overhead crane wire rope changing procedure for sale

Buying new crane ropes is a detailed and thorough process. While it may be time-consuming, wire rope replacement prioritizes safety for your workers, minimizes downtime on a jobsite, maximizes the lifespan of the crane and avoids the costly and time-consuming process of getting correct rope onsite and respooling your crane.

Sometimes, it can seem like the wire rope buying process is overly complicated. This is done on purpose to avoid as many issues as possible when the new rope is installed. The reason for that is so buyers avoid putting the wrong types of ropes on cranes and unnecessarily increasing the risk of injuries to workers or damage to loads being lifted. The processes are to make sure to prevent that added risk and put the correct rope on the correct machine, per Original Equipment Manufacturer (OEM) specifications.

Wire rope specialists ask these questions to understand your circumstances and what your needs are. With this information, they are better prepared to get the absolute correct rope.

Most of the time, the customer should have access to their crane’s operations manual that will show what rope diameter and length is specified. The customer may have to measure or come up with his own calculations on length. The crane manufacturer is going to make a specific drum for that specific type of wire rope.

The rope has to be specific to the lagging of the drum for that machine, which is why there are multiple variations for each size of wire rope because each kind is specific to the type of crane, and it shouldn’t be substituted. Mazzella will only install the rope that is the correct brand and tolerance on a particular crane.

Ordering the correct crane rope will prevent crane rope damage. The wrong rope could cause damage to the equipment, and at worst, boom failure. On the less severe side, you will have bad performance or it might not work at all. You could have twist and/or spooling issues. That could lead to the crane failing altogether, which creates downtime as you wait for the correct wire rope to be ordered/delivered and installed.

Many crane owners are working for somebody else when they’re doing jobs, so if the rope doesn’t work, they’re paying for work that is not getting done and falling behind schedule.

On the more severe side, you could total your crane and/or irreparably damage the load being lifted if you use the wrong wire rope. In the worst-case scenario, using the incorrect rope could result in severe injury and/or the loss of life.

Sometimes, customers assume that there’s a one-size-fits-all replacement, that if it’s a non-rotating rope, it should work on every application. There’s a lot of misinformation on what will work and what won’t work. With our experience and access to all brands of wire rope, Mazzella guarantees we can get you the right rope for your cranes. If Mazzella isn’t comfortable with the project, we won’t supply the wire rope.

If the wrong wire rope is ordered and delivered, it could be hours or days before the correct rope is on location. Especially with a lot of the larger cranes, manufacturers are shipping model-specific ropes all over the country, and depending on location and money, that could cause delays on your jobsite.

With our large inventory of rope, Mazzella can have a new spool of wire on a truck and out for delivery in a matter of hours. Avoid the pitfalls of ordering the wrong crane rope and you’ll have a new spool of wire rope on its way. Once the order process is done, what can your company do to prepare for delivery and installation?

It is a good idea to give management the proper notice of when the installer will be on-site, have the necessary technicians on-site to help the installer with the rope replacement and make sure the installer/technicians have a clear working space.

There’s a lot of downtime associated with making a mistake in the preparation process, so the more prepared you can be for the install, the better. You don’t want a situation where your crane is inactive because of an oversight or completely avoidable situation.

Also, Mazzella recommends you measure your sheaves with a sheave gauge. A sheave gauge will help you measure the wear of the root, the amount of wear on the groove wall and the diameter of the wire rope.

After ordering the correct rope and having the requisite space and approval for installation, how long will it take to remove and replace the old rope when the technician, assistants and supplies arrive onsite? For some small cranes, the timeframe could be as little as 45 minutes, but for larger cranes, removing the old rope and installing the new one could be a several-hour process.

There’s a lot of factors that go into a successful crane rope installation. The most important thing is the quicker your supplier responds to your order and gets a rope on location, the quicker that rope gets installed properly, saving time and money. Downtime is the key, and it could cost companies tens of thousands of dollars per day if their crane(s) are inoperable.

