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Over the past decade, a handful of crane OEMs have partnered with wire and synthetic rope manufacturers to research the idea of replacing heavy wire rope with lighter fiber rope. The idea is to reduce weight without conceding strength.

“We do not see too much interest in this topic amongst our OEMs,” Balbiani said. “There is one overhead crane manufacturer who has put up a whole product line that can be equipped with fiber rope or steel wire rope.”

“The primary purpose in doing so is to reduce weight without compromising strength, increasingly a concern as lifts become higher, heavier and more complex,” said, Andreas Schmeiss, vice president of WireCo. “Synthetic ropes also tend to be easier to handle and install, reducing fatigue and the possibility of injury for those who conduct installations, inspections and change-outs. And, without any need for lubrication, fiber ropes offer environmental benefit.”

“In the industrial environment, in which ropes frequently encounter sharp edges and abrasive surfaces, steel is generally impervious, while fibers are susceptible to fraying,” he said. “Fibers are also sensitive to ultraviolet radiation and excessive heat. High temperatures can cause a condition known as ‘creep,’ in which a rope becomes pliable and stretches to a point beyond its original form.”

“Retirement criteria are also more difficult to determine with synthetic ropes, where the nondestructive testing methods used to judge the condition of a steel rope are not suitable,” he said. “Synthetic ropes tend to be more expensive than steel wire ropes. For the same application, the cost of fiber can exceed that of steel by up to three or four times.”

“Fiber rope helps reduce the required rope diameter tremendously,” Balbiani said. “In some cases, steel is the clear winner. In other cases, fiber. Advanced coatings might one day tip the balance in favor of synthetics, but, for now, it would be difficult to imagine that fiber rope would fully displace steel any time soon.”

“These include applications in which ropes are not continually wound and unwound over drums,” said Schmeiss. “WireCo, through Lankhorst Ropes, has a long history of employing synthetic ropes to moor ships, offshore energy platforms and, more recently, floating wind turbines. These ropes are transported and installed at sea, making synthetics’ reduced weight, high strength, ease-of-handling and corrosion resistance the preferred choice over steel.”

Schmeiss said both the limited axle loads of road-approved vehicular cranes and weight limitations for crawler cranes require that ropes provide a steadily increasing breaking load at a constant diameter. To meet these requirements, synthetic alternatives must employ special fibers with tensile strengths similar to those of steel, he said.

Lankhorst Ropes’ LankoLift S does this, Schmeiss said. The yellow rope consists of 12 braided outer strands made of high-tech Dyneema and provides a breaking strength equal to that of steel rope of the same thickness. LankoLift’s core is designed to resist transverse pressures, and laboratory tests involving reversed bending cycles have yielded promising results. The rope also features a special fiber coating that reduces interior friction and increases ultraviolet resistance.

“LankoLift crane test participants have been consistently impressed with the product’s low weight, flexibility and ease of handling during installation and hook block changes,” Schmeiss said. “The rope has proven suitable for higher payloads, especially those involving higher lifting heights and longer jib lengths. The low maintenance requirements offer further advantage, since synthetic ropes of this type are corrosion-proof and require no further lubrication.”

“The bottom line is that fiber rope bears a cost disadvantage that only becomes balanced when the operations are very expensive, for example deep shaft mining, and the relatively low reduction in total weight accumulates over a long length in favor of payload, [like] increasing a skip’s capacity from 30 to 40 tons in a 3,000 meter deep shaft,” said Balbiani. “Due to economic turbulences, we have currently iced these projects and will go ahead when supply chain problems have resolved.”

WireCo offers the Casar TurboLite M, a hybrid mining rope with a plastic-coated, high-strength fiber core, surrounded by steel-wire strands. This construction provides a high strength-to-weight ratio, as well as resistance to abrasion and bending fatigue. It was designed for use in underground mining, where shafts have become progressively deeper and weight the limiting factor in hoisting capacity, Schmeiss said.

“As with other applications that favor synthetics, reduced weight is a clear benefit,” Schmeiss said. “The same is true of the added durability and reduced creep provided by hybrid ropes. In terms of downside and factors that would limit wider use, cost is likely the most significant.”

