sheave design for wire rope quotation

Have a steel sheave, pulley, wire rope, or application question?Ready to start a new project? Have a requirement you need met? Know your sheave specification and need custom pricing? You’ve found the right resource. eSheaves engineers are ready to answer your inquiry, work on your request for quote, or assist with the particulars of a new custom engineered project.

Looking for pricing?Visit the eSheaves shop to to see individual item pricing and to order from stock today. For larger inquiries, or to request additional information, choose the option that most closely matches below and let us know how we can help.You can also reach us via email through [email protected], or by calling us directly at 800-321-5667.

For over 60 years, Loos & Co., Inc. has pioneered and thrived in the highly critical profession of wire, wire rope, and hardware manufacturing for use in applications critical outcomes are directly at stake. This valuable experience has taught us “the ropes” about what a difference quality and performance make in your applications. Now, we can help make the difference for you with your pulley and sheave applications, too.

We’re proud to offer a wide variety of military specification and commercial wire rope, aircraft cable, and fittings to compliment your complete sheaves or pulley system. These products are the perfect compliment to the high performance products offered by esheaves.com. Pairing Loos & Co., Inc. tools, hardware, and accessories with the highest quality pulleys and sheaves will repay you with the performance you have come to expect from our products.

Selecting the right size for sheaves will help prevent frequent wire rope damage which in some instances occurs after just one run. Many common operational issues including the wireline getting dislodged or losing its strength are caused by improper sheave sizing and alignment problems. Our experts offer 3 valuable tips to eliminate stress failure, improve equipment safety and efficiency, as well as increase the lifespan of your sheaves and wire rope.

Pay attention to sheave groove size and diameter: When sheaves for your wire rope are too large or too small, there is greater stress on both resulting in spooling trouble and premature wear. For instance, grooves that are too large have proven to cause the wire rope to flatten and unbalance leading to the wire breaking. When properly sized, the groove provides maximum support to the rope lowering the sheave bearing pressure and increasing sheave and rope lifespan. Typically the groove diameter should exceed that of the wire rope by 5% while groove depth should be one-and-a-half times the rope diameter. A groove angle between 30° and 45° offers the best support for the wire rope. Specific dimensions and angles may vary depending on your application.

Ensure sheave groove hardness: The hardness of sheaves is a factor that is often overlooked. Since the wire rope is hard, the pressure it exerts on the groove can lead to corrugations if the sheave is not properly hardened. To avoid this, ensure your steel cable sheaves are flame hardened. (A simple way to determine if your grooves are worn out is by using a sheave gauge.) At Rockett Inc., we can provide flame hardening for wear resistance along the contact area.

Correct sheave groove alignment: Poor alignment of your sheaves wears out the wire rope and sheave flange. This is because the rope comes into constant contact with the flange creating stress on the rope, abrasion damage and fatigue breaks. Any alignment issues should be corrected immediately.

To avoid operational problems, opt for custom made steel sheaves. This way the sheaves for your wire ropes are tailored to your specific requirements instead of the other way around. As an experienced sheave manufacturer with a state-of-the-art facility in Mississippi, Rockett Inc. offers comprehensive custom solutions for diverse industrial and commercial needs.

Should you have a specific requirement, our experienced engineers can work closely with you to design and manufacture the product your application requires. Precision engineering and state-of-the-art metal fabrication equipment result in a closer tolerance fit to the wire rope to reduce fatigue and wear. Inspection at every stage of our manufacturing process ensures that the final output meets your specifications.

Need assistance with designing sheaves for wire rope? We are always happy to help. Our team can work directly from your drawings and specifications, or offer 3D CAD design and engineering support optimized for practical, cost-effective results. Over the years, we have produced the most diverse range of custom steel cable sheaves for our clients across the globe.  Having the ISO 9001:2008 Certification means we take pride in quality and customer satisfaction.

Sheaves are widely used throughout the industry for a variety of pulling and lifting functions. Sheaves are available in a variety of materials including steel, plastic, or stainless steel. There are many configurations available including HiLoad sheaves, LoLoad sheaves, fibrous rope sheaves, and wire rope sheaves. You can source sheaves with bearings or bushings and some sheaves come very specialized.

