According to Federal Specifications RR-W-410D, preformed, right regular lay, strand core, drawn galvanized. Aircraft cable is very versatile and is used for everything from hoisting ropes and tie-backs to safety barricades. It is available galvanized, stainless, or vinyl coated.

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 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.

Wire rope is technically defined as multi-wire strands laid geometrically around a core while also used more generally as a term to classify multiple product families including aircraft cable, coated aircraft cable, general purpose wire rope, strand, rotation resistant wire rope, compacted/swaged wire rope, and cable laid wire rope.

Aircraft cable does not fit the definition of wire rope in the strictest sense as it does not have an independent core, but rather a strand core, in which the center is one of the strands that is laid with the outside strand layers. Aircraft cable is available in diameters 3/8" or less with breaking strengths similar to that of equal diameter independent wire rope core (IWRC) and is available in stainless steel and galvanized steel.

Wire rope can be galvanized via three processes. Listed from least corrosion-resistant to the most corrosion-resistant, they are electro-galvanizing, hot-dip galvanizing, and drawn-galvanizing. In addition to being the most corrosion-resistant types of galvanized wire rope, drawn-galvanized has another added benefit which is a breaking strength that is the same as bright wire rope does. Electro-galvanized and hot-dip galvanized wire rope have breaking strengths that are approximately 10% lower.

Wire rope is specified by the number of strands in the rope, the number of wires in each strand, and a description of the core’s material of construction. For example, the notation “6x7 FC” means that the rope has six strands with seven wires in each strand and a fiber core. Commonly used core designations include FC (fiber core), independent wire rope core (IWRC), wire strand core (WSC), and poly core (PC).

There are two elements to wire rope lubrication, the core, and outer strands. IWRC wire rope always has a lubricated core (unless specially ordered as otherwise). Bright wire rope always has lubricated outer strands.  Galvanized wire rope can be manufactured in either dry finish or lubricated with respect to the outer strands.  Typically stainless steel wire rope is manufactured with a lubricated IWRC and dry finish outer strands.

RF2BAR5HN–Old wire rope cable, block, pulley fixed to the the ground, used to winch fishing boats up the beach in the village of Cadgwith, Cornwall, England

RF2HB492T–Padlocks hanging on a wire rope. Love locks on netting fence at the brigde in New Wesminster BC. Street view, nobody, selective focus, blurred backgro

RMKWDWP7–Sample of Roebling"s wire rope used on the Brooklyn Bridge on display in Allegheny Portage Railroad National Historic site, Pennsylvania, USA.

RF2BAR5GG–Old wire rope cable, block, pulley fixed to the the ground, used to winch fishing boats up the beach in the village of Cadgwith, Cornwall, England

RF2HB48H5–Padlocks hanging on a wire rope. Love locks on netting fence at the brigde in New Wesminster BC. Street view, nobody, selective focus, blurred backgro

RM2G993D5–A pair of used, grey, polyester working gloves pinned on twisted steel wire rope by a blue plastic peg, closeup view with green foliage background.

RF2G4GART–Loops of metal cable close up on white background isolated, space for text. Texture of heavy duty steel cable, steel wire rope or steel sling. Use for

RF2BAR5H5–Old wire rope cable, block, pulley fixed to the the ground, used to winch fishing boats up the beach in the village of Cadgwith, Cornwall, England

RF2HMD522–Close - up of a hand rail along a difficult hiking trail in the Franconian Switzerland, Germany, made of steel wire rope with a wire rope clip mounted

RF2HMD51T–Close - up of a hand rail along a difficult hiking trail in the Franconian Switzerland, Germany, made of steel wire rope with a wire rope clip mounted

Rope diameter is specified by the user and is generally given in the equipment manufacturer’s instruction manual accompanying the machine on which the rope is to be used.

Rope diameters are determined by measuring the circle that just touches the extreme outer limits of the strands— that is, the greatest dimension that can be measured with a pair of parallel-jawed calipers or machinist’s caliper square. A mistake could be made by measuring the smaller dimension.

The right way to unreel.To unreel wire rope from a heavy reel, place a shaft through the center and jack up the reel far enough to clear the floor and revolve easily. One person holds the end of the rope and walks a straight line away from the reel, taking the wire rope off the top of the reel. A second person regulates the speed of the turning reel by holding a wood block against the flange as a brake, taking care to keep slack from developing on the reel, as this can easily cause a kink in the rope. Lightweight reels can be properly unreeled using a vertical shaft; the same care should be taken to keep the rope taut.

The wrong way to unreel.If a reel of wire rope is laid on its flange with its axis vertical to the floor and the rope unreeled by throwing off the turns, spirals will occur and kinks are likely to form in the rope. Wire rope always should be handled in a way that neither twists nor unlays it. If handled in a careless manner, reverse bends and kinks can easily occur.

The right way to uncoil.There is only one correct way to uncoil wire rope. One person must hold the end of the rope while a second person rolls the coil along the floor, backing away. The rope is allowed to uncoil naturally with the lay, without spiraling or twisting. Always uncoil wire rope as shown.