Once a new crane rope is installed, a break-in period or tension period is recommended to make sure everything is performing correctly, and help you avoid shock-loading the newly installed wire rope. The break-in period is recommended because installation and spooling equipment are not going to put adequate tension on the rope. A break-in period consists of putting a low percentage of the working load limit weight on the rope for several lift cycles, and running the blocks up to the boom length (working height) and back down. For the most specific guidelines on the breaking-in process for your new wire rope, refer to the manufacturer’s recommendations.

If a brand-new wire rope on a crane is not broken in properly before lifting a large load, it potentially could damage the rope and render useless the equipment that was just installed on your machine.

When Mazzella fulfills a crane ropes order, it is not just about the sale and the bottom line. While we’re in the business of selling crane ropes, we’re also in the business of building relationships and trust. We are committed to making sure you get the correct products for the right applications.

Crane rope issues don’t just happen 9-to-5 during the normal work week. They happen Friday nights, holidays, weekends and early mornings. They’re always on the clock, and it is just about being honest with the customer and letting them know, they type of rope that is required. That honesty and trust is of utmost importance for the safety of your workers and the proper maintenance of your cranes.

Mazzella has one of the largest crane ropes inventories in the United States. The company provides wire rope assemblies and manufactures bridge cables, crane cables, steel mill cables and thousands of OEM assemblies in sizes from ¼ to 3-inch diameter and 9 to 52 millimeter diameter, domestic and non-domestic and in stock and ready for same or next-day shipment.

Single girder overhead travelling crane on the rope guide, also known as rope row device, is a relatively simple damage to the attachment. However, many customers do not know how to replace the rope guide. This article briefly introduced the replacement guide rope device approach and process, for your reference.

Single girder overhead travelling crane replacement guide rope device is necessary with matching. Some manufacturers produce can not use the traditional rope guide. Please pay attention to communicate with us when you buy. When replacing the rope guide, should first cut off the power, remove the wire rope. After removing the hexagonal screw of the rope guide, you can take down the rope guide along the wire rope. During this period, it is necessary to pay attention to the wire rope into the rope groove before installing the rope guide, so that the wire rope does not enter the groove, there may again crush the rope guide.

First remove the fixed screws fixed in the rope guide; open the rope guide, the block in the rope guide on the side facing outward, the rope guide into the; wire rope head into the rope guide, adjust the rope guide, straighten out the winding order of the wire rope; wire rope head into the fixed pile, wedge it with iron wedge; fixed rope guide, install all the fixed screws of the rope guide; start, adjust the rope guide. This is to ensure that the upper and lower rope guide can accurately cut off the fire source, do not let the wire rope relax the good position; single girder overhead crane guide rope device device is simple, the device is strong.

Radically redesigned with never-before-seen features – both inside and out – the S-series will set the standard in lifting for years to come. The newly designed structure includes next-generation features such as off-set reeving, stepless hoisting movement and synthetic rope. The tilted rope drum enables more direct rope angles to decrease the wear and tear of reeving components. And offset reeving means more balanced wheel loads for less stress on the crane structure.

The evolutionary synthetic rope is durable but light and doesn’t require lubrication. The rope also features a strong, symmetric structure for less rope defects and safer handling. Rope angle measurement allows for the use of Smart Features including Hook Centering, Snag Prevention and Follow Me.

Crane Ropes, like any machine or spares, deteriorate during storage as well as in service.  Therefore, the assurance of safety and economy in use of the equipment, dictates the requirement for a procedure of proper storage, handling & installation of Crane ropes.

In this Crane Rope Products brochure, you’ll find valuable product information and specifications to help you choose the right rope for your application.

Twisted hoist lines can bring a construction project to a sudden halt, resulting in downtime. But the good news is that you can minimize block rotation through proper installation, handling and corrective measures. In this reference document, you will better understand torque and gain tips on how to reduce block rotation.

No single rope can do it all. In this reference document, you will learn how the characteristics of specific ropes should greatly influence your rope choice including: strength, fatigue resistance, crushing resistance, resistance to metal loss and deformation, and resistance to rotation.