HiLOAD indicates a premium, larger diameter sheave suitable for 180° degree rope turns (see Figure 1) with a high D/d ratio, which is the ratio of the diameter around which the rope is bent, divided by the body diameter of the rope (see Figure 3). LoLOAD indicates a smaller diameter sheave designed for economical small deflection turns less than 90 degrees with a lower D/d ratio (see Figure 2).

Work load is important for both wire rope and fibrous rope sheaves, but work load limit (WLL) is critical with wire rope sheaves due to the comparative increased capacity of wire rope.

Quality sheaves should meet ASME B30.26-2610 and exceed the minimum 4:1 design factor. In most instances, the WLL for Suncor sheaves is significantly higher than comparable products and proof loads (or max WLL) are twice the WLL. Generally, twice the WLL of the wire represents the wire maximum load with a 180° wire wrap around the sheave.

A critical, and often overlooked area, is the wear exerted on the sheave during use. Throat angle, groove diameter, and sheave size are three significant factors of wear for sheaves. Sheaves are often designed with thin straight sided grooves which can cause scrubbing on the side walls and unnecessary wear on the rope and the sheave (see Figure 6). Suncor’s sheaves were designed with wide sheave grooves that provide a proper throat angle to permit slight rope lead misalignment without damaging the rope or wearing the sheave groove (see Figure 5).

The groove diameter is critical for proper wire rope support under load and has a significant effect on the overall safety and lifespan of the sheave and rope. If the sheave groove diameter has too much clearance, it will not support the rope properly leading to distortion, increased fatigue, failure, and costly repair. Conversely, if the sheave groove diameter has too little clearance the rope will not fit properly causing excessive wear and accelerated abrasion, which results in lost performance (see Figure 7).

Sheaves facilitate the smooth and safe operation of overhead crane hoists. Damaged sheaves can wear ropes prematurely and cause other dangerous hazards, such as binding wire rope. Konecranes technicians are trained to identify and correct problems with sheaves and other parts of hoisting equipment.

Sheaves carrying ropes which can be momentarily unloaded shall be provided with close-fitting guards or other suitable devices to guide the rope back into the groove when the load is applied again.

The sheaves in the bottom block shall be equipped with close-fitting guards that will prevent ropes from becoming fouled when the block is lying on the ground with ropes loose.

In using hoisting ropes, the crane manufacturer"s recommendation shall be followed. The rated load divided by the number of parts of rope shall not exceed 20 percent of the nominal breaking strength of the rope.

Rope clips attached with U-bolts shall have the U-bolts on the dead or short end of the rope. Spacing and number of all types of clips shall be in accordance with the clip manufacturer"s recommendation. Clips shall be drop-forged steel in all sizes manufactured commercially. When a newly installed rope has been in operation for an hour, all nuts on the clip bolts shall be retightened.

Wherever exposed to temperatures, at which fiber cores would be damaged, rope having an independent wirerope or wire-strand core, or other temperature-damage resistant core shall be used.

Replacement rope shall be the same size, grade, and construction as the original rope furnished by the crane manufacturer, unless otherwise recommended by a wire rope manufacturer due to actual working condition requirements.

Konecranes wire rope inspections can help crane users extend the life of hoist ropes. Ropes, sheaves and other reeving system components are inspected for compliance with crane standards, and to determine if they have flaws that could hinder safe operation. Contact us today to schedule an assessment.

*The foregoing OSHA regulations are not intended to be a comprehensive overview of all applicable regulations pertaining to the designated topic. State laws may mandate different safety and maintenance standards. Accordingly, please consult applicable state laws as well as original equipment manufacturer specifications for further guidance. The statements and descriptions contained herein constitute the opinion/recommendation of the seller and are not intended to create any express warranties.

The service life of cable and wire rope can be increased if (1) it operates over the largest possible pulley or sheave diameter, and (2) it is properly supported in the pulley or sheave groove. The working life of the individual wire strands is greatly reduced as the pulley or sheave diameter is diminished. The chart below shows minimum tread diameters over which various sizes and constructions of cable should operate.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

American Block is an industry leader in design and manufacture of wire rope sheaves, a reputation backed up by over 40 years of experience and field performance. Sheaves are available in diameters ranging from 20″ to 120″ and for any size of wire rope. Sheave bores can be made to accommodate roller bearings, bushings, snap rings or special designs. Our standard welded sheaves feature forged rings for reliable strength and durability, and full penetration welds between the web and hub for the strongest possible connection. Sheave grooves are flame hardened to 35 RC minimum for extended resistance against wear. The option for custom-designed sheaves is readily available, as most features can be easily adjusted to meet customer requirements. Sheaves assemblies are available with bearing, bushing, seals, snap rings and cover plates as installed options. We manufacture sheaves to API 8C, and third party certification such as ABS or DNV is available upon request.