The wrong way to uncoil.If a coil of wire rope is laid flat on the floor and uncoiled by pulling it straight off, spirals will occur and kinking is likely. Torsions are put into the rope by every loop that is pulled off, and the rope becomes twisted and unmanageable. Also, wire rope cannot be uncoiled like hemp rope. Pulling one end through the middle of the coil will only result in kinking.

Great stress has been placed on the care that should be taken to avoid kinks in wire rope. Kinks are places where the rope has been unintentionally bent to a permanent set. This happens where loops are pulled through by tension on the rope until the diameter of the loop is only a few inches. They also are caused by bending a rope around a sheave having too severe a radius. Wires in the strands at the kink are permanently damagedand will not give normal service, even after apparent “re-straightening.”

When wire rope is wound onto a sheave or drum, it should bend in the manner in which it was originally wound. This will avoid causing a reverse bend in the rope. Always wind wire rope from the top of the one reel onto the top of the other.Also acceptable, but less so, is re-reeling from the bottom of one reel to the bottom of another. Re-reeling also may be done with reels having their shafts vertical, but extreme care must be taken to ensure that the rope always remains taut. It should never be allowed to drop below the lower flange of the reel. A reel resting on the floor with its axis horizontal may also be rolled along the floor to unreel the rope.

Wire rope should be attached at the correct location on a flat or smooth-faced drum, so that the rope will spool evenly, with the turns lying snugly against each other in even layers. If wire rope is wound on a smooth-face drum in the wrong direction, the turns in the first layer of rope will tend to spread apart on the drum. This results in the second layer of rope wedging between the open coils, crushing and flattening the rope as successive layers are spooled.

A simple method of determining how a wire rope should be started on a drum. The observer stands behind the drum, with the rope coming towards him. Using the right hand for right-lay wire rope, and the left hand for left lay wire rope, the clenched fist denotes the drum, the extended index finger the oncoming rope.

Clips are usually spaced about six wire rope diameters apart to give adequate holding power. They should be tightened before the rope is placed under tension. After the load is placed on the rope, tighten the clips again to take care of any lessening in rope diameter caused by tension of the load. A wire rope thimble should be used in the eye of the loop to prevent kinking.

U-bolt Clips.There is only one correct method for attaching U-bolt clips to wire rope ends, as shown in TheRightWayimage below. The base of the clip bears on the live end of the rope; the “U” of the bolt bears on the dead end.

Compare this with the incorrect methods. Five of the six clips shown are incorrectly attached—only the center clip in the top view is correct. When the “U” of the clip bears on the live end of the rope, there is a possibility of the rope being cut or kinked, with subsequent failure.

Proper seizing and cutting operations are not difficult to perform, and they ensure that the wire rope will meet the user’s performance expectations. Proper seizings must be applied on both sides of the place where the cut is to be made. In a wire rope, carelessly or inadequately seized ends may become distorted and flattened, and the strands may loosen. Subsequently, when the rope is operated, there may be an uneven distribution of loads to the strands; a condition that will significantly shorten the life of the rope.

Either of the following seizing methods is acceptable. Method No. 1 is usually used on wire ropes over one inch in diameter. Method No. 2 applies to ropes one inch and under.

Method No. 1: Place one end of the seizing wire in the valley between two strands. Then turn its long end at right angles to the rope and closely and tightly wind the wire back over itself and the rope until the proper length of seizing has been applied. Twist the two ends of the wire together, and by alternately pulling and twisting, draw the seizing tight.

The Seizing Wire. The seizing wire should be soft or annealed wire or strand. Seizing wire diameter and the length of the seize will depend on the diameter of the wire rope. The length of the seizing should never be less than the diameter of the rope being seized.

Proper end seizing while cutting and installing, particularly on rotation-resistant ropes, is critical. Failure to adhere to simple precautionary measures may cause core slippage and loose strands, resulting in serious rope damage. Refer to the table below ("Suggested Seizing Wire Diameters") for established guidelines. If core protrusion occurs beyond the outer strands, or core retraction within the outer strands, cut the rope flush to allow for proper seizing of both the core and outer strands.

The majority of wire rope problems occurring during operation actually begin during installation, when the rope is at its greatest risk of being damaged. Proper installation procedures are vital in the protection and performance of wire rope products.

Until the rope is installed it should be stored on a rack, pallet or reel stand in a dry, well-ventilated storage shed or building. Tightly sealed and unheated structures should be avoided as condensation between rope strands may occur and cause corrosion problems. If site conditions demand outside storage, cover the rope with waterproof material and place the reel or coil on a support platform to keep it from coming directly in contact with the ground.

While lubrication is applied during the manufacturing process, the wire rope must still be protected by additional lubrication once it is installed. Lubricants will dry out over a period of time and corrosion from the elements will occur unless measures are taken to prevent this from happening. When the machine becomes idle for a period of time, apply a protective coating of lubricant to the wire rope. Moisture (dew, rain, and snow) trapped between strands and wires will create corrosion if the rope is unprotected. Also apply lubricant to each layer of wire rope on a drum because moisture trapped between layers will increase the likelihood of corrosion.