In this Product Bulletin, you will learn about the various causes of crushing, the effects of crushing and how to properly evaluate the crushing. Additionally, observations about drum crushing from WireCo WorldGroup engineers are included.

In this product bulletin, you will learn why Category 1 Ropes are special wire ropes that must be handled differently than other wire ropes. Understand why WireCo WorldGroup recommends not removing the welded ends. And, learn the proper step-by-step recommended procedure for cutting and preparing Category 1 Ropes.

In this product bulletin, you will learn WireCo WorldGroup’s preferred technique for installing a hoist rope onto a crane. Learn tips on relieving twist during installation.

In this reference document, you will learn WireCo WorldGroup’s preferred technique for installing rope onto a crane. Additionally, you will learn tips on breaking in your new wire rope, relieving twist, rigging in tight quarters, and cleaning and lubricating ropes.

Despite their durability and strength, wire ropes used on cranes will wear out and need to be retired from service. This reference document will better explain why regular inspection is so crucial to your long-term success.

Learn how to properly install wire rope on mobile cranes. Two factors are key to proper installation no matter what type of equipment, or which wire rope is being used: making sure the rope is free of twist and assuring that the rope is tightly spooled on the drum.

When a load is placed on a rope, torques are created within the rope as wires and strands try to straighten out. Ropes are designed to operate with these load-created torques within them. In this product bulletin, learn four methods of making a lift that is within the capacity of a single-part line. And finally, you will understand the removal criteria of rotation resistant rope.

Using an active, in-line, anti-friction swivel with the majority of types and classes of wire ropes is detrimental to their service life and can lead to unpredictable conditions during operation. This product bulletin provides the basic reasoning behind why swivels aren"t recommended for use with wire ropes except for those that exhibit a similar torque characteristic to that of a category 1 rotation-resistant rope.

XLT4 is designed to be used with a design factor as low as 3.5 on mobile cranes. In this product bulletin, you will learn more about the ASME B30.5 design factor requirements.

XLT4 was designed and engineered to be compatible with a full complement of end terminations including wire rope clips, wedges and swaged crane buttons. In this product bulletin, learn how Union’s 4-strand crane rope delivers more strength than premium 6-strand, and equal or greater stability under load than Category 1 35x7 style rotation-resistance ropes.

XLT4 is truly the four strand mobile crane hoist rope that is unequaled. After reading this product bulletin, you will understand why. You will learn how XLT4 was designed specifically to meet the special wire rope requirements of mobile crane operations and how XLT4 offers a unique combination of characteristics.

More area equals less wear. In this product bulletin, learn why this is important for our XLT4 rope product. After reading this product bulletin, you will understand why XLT4 Crane Rope provides a greater rope footprint when in contact with drums and sheaves and what this means for your application performance. Additionally, you will learn why XLT4 offers less scrubbing and abrasion and why this reduces contact pressure on ropes.

Wire ropes are mechanical devices that consist of moving parts working in sync to support a heavy load and move it to its desired direction. The rigging and lifting industry benefits largely from the utilities of the wire rope. Especially when they are used in overhead lifting equipment such as cranes and hoists. The wire rope is attached firmly to a hoist or crane, and the load is fitted using swivels, hooks, or shackles, facilitating controlled movement. It is used in many applications to support suspension towers or bridges and lower or lift elevators.

Wire ropes have become the preferred lifting device in many industrial applications. It has its fair share of reasons as well. Firstly, the unique design allows flexibility, strength, and the ability to handle bending stresses. Depending on the rope"s material, wire, and strand structure, it will provide different sets of benefits for the specific application it is used in.

Selecting the right wire rope for the right application is a process that involves careful thought. Thoughts involving proper analysis of the above aspects of the wire rope and the particular lifting application is required.

The following factors might prove to be impactful in damaging or breaking a wire rope. Wear and tear on areas that are directly in contact with drums and hoist sheaves.

Lack of proper lubrication and heat exposure leading to corrosion. At temp beyond 120 degrees Celsius, a fibre core wire rope will give way and break.

