overhead crane wire rope lubricant brands

Proper lubrication of your wire rope, chain and cable can safely extend its operational life regardless of application. Cranes, elevators, shovels, drilling rigs, suspension bridges and draglines are some of the many applications that use wire rope, chain or cable to perform work such as pulling, dragging or hoisting. These applications often are exposed to harsh environmental conditions, including extreme weather. Lubrication Engineers can help your wire rope, chain and cable last longer and operate safely by implementing a lubricant reliability program and recommending the right lubricants for the job.

Most wire ropes are lubricated during the manufacturing process, but this lubricant will not last the entire life of the rope. When looking for a lubricant to relubricate your wire rope, choose one that contains no acids or alkalis, possesses the adhesive strength to stay on the rope, can penetrate between wires and strands, has high fluid film strength, resists oxidation and remains pliable. It is important to remember that most wire ropes fail from the inside out. Corroded rope can be a safety hazard, as there is no way to determine its remaining strength and life. Proper lubrication will help prevent deterioration of wire rope due to rust and corrosion.

Because most wire ropes fail from the inside, it is critical to ensure the center core receives sufficient lubricant. LE recommends a combined regimen in which a penetrating lubricant is used to saturate the core, followed by a coating lubricant to seal and protect the outer surface. LE offers several penetrating and coating type wire rope lubricants to suit your specific needs.

Penetrating lubricants contain an evaporative solvent that facilitates migration of the lubricant into the core of the wire rope, then evaporates, leaving behind a heavy lubricating film that protects and lubricates each strand.

Wirelife Almasol Coating Grease (451-453) is a soft, semifluid calcium-based grease designed to coat wire rope as well as moving chain and cable parts to ensure long life and smooth, quiet operation. Its tacky, water-resistant characteristics enable it to adhere strongly to rapidly moving parts, seal out damaging moisture, protect against premature wear and shield metal against corrosive attack.

Typical Applications: Wire rope, chain links, pins, bushings, cable sheave bushings, cables, open and closed silent and roller chains, and small, slow-turning gearboxes that require a semifluid lubricant

Wirelife Almasol Coating Lubricant (2002) is a fluid wire rope lubricant that provides a tough outer coating to seal and protect against fretting corrosion, wear and rust – even under extreme load and moisture. It seals and protects better than any product available. When used in conjunction with Wirelife Monolec Penetrating Lubricant, maximum protection and wear reduction is achieved.

Typical Applications: Mining and construction applications such as standing and running lines, draglines, cranes and derricks; marine applications such as cranes, hoists and drilling rigs; as a rust preventative for any metal in harsh environments and for metal parts in long-term storage.

Wirelife Almasol Syn Coating Lubricant (2022) is an extremely tacky, nonasphaltic synthetic lubricant with exceptionally high film strength. Perfect for extreme environments and conditions, it is the ultimate outer surface protector for wire rope and cable and comes from the same advanced technology that LE developed to protect large open gears in the mining and quarry industries. It derives its high load-carrying capacity from its synergistic blend of an extreme pressure additive and Almasol, LE’s exclusive wear-reducing additive.

Typical Applications: Mining and construction applications such as standing and running lines, draglines, cranes and derricks; marine applications such as cranes, hoists and drilling rigs.

Wirelife Monolec Penetrating Lubricant (2001) has excellent corrosion resistance and high load-carrying (EP) properties. It penetrates to the core of wire ropes, whether they are running or stationary. It is also excellent as a penetrating lubricant for chains of all sizes and works well in a variety of other industrial applications. When used in conjunction with Wirelife Almasol Coating Lubricant, maximum protection and wear reduction is achieved.

It contains a petroleum solvent to enhance its ability to penetrate. The solvent evaporates, leaving behind a film of heavy-bodied lubricant that protects and lubricates each strand and resists leakage from the wire rope core. Available in bulk sizes or in an aerosol version.

Typical Applications: All stationary or moving wire ropes or cables under heavy loads; chains of all sizes; mining and construction applications such as standing and running lines, draglines, cranes and derricks; marine applications such as cranes, hoists and drilling rigs; any other application that requires excellent rust protection for steel parts.