Process Sheaves offers plastic and aluminum lightweight sheaves for wire and cable manufacturing. We provide high-quality products for your production equipment in addition to the exceptional service and expert engineering advice you have come to expect from eSheaves. What kinds of sheaves do we have available?

Need stock process sheaves and pulleys? Choose from a variety of in-stock and existing variations. These products are ideal for low-and-high-speed applications, including processing insulated wire, synthetic rope, tubing, wire, cable, and other linear products. Our sheave materials include aluminum, alum-ceramic, SX polymer, cast nylon, and other plastics. We have a range of imperial and metric sizes for U-Groove, V-Groove, Flat-Groove, and interlocking styles.

If you need to replace your discontinued Bomco sheaves, do so with our high-quality, SX polymer process sheaves. We have exact replacements that are available in U-Groove and V-Groove interlocking styles.

If you manufacture electrical wire and cable, medical tubing, optical fibers, or similar products and can"t find the exact sheave design you need, eSheaves engineers and sells a complete line of custom sheaves and pulleys for processing of linear products. With a guarantee of exceptional service and expert engineering advice, we are your go-to for all sheaves needs.

• Gar-Dur is what our sheaves are most often machined from. It"s the densest and toughest thermoplastic available today. Gar-Dur has numerous properties that render it ideal for sheaves; toughness, abrasion resistance, chemical resistance, moisture resistance, low-weight, low-cost, color, and temperature range.

• High density polyethylene (HDPE) which has lower properties and prices. It is ideal for tubing, hose, synthetic rope, and similar materials with less demanding wear and load requirements.

• Ceram-P™ is ceramic-filled UMHW recommended for high-load and severe sliding abrasion. It is shatter-resistant and an alternative to sintered ceramic but is markedly heavier and more expensive than UHMW.

• Other options include: Nylon (polyamide), MoS2-filled nylon, and Derlin™ (Acetal). Special sheaves require other materials including teflon, phenolic, aluminum, steel, stainless steel, and composites.

Process Sheaves has all the plastic and aluminum lightweight sheaves you need. Coupled with expert engineering advice, our exceptional service also puts us a step above. Find out more about our line or request a quote by visiting www.esheaves.com

An importantpoint to consider is the selection of the proper type of core needed in the rope. Wire Ropes are made with either fiber core or steel wire core.

This center is usually composed of a separate 7×7 wire rope designated as IWRC. The steel core increases the strength by 7% and the weight by 10%. These steel cores provide more substantial support than fiber cores to the outer strands during the rope’s operating life. Steel centers resist crushing, are more resistant to heat and increase the strength of the rope.

The Design Factor being both the ratio between the minimum Breaking load of the rope and the rated capacity (RC) tells at what percentage of its ultimate strength a wire rope is operating. The Design Factor takes into consideration both normal rope wear and potential stresses in various applications. The best practice in determining an adequate design factor is to analyze the specific conditions involved inn each individual installation. The following example shows how to determine the Design Factor: If a rope is working under a max. operating load of 10,000 lbs. and is having an ultimate strength of 50,000 lbs., the factor is 5 which means it is operating at 20% of its ultimate strength.

The fleet angle is the angle formed between the rope running to or from the extreme left or right of the drum and a line drawn from the center of the sheave normal to the axis of the drum. For optimum efficiency, the angle here should not exceed 1 1/2 degrees for a smooth drum, or 2 degrees for a grooved drum. If the fleet angle is larger than the recommended limits, it can cause bad winding on smooth drums and rubbing against the flanges of the grooves. Too small a fleet angle should also be avoided since it will cause the rope to pile up against the flange head.

Proper alignment of sheaves is essential. The main sheave should line up with the center of the hoisting drum, otherwise both the rope and sheave flanges will be subjected to severe and rapid deterioration will occur. If rope speeds are high, sheaves should also be balanced.

Wire rope products will break if abused, misused or overused. Regular inspection and maintenance are necessary. Consult industry recommendation and OSHA standards before using.