Improper installations are also a common issue that can cause the wire rope to break. Improper installation kinks create a weak section in the rope, which is exploited with prolonged use.

1 LOWER THE HOOK AND SECURE THE BLOCK2 BRIDGE THE SLACK ROPE DEVICE3 DISCONNECT THE LIMIT SWITCH FOR RUNNER DRUM.( mark the exact position ofdrum and turn on the drum to established exact position at later connection)4 DISCONNECT THE THIMBLE AT THE CRANE HOUSE AND LOWER THIS ENDOF THE WIRE TO THE DECK5 MAKE A WHIPPING (see photo A) BEHIND THE TIMBLE AND CUT THE TIMBLE OFF

6 CONNECT THE NEW WIRE TO THE OLD WIRE BY USING SNAKE WIRE.(the drum of the wire has to set on the block and the turns should come from the top of the drumsee photo B,supply breaking device)

Remarks:If snake wire is not available,the connection between the old and new wires can bedone by rings(see photo D) welded at the end of each wire,connected with a small shackle make sure that the shackle and rings will pass clear through the sheaves. See photo C

9 SET A STOPPER INSIDE THE CRANE HOUSE ( 2 or even 3 stoppers)10 SLACK THE WIRE A LITTLE IN THE CRANE HOUSE AND DISCONNECT THE OLD WIREFROM THE NEW WIRE11 SLACK DOWN THE OLD WIRE ON DECK UNTIL TWO TURNS ARE ON THE DRUM12 DISCONNECT THE THE OLD WIRE FROM THE DRUM AND LOWER THE REST OF THEWIRE SLOWLY WITH A ROPE ON DECK,LOWERING FROM INSIDE THE CRANE HOUSEIS MUCH EASIER.13 CONNECT THE NEW WIRE TO THE DRUM14 CONTINUE HEAVING UP SLOWLY.BREAK THE DRUM ON DECK TO AVOID SLACK IN THENEW WIRE15 WHEN TEN (10) TURNS ARE LEFT ON THE DRUM DISCONNECT THE NEW THIMBLE FROMTHE DRUM AND LAY THE WIRE IN LONG WAYS ON DECK16 PULL THE THIMBLE UP AND RECONNECT THIMBLE TO CRANE HOUSERemarks:

In case of crane no.1,forward mooring winches can be use to heave up the thimbleinto the top of the crane house.For crane no.2, in order to heave up the thimble on top of the crane,use pilot ladder winch.This must be done cautiously,at slow speed,everybody must stand clear of the area.see photo E

17 CONTINUE HEAVING THE WIRE TO THE POSITION MARK IN STEP 318 RE-CONNECT THE LIMIT SWITCHES19 DISCONNECT THE SLACK ROPE DEVICE20 CHECK ALL LIMITS21 FINALLY HEAVE AND SLACK THE WIRE 3 TO 4 TIMES TO LAY THE WIRE.

Sometimes, it can seem like the buying process is overly complicated, and Mazzella does that on purpose to avoid as many issues as possible when the new rope is installed.

The reason for that is so our customers avoid putting the wrong types of ropes on cranes and unnecessarily increasing the risk of injuries to workers or damage to loads being lifted. The processes that we go through are to make sure we prevent that added risk and put the correct rope on the correct machine, per Original Equipment Manufacturer (OEM) specifications.

Mazzella wire ropes specialists ask these questions to understand your circumstances and what your needs are. With this information, Mazzella will be better prepared to get the correct rope to match your company’s needs.

Most of the time, the customer should have access to an operations manual in their crane that will show what rope diameter and length is specified for that machine and that configuration. The customer may have to measure or come up with his own calculations on length.

The rope has to be specific to the lagging of the drum for that machine, which is why there are multiple variations for each size of wire rope because each kind is specific to the type of crane, and it shouldn’t be substituted. Mazzella will only install the rope that is the correct brand and tolerance on a particular crane.

On the less severe side, you’re just going to have bad performance, or it might not work at all. You could have twist and/or spooling issues. That could lead to the crane failing altogether, which creates downtime as you wait for the correct wire rope to be ordered/delivered, and then, installed.