A lot of research has been conducted on hybrid ropes. The main objective has been to substitute the independent wire rope core of a conventional steel wire rope with a high performance synthetic rope that also has supportive load-bearing features.

High performance synthetic ropes are used on utility truck cranes for transmission wire and transformer applications. These ropes are being used on tower cranes, RTs and even overhead cranes. The elevator industry is also researching the use of hybrid ropes.

We are always looking for ways to decrease weight on a crane without compromising the mechanical properties for lifting. The mobile crane market demands ropes with a high break strength and non-rotating characteristics for long lifts and increased weights. Also, we must realize that end fittings – such as swage or spelter buttons, sockets and wedge sockets – have the ability to make the termination of the hybrid rope to complete the installation.

Inspection criteria of standard wire ropes have been in place for a long time. Since the introduction of high performance synthetic ropes, inspection criteria is also documented. High performance synthetic ropes have been predominantly used in the utility truck applications with much shorter lifts and very few, if any, parts of line through the block. With that said, inspection criteria for high performance synthetic ropes is very important, requiring proper education for daily inspection and third-party inspection. Inspection of these ropes has generated a lot of discussion. A critical subject is damage. If a steel wire rope jumps a sheave, the outer steel wires can withstand the abuse. But with high performance synthetic rope, very small diameter fibers can be cut between the sheave and block.

Research will undoubtedly continue. A hybrid robe gives more answers when it comes to inspection and damage assessment. And there maybe be some comfort knowing that a hybrid rope is protected by steel wire with the internal lighter fibers fulfilling the strength, flexibility and torque balance characteristics.

Tony Fastuca, Vice President of ASC Industries Python America, has been in the wire rope industry since 1979. Based in Germany, Python provides engineered ropes for customers around the world.

The company has pioneered and thrived in the highly critical profession of cable and wire ropemanufacturing for use in aerospace flight controls, elevators, rigging, and scaffolding, where human lives are directly at stake.

Other artifacts that will help archaeologists further identify and date the shipwreck include ceramic dinnerware, glass bottles, stoneware jugs, an anchor, wire roperigging, a windlass, and a ship"s bell, reported NOAA.

These example sentences are selected automatically from various online news sources to reflect current usage of the word "wire rope." Views expressed in the examples do not represent the opinion of Merriam-Webster or its editors. Send us feedback.

CLEVELAND, OH – Mazzella Lifting Technologies, a Mazzella Company, is pleased to announce the acquisition of Denver Wire Rope & Supply. This acquisition will strengthen Mazzella’s footprint west of the Mississippi River and reinforce Mazzella’s commitment to be a one-stop resource for lifting and rigging services and solutions.

Denver Wire Rope & Supply has been in business since 1983 and services a variety of industries out of their location in Denver, CO. Denver Wire Rope & Supply is a leading supplier of rigging products, crane and hoist service, below-the-hook lifting devices, and certified rigging inspection and training. Effective immediately, Denver Wire Rope & Supply will operate as Mazzella / Denver Wire Rope. Terms of the transaction are not being disclosed.

“Denver Wire Rope & Supply will complement the wide range of products and services that Mazzella Companies offers. We are dedicated to being a single-source provider for rigging products, overhead cranes, rigging inspections, and rigging training. Both companies commit to a customer-first mentality, providing the highest-quality products, and leading by example when it comes to safety and sharing our expertise with customers and the market,” says Tony Mazzella, CEO of Mazzella Companies.

“Our team and family are excited to be part of the Mazzella Companies. This acquisition strengthens our place in the market and allows our team to continue to provide excellent service and products to our valued customer base and expand our offering,” says Ken Gubanich, President of Denver Wire Rope & Supply.

“Over the years, we have had numerous companies show interest in purchasing Denver Wire Rope & Supply, none seemed to be the right fit. We are looking forward to becoming a part of an aggressive, passionate, and progressive organization. As a family business for over 36 years, it is important to us that our customers/friends, suppliers, and team members continue to be treated with first-class service, products, and employment opportunities. Again, we are very enthusiastic about our future and look forward to being a quality supplier for your crane, safety training, rigging, and hoisting needs for years to come,” says Gubanich.