Designed for marine environments and other applications where environmental concerns require the use of a very low toxicity wire rope and chain lubricant, LE’s Wirelife Low Tox Penetrating Lubricant (2011) has excellent load-carrying capability and provides outstanding protection against rust, while having the lowest possible toxic effect on the environment.

Earthwise EAL Wire Rope Grease (3353) is recommended for use in applications on or near the waterways. It is an EAL and meets the specifications required by the EPA’s Vessel General Permit (VGP). It is readily biodegradable, exhibits minimal aquatic toxicity and will not accumulate in the cells of fish and other aquatic life forms. It is a soft, semifluid formulation designed to coat wire rope as well as moving chain and cable parts to ensure long life and smooth, quiet operation. Its semi-tacky, water-resistant characteristics enable it to adhere to the application and seal out damaging moisture and protect against rust formation.

Typical Applications: Applications near or around waterways including: Wire rope; chain links, pins and bushings; cable sheave bushings, bearings and strands; open and closed silent and roller chains. Ideal for use in automatic lubrication systems.

LE is happy to offer industrial lubricant and reliability recommendations for a variety of applications, and to provide product-specific data on all of our items to help you make the right decision. To learn more about our wire rope lubricants, wire rope lubricators as well as our other enhanced lubricants and lubricant reliability products, please

Crosby’s Vitalife®products are the preferred wire rope lubricants in the industry because of their ability to penetrate into wire rope and displace water and contaminants, thus reducing wear and corrosion throughout the rope.Available in a variety of container sizes.

Whitmore’s Wire Rope Lubricant products also coat these strands to prevent friction and wear. This results in longer wire rope life, less downtime for rope changes and more production.

Whitmore’s Wire Rope Lubricant is easily pumpable at temperatures down to -25°F (-35°C). Its nondrying film remains flexible in the most extreme weather conditions, which eliminates flaking and peeling.Whitmore’s Wire Rope Lubricant can be used to lubricate all sizes of wire rope, as well as chains, leaf springs and other applications where penetrating oil is needed. It may be applied by hand or automatic lube system.

Do your wire ropes, cables and draglines become rusted, corroded or frayed? You can protect your wire rope and cable from high stress loading, shock loading, jerking and heavy loads with LE"s full line of penetrating and coating wire rope lubricants. Whether you want lubricant to penetrate to the core or to coat and seal, LE has a full range of protective lubricant solutions, including wire rope lubricant applicators to reduce labor costs and ensure safe, reliable operation.

New Extended Warranty: Documented use of LE452, LE453 Wirelife™ Almasol Wire Rope Lubricant or Earthwise™ EAL Wire Rope Lubricant will double the Viper warranty period to 24 months.

Wire rope forms an important part of many machines and structures. It is comprised of continuous wire strands wound around a central core. There are many kinds of wire rope designed for different applications. Most of them are steel wires made into strands wound with each other. The core can be made of steel, rope or even plastics.

Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or not it is preformed, by its lay, the number of strands and the number of wires in each strand.

A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small sheaves (pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through abrasives.

There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with a 1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking strength than a fiber core rope and a high resistance to crushing and deformation.

A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope core. WSC ropes are high strength and are mostly used as static or standing ropes.

Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also use plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core ropes are quite flexible and are used in many overhead crane applications.

The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope the strands twist to the right as it winds away from the observer. A left lay twists to the left. A regular lay rope has the wires in the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to have better fatigue resistance due to the flatter exposure of the wires.

Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability and for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used and are described in Table 1.

Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will straighten and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires that are shaped so that they lie naturally in their position in the strand, preventing the wires from protruding and potentially causing injury. Preformed wire ropes also have better fatigue resistance than nonpreformed ropes and are ideal for working over small sheaves and around sharp angles.

Lubricating wire ropes is a difficult proposition, regardless of the construction and composition. Ropes with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials. For this reason, it is important to carefully consider the issue of field relubrication when selecting rope for an application.

There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain a petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants penetrate slightly, sealing the outside of the cable from moisture and reducing wear and fretting corrosion from contact with external bodies.