Many people who own cranes are working for somebody else when they’re doing jobs, so if the rope doesn’t work, they’re paying for work that is not getting done, and then, falling behind schedule.

Sometimes, customers assume that there’s a one-size-fits-all replacement, that if it’s a non-rotating rope, it should work on every application. There’s a lot of misinformation on what will work and what won’t work.

With our experience and access to all brands of wire rope, Mazzella guarantees we can get you the right rope for your cranes. If Mazzella isn’t comfortable with the project, we won’t supply the wire rope.

If the wrong wire rope is ordered and delivered, it could be hours or days before the correct rope is on location. Especially with a lot of the larger cranes, manufacturers are shipping model-specific ropes all over the country, and depending on location and money, that could add time to the replacement process and cause delays on your worksite.

With our large inventory of rope and commitment to 24-hour service, Mazzella can have a new spool of wire on a truck and out for delivery to you in a matter of hours.

Say you and your company avoid the pitfalls of ordering the wrong crane rope and have a new spool of wire rope on its way. Once the order process is done, what can your company do to prepare for delivery and installation?

There’s a lot of downtime and sitting around waiting associated with making a mistake in the preparation process, so the more prepared you can be for the install, the better. You don’t want a situation where your crane is inactive because of an oversight or completely avoidable situation.

Also, Mazzella recommends you measure your sheaves with a sheave gauge. A sheave gauge will help you measure the wear of the root, the amount of wear on the groove wall and the diameter of the wire rope.

Okay, so after you order the correct rope and have the requisite space and approval for installation, how long will it take to remove and replace the old rope when the technician, assistants, and supplies arrive on-site?

For some small cranes, the timeframe could be as little as 45 minutes, but for larger cranes, removing the old rope and installing the new one could be a several-hour process.The application

There’s a lot of factors that go into a successful crane ropes installation. The most important thing is the quicker your supplier responds to your order and gets a rope on location, the quicker that rope gets installed properly, which saves you time and money.

Once a new crane rope is installed, a break-in period or tension period is recommended to make sure everything is performing correctly, and help you avoid shock-loading the newly installed wire rope.

The break-in period is recommended because installation and spooling equipment are not going to put adequate tension on the rope. A break-in period consists of putting a low percentage of the working load limit weight on the rope for several lift cycles, and running the blocks up to the boom length (working height) and back down.

If a brand-new wire rope on a crane is not broken in properly before lifting a large load, it potentially could damage the rope and render useless the equipment that was just installed on your machine.

While we’re in the business of selling crane ropes, we’re also in the business of building relationships and trust. We’ll always work with and serve you, and are committed to making sure you get the correct products for the right applications.

Crane rope issues don’t happen just 9-to-5, Monday through Friday. They happen Friday nights, holidays, weekends, early mornings. They’re always on the clock, and it’s just about being honest with the customer and letting them know, ‘this is the rope you need.’

We have one of the largest crane ropes inventories in the United States…ready for immediate delivery! We provide wire rope assemblies, and manufacture bridge cables, crane cables, steel mill cables, and thousands of OEM assemblies:In sizes from ¼” to 3” diameter and 9mm to 52mm diameter

We stock a large inventory of high-performance wire ropes available for immediate delivery. We stock our various high-performance ropes at our many locations in sizes from 1/4” to 3” diameter and 9 mm to 52 mm diameter.

Steel Wire rope is a very complex machinery element which primary function is the transmission of tensile forces. Its basic constructional design allows repeated changes in the direction of pull through reeving systems incorporating drums and sheaves. General purpose wire ropeshave been developed and standardized in national and international standards . However the increasing demand for higher breaking strength, greater flexibility, better rotation resistance , and extended rope life cannot be met by such general purpose steel wire ropeconstructions. Horizon Cable is a stocking distributor for Python Wire Rope, which through research, development and engineering over many years has developed rope constructions that have significantly improved operating life. There are vast array of applications that Python Wire Rope can be installed by Horizon Cable Service in Oklahoma, Texas, Wyoming, Kansas, North Dakota and New Mexico to improve service life. Below are a few of the proven applications for our high performance wire ropes:

One benefit to High Performance Wire Rope is the increased breaking strength over standard wire ropes. This is achieved in the manufacturing process by compaction processes. Standard ropes are drawn which create a round outer circumference, but compacted ropes have flat outer service. The two types of compaction are STRAND COMPACTION and SWAGE COMPACTION. Strand compaction is the most popular, in this process the compaction is applied to the individual wires, where the swage compaction is applied to the entire wire rope itself. Both have their advantages for particular applications.