“We wish Ed and Carol Gubanich all the best in their retirement. We welcome Ken and the other second and third-generation Gubanich family members, as well as the entire Denver Wire Rope Team, into the Mazzella organization,” says Mazzella.

We’ve changed our name from Denver Wire Rope to Mazzella. Aside from the new name and logo, our member experience is virtually unchanged. Here are some common questions and answers related to this change.

In 2019, Denver Wire Rope & Supply was acquired by Mazzella Companies to expand lifting and rigging products and services to the western half of the United States.

In 1954, James Mazzella founded Mazzella Wire Rope & Sling Co. in Cleveland, OH. For over 65 years, the company has grown organically by nurturing historic relationships, expanding its product offerings, and entering new markets through acquisition.

KANSAS CITY, Mo., Aug. 30, 2022 (GLOBE NEWSWIRE) -- WireCo, the world’s leading manufacturer of mission-critical wire rope, synthetic rope and netting, and electromechanical cable, announced today the launch of its new line of Union Gladiator pendants, designed to improve the service life of shovels and draglines by 10-15 times over traditional technologies.

WireCo’s Union brand is well known for delivering exceptional rope quality and outstanding performance. The Gladiator pendants are made with synthetic fibers, which significantly increase the service life by absorbing loads and reducing vibration.

“I am excited to participate in the release of this groundbreaking product that is a testament to our organization’s strength in both the surface mining application and synthetic rope capabilities,” said Dustin Dunning, senior vice president of Global Energy & Mining. “Gladiator is a true technology step change for our customers who are looking to lower HS&E risks while also improving operating costs of their mining fleets.”

Surface mining is among the most punishing environments for ropes and boom pendants on the planet. To transmit raw power into cubic yards moved, the entire rope system must be rugged and reliable. For decades, customers have relied on steel pendants to consistently deliver outstanding performance. Gladiator pendants solve these challenges with innovative design.

“Compared to conventional steel pendants, Gladiator’s synthetic Aramid fibers act like a shock absorber during digging operations, reducing fatigue-related issues for both the shovel equipment and those operating them,” Dunning said. “As surface mining continues to take the lead in meeting the world’s current and future energy needs, the Gladiator synthetic boom pendant is just another example of how WireCo is leading the rope industry through novel innovation and forward-thinking products.”

WireCo is introducing a full line of Union Synthetic Mining Rope Solutions, including GLADIATOR CABLETM Main Boom Synthetic Pendants and ARA-Boom Aramid Fiber Mid-Boom Synthetic Pendants, which significantly increase the service life for shovels and draglines by absorbing loads and reducing vibration.

WireCo’s new GLADIATOR CABLE Main Boom Pendants include more than just ordinary sockets and rope fibers. Key elements of the new product lines include:

New Patent Pending Union Uni-HatchTM Inspection Port:Tool-less inspectability – opens without the need for tools during routine inspections and features the socket measurement device embedded in the socket.

Eco-Friendly: The pendant ropes used in the Union Synthetic Mining Rope Solutions are fully recyclable. The Aramid fibers can be reused in various applications, such as in the production of car and truck tires.

For more information about WireCo and its product lines, visit wireco.com, or follow WireCo on social media at facebook.com/WireCoWorldGroup, twitter.com/wirecoand linkedin.com/company/wireco-worldgroup.

WireCo markets value-added products under several brands that are recognized throughout the world and used in a wide range of market applications. WireCo is headquartered in Prairie Village, Kansas, with manufacturing plants, distribution facilities and research and development centers worldwide.

Wire ropes used on powered scaffold hoists are not designed to be used with a swivel. In this product bulletin, learn why you should never use a swivel that allows rope to rotate under load and truly understand the information that supports WireCo WorldGroup’s recommendation.

Wire ropes used with traction hoists frequently have their ends brazed or welded into a “bullet” to allow automatic reeving of the traction drive. This is necessary to keep wires and strands from being pushed apart. In this product bulletin, learn why this is necessary to keep wires and strands from being pushed apart.

Engineering and producing wire rope slings for your application is a highly specialized field - with exacting standards that we gladly live by. In this marketing flier, learn the different Union Wire Rope Sling constructions. Additionally learn more about Union Spelter Sockets (both open and closed). There are capacity and diameter charts associated with each product.