Both types of wire rope lubricants are used. But because most wire ropes fail from the inside, it is important to make sure that the center core receives sufficient lubricant. A combination approach in which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect the outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease, petroleum oils or vegetable oil-based (Figure 3).

Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection. Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold temperature conditions.

Various types of greases are used for wire rope lubrication. These are the coating types that penetrate partially but usually do not saturate the rope core. Common grease thickeners include sodium, lithium, lithium complex and aluminum complex soaps. Greases used for this application generally have a soft semifluid consistency. They coat and achieve partial penetration if applied with pressure lubricators.

Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil type lubricants helps to wash the rope to remove abrasive external contaminants.

Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and function as a reservoir for prolonged lubrication while in service.

If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of the die that twists the wires into a strand. This allows complete coverage of all wires.

After the cable is put into service, relubrication is required due to loss of the original lubricant from loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect and preserve the rope core and wires, and thus extend the service life of the wire rope.

If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication. The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave where the rope strands have a tendency to separate slightly due to bending to facilitate maximum penetration to the core. If a pressure boot application is used, the lubricant is applied to the rope under slight tension in a straight condition. Excessive lubricant application should be avoided to prevent safety hazards.

Some key performance attributes to look for in a wire rope lubricant are wear resistance and corrosion prevention. Some useful performance benchmarks include high four-ball EP test values, such as a weld point (ASTM D2783) of above 350 kg and a load wear index of above 50. For corrosion protection, look for wire rope lubricants with salt spray (ASTM B117) resistance values above 60 hours and humidity cabinet (ASTM D1748) values of more than 60 days. Most manufacturers provide this type of data on product data sheets.

Cable life cycle and performance are influenced by several factors, including type of operation, care and environment. Cables can be damaged by worn sheaves, improper winding and splicing practices, and improper storage. High stress loading, shock loading, jerking heavy loads or rapid acceleration or deceleration (speed of the cable stopping and starting) will accelerate the wear rate.

Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If a machine is to be shut down for an extended period, the cables should be removed, cleaned, lubricated and properly stored. In service, corrosion and oxidation are caused by fumes, acids, salt brines, sulfur, gases, salt air, humidity and are accelerated by elevated temperatures. Proper and adequate lubricant application in the field can reduce corrosive attack of the cable.

Abrasive wear occurs on the inside and outside of wire ropes. Individual strands inside the rope move and rub against one another during normal operation, creating internal two-body abrasive wear. The outside of the cable accumulates dirt and contaminants from sheaves and drums. This causes three-body abrasive wear, which erodes the outer wires and strands. Abrasive wear usually reduces rope diameter and can result in core failure and internal wire breakage. Penetrating wire rope lubricants reduce abrasive wear inside the rope and also wash off the external surfaces to remove contaminants and dirt.

Many types of machines and structures use wire ropes, including draglines, cranes, elevators, shovels, drilling rigs, suspension bridges and cable-stayed towers. Each application has specific needs for the type and size of wire rope required. All wire ropes, regardless of the application, will perform at a higher level, last longer and provide greater user benefits when properly maintained.

Lubrication Engineers, Inc. has found through years of field experience, that longer wire rope life can be obtained through the use of penetrating lubricants, either alone or when used in conjunction with a coating lubricant. Practical experience at a South African mine suggests that life cycles may be doubled with this approach. At one mine site, the replacement rate for four 44-mm ropes was extended from an average 18.5 months to 43 months. At another mine, life cycles of four 43-mm x 2073 meter ropes were extended from an average 8 months to 12 months.

In another study involving 5-ton and 10-ton overhead cranes in the United States that used 3/8-inch and 5/8-inch diameter ropes, the average life of the ropes was doubled. The authors attribute this increased performance to the ability of the penetrating lubricant to displace water and contaminants while replacing them with oil, which reduces the wear and corrosion occurring throughout the rope. A good spray with penetrating wire rope lubricant effectively acts as an oil change for wire ropes.

In these examples, the savings in wire rope replacement costs (downtime, labor and capital costs) were substantial and dwarfed the cost of the lubricants. Companies who have realized the importance of proper wire rope lubrication have gained a huge advantage over those who purchase the lowest priced lubricant, or no lubricant at all, while replacing ropes on a much more frequent basis.