Always use the nominal diameter as specified by the equipment manufacturer. Using a smaller diameter rope will cause increased stresses on the rope and the probability of a critical failure is increased if the rated breaking strength does not match that of the specified diameter. Using a larger diameter rope leads to shorter service life as the rope is pinched in the sheave and drum grooves which were originally designed for a smaller diameter rope. Just as using a different diameter rope can create performance problems, so can the use of an excessively undersized or oversized rope.

Measure the wire rope using a parallel-jawed caliper as discussed in Measuring Rope Diameter at the top of this page. If the rope is the wrong size or outside the recommended tolerance, return the rope to the wire rope supplier. It is never recommended nor permitted by federal standards to operate cranes with the incorrect rope diameter. Doing so will affect the safety factor or reduce service life and damage the sheaves and drum. Note that in a grooved drum application, the pitch of the groove may be designed for the rope’s nominal diameter and not the actual diameter as permitted by federal standards.

Wire rope can be permanently damaged by improper unreeling or uncoiling practices. The majority of wire rope performance problems start here.Improper unreeling practices lead to premature rope replacement, hoisting problems and rope failure.

Place the payout reel as far away from the boom tip as is practical, moving away from the crane chassis. Never place the payout reel closer to the crane chassis than the boom point sheave. Doing so may introduce a reverse bend into the rope and cause spooling problems. Follow the guidelines highlighted under Unreeling and Uncoiling and Drum Winding. Take care to determine whether the wire rope will wind over or under the drum before proceeding. If the wire rope supplier secured the end of the rope to the reel by driving a nail through the strands, ask that in the future a U-bolt or other nondestructive tie-down method be used; nails used in this manner damage the rope.

Take extra precaution when installing lang lay, rotation-resistant, flattened strand or compacted ropes. Loss of twist must be avoided to prevent the strands from becoming loosened, causing looped wire problems.

The end of the rope must be securely and evenly attached to the drum anchorage point by the method recommended by the equipment manufacturer. Depending on the crane’s regulatory requirements, at least two to three wraps must remain on the drum as dead wraps when the rope is unwound during normal operations. Locate the dead end rope anchorage point on the drum in relation to the direction of the lay of the rope. Do not use an anchorage point that does not correspond with the rope lay. Mismatching rope lay and anchorage point will cause the wraps to spread apart from each other and allow the rope to cross over on the drum. Very gappy winding will occur resulting in crushing damage in multilayer applications.

Back tension must be continually applied to the payout reel and the crewman installing the rope must proceed at a slow and steady pace whether the drum is smooth or grooved.Regardless of the benefits of a grooved drum, tension must be applied to ensure proper spooling. An improperly installed rope on a grooved drum will wear just as quickly as an improperly installed rope on a smooth drum. If a wire rope is poorly wound and as a result jumps the grooves, it will be crushed and cut under operating load conditions where it crosses the grooves.

Every wrap on the first or foundation layer must be installed very tightly and be without gaps. Careless winding results in poor spooling and will eventually lead to short service life. The following layers of rope must lay in the grooves formed between adjacent turns of the preceding layer of rope. If any type of overwind or cross-winding occurs at this stage of installation and is not corrected immediately, poor spooling and crushing damage will occur.

On a multilayer spooling drum be sure that the last layer remains at least two rope diameters below the drum flange top. Do not use a longer length than is required because the excess wire rope will cause unnecessary crushing and may jump the flange. Loose wraps that occur at any time must be corrected immediately to prevent catastrophic rope failure.

The use of a mallet is acceptable to ensure tight wraps, however a steel-faced mallet should be covered with plastic or rubber to prevent damage to the rope wires and strands.

Rotation-resistant ropes of all constructions require extra care in handling to prevent rope damage during installation. The lay length of a rotation-resistant rope must not be disturbed during the various stages of installation. By introducing twist or torque into the rope, core slippage may occur—the outer strands become shorter in length, the core slips and protrudes from the rope. In this condition the outer strands become over- loaded because the core is no longer taking its designed share of the load. Conversely, when torque is removed from a rotation-resistant rope core slippage can also occur. The outer strands become longer and the inner layers or core become overloaded, reducing service life and causing rope failure.

The plain end of a wire rope must be properly secured. If the entire cross section of the rope is not firmly secured, core slippage may occur, causing the core to pull inside the rope’s end and allowing it to protrude elsewhere, either through the outer strands (popped core) or out the other end of the line. The outer layer of the outside strands may also become overloaded as there is no complete core-to-strand support.

Secure the ends of the rope with either seizing or welding methods as recommended under Seizing Wire Rope. It is imperative that the ends be held together tightly and uniformly throughout the entire installation procedure, including attaching the end through the wedge socket and the drum dead end wedge

When installing a new line, connect the old line to the new line by using a swivel-equipped cable snake or Chinese finger securely attached to the rope ends. The connection between the ropes during change-out must be very strong and prevent torque from the old rope being transferred into the new rope.Welding ropes together or using a cable snake without the benefit of a swivel increases the likelihood of introducing torque into the new rope. A swivel-equipped cable snake is not as easy as welding the ropes, but this procedure can be mastered with a little patience and practice.