While there is not a simple answer, there are several factors involved. Below is a reprint of an article from Union Wire Rope which outlines many of the variables which contribute to the serviceable life of wire rope. If you utilize wire rope in your business this is well worth the read!

We’ve outlined several recommended practices you may use to extend your rope’s useful life. It’s also important to note that all sections of this outline, in some respect, also review ways to help you get greater useful life from your rope, and that’s why you need to thoroughly understand all the material here.

The primary concern when installing a new rope is to not trap any twist in the rope system. Proper handling of the rope from the reel or coil to your equipment will help avoid this situation. Another important step on smooth faced drums is to spool with tensioned wraps tight and close together on the first layer. This layer forms the foundation for succeeding layers. Finally, spool the remaining rope on the drum with tension approximating 1% to 2% of the rope’s minimum breaking force.

Handle the rope properly from the reel or coil to your equipment and, on smooth-faced drums, spool with wraps tight and close together on the first layer.

When you install a new operating rope, you should first run it for a brief period of time with no load. Then, for best results, run it under controlled loads and speeds to enable the wires and strands in the rope to adjust to themselves.

When first put into service, new ropes normally elongate while strands go through a process of seating with one another and with the rope core. This is called “constructional” stretch because it is inherent in the construction of the rope, and the amount of elongation may vary from one rope to another. For standard ropes, this stretch will be about 1/4% to 1% of the rope’s length.

If you observe wear developing in a localized area, it may be beneficial to cut off short lengths of rope. This may require an original length slightly longer than you normally use. When severe abrasion or numerous fatigue breaks occur near one end or at any one concentrated area – such as drag ropes on draglines or closing lines in clamshell buckets, for example – the movement of this worn section can prolong rope life.

We lubricate our wire rope during manufacture so that the strands – as well as the individual wires in the strands – may move and adjust as the rope moves and bends. But no wire rope can be lubricated sufficiently during manufacture to last its entire life. That’s why it’s important to lubricate periodically throughout the life of the rope.

The surface of some ropes may become covered with dirt, rock dust or other material during their operation. This can prevent field-applied lubricants from properly penetrating into the rope, so it’s a good practice to clean these ropes before you lubricate them.

The lubricant you apply should be light-bodied enough to penetrate to the rope’s core. You can normally apply lubricant by using one of three methods: drip it on rope, spray it on or brush it on. In all cases, you should apply it at a place where the rope is bending, such as around a sheave. We recommend you apply it at the top of the bend because that’s where the rope’s strands are spread by bending and more easily penetrated. In addition, there are pressure lubricators available commercially. Your rope’s service life will be directly proportional to the effectiveness of the method you use and the amount of lubricant that reaches the rope’s working parts.

A proper lubricant must reduce friction, protect against corrosion and adhere to every wire. It should also be pliable and not crack or separate when cold – yet not drip when warm. Never apply heavy grease to the rope because it can trap excessive grit, which can damage the rope. Nor should you apply used “engine oil” because it contains materials that can damage the rope. For unusual conditions, you can specify special lubricants that we can apply at the factory.

Wire breaks from vibration fatigue occur at end terminations, so short lengths cut off there with reattachment of the socket may prolong the rope’s life. When broken wires are found, you should cut off sections of rope. In the case of a socket, you should cut off at least five or six feet. In the case of clips or clamps, you should cut off the entire length covered by them.

Where there is an equalizing sheave, such as that found in many overhead cranes, fatigue is localized at rope tangency points to the equalizing sheave. Rope life may be increased if you shift this point by cutting off a short length at the end of one of the drums. Be sure to make this cutoff before significant wear occurs at the equalizing sheave, and always do so at the same drum. You must maintain the required minimum number of dead wraps on the drum.

Frequently, the most severe deterioration occurs at a point too far from the end or is too long to allow the worn section to be cut off. In such cases, you may turn the rope end for end to bring a less worn section into the area where conditions are most damaging. This practice is beneficial for incline rope and draglines. The change must be made well before the wear reaches the removal criteria. When changing ends, be careful to avoid kinking or otherwise damaging the rope.