What lubricant or oil do I use in Demag gearboxes? This is a frequent question we get from crane technicians and maintenance personnel alike. Find out why changing the lubricant at regular intervals is so important and Click here to download our Technicians Guide to Demag Oils & Lubricants.

Depending on the model, Demag uses a variety of different lubricants and oils that optimize the performance and life of gearboxes, chains, and wire rope. Some models use mineral oil with high pressure additives, some use gear grease, and others use specialized gear oils. Some of these lubricants are packaged specifically for Demag while others use lubricant products from brands like Whitmore, Kluber, and ESSO Spartan. Always make sure you use the correct oil and lubricant for the specific Demag product you are working on.

Looking for a quick guide on what lubricants and oils are used in Demag products? Click here to download the Technician’s Guide to Oils and Lubricants Used in Demag Gearboxes and Hoists.

Regular lubrication helps to increase the lifetime of a steel wire rope significantly compared to a wire rope that has not been lubricated. Also, lubricating a wire rope while in service helps to prevent corrosion of the wires. Corrosion can be internal and external, and it often is caused by acids, alkaline waters, salt air, humidity, fumes, and abrasive and industrial environments in general.

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The product penetrates deeply for internal protection of open gears, wire ropes, racks and pinions, crown wheels and cams and driving mechanisms in the Construction, Shipyard, Docks and Marine, Quarrying, Plant Hire, Heavy Engineering, Automotive and Manufacturing industries:

Quick to dry, the product adheres strongly to all treated areas and forms a dry, solids-enhanced, non-peeling film which reduces wear and extends the operational life of the equipment. The tough, durable coating resists corrosion, abrasion, dust absorption, water wash and extremes of temperature, making it ideal for external use or for dust-laden atmospheres. Apply a light, even coating from 9″ -12″ (25 -30 cm) and re-apply as necessary. Can be applied to running gear mechanisms if required. On wire ropes, allow 15 minutes for full penetration before use of equipment.

At Northern Strands we know first-hand the importance of wire rope lubrication. It is required during manufacturing, installation, and ongoing maintenance. Different hoists and applications require different types of lubrication. We carry everything from basic asphalt lube to soap grease and no- petroleum based lubes. With Northern Strands’ knowledge of wire rope, we can recommend and supply appropriate lubrication products and suggest the best lubrication methods.

CoreLube Equipment"s Helix Groove Cleaners are designed to remove contaminants from the valleys between the strands of wire rope. The cleaner works by rotating with the helical lay of the wire rope. The Helix Groove Cleaners are designed to work with CoreLubes applicator collars or thrust block.

It is important to maintain and protect your steel wire ropes, and for that we offer both Brilube lubricant and Verolube spray. Contact us for advice and guidance.

Kirkpatrick Wire Rope Lubrication Systems are excellent for Wire Rope & Cable Lubrication and Cleaning. In only one application, wire rope can have its surface and groove pattern scraped clean of product build-up and grit, while at the same time new lubricant is uniformly applied to the newly cleaned surface. Coating product then fills any open spaces within the groove pattern, and internal strands open to receive it. This is accomplished as the wire rope passes through a controlled, 100% pressurized, immersion within the Internal Seal Lubrication Chamber. Surface moisture trapped within the internal strands is displaced and replaced with the newly applied wire rope coating product. Kirkpatrick Systems are functional with both low and high viscosity coatings. They can be incorporated as a Grease Applicator for tough applications where higher viscosity coatings are required to fight friction wear due to strand rubbing, as well as a low viscosity oiling system required for certain Cable Cleaning & Lubrication applications.

A great deal of time has been taken by our company to determine what characteristics our wire rope lubricants should have in meeting the stringent corrosion / wear and environmental requirements as set forth by our users of wire Dynagard™ “Blue” , Dynagard™ Blue CSS13, Dynagard™ “E” and Dynagard™ LVL are the result and are formulated to give the user the most complete coating and penetration rope possible. In addition, their environmental field performance has resulted in their use by the United States Navy, United States Coast Guard, United States Army Corps of Engineers, TVA, Bureau of Land Reclamation, NOAA and many other governmental organizations worldwide.