Rotation resistant ropes can fall under three different classes Spin Resistant, Rotation Resistant, and Non Rotating. In all of these types of wire ropes the outer layer is twisted opposite for the inner layers. Rotation resistant and spin resistant ropes will have one inner layer, while non-rotating lines will have multiple inner strands rotating a different direction from the outers.

6 strand high strength swage compacted rope that is perfect for applications that require a crush resistant rope to be used in multi-layer winding systems; e.g. boom hoist on lattice boom mobile and tower cranes

Python Compac 18 is recommended for bot multipart load and single part applications where medium rotational stability is needed. Use as main and auxiliary hoist line on Grove, link belt, Manitowoc, Terex and other us made mobile and truck cranes. Also used very successfully as a pulling rope on underground cable pulling winches.

Main and auxiliary hoist line for European type mobile and for all types of construction tower cranes which require a high strength rotation resistant rope construction. Excellent rotation resistant properties make this rope the preferred choice for all single and multiple line reeving systems.

The importance of the wire rope that holds the hook and hoists together is often overlooked. This component is often replaced, and it is similar to why we replace car tires. Wire ropes are prone to wear as time goes on and how often they are used. The more they are used, and the heavier the load is, the faster they wear down. If the rope is maintained well, then it will last till the specified time.

If a wire rope isn’t installed correctly, it can be susceptible to damage from an external source or operated the wrong way. This is why it’s essential to

We recommend getting the wire rope or the details you need for the hoist from the original manufacturer to end up with a compatible one. Installing the new rope is also critical, as this ensures that the twists aren’t introduced and the optimal revving procedure is maintained.

When is wire rope replacement necessary? Corrosion:Corrosion is a more severe sign of damage as many stronger ropes are made from steel wires. This occurs when those wires have degraded badly and are usually the result of no lubrication care. Corrosion generally starts from the inside of the wires before it becomes visible on the outside. Rusting leads to a mild discolouration that can be resolved using lubricants and as quickly as possible. In some cases, this condition can persist and result in extreme corrosion and premature fatigue. The strands become weak, and that’s when you need to remove the rope.

Replacing the wire rope on a hoist, especially for an underhung hoist model, is essential and is determined during the load test requirements. Its manufacturer should have already tested out the rope being used on the hoist after producing it – this is a standard test carried out to ensure the quality of the completed wire rope.

Once you purchase it, the wire rope should be tested by the technician who evaluates the lowering function, lifting speed, limit switches and brake operation. These assessments are made without the lifting loads. Manufacturers may recommend this process for replacing a new wire rope. After the rope has been installed, start with a small load weight recommended by the manufacturer’s instructions. Next, run through all the lowering and lifting cycles that the rope intends to serve, then gradually move up to the full load capacity. This pattern lets the rope adjust and get seated on the hoist. After completing this break-in period, ensure that the hook block is secured. Then, disconnect the rope end for relaxing, correcting any twist or torque that may have crept in during the installation.

No matter what type of hoist you need, it is always important to choose the right equipment to do the job. Chain hoists are great pieces of equipment to handle light loads and can even replace manual material handling in your current processes. Wire rope hoists are the workhorses that can handle the heaviest capacities and make lifting heavy loads efficient. Always make sure you consider all factors when choosing your lifting equipment and work with the experts as you evaluate the options so you choose the right equipment for the job for safe lifting. Need help designing your next project? Contact us to find the right lifting solution for your needs!

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.

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.

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.

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.