WireCoHandbook - Form 1001M-Low Res

Wire Rope Users
Handbook
Contents
WIRE ROPE BASICS Page(s)

Importance of rope strands, construction and classification.. . . . . . . . . 4- 7
Relationship of wire, lay and preforming to wire rope. . . . . . . . . . . . . . . . 8- 9
performance and operation
Choosing the right wire rope for your application.. . . . . . . . . . . . . . . . . 10- 11
How to measure wire rope diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 13
> Metric conversions
> Design factors and how to use them
WIRE ROPE PRODUCTS

6 x 19 and 6 x 36 classifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 15
Rotation-resistant and low- torque ropes. . . . . . . . . . . . . . . . . . . . . . . . . 16- 19
>Category 1 ropes, Flex-X 19, XLT4
Premium value ropes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-- 23
> Flex-X 6, Flex-X 9, PF V, 7-Flex and Flex-X 7CC
Mining wire ropes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
> TUF-MAX shovel ropes, PowerMax drag ropes,
PowerMax MD drag ropes
Flattened strand ropes and 6 x 7 sandlines.. . . . . . . . . . . . . . . . . . . . . . . . . 25
Swaged ropes and PowerFlex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Specialty small ropes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Galvanized strand products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PROPER wire ROPE USE

Wire rope end treatments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to extend wire rope service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 31
Wire rope inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32- 33
Wire rope wear, abuse and removal criteria. . . . . . . . . . . . . . . . . . . . . . 34- 35
How to unreel, uncoil and store wire rope . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Standard wire rope abbreviations and warning. . . . . . . . . . . . . . . . . . . . . . 37
Glossary of wire rope terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38- 39
2 Union A WireCo WorldGroup Brand

Wire rope like no other
When it comes to showing you the ropes, no one We apply thorough design and manufacturing
does it like Union. Our products are backed by controls including complete material traceability.
years of experience in the field, at your side And we are the only manufacturer in the world that
solving tough problems in unique applications. is QPL qualified, API Spec 9A certified, and regis-
tered to both ISO 9001 and AS-9100 Quality Systems.
Weve matched the science of design with the art
of skillful manufacturing craftsmanship to build So, look to the best: the Union brand backed by the
the best wire rope in the world. WireCo WorldGroup organization. Were dedicated to
providing the products you need for your dynamic
No matter where you are in the world, Union applications throughout the world.
delivers hard-working products, exceptional
service and unmatched support. At Union, were With a global manufacturing and distribution base,
with you in the field, on the rig and in the mine, along with our unmatched technical expertise, the
getting our hands dirty to supply tough ropes that world is our worksite.
help you get the job done better.
Learn the ropes with our handbook
Small town roots, global leadership Wire rope basics Learn the basics of wire rope,
From simple beginnings, Union has grown to be including the nomenclature, how it is constructed,
the worlds premier wire rope brand. Union is part and how diameter and lay measurements are made.
of WireCo WorldGroup, the global leader in manu-
facturing, engineering and distributing wire ropes Wire rope products View the industrys most
and synthetic ropes, wire rope assemblies, high complete line of wire rope products including Flex-X
carbon wire, and electromechanical cable. ropes, Tuf-Max, PowerMax, PFV, 7-Flex,
rotation-resistant and swaged ropes, and other
With the global reach of WireCo WorldGroup be- special types.
hind it, Union can deliver the right ropes for your
machine and application no matter where your Proper rope use Learn how to choose the
worksite may be. right ropes for your needs, how to extend rope
service life, the importance of inspection, and
wireco worldgroup: how to properly store and handle wire rope.
the world is our worksite
Engineering wire rope for your application is a
highly specialized field with exacting standards
that we gladly live by. Across the entire WireCo
WorldGroup organization, we draw from our global
pool of talented engineers to drive results for
your application.
WireCo WorldGroup has manufacturing operations

and distribution centers across North America,
South America, Europe and Australia to give our
customers unparalleled support and global reach.
Our manufacturing standards typically exceed

the minimum design standards for a wire rope.
We take an active role in industry associations that
develop wire rope specifications and standards,
such as ASTM A1023.
Union A WireCo WorldGroup Brand 3

Wire rope classifications and features
Number of strands and The strands provide all the tensile

construction determine strength of a fiber core rope and over
wire rope classification 90% of the strength of a typical 6-strand
Wires are the basic building blocks of wire rope with an independent wire
a wire rope. They lay around a center rope core.
in a specified pattern in one or more
layers to form a strand. The strands Properties like fatigue resistance and
are helically laid together around a resistance to abrasion are directly af-
center, typically some type of core, to fected by the design of strands.
form a wire rope.
In most strands with two or more layers
of wires, inner layers support outer
layers in such a manner that all wires
may slide and adjust freely when the
rope bends.
As a general rule, a rope that has

strands made up of a few large wires
will be more abrasion resistant and
less fatigue resistant than a rope of
the same size made up of strands with
many smaller wires. The basic strand
constructions are illustrated at right.

Single layer The most common Filler wire This construction has
example of the single layer two layers of uniform-size wire around
construction is a 7 a center with the inner
wire strand. It has layer having half the
a single-wire center number of wires
with six wires of as the outer layer.
the same diameter Small filler wires,
around it. equal in number to
the inner layer, are
Seale This construction has two laid in valleys of the
layers of wires around a center with inner layer. Example: 25 Filler Wire
the same number of wires in each (1-6-6f -12) strand.
layer. All wires in each
layer are the same Warrington This construction has
diameter. The two layers of wires around a center
strand is designed with one diameter of wire
so that the large in the inner layer,
outer wires rest in and two diameters
the valleys between of wire alternating
the smaller inner wires. large and small in
Example: 19 Seale (1-9-9) strand. the outer layer.
The larger outer-
layer wires rest in the
valleys, and the smaller ones on the
crowns, of the inner layer. Example:
19 Warrington [1-6-(6+6)].
Combined patterns When a strand

is formed in a single
operation using two
or more of the above
constructions, it
is referred to as a
combined pattern.
This example is a
Seale construction in
its first two layers. The third layer
utilizes the Warrington construction, and
the outer layer is a Seale construction.
Its described as: 49 Seale Warrington
Seale [1-8-8-(8+8)-16].

Wire rope classifications and features (continued)
Standard rope classifications > TUF-KOTE /PFV A plastic

All rope of the same size, grade and impregnated wire rope proven to
core in each classification have the provide longer service life and a
same minimum breaking force and cleaner operation.
weight per foot. Different constructions On the inside,
within each classification differ in top-of-the-line
working properties. Consider these wire rope resists
features whenever youre selecting the demanding
a rope for a specific application. pressures of your job.
The polymer is applied
at high pressure to force the material
Classification* Wires per strand into the rope, serving to cushion the
strands, distribute internal stresses,
6 x 7 7 through 15 keep in wire rope lubricant and keep
6 x 19 16 through 26
unusual 6 x 36 27 through 49
out dirt and debris. On the outside,
operating 6 x 61 50 through 74 the engineered polymer plastic
conditions is designed to provide a cleaner
often require *Classifications are the same in 7
ropes of
operation and reduces wear on
and 8 strand wire ropes
special design sheaves and drums.
> Stresses or environ- > 7-Flex A wire rope that offers

ments of some Special rope constructions improved resistance to bending
applications can Unusual operating conditions often fatigue when compared to standard
seriously impair require ropes of special ropes to better 6x19S and 6x26WS constructions
the performance of withstand stresses or environments of the same
standard ropes. that would seriously impair performance diameter due to a
of standard ropes. Ropes that may meet combination of the
these needs include the following: outer wire size
and the seventh
> Flex-X A special process that strand. Its strand
creates more strand surface area constructions
on the rope to help spread contact, provide a good
decrease wear, reduce drum and combination of overall operating
sheave wear and extend service life. properties.
With greater surface
area and more steel
per diameter than
conventional ropes,
Flex-X provides higher
strength and better
wear resistance. Its
high-density strands are compacted
for extra strength and resistance to
abrasion, crushing and bending fatigue.

> Flex-X 7 CC Already a preferred > Swaged ropes These ropes offer
rope for container cranes, Flex-X 7 CC higher strength than standard ropes
is now providing extended service of the same diameter while providing
life in carriage op- greater resistance to
erations and other drum crushing,
applications where scrubbing and
multi-sheave equip- similar surface
ment and rigorous wear. During
duty cycles induce manufacturing, the
fatigue stresses. rope is swaged to
produce a compact
> TUF-MAX These shovel ropes cross-section with minimum voids
are manufactured and greater surface area.
with an enhanced
coating process
that makes them
Rope cores form a
more resistant to foundation for the strands
external rope wear The primary function of the ropes core
and helps extend is to serve as the foundation for the Three types of
drum and sheave life. rope cores:
strands to keep the rope round and
the strands properly positioned during
> PowerMax An 8-strand wire operation. Your choice of core will have
rope created to provide operating an effect upon the ropes performance.
properties essential
to drag and hoist Three types of cores
ropes. PowerMax are commonly used:
is more fatigue > Fiber Core
resistant than 1. Fiber core Polypropylene is
6-strand ropes of standard, but either natural sisal (or
the same diameter, hemp) fiber or other man-made fibers
plus, its greater are available on special request.
surface area puts more
steel in touch with contact surfaces 2. Independent Wire Rope Core
reducing wear and abrasion. Literally an independent wire rope
with strands and a core, called IWRC. > Independent Wire
> Flattened (triangular) Most wire ropes made with steel core Rope Core
strand These ropes feature use an IWRC.
shaped strands
formed so they will 3. Strand core A strand made of
close together to wires. Typically, strand cores are
achieve greater used in utility cables only. > Strand Core
metallic area in
the ropes cross-
section and greater
bearing surface for contact with
sheaves and drums.

Wire, lay and preforming affect rope
performance and operation
The basic types of wire used in ropes standard zinc coated wires. The coating
Preforming Bright wire Most wire ropes are made also provides an anodic feature that
preshapes
strands before with uncoated (bright) high-carbon steel heals over the exposed steel when the
the rope wires. The chemistries of the steel and wire is abraded or scratched.
is closed. the wire drawing practices are varied to
Stainless steel wire This is a
supply the ultimate combination of tensile
special alloy containing approximately
strength, fatigue resistance, and wear
18% chromium and 8% nickel. It has high
resistance in the finished wire rope.
resistance to many corrosive conditions
> Preforming and is used extensively in yachting ropes
Galvanized wire is often used to
helically shapes and control cables.
improve corrosion resistance of wire
the wires and
ropes. The following two types are used:
strands into the Wire rope grades
shape they will Galvanized-to-finished size wire The most common strength grades
assume in the starts as a smaller diameter bright wire of wire rope are Extra Improved Plow
finished wire and is then coated with a zinc layer that Steel (XIP) and 1960 grade. For many
rope. It improves increases the diameter to the designed applications these are the grades
handling and finished size. supplied. XIP grade wire ropes have
resistance approximately 15% higher minimum
to kinking by Galvanized-to-finished wires are 10% breaking forces over the same ropes made
conforming the lower in strength than the same size and with the former standard of Improved
strands to the grade bright wire. Therefore, ropes made Plow Steel (IPS).
position they with these wires have minimum breaking
take in the wire forces that are 10% lower in strength The next step up in strength grades
rope. It also when compared to their bright version. includes Extra Extra Improved Plow Steel
helps to minimize (XXIP) and 2160 grade. The minimum
internal stresses Drawn galvanized wire is bright wire breaking forces of XXIP grade wire ropes
within the ropes galvanized just prior to it being drawn are approximately 10% higher than their
structure. down to its final finished diameter. This XIP grade versions.
leaves a much thinner zinc coating than
> Today, preforming is on galvanized-to-finished wires. Drawn The minimum breaking force values
is virtually galvanized wires are equal in strength to associated with IPS, XIP, XXIP, and XXXIP
standard in the same size and grade of bright wire. are typically expressed in pounds (lbs)
most non- Therefore, ropes made with these wires and/or short tons of 2,000 lbs.
rotation-resistant have minimum breaking forces that are
(standard) The 1570, 1770, 1960, and 2160 values
equal to their bright versions.
ropes. But, in the ISO grades indicate the number
some specialty Galfan wire The most rapidly growing of newton force units required for each
ropes may be hot-dip coating for steel wire is made with square millimeter of area of cross-
non-preformed the Galfan process. The process requires sectional metal in a rope to make up its
due to their 95% zinc and 5% aluminum coating be minimum breaking force. The associated
unique designs applied to the wire. Basic Galfan coated minimum breaking force values are
and operating carbon steel wire is addressed in ASTM typically expressed in kilonewtons (kN) or
characteristic A856 and EN 10244. metric tons of 2,204 lbs.
requirements. Common - USA Union - USA International
Combining the passive corrosion
IPS IPS 1570 N/mm2
inhibition of aluminum oxidation with the
active and passive effects of zinc results
EIP XIP 1770 N/mm2
in approximately three times the amount EEIP XXIP 1960 N/mm2

of corrosion protection compared to EEEIP XXXIP 2160 N/mm2

Lay has three meanings in rope design
> Right lay Regular lay
> Left lay Regular lay
> Right lay Lang lay
> Left lay Lang lay
T
he first two meanings of lay 3. The length along the rope that a strand
are descriptive of the wire and makes one complete spiral around
strand positions in the rope. The the rope core. This is a measurement
third meaning is a length measurement frequently used in wire rope inspection.
used in manufacturing and inspection. Standards and regulations require
removal when a certain number of
1. The direction strands lay in the rope broken wires per rope lay are found.
right or left. When you look down a
rope, strands of a right lay rope go
away from you to the right. Left lay The lay of a rope affects its
is the opposite. (It doesnt matter operational properties
which direction you look.)
Regular lay is more stable and more resistant
to crushing than lang lay, while lang lay is
2. The relationship between the more fatigue resistant and abrasion resistant.
direction strands lay in the rope and For standard non-rotation-resistant ropes,
the direction wires lay in the strands. lang lay use is normally limited to single layer
In appearance, wires in regular lay spooling and when the rope and load are
restrained from rotation.
appear to run straight down the
length of the rope, and in lang lay,
they appear to angle across the rope.
In regular lay, wires are laid in the
strand opposite the direction the
strands lay in the rope. In lang lay,
the wires are laid the same direction
in the strand as the strands lay in
the rope.

Choosing the right rope for your application
W
ith each application, your strength. These refer to calculated
choices of wire ropes can strength figures that have been
be many. How do you know accepted by the wire rope industry.
which one works best for you? Ropes
include a combination of properties that When placed under tension on a test
give them specific performance abili- device, a new rope should break at a
ties. Before you choose, it pays figure equal to or higher than the
to look closely at each ropes special minimum breaking force shown for that
properties. rope.
No single wire rope The values in this handbook apply to

can do it all new, unused rope. A rope should never
All wire ropes feature design operate at or near the minimum
property tradeoffs. In most cases, breaking force. During its useful life,
If you need a wire rope cannot increase both fatigue a rope loses strength gradually due
abrasion resistance and abrasion resistance. to natural causes such as surface
resistance For example, when you increase wear and metal fatigue.
> Abrasion resistance fatigue resistance by selecting a rope
increases with fewer, with more wires, the rope will have Fatigue resistance Fatigue
larger outside wires less abrasion resistance because of its resistance involves metal fatigue of
per strand. greater number of smaller outer wires. the wires that make up a rope. To have
high fatigue resistance, wires must be
When you need wire rope with greater capable of bending repeatedly under
abrasion resistance, one choice is a stress for example, a rope passing
rope with fewer (and larger) outer over a sheave.
wires to reduce the effects of surface
wear. But that means the ropes fatigue Increased fatigue resistance is achieved
resistance will decrease. Thats why in a rope design by using a large number
you need to choose your wire rope like of wires. It involves both the basic
If you need you would any other machine. Very metallurgy and the diameters of wires.
fatigue carefully. You must consider all operating
resistance
conditions and rope properties. In general, a rope made of many wires
> Fatigue resistance
will have greater fatigue resistance
increases with more,
The basic properties than a same-size rope made of fewer,
smaller outside wires of wire rope larger wires because smaller wires
per strand. How do you choose the wire rope thats have greater ability to bend as the rope
best suited for your job? Following are passes over sheaves or around drums.
the most common properties to be con- To reduce the effects of fatigue, ropes
sidered when selecting a rope for must never bend over sheaves or drums
an application. with a diameter so small as to bend
wires excessively. There are precise
Strength Wire rope strength is recommendations for sheave and drum
usually measured in tons of 2,000 sizes to properly accommodate all sizes
lbs. In published material, wire rope and types of ropes.
strength is shown as minimum breaking
force (MBF) or nominal (catalog)

Every rope is subject to metal fatigue The most common form of metal defor-
from bending stress while in operation, mation is generally called peening
and therefore the ropes strength since outside wires of a peened rope
gradually diminishes as the rope is used. appear to have been hammered
along their exposed surface.
Crushing resistance Crushing squared ends
is the effect of external pressure on a Peening usually occurs on drums, > Typical example of
rope, which damages it by distorting caused by rope-to-rope contact during breaks due to fatigue.
the cross-section shape of the rope, spooling of the rope on the drum. It
its strands or core or all three. may also occur on sheaves.
Crushing resistance therefore is a ropes Peening causes metal fatigue, which

ability to withstand or resist external in turn may cause wire failure. The
forces, and is a term generally used to hammering which causes the metal crushing
express comparison between ropes. of the wire to flow into a new shape
> Typical example of
realigns the grain structure of the metal,
external pressure on
When a rope is damaged by crushing, thereby affecting its fatigue resistance.
a wire rope.
the wires, strands and core are prevented The out-of-round shape also impairs
from moving and adjusting normally wire movement when the rope bends.
during operation.
Resistance to rotation When
In general, IWRC ropes are more crush a load is placed on a rope, torque is
resistant than fiber core ropes. Regular created within the rope as wires and CROSS-SECTION
lay ropes are more crush resistant than strands try to straighten out. This is OF A WORN WIRE
lang lay ropes. Six strand ropes have normal and the rope is designed to > Original
greater crush resistance than 8 strand operate with this load-induced torque. cross-section
ropes or 19 strand ropes. Flex-X ropes However, this torque can cause loads > Worn
are more crush resistant than standard to rotate. Load-induced torque can be surface
round-strand ropes. reduced by specially designed rotation
resistant ropes.
Resistance to metal loss and
deformation Metal loss refers to In standard 6 and 8 strand ropes, the
the actual wearing away of metal from torques produced by the outer strands
the outer wires of a rope, and metal and the IWRC is in the same direction
deformation is the changing of the and add together. In rotation resistant cross- section
shape of outer wires of a rope. ropes, the lay of the outer strands is in of a peened wire
the opposite direction to the lay of the > Original
In general, resistance to metal loss inner strands, thus the torques produced cross-section
by abrasion (usually called abrasion are in opposite directions and the torques > Peened
resistance) refers to a ropes ability subtract from each other. surface
to withstand metal being worn away
along its exterior. This reduces strength Depending upon your application,
of a rope. other wire rope properties such
as stability, bendability or reserve
strength may need to be considered.

How to measure wire rope diameter
T
he actual diameter of a wire The illustrations at left
rope is the diameter of a show the correct and
circumscribed circle that incorrect methods
will enclose all the strands. Its the of measuring wire
largest cross-sectional measurement ropes with even
as shown here. You should make the numbers of outer
measurement carefully with calipers. strands.
Metric conversion and equivalents
True diameter
A s we move toward metric
measurements, it will become
increasingly necessary to convert English
Nominal wire rope diameter
Inches Millimeters Inches Millimeters
units into SI International System of Units 1/4 6.5 2 1/8 54

(or metrics), and vice versa. The following 5/16 8 2 1/4 58
table and conversion factors are included 3/8 9.5 2 3/8 60
in this handbook to help you.
7/16 11.5 2 1/2 64
1/2 13 2 5/8 67
Rope diameter
9/16 14.5 2 3/4 71
For standard, general purpose wire ropes,
in measuring diameter, the industry is 5/8 16 2 7/8 74
leaning toward a soft conversion to metric 3/4 19 3 77
Correct during the transition period. For example, 7/8 22 3 1/8 80
a 1 diameter rope converts to 25.4 mm
in metrics. Using the soft conversion, this 1 26 3 1/4 83
is changed to the whole metric size that 1 1/8 29 3 3/8 87
most nearly parallels the 1 size range, or 1 1/4 32 3 1/2 90
26 mm. In sizes smaller than 5/8, the rope
diameter is rounded to the nearest 0.5 mm. 1 3/8 35 3 3/4 96
1 1/2 38 4 103
Incorrect Strengths and weights 1 5/8 42 4 1/4 109
The following table gives the closest 1 3/4 45 4 1/2 115
equivalent metric diameters for rope 1 7/8 48 4 3/4 122
sizes up through 5 inches. Again, these 2 52 5 128
metric sizes are based on the industrys
soft conversion. Your application may > To convert rope minimum breaking force
have tighter tolerances that require a hard in tons (T) to kilonewtons (kN), multiply by
conversion. Therefore, the values in the 8.897; 1 lb equals 4.448 newtons (N).
table would not apply.
> To convert rope minimum breaking force
Since rope minimum breaking force and in tons (T) to kilograms (kg), multiply by
weight per unit of length vary for different 907.2.
types and grade of ropes, the following
conversion factors are given to help you Note: The newton (a unit of force) is the
convert the figures you need: correct unit for measurement of minimum
breaking force in the SI system of units.
> To convert rope weight in pounds per foot We have included a conversion factor
(lb/ft) to kilograms per meter from tons to kilograms because a ropes
(kg/m), multiply by 1.488. minimum breaking force is often referred
to in terms of kilograms (a unit of mass).

Allowable tolerance
in wire rope diameter Nominal Diameter Tolerance Nominal Diameter
Wire rope is normally made slightly (in) Under Over (mm)
larger than its catalog (or nominal)
size. The following chart lists the Through 1/8 -0 + 8% From 2 to <4
size tolerances of standard wire rope. Over 1/8 through 3/16 -0 + 7% From 4 to <6
Over 3/16 through 5/16 -0 + 6% From 6 to < 8
Over 5/16 and larger -0 + 5% 8 and greater
Design factors
T he design factor is defined as the

ratio of the minimum breaking
force of a wire rope to the total load
types on the same application may have
different design factor requirements.
it is expected to carry. How to use design factors

Standards and regulations require that
Use of design factors provides rope design factors be applied to the ropes
installations with reasonable assurance minimum breaking force to determine
of adequate capacity for the work to be the maximum working load. To deter-
done throughout a ropes service life. mine the maximum working load for
Considerations in establishing design which an operating rope may be used,
factors include the type of service, divide the ropes minimum breaking
design of equipment and consequences force by the required design factor. This
*Note
of failure. is the ropes maximum working load.
> The rated capacity
There may be other limiting factors in
of a wire rope sling
In most applications, the selection of a an application that make the maximum
incorporates both
rope based on the proper design factor load the equipment can handle less than
a design factor
has been made by the equipment the ropes maximum working load.*
and a splicing or
manufacturer. In an application where
attachment efficiency.
a different rope is to be used, or in a Remember, an installation is only at
new application, check government the prescribed design factor when the
and industry regulations for the rope is new. As a rope is used, it loses
required design factor. Different rope strength and literally is used up.

Standard 6 x 19 and 6 x 36 classification ropes
T
he 6 x 19 classification of wire important for their fatigue resistance.
ropes includes standard 6 strand, This fatigue resistance is made possible
round strand ropes with 16 by the greater number of small wires
6 x 19 vs. through 26 wires per strand. The 6 x 36 per strand.
6 x 36 classification of wire ropes includes
> Its a question of standard 6 strand, round strand ropes Although there are exceptions for
what your needs with 27 through 49 wires per strand. special applications, the constructions
are. The 6 x 19 ropes Although their operating properties in 6 x 36 classification are primarily
emphasize abrasion vary, all have the same weight per foot designed to be the most efficient for
resistance while and the same minimum breaking force, each rope diameter. As the rope size
the 6 x 36 ropes are size for size. increases, for instance, a large number
important for their of wires can be used to achieve required
fatigue resistance. While the 6 x 19 ropes give primary fatigue resistance, and still those wires
emphasis to abrasion resistance in will be large enough to offer adequate
varying degrees, the 6 x 36 ropes are resistance to abrasion.
Properties OF STANDARD 6 X 19 AND 6 X 36 WIRE ROPES
6 x 19 Class ropes 6 x 36 Class ropes

6 x 19S (Seale) This In most rope sizes, only
is a good rope one 6 x 36 classifica-
to withstand abrasion tion rope is made.
or crushing on the These constructions
drum but its fatigue were selected to
resistance is provide fatigue
decreased. resistance without
having wires that
6 x 25F (Filler 6 x 19S 6 x 31WS
are too small.
Wire) To most wire
rope users, 6 x 19 The greater number
means 6 x 25 filler of wires in the
wire. It is a common 6 x 36 classification
rope in the 6 x 19 clas- makes these ropes
sification. more susceptible to
crushing. This can be
6 x 26WS minimized, however,
(Warrington 6 x 25F by specifying an 6 x 36WS
Seale) A standard Independent Wire
6 x 26WS design pro- Rope Core (IWRC) and
vides the best rope by using well-designed
for a wide range of sheaves, grooved
applications. drums and proper
In general, we operating
recommend the techniques.
use of a 6 x 26WS in
any application where
a 6 x 25F is used. 6 x 26WS 6 x 49SWS

Minimum breaking force and weights for standard
6 x 19 and 6 x 36 classification ropes
Fiber core IWRC

Approx. Approx.
Diameter wt./ft. Minimum breaking force wt./ft. Minimum breaking force
(in.) (lb.) (tons of 2,000 lb.) (lb.) (tons of 2,000 lb.)
IPS XIP IPS XIP XXIP
3/16 0.059 1.55 1.71

1/4 0.105 2.74 3.02 0.116 2.94 3.40
5/16 0.164 4.26 4.69 0.18 4.58 5.27
3/8 0.236 6.10 6.72 0.26 6.56 7.55 8.30
7/16 0.32 8.27 9.10 0.35 8.89 10.2 11.2
1/2 0.42 10.7 11.8 0.46 11.5 13.3 14.6
9/16 0.53 13.5 14.9 0.59 14.5 16.8 18.5
5/8 0.66 16.7 18.3 0.72 17.9 20.6 22.7
3/4 0.95 23.8 26.2 1.04 25.6 29.4 32.4
7/8 1.29 32.2 35.4 1.42 34.6 39.8 43.8
1 1.68 41.8 46.0 1.85 44.9 51.7 56.9
1 1/8 2.13 52.6 57.8 2.34 56.5 65.0 71.5
1 1/4 2.63 64.6 71.1 2.89 69.4 79.9 87.9
1 3/8 3.18 77.7 85.5 3.50 83.5 96.0 106
1 1/2 3.78 92.0 101 4.16 98.9 114 125
1 5/8 4.44 107 118 4.88 115 132 146
1 3/4 5.15 124 137 5.67 133 153 169
1 7/8 5.91 141 156 6.50 152 174 192
2 6.72 160 176 7.39 172 198 217
2 1/8 7.59 179 197 8.35 192 221 244
2 1/4 8.51 200 220 9.36 215 247 272
2 3/8 10.4 239 274
2 1/2 11.6 262 302
2 5/8 12.8 288 331
2 3/4 14.0 314 361
2 7/8 15.3 341 392
3 16.6 370 425
3 1/8 18.0 399 458
3 1/4 19.5 429 492
3 3/8 21.0 459 529
3 1/2 22.7 491 564
3 5/8 24.3 523 602
3 3/4 26.0 557 641
3 7/8 27.7 591 680
4 29.6 627 720
4 1/8 31.7 658 757
4 1/4 33.3 694 799
4 3/8 35.4 734 844
Available galvanized at 10% lower strengths, or in equivalent strengths

on special request.
Should not be used with a swivel.

Rotation-resistant and low-torque ropes
R
otation-resistant ropes can Category 2 rotation-resistant rope
frequently provide the best has 10 or more outer strands, has
and most economical service in two or more layers of strands (over a
specific applications when you choose, center) and has a significant resistance
handle and use them properly. to rotation.
Contra-helically laid, rotation-resistant Category 3 rotation-resistant rope

ropes are different from standard ropes has no more than 9 outer strands, has
because theyre designed to reduce two layers of strands (over a center)
rope torque. Modes of failure and and has limited resistance to rotation.
wear for rotation-resistant ropes For best performance, Category 2 and
use extra care can differ from those for standard 3 rotation resistant ropes should not
> The very nature of rope constructions. The very nature of be used with a swivel. Category 1
rotation-resistant these ropes requires special handling, rotation-resistant rope may be used
ropes requires spe- selection and usage. They are more with a swivel.
cial handling, selec- susceptible to kinking, crushing and
tion and usage. unbalancing in the form of core pops Because rotation-resistant ropes are
and birdcages. Use extreme care to special, there are separate design,
avoid operational practices that can maintenance, inspection and removal
possibly lead to these conditions. criteria established for them in many
industry regulations and standards.
There are different types Rotation-resistant ropes must be
of rotation-resistant ropes replaced when you see two randomly
in astm a1023, categorized by their distributed crown wire breaks in six
resistance to rotation.
rope diameters or four randomly
distributed crown wire breaks in
Category 1 rotation-resistant rope
30 rope diameters. If any significant
has at least 15 outer strands, has
reduction in diameter is found in a
three layers of strands (over a center)
short length of a rotation-resistant
and has little or no tendency to rotate,
rope, the rope needs to be replaced.
or, if guided, transmits little or no
torque.
Rotation-resistant ropes must be used with
a minimum design factor of 5.0.
Because Category 1 rotation resistant
ropes are manufactured with little or no
preforming, it is critical to not remove
the welded ends. If the welded ends
are removed the rope can become
unbalanced.

how to REDUCE rotation and torque starlift xtra
Category 1 rotation-resistant ropes
feature a unique design that minimizes Diameter Weight Minimum breaking force
the torque and rotation of the rope at (in.) (mm) (lb./ft.) tons (2,000 lb.) lb.
normal load ranges of zero to 20% 14 0.67 23.38 46,760
of the ropes minimum breaking force 15 0.77 26.42 52,830
5/8 16 0.88 30.57 61,148
(MBF). These ropes are engineered
to give you maximum strength per 17 0.99 33.95 67,892
18 1.12 38.22 74,435
diameter while also achieving superior
3/4 19 1.24 42.94 85,877
fatigue resistance. These factors
combine to give you the maximum 20 1.38 47.32 94,645 > A Category 1
21 1.52 51.71 103,412 rotation-resistant
service life when you have long block 7/8 22 1.67 57.21 114,428
falls or load control is critical. Unlike rope features a
other rotation-resistant ropes, swivels 1 25.4 2.22 75.87 151,746 unique design that
26 2.33 79.25 158,490 minimizes the torque
can be used in your system with 28 2.69 91.61 183,219
Category 1 ropes. and rotation of the
30 3.09 104.99 209,972 rope at normal load
1 1/4 32 3.51 121.96 243,918
Starlift Xtra wire rope has one of the ranges of zero to 20%
34 3.97 134.89 269,771
highest strength-to-diameter ratios on 36 4.46 150.62 301,244 of the ropes minimum
the market. ASME B30.5 Mobile and breaking force.
Locomotive Cranes requires a design
factor of 3.5 for 6-strand hoist ropes. eurolift
The same standard requires a design Minimum breaking force
factor of 5.0 for rotation-resistant Diameter Weight 1960 N/mm2 2160 N/mm2
ropes. The MBF of Starlift Xtra is such (in.) (mm) (lb./ft.) tons (2,000 lb.) lb. tons (2,000 lb.) lb.
that even with the 5.0 design factor, 5/8 16 0.85 25.92 51,841 28.00 56,000
it has lifting capacities that equal or 17 0.95 28.99 57,978 31.54 63,081
exceed 6-strand XIP ropes utilizing a 18 1.08 33.04 66,071 35.69 71,377
3.5 design factor. Other ropes of similar 3/4 19 1.20 36.98 73,962 39.66 79,313
construction do not provide this benefit. 20 1.33 40.71 81,426 44.03 88,058
21 1.46 44.52 89,047 48.44 96,870
Eurolift is a premier hoist rope for 7/8 22 1.60 49.62 99,231 53.05 106,110
applications where rotation-resistant 23 1.75 53.03 106,065 57.69 115,372
ropes are required, and it is especially 24 1.91 58.93 117,867 63.41 126,815
suitable for mulitple-layer spooling. Its 25 2.04 63.83 127,669 68.50 136,999
core is specially designed to prevent 1 25.4 2.11 65.96 131,918 70.52 141,045
26 2.21 69.12 138,235 73.89 147,789
crossover between the strands of the
core and internal rope destruction. The 27 2.40 73.53 147,070 80.00 159,996
balanced design of Eurolift results in 28 2.59 80.13 160,266 86.06 172,114
1 1/8 28.6 2.69 82.35 164,695 89.59 179,173
minimal torque under load, providing
superior rotation resistance. Under a 29 2.77 84.82 169,641 92.28 184,568
normal working load range, Eurolift has 30 2.96 91.88 183,759 98.68 197,360
31 3.16 97.76 195,516 107.73 215,457
virtually no tendency to rotate, making
it ideal for both single-part and multi- 1 1/4 32 3.39 104.54 209,072 112.72 225,438
part hoist systems but also for those
involving long falls where rotation > WireCo WorldGroup manufactures and
resistance is required. markets Category 1 crane ropes under
the CASAR brand.

Rotation-resistant and low-torque ropes (continued)
Flex-X 19 XLT4
Flex-X 19, a Category 2 rotation- XLT4 ropes are specially designed to
resistant rope, is made from 19 strands. provide very low torque, a high minimum
Six strands are laid around breaking force and high resistance to
a core strand in one wear in multi-layer spooling.
direction, and then
12 strands are laid Under load, XLT4 generates near-zero
around this first torque, matching or surpassing the
operation in the stability of Category 1 35 x 7 class
opposite direction. rotation-resistant ropes. Yet, thanks to its
Because of its tightly unique design, XLT4 is not classified as a
XLT 4 compacted smooth design, rotation-resistant rope. It can be used
> With its unique Flex-X 19 offers more crushing with or without a swivel as a mobile
design, XLT4 brings resistance than standard 19 x 7 rope, crane hoist rope at design factors as low
more high-tensile higher strength-to-diameter, resistance as 3.5 to 1.
steel into the ropes to bending fatigue, exceptional stability,
diameter, resulting reduced wear to sheaves and drums, XLT4 ropes compact construction keeps
in one of the and improved handling, operating and more steel in contact with sheaves and
highest strength- spooling properties. drums for unmatched
to-diameter ratios. resistance to crushing
Flex-X 19 has also demonstrated and wear for lower
greater fatigue resistance to maintenance, less
substantially cut rope expense and downtime and longer
extend service life. May be used service life. With the
in single or multiple part hoisting ropes high capacity,
applications. However, its ideal for lifts may be feasible
multi-part hoist lines wherever you using fewer parts of line boosting the
encounter spooling problems, drum speed, efficiency and productivity of
crushing, block twisting or have fast crane work.
line speeds.
Because of its unique construction, XLT4
Flex-X 19 should not be used with a performs best on grooved drums that
swivel. are larger than the minimum required
D/d and where the entire length of the
rope is subjected to loading in normal
operation. Where there is multiple layer
spooling, the base layers on the drum
must be under tension to assure proper
spooling and to avoid pull-in of the
upper layers. The tension on these lower
layers ensures that the rope is both tight
against adjacent wraps and tight around
the drum which establishes a solid
foundation for the upper layers.

Minimum breaking force and weights for rotation-resistant and low torque crane ropes

Flex-X 19 XLT4 19 x 7 XIP 8 x 25 XIP
Minimum Minimum Minimum Minimum
Diameter Approx. breaking Approx. breaking Approx. breaking Approx. breaking
(in.) wt./ft. force wt./ft. force wt./ft. force wt./ft. force
(lb.) (tons of (lb.) (tons of (lb.) (tons of (lb.) (tons of
2,000 lb.)* 2,000 lb.) 2,000 lb.)* 2,000 lb.)*
3/16 0.064 1.57

1/4 0.113 2.77
5/16 0.177 4.30 0.18 4.63
3/8 0.25 6.15 0.26 6.63
7/16 0.43 11.2 0.35 8.33 0.36 8.97
1/2 0.49 14.6 0.51 17.7 0.45 10.8 0.47 11.6

9/16 0.65 18.5 0.65 22.3 0.58 13.6 0.60 14.7

5/8 0.78 22.7 0.79 27.4 0.71 16.8 0.73 18.1

3/4 1.16 32.4 1.1 39.2 1.02 24.0 1.06 25.9
7/8 1.58 43.8 1.5 53 1.39 32.5 1.44 35.0
1 2.05 56.9 2.1 68.9 1.82 42.2 1.88 45.5
1 1/8 2.57 71.5 2.6 86.7 2.30 53.1 2.39 57.3
1 1/4 2.83 65.1 2.94 70.5
1 3/8 3.43 78.4 3.56 84.9
1 1/2 4.08 92.8 4.24 100
* The minimum breaking force applies only when a test is conducted with both ends fixed. When in use,
the minimum breaking force of these ropes may be significantly reduced if one end is free to rotate.

Premium value ropes
Flex-X 6 Flex-X 9
Most applications for wire rope are Designed to combat drum crushing
extremely demanding. Wire rope must challenges in boom hoisting applications,
resist crushing, bending fatigue and Flex-X 9 features compacted strands
abrasion. For example, clamshell closing and swaging for extra drum crushing
Flex-x and
increased lines must resist bending fatigue and resistance and increased stability.
surface area boom hoists are subject Its high-density strands deliver extra
> Flex-X ropes provide to pressures that strength, surprising bendability and a
greater surface cause crushing. stubborn resistance to abrasion.
area and more steel Overhead hoists test
per given diameter, the stability and Flex-X 9 is manufactured with a dual
increasing rope strength of a wire compaction process to produce a compact
stability, strength rope. All drum-related cross-section with minimum voids and
and service life. applications demand a greater surface area on
rope that will spool and outer wires that contact
operate smoothly and dependably. drums, sheaves and
the rope, itself, during
Flex-X 6 users receive superior operation. The high-
performance and increased service life in density, compacted
many applications compared to the ropes strands minimize nicking
they had previously employed. When at strand-to-strand contact points.
compared to conventional 6 strand ropes,
Flex-X 6 ropes provide greater surface area And Flex-X 9 makes inspection easier
and more steel per given diameter, which for you. While standard swaged ropes
increases rope stability and strength, too. may develop internal broken wires
This results in longer service life and less before they do externally, Flex-X 9s
sheave and drum wear. design minimizes internal stresses,
making external wire breaks more likely
Flex-X 6 should not be used with a swivel. to develop first.
Flex-X 9 should not be used with a swivel.

Flex-X vs standard 6 x 26 WS
Drum scrubbing between the lead
line and the previous wrap is reduced.
The increased
surface area of
Flex-X can be
seen in the Force
comparison of
the contact points
of a standard
6 x 26 WS (top)
and Flex-X
(bottom).
Smooth contact creates less

interference, less metal loss
and wire deformation.

Minimum breaking force and weights
for Flex-X 6 and Flex-X 9

Flex-X 6 Flex-X 9
Minimum Minimum
Approx. breaking force Approx. breaking force
Diameter wt./ft. (tons of wt./ft. (tons of
(in.) (lb.) 2,000 lb.) (lb.) 2,000 lb.)
3/8 0.32 8.8

7/16 0.41 11.9
1/2 0.55 15.3
9/16 0.70 19.3
5/8 0.86 22.7 0.90 26.2
3/4 1.25 32.4 1.30 37.4
7/8 1.67 43.8 1.79 50.6
1 2.18 56.9 2.33 65.7
1 1/8 2.71 71.5 2.93 82.7
1 1/4 3.43 87.9
1 3/8 4.25 106
1 1/2 5.01 125

Premium value ropes (continued)
PFV 7-Flex
PFV, the plastic-impregnated wire We offer 7-Flex ropes for many applica-
rope, has proven in many applications tions that currently use 6 x 19 or 6 x 36
to give you longer service life and classification ropes. Their operating
cleaner operation than conventional properties are similar in
wire ropes. many ways to 6 x 36
classification ropes.
On the inside, youll find our top-of- Typical applications
the-line wire rope that effectively such as container
withstands the tough pressures of cranes, logging
your demanding jobs. On the outside, portal cranes and
youll see a specially engineered sawmill carriages have
polymer plastic designed to overcome reported increased service life with the
even harsher conditions. This polymer 7-Flex rope.
polymer
penetration is applied at high pressure to force
the material into the rope, filling the The 7-Flex construction offers improved
> With one strand and
valleys of the strands. resistance to bending fatigue compared
part of the polymer
plastic removed,
to a 6 x 19S and 6 x 26WS due to a
PFV cushions the strands, distributes combination of the outer wire size and
you can see how
internal stresses, keeps in wire rope the seventh strand. These products are
deep the polymer
lubricant and keeps out dirt and debris. also available in a PFV option to further
penetrates into
the rope, giving
enhance service.
PFV doesnt melt or soften from the heat
you uniform and Minimum breaking force and
of normal operating temperatures. Its
continuous support weights for all 7-Flex ropes
also virtually unaffected by sunlight
for all strands
and cold weather. The result is longer Minimum
throughout the length
service life from your wire rope. Approx. breaking force
of the rope. Diameter wt./ft. (tons of
(in.) (lb.) 2,000 lb.)
PFV also helps shed water and dirt, XIP IWRC
giving you a clean, smooth surface
to make it easy to pass over sheaves 3/8 0.26 7.55
7/16 0.35 10.2
and onto drums. This smooth surface 1/2 0.46 13.3
works to clean and polish as it extends
9/16 0.59 16.8
the service life of your sheaves and 5/8 0.72 20.6
drums, while also reducing your 3/4 1.04 29.4
cleanup requirements and your 7/8 1.42 39.8
maintenance costs. 1 1.85 51.7
1 1/8 2.34 65.0
1 1/4 2.89 79.9

FLEX-X 7 CC Minimum breaking force and
Container crane hoist and trolley weights for fLEX-x 7 cc
ropes are subjected to the stressful Minimum
combination of bending fatigue Approx. breaking force
and abrasion from Diameter wt./ft. (tons of
(in.) (lb.) 2,000 lb.)
operating over a
IWRC
series of intricate
sheaves and drums. 1/2 0.50 15.3
Flex-X 7 CC is a wire 9/16 0.63 19.3
5/8 0.80 22.7
rope for container
cranes thats so 3/4 1.13 32.4
7/8 1.55 43.8
revolutionary its 1 2.01 56.9
guaranteed to provide you with a
1 1/8 2.54 71.5
significant lift in service life when 1 1/4 3.14 87.9
compared with standard ropes. 1 3/8 3.80 106
1 1/2 4.43 125
Flex-X 7 CC will operate longer no
matter what load conditions you put
it under. A combination of superior application currently using a 6 x 36
design and manufacturing technique construction can gain an increase
helps reduce metal fatigue, internally in service life with Flex-X 7 CC.
and externally, while helping to extend
the life of sheaves and drums. Fatigue tests have shown that Flex-X 7 CC
will outperform competitors premium
In addition to container crane 8-strand compacted, coated core ropes
applications, Flex-X 7 CC is now by 60% or more. These tests have
providing extended service life in also shown that FLEX-X 7 CC can
carriage operations and other provide up to 88% longer service
applications where multi-sheave life over standard ropes.
equipment and rigorous duty cycles
induce fatigue stresses. Almost any

Mining wire ropes
TUF-MAX shovel ropes plus, its greater surface area puts

TUF-MAXshovel ropes are the latest more steel in touch with contact
development in PFV mining rope surfaces reducing wear and abrasion.
technology. These 8-strand ropes utilize Just as importantly, no drag or hoist
improved design and rope available is subjected to more
enhanced application rigorous standards of manufacturing
and formulation of than PowerMax.
the polymer plastic
to achieve superior PowerMax MD drag ropes
performance for shovel PowerMax MD is a unique drag rope,
hoist applications. Field tests have designed specifically for exceptional
shown up to 20% or more increases in performance and extended service
service life when compared to other life on draglines with
premium shovel hoist ropes. reverse bend fairlead
systems. Built around
a plastic-impregnated
independent wire rope
core (IWRC) are eight
compacted strands of cold-drawn,
high-carbon steel wires, a construction
that delivers the optimal combination
of strength and resistance to bending
fatigue and abrasion.
With eight outer strands fortifying the

compacted-strand design of PowerMax
MD, this rope delivers approximately
10% higher minimum breaking force
than the standard 6-strand drag ropes.
It also supplies the ability to handle
PowerMax drag and the bending stresses at the fairleads.
hoist ropes
PowerMax, an 8-strand rope,
provides operating properties
essential to drag and hoist ropes.
Proprietary WireCo WorldGroup
metallurgy was utilized in the
development of special rod
chemistry requirements
to provide optimum wire
properties for mining ropes.
With eight outer strands, PowerMax

is more fatigue resistant than
6-strand ropes of the same diameter,

Flattened strand ropes/6 x7 classification sandlines
A
lso called triangular strand, Minimum breaking force and weights for
flattened strand ropes flattened strand XIP ropes
perform exceptionally well on Fiber core iwrc
certain installations, especially those Minimum Minimum
involving heavy loads where the speed Approx. breaking force Approx. breaking force
of operation is slow, where adequate Diameter wt./ft. (tons of wt./ft. (tons of
(in.) (lb.) 2,000 lb.) (lb.) 2,000 lb.)
diameter sheaves and drums are used,
or where a crush-resistant rope is 5/8 0.70 20.1 0.74 21.7
required. Typical installations include 3/4 1.01 28.8 1.06 31.0
7/8 1.39 39.0 1.46 41.9
skip hoists, large overhead cranes and
boom hoist ropes. 1 1.80 50.6 1.89 54.4
1 1/8 2.28 63.7 2.39 68.5
1 1/4 2.81 78.2 2.95 84
Their distinguishing physical feature
1 3/8 3.40 93.9 3.57 101
is their relatively flat exposed surfaces
1 1/2 4.05 111 4.25 119
of strands. As a result, the rope 1 5/8 4.75 130 4.99 140
exterior is more nearly
1 3/4 5.51 151 5.79 161
a smooth, continuous
circle than that of
regular round-strand
6 x 7 classification sandlines
wire rope. Flattened
In a 6 x 7 rope, the wires are larger
strand ropes are made
than those of other constructions of
with two layers of 12 wires around a
the same diameter. Wires of a 6 x 7 are
triangular-shaped center. We offer a
approximately twice the diameter of
6 x 30 Style G using a six-wire center
outer wires of a 6 x 25F rope. The large
as the standard construction.
size of the outer wires gives this class
excellent abrasion resistance
The advantages of
flattened strand ropes at great sacrifice of bendability and
The flattened shape forms a bearing resistance to fatigue. The standard
surface with more contact points on 6 x 7 rope construction is made with
each strand than a round-strand rope. fiber core and right regular lay.
With more sheave contact, weight
and wear on the rope are distributed Minimum breaking force and
weights for 6 x 7 IPSfiber core
more uniformly than on a typical round-
strand rope. The triangular strand bright
structure also results in more steel Minimum
in the cross-section than a standard Approx. breaking force
Diameter wt./ft. (tons of
round-strand rope of equal size.
(in.) (lb.) 2,000 lb.)
3/16 0.056 1.50

1/4 0.094 2.64
5/16 0.15 4.10
3/8 0.21 5.86
7/16 0.29 7.93
1/2 0.38 10.3
9/16 0.48 13.0
5/8 0.59 15.9
3/4 0.84 22.7

Swaged wire ropes
PowerFlex Minimum breaking force and
Sometimes referred to as double- weights for 6 x 19 classification
and 6 x 36 classification swaged
swaged in the industry, PowerFlex wire ropes
is compacted not once, but twice, to
yield excellent strength for your logging Minimum
applications. PowerFlex works hard Approx. breaking force
Powerflex Diameter wt./ft. (tons of
to lift your heavy loads while resisting (in.) (lb.) 2,000 lb.)
drum crushing and giving you better
spooling performance, with greater 1/2 0.55 16.0
9/16 0.71 20.2
resistance to stretch. 5/8 0.96 24.7
3/4 1.32 35.3
PowerFlex keeps its structural integrity 7/8 1.70 47.8
and its size to add longer service life to 1 2.22 62.0
6 x 19
1 1/8 2.66 79.3
classification your logging wire ropes. 1 1/4 3.47 97.5
swaged
1 3/8 4.20 117
Minimum breaking force and
weights for PowerFlex ropes
3 x 19 and 3 x 36 classification
swaged wire rope
Minimum
Approx. breaking force These 3 strand ropes are ideal for
Diameter wt./ft. (tons of pulling lines in electrical transmission
(in.) (lb.) 2,000 lb.) line construction. Rotary swaging
6 x 36 the rope results in an exceptionally
classification 9/16 0.83 24.0
5/8 1.0 28.0 compact rope cross-section. This
swaged
3/4 1.5 43.0 increases surface area, which improves
7/8 2.1 57.5
1 2.7 75.5
rope contact with sheaves and on drums,
1 1/8 3.5 93.0 thereby providing greater resistance
to surface wear and abrasion while
reducing wear on sheaves. The smooth
surface also helps reduce wear on
underground conduits. Lengths may
3 x 19 6 x 19 and 6 x 36 classification
classification be fitted with flemish-eye ends.
swaged wire rope
swaged Minimum breaking force and
These ropes offer greater strength weights for 3 x 19 classification
than standard ropes of the same and 3 x 36 classification swaged
diameter while providing greater wire ropes
resistance to drum crushing, scrubbing
Minimum
and similar surface wear. To enhance Approx. breaking force
the performance of our swaged ropes in Diameter wt./ft. (tons of
the field, we utilize a special wire (in.) (lb.) 2,000 lb.)
chemistry in the outer wires of the
3/16* 0.074 2.14
strands. Then during production, the 1/4* 0.131 3.77
rope is rotary swaged to produce a 5/16 0.205 5.86
compact cross-section with minimum 3/8 0.30 8.39
1/2 0.53 14.8
voids and greater surface area on outer 9/16 0.66 18.6
wires. In addition to reducing rope 5/8 0.83 22.9
surface wear, this compact design helps 3/4 1.19 32.7
7/8 1.69 45.3
reduce wear to sheaves and minimizes
1 2.09 57.5
crushing of the rope on the drum.
*Made in 3 x 7 construction.

Specialty small ropes
T
his category includes wire ropes Minimum breaking force and weights for
in sizes as small as 1/32 in 7 x 7 utility cable - galvanized or stainless
diameter. Theyre used in a
Approx. Minimum breaking force
variety of applications, including Diameter wt./100 ft. (lb.)
control cables, window and door (in.) (lb.) Galvanized Stainless
closures, different kinds of remote
1/32* 0.16 110 110
control systems, boat rigging and others. 3/64 0.42 270 270
1/16 0.75 480 480
They can be made of galvanized or 5/64 1.1 650 650
3/32 1.6 920 920
stainless steel aircraft wire.
7/64 2.2 1,260 1,260
1/8 2.8 1,700 1,700
Each of these products is carefully 5/32 4.3 2,600 2,400
engineered and fabricated to uniform 3/16 6.2 3,700 3,700
7/32 8.3 4,800 4,800
size and quality. For example, 1/16 1/4 10.6 6,100 6,100
7 x 19 contains 133 separate wires, 9/32 13.4 7,600 7,600
making the wires approximately the 5/16 16.7 9,200 9,000
3/8 23.6 13,100 12,000
diameter of a human hair. Yet the rope
has high strength, bendability and *1/32 is made in 3 x 7 construction.
fatigue resistance.
Minimum breaking force and weights for
These ropes are produced for the most 7 x 19 utility cable - galvanized or stainless
common applications in the market.
Utility grade is made to ASTM A1023. Approx. Minimum breaking force
Diameter wt./100 ft. (lb.)
These cables have historically been (in.) (lb.) Galvanized Stainless
called aircraft cable. Since most
applications do not require that 1/16 0.75 480 480
3/32 1.7 1,000 920
designation, we changed the name to
7/64 2.2 1,400 1,260
utility cable. We are on the Qualified 1/8 2.9 2,000 1,760
Producers List (QPL) and can provide 5/32 4.5 2,800 2,400
these ropes to the MIL-DTL-83420 3/16 6.5 4,200 3,700
7/32 8.6 5,600 5,000
aircraft specifications on request. 1/4 11.0 7,000 6,400
They require special lubrication, 9/32 13.9 8,000 7,800
internal marking and fatigue testing. 5/16 17.3 9,800 9,000
11/32 20.7 12,500
3/8 24.3 14,400 12,000

Galvanized strand products
O
ur galvanized strand products > Individual wire tolerances.
meet or exceed ASTM
Specifications A475 and ASTM > Wire coating weight ASTM
A363. Strands are tested for: Method A90.
> Minimum breaking force. > Wire wrap test for coating adherence.
> Elongation (High Strength 5%; Extra > Wire wrap test for steel ductility.
High Strength and Utilities Grade 4%).
> Preforming check.
Physical properties of zinc-coated steel wire strand
Minimum breaking

Nominal Nominal
Approx. force of strand (lb.)
diameter diameter weight High Extra-High
of strand Number of coated of strand Utilities Strength Strength
(in.) of wires wires (in.) (lb./1000 ft.) Grade Grade Grade
3/16 7 .062 73 2,850 3,990

7/32 7 .072 98 3,850 5,400
1/4 7 .080 121 4,750 6,650
9/32 7 .093 164 6,400 8,950
5/16 7 .104 205 8,000* 11,200*
3/8 7 .120 273 11,500* 10,800* 15,400*
7/16 7 .145 399 18,000 14,500* 20,800*
1/2 7 .165 517 25,000 18,800* 26,900*
1/2 19 .100 504 19,100 26,700
9/16 7 .188 671 24,500 35,000
9/16 19 .113 637 24,100 33,700
5/8 7 .207 813 29,600 42,400
5/8 19 .125 796 28,100 40,200
3/4 19 .150 1,155 40,800 58,300
7/8 19 .177 1,581 55,800 79,700
1 19 .200 2,073 73,200 104,500
1 1/8 37 .161 2,691 91,600 130,800
1 1/4 37 .179 3,248 113,600 162,200
*ASTM A363 (weldless) is also available in these sizes and grades upon request.

Wire rope end treatments
Preparation for installation Some of these special end preparations

Most ropes are shipped with the ends are shown here.
seized as they are prepared for cutting. steel end link
You can usually install seized ropes With the exception of category 1
without further preparation. In some rotation-resistant ropes, any end
cases, though, tight openings in preparation that results in welding or
drums and wedge sockets or even fusing of the rope must be cut off in
complicated reeving systems require a manner that leaves the strands and seized and torch-
special end preparation. Then, the wires free to adjust before you clamp or cut with ends fused
strands must be tightly held without seat it in an end termination. Welded
increasing the rope diameter. In such ends must remain on category 1 rotation-
cases, the ends are tapered and welded, resistant ropes and XLT4. If a situation
or the ends fused. Its sometimes arises in the field that requires the Tapered and
necessary to provide a loop or link to cutting of a category 1 rotation-resistant welded end
which a lighter line is fastened to pull rope, we have special preparation and
the rope into place or around sheaves. cutting instructions available.
seized end
Two techniques for seizing cut ends
Wire seizing is soft wire used to keep the diameter length along the wire rope. Lower
individual wire rope component ends bound preformed ropes would require two or more
together while cutting, preparing, and seizings. Rotation-resistant ropes, due to their
handling a wire rope. It keeps them from unique design and operating characteristics,
opening up, helps maintain lay lengths, require seizing or taper-welding procedures
and lowers the chances of distortion at that differ significantly from those for standard
the ends when cut that could lead to non-rotation-resistant ropes. For category
issues. Standard preformed non-rotation- 1 rotation-resistant wire ropes, reference
resistant wire ropes would require only WireCos Product Bulletin, Field Cutting of
one seizing covering at least one rope Category 1 Rotation-Resistant Ropes.
1.
1. 2. 3.
First method
1. Wind seizing around rope for a length
equal to the rope diameter, keeping
wraps parallel, close together and in 2.
tension. Twist ends of strand together
by hand. second method
1. Lay one end of the seizing in the groove
2. Continue twisting with pliers to take between two strands in the wire rope and
up slack and tighten. wrap the other end tightly over the portion
in the groove.
3. Twist strand tightly against serving,
winding twisted strand into knot before 2. Complete steps 2 and 3 at left.
cutting off ends of the strand. Pound
knot snugly against rope.

How to extend rope service life
H
ow long will your rope last? Break in your new rope properly
There is not a simple answer When you install a new operating
but, rather, there are several rope, you should first run it for a brief
factors involved, including: period of time with no load. Then, for
best results, run it under controlled
> The manner in which you install and loads and speeds to enable the wires
break in your new rope. and strands in the rope to adjust to
themselves.
> The operating technique and work
habits of the machine operators. Constructional stretch
When first put into service, new ropes
> Physical maintenance of the rope normally elongate while strands go
throughout its service life. through a process of seating with one
another and with the rope core. This is
> Physical maintenance of the system called constructional stretch because
in which your rope operates. it is inherent in the construction of the
avoid twisting
of new wire rope, and the amount of elongation may
rope during Recommended practices vary from one rope to another. For
installation Weve outlined several recommended standard ropes, this stretch will be
> Handle the rope practices you may use to extend your about 1/4% to 1% of the ropes length.
properly from the ropes useful life. Its also important to
reel or coil to your note that all sections of this handbook, When constructional stretch needs
equipment and, on in some respect, also review ways to to be minimized, ropes may be factory
smooth-faced drums, help you get greater useful life from prestretched. Please specify when
spool with wraps tight your rope, and thats why you need placing your order.
and close together to thoroughly understand all the
on the first layer. material here. Another type of stretch, elastic stretch,
results from recoverable elongation of
Install your rope correctly the metal itself.
The primary concern when installing
a new rope is to not trap any twist in Cut off ends to move wear points
the rope system. Proper handling of If you observe wear developing in a
the rope from the reel or coil to your localized area, it may be beneficial
equipment will help avoid this situation. to cut off short lengths of rope. This
Another important step on smooth may require an original length slightly
faced drums is to spool with tensioned longer than you normally use. When
wraps tight and close together on the severe abrasion or numerous fatigue
first layer. This layer forms the foun- breaks occur near one end or at any
dation for succeeding layers. Finally, one concentrated area such as drag
spool the remaining rope on the drum ropes on draglines or closing lines in
with tension approximating 1% to 2% of clamshell buckets, for example the
the ropes minimum breaking force. movement of this worn section can
prolong rope life.

Clean and lubricate regularly to reduce wear
We lubricate our wire rope during should apply it at a place where the rope is
manufacture so that the strands as well bending, such as around a sheave. We
as the individual wires in the strands may recommend you apply it at the top of the
move and adjust as the rope moves and bend because thats where the ropes
bends. But no wire rope can be lubricated strands are spread by bending and more
sufficiently during manufacture to last its easily penetrated. In addition, there are
entire life. Thats why its important to pressure lubricators available commercially.
lubricate periodically throughout the life of Your ropes service life will be directly
Three methods
the rope. proportional to the effectiveness of the of applying
method you use and the amount of lubricant lubrication:
The surface of some ropes may become that reaches the ropes working parts.
covered with dirt, rock dust or other material > Drip
during their operation. This can prevent A proper lubricant must reduce friction,
field-applied lubricants from properly protect against corrosion and adhere to
penetrating into the rope, so its a good every wire. It should also be pliable and not
practice to clean these ropes before you crack or separate when cold yet not drip
lubricate them. when warm. Never apply heavy grease to
the rope because it can trap excessive grit,
The lubricant you apply should be light- which can damage the rope. Nor should you
bodied enough to penetrate to the ropes apply used engine oil because it contains
core. You can normally apply lubricant by materials that can damage the rope. For
using one of three methods: drip it on rope, unusual conditions, you can specify special
spray it on or brush it on. In all cases, you lubricants that we can apply at the factory.
> Spray
Wire breaks from vibration fatigue before significant wear occurs at the
occur at end terminations, so short equalizing sheave, and always do so
lengths cut off there with reattachment at the same drum. You must maintain
of the socket may prolong the ropes the required minimum number of dead
life. When broken wires are found, you wraps on the drum.
should cut off sections of rope. In the
case of a socket, you should cut off at Reversing ends
least five or six feet. In the case of clips Frequently, the most severe deterioration
or clamps, you should cut off the entire occurs at a point too far from the end > Brush
length covered by them. or is too long to allow the worn section
to be cut off. In such cases, you may
Where there is an equalizing sheave, turn the rope end for end to bring a
such as that found in many overhead less worn section into the area where
cranes, fatigue is localized at rope conditions are most damaging. This
tangency points to the equalizing practice is beneficial for incline rope
sheave. Rope life may be increased if and draglines. The change must be
you shift this point by cutting off a made well before the wear reaches the
short length at the end of one of the removal criteria. When changing ends,
drums. Be sure to make this cutoff be careful to avoid kinking or otherwise
damaging the rope.

Wire rope inspection
A
ll wire ropes will wear out How often
eventually and gradually lose All wire ropes should be thoroughly
work capability throughout inspected at regular intervals. The longer
their service life. Thats why periodic it has been in service or the more severe
inspections are critical. Applicable the service, the more thoroughly and
industry standards such as ASME frequently it should be inspected.
B30.2 for overhead and gantry cranes Be sure to maintain records of each
or federal regulations such as OSHA inspection.
refer to specific inspection criteria
for varied applications. Appoint a qualified person
to inspect
Three purposes for inspection Inspections should be carried out by a
Regular inspection of wire rope and person who has learned through special
equipment should be performed for training or practical experience what
inspect your to look for and who knows how to
three good reasons:
wire rope
regularly
judge the importance of any abnormal
> It reveals the ropes condition and conditions they may discover. It is the
> Inspection should
indicates the need for replacement. inspectors responsibility to obtain and
be performed by a
follow the proper inspection criteria for
person with special
> It can indicate if youre using the each application inspected.
training or practical
experience. most suitable type of rope.
For information on inspection methods and
> It makes possible the discovery and techniques, our Techreport 107: Wire Rope
correction of faults in equipment Inspection, is available on the unionrope.
or operation that can cause costly com website for download. If you need
accelerated rope wear. further assistance with our ropes, contact
our Product Engineering Department.

What to look for
Heres what happens when a wire This is an example of fatigue failure of

breaks under tensile load exceeding a wire rope subjected to heavy loads
its strength. Its typically recognized by over small sheaves. The breaks in
the cup and cone appearance at the the valleys of the strands are caused
point of failure. The necking down of by strand nicking. There may be
the wire at the point of failure to form crown breaks, too.
the cup and cone indicates failure has
occurred while the wire retained its
ductility.
Here you see a single strand removed

from a wire rope subjected to strand
This is a wire with a distinct fatigue nicking. This condition is a result
break. Its recognized by the square of adjacent strands rubbing against
end perpendicular to the wire. This one another. While this is normal in a
break was produced by a torsion ropes operation, the nicking can be
machine thats used to measure the accentuated by high loads, small
ductility. This break is similar to wire sheaves or loss of core support. The
failures in the field caused by fatigue. ultimate result will be individual wire
breaks in the valleys of the strands.
Shown here is a wire rope that has

been subjected to repeated bending
over sheaves under normal loads. This
results in fatigue breaks in individual
wires these breaks are square and
usually in the crown of the strands.

Wire rope wear, abuse and removal criteria
Typical evidence
of wear and abuse
This is a wire rope with a high strand

a condition in which one or more
strands are worn before adjoining
A
birdcage is caused by strands. This is caused by improper
sudden release of tension and socketing or seizing, kinks or dog-
know when the resulting rebound of rope. legs. At top, you see a closeup of the
to remove your These strands and wires will not be concentration of wear. At bottom, you
wire rope
returned to their original positions. The see how it recurs every sixth strand in
> The chart on the a 6 strand rope.
rope should be replaced immediately.
facing page offers a
guide for removal,
based on the
number of wires
involved.
This shows a typical failure of a rotary A kinked wire rope is shown here.
drill line with a poor cutoff practice. Its caused by pulling down a loop in a
These wires have been subjected to slack line during handling, installation
continued peening, causing fatigue or operation. Note the distortion of the
type failures. A predetermined, regu- strands and individual wires. This rope
larly scheduled cutoff practice can help must be replaced.
eliminate this type of problem.
Heres a
wire rope
that has
jumped a
This is localized wear over an equal- sheave. The rope curled
ized sheave. The danger here is that its as it went over the edge of
invisible during the ropes operation, the sheave. When you study
and thats why you need to inspect this the wires, youll see two types
portion of an operating rope regularly. of breaks here: tensile cup
The rope should be pulled off the sheave and cone breaks and shear
during inspection and bent to check for breaks that appear to have
broken wires. been cut on an angle.
Drum crushing is caused by small

drums, high loads and multiple
winding conditions.

Removal criteria wire protrudes between strands
A major portion of any wire rope are treated differently than those that
inspection is the detection of broken occur on the outer surface of the rope.
wires. The number and type of broken When there is more than one valley
wires are an indication of the ropes break, replace the rope.
general condition and a benchmark
for its replacement. Broken wire removal criteria cited in
many standards and specifications, like
Frequent inspections and written those listed below, apply to wire ropes
records help determine the rate at operating on steel sheaves and drums.
which wires are breaking. Replace For wire ropes operating on sheaves
the rope when the values given in and drums made with material other
the table below are reached. than steel, please contact the sheave,
drum or equipment manufacturer or a
Valley wire breaks where the wire qualified person for proper broken wire
fractures between strands or a broken removal criteria.
When to replace wire rope based on number of broken wires

# of broken wires in
# of broken wires in running ropes standing ropes
In one At end In one At end
Standard Equipment Rope Type In one rope lay strand connection rope lay connection
ASME B30.2 Overhead and Gantry Cranes All 12** 4 2 N/A N/A
ASME B30.3 Construction Tower Cranes Standard 12** 4 3 Not specified 3
Rotation-resistant 2 randomly distributed broken wires in 6 rope diameters or N/A 3 N/A 3

4 randomly distributed broken wires in 30 rope diameters**
ASME B30.4 Portal and Pedestal Cranes Standard 6** 3 2 3 2
Rotation-resistant 2 randomly distributed broken wires in 6 rope diameters or N/A 2 N/A N/A
ASME B30.5 Mobile and Locomotive Cranes Standard 6** 3 Not specified 3 2
Rotation-resistant 2 randomly distributed broken wires in 6 rope diameters or N/A Not specified N/A N/A
ASME B30.6 Derricks Standard 6** 3 Not specified 3 2
ASME B30.7 Winches Standard 6 randomly distributed broken wires in 6 rope diameters or N/A Not specified N/A N/A
3 broken wires in one strand in 6 rope diameters**
ASME B30.8 Floating Cranes and Floating Derricks Standard 6 randomly distributed broken wires in 6 rope diameters or N/A Not specified 3 2
3 broken wires in one strand in 6 rope diameters**
ASME B30.16 Overhead Hoists (Underhung) Standard 6 randomly distributed broken wires in 6 rope diameters or N/A 2 N/A N/A
ASME B30.29 Self-Erecting Tower Cranes Standard 6** 3 3 3 2
ANSI A10.4 Personnel Hoists All 6** 3 Not specified Not specified Not specified
ANSI A10.5 Material Hoists All 6** 3 2** 1
** Also remove for 1 valley break

Contact technical service engineering regarding rotation-resistant ropes

How to unreel, uncoil and store wire rope
The right way to unreel The three stages of kinking

correct ways to and uncoil a wire rope
unreel and
uncoil wire rope There is always a danger of kinking
a wire rope if you improperly unreel or
uncoil it. You should mount a reel on
jacks or a turntable so that it will
revolve as you pull the rope off.
Apply sufficient tension by means
of a board acting as a brake against 1. The start: A rope should never be
the reel flange to keep slack from allowed to accumulate twist as
accumulating. With a coil, stand it on shown here because it will loop
edge and roll it in a straight line away and eventually form a kink. If this
from the free end. You may also place loop is removed before being pulled
a coil on a revolving stand and pull down tight, you can normally avoid
the rope as you would from a reel the kink.
on a turntable.
How to store wire rope properly
We recommend you store your wire rope under a roof or a weatherproof

covering so that moisture cannot reach it. Similarly, you must avoid acid
fumes or any other corrosive atmosphere including ocean spray in 2. The kink: By now, the damage is
order to protect the rope from rust. If youre storing a reel for a lengthy done, and the rope must not be used.
period, you may want to order your rope with a protective wrap. If not, at
least coat the outer layers of rope with a good rope lubricant.
If you ever take a rope out of service and want to store it for future use,
you should place it on a reel after youve thoroughly cleaned and relubri-
cated it. Give the same storage considerations to your used rope as you
would your new rope.
Be sure to keep your wire rope in storage away from steam or hot water
pipes, heated air ducts or any other source of heat that can thin out
3. The result: Even if the wires do not
lubricant and cause it to drain out of your rope.
appear badly damaged, the rope is
still damaged and must be replaced.
If a twist develops, remove the twist

from the rope before a kink can form.

Wire rope abbreviations
Strand construction Rope grades (continued)
S Seale 1570, 1770, ISO nominal strength classes in Newtons
W Warrington 1960, 2160 per millimeter squared (N/mm2)
WS Warrington Seale
F Filler Wire Wire Materials
SWS Seale Warrington Seale U Bright or uncoated high carbon steel
SF Seale Filler Wire B Drawn galvanized
FS Filler Wire Seale A Galvanized-to-finished size
G Flattened strand construction with a
6 wire triangular-shaped center Special rope descriptions
Flex-X 7 CC Extended duty crane and hoist rope
Lays PowerMax 8-strand dragline rope
SZ (RR) Right regular PowerMax MD 8-strand dragline rope designed
ZS (LR) Left regular specifically for draglines with reverse
ZZ (RL) Right lang bend fairlead systems
SS (LL) Left lang Starlift Xtra High-strength rotation-resistant rope
Eurolift Category 1 rotation-resistant rope
Type of core
Flex-X Indicates compacted outer strand rope
NF C Natural fiber core
TUF-MAX Special shovel hoist rope with features
SFC Synthetic fiber core
to increase service life
SPC Solid poly core
XLT 4 High strength, low torque wire rope
WSC Wire strand core
7-Flex 7-strand wire rope
IWRC Independent wire rope core
PowerFlex Swaged rope with compacted strands;
IWRC(K) IWRC w/compacted strands used in logging applications
EPIWRC Plastic extruded IWRC DPRS Dynamically pre-stretched
Rope grades PRS Statically pre-stretched
IPS Improved plow steel L## Lube code indicating other than standard
GIPS Galvanized-to-finished size IPS lubrication
DGIPS Drawn galvanized IPS PFV Plastic-extruded product
XIP (EIP) Extra improved plow steel PRS PFV Statically pre-stretched plastic-extruded
GXIP Galvanized-to-finished size XIP product
DGXIP Drawn galvanized XIP RTY Rotary drill line
XXIP (EEIP) Extra extra improved plow steel TBG Tubing line
GAC Galvanized aircraft
GUC Galvanized utility
Warning
In the real world, accidents do happen, and thats installing wire rope in your applications, always read
why you need to take special precautions. Before and follow the warning label attached to each product.

Wire rope glossary
Abrasion Surface wear on the wires of a wire rope. Efficiency of wire rope Percentage ratio of
measured breaking strength of a wire rope to the aggre-
Aircraft cables Strands and wire ropes made of gate strength of all individual wires tested separately.
special strength wire primarily for aircraft controls and
miscellaneous uses. Elastic limit Limit of stress above which a permanent
deformation occurs.
Alternate lay Lay of a wire rope in which the strands
are alternately regular and lang lay. Equalizing Sheave The sheave at the center of a rope
system over which no rope movement occurs other than
Area, metallic Sum of the cross-sectional areas of equalizing movement. It is frequently overlooked during
individual wires in a wire rope or strand. crane inspections with disastrous consequences. It can be
a source of severe degradation.
Becket loop A loop of small rope or strand fastened
to the end of a large wire rope to facilitate installation. Fatigue resistance The characteristic of a wire rope
which allows it to bend repeatedly under stress.
Bending stress Stress imposed on wires of a wire
rope by bending. Fiber core Rope made of vegetable or synthetic fiber
used in the core of a wire rope.
Cable-laid wire rope A wire rope made of several
wire ropes laid into a single wire rope. Filler wire A strand construction that has small
auxiliary wires for spacing and positioning other wires.
Centers Wire, strand or fiber in the center of a strand
about which the wires are laid. Fitting Any accessory used as an attachment to a wire
rope.
Closing line Wire rope that closes a clamshell or
orange peel bucket. Flattened strand rope Wire rope with triangular
shaped strands that presents a flattened rope surface.
Common strand A grade of galvanized strand.
Grades, rope Classification of wire rope by its minimum
Construction Design of the wire rope including
breaking force. See the table of common grades on page 8,
number of strands, the number of wires per strand and
listed in order of increasing strength.
the arrangement of wires in each strand.
Core The axial member of a wire rope about which Grades, strand Classification of zinc-coated strand by
the strands are laid. It may be fiber, a wire strand or an its minimum breaking force. In order of increasing mini-
independent wire rope. mum breaking force, they are: Common, Siemens-Martin,
High Strength and Extra-High Strength. A Utilities grade
Corrosion Chemical decomposition of the wires in strand is also made to meet special requirements.
a rope by exposure to moisture, acids, alkalines or other
destructive agents. Grooved drum Drum with a grooved surface to guide
the rope for proper winding.
Corrugated The term used to describe the grooves
of a sheave or drum when worn so as to show the Grooves Depressions in the periphery of a sheave or
impression of a wire rope. drum that are shaped to position and support the rope.
Design factor The ratio of the minimum breaking Idler Sheave or roller used to guide or support a rope.
force to the design maximum working force. The minimum
Improved Plow Steel Rope See grades, rope.
breaking force is the published catalog strength of the
wire rope involved, and the design maximum working Independent Wire Rope Core (IWRC) A wire
force is the maximum calculated static load to be applied. rope used as the core of a larger wire rope.
Diameter, rope The distance measured across the Inner wires All wires of a strand except the
center of a circle circumscribing the strands of a wire rope. outer wires.
Dog-leg Permanent short bend in a wire rope caused IWRC See Independent Wire Rope Core.
by improper use.
Kink A sharp bend in a wire rope that permanently
Drum A cylindrical flanged barrel, either of uniform distorts the wires and strands; the result of a loop being
or tapering diameter, on which rope is wound either pulled through.
for operation or storage. Its surface may be smooth
or grooved. Lang lay rope Wire rope in which the wires in the
strands are laid in the same direction that the strands in
the rope are laid.

Lay (1) The manner in which the wires are helically Seale A strand construction having one size of cover
laid into a strand or the strands in a rope, or (2) the wires with the same number of one size of wires in the
length along the rope that one strand uses to make inner layer.
one complete revolution around the core.
Seize To bind securely the end of a wire rope or strand
Left lay (1) Strand a rope strand in which the with seizing wire or strand.
cover wires are laid in a helix having a left-hand pitch,
or (2) Rope a rope in which the strands are laid in a Seizing strand Small diameter strand usually of
helix having a left-hand pitch. seven wires made of soft annealed iron wire.
Marline clad rope A rope with individual strands Seizing wire A soft annealed iron wire.
spirally wrapped with marline or synthetic fiber cord.
Sheave A grooved pulley for wire rope.
Minimum breaking force Published strength thats
Slings Wire ropes made into forms, with or without
been calculated and accepted by the wire rope industry
fittings, for handling loads and made to permit the
following a set standard procedure. The wire rope
attachment of an operating rope.
manufacturer uses this strength as a minimum strength
when designing the wire rope, and the user should Smooth-faced drum A drum with a plain,
consider this to be the strength when making his design ungrooved surface.
calculations.
Splicing Interweaving of two ends of ropes so
Non-Rotation-Resistant WIRE ROPE Stranded as to make a continuous or endless length without
wire rope, the design of which is not intended to reduce appreciably increasing the diameter. Also making a loop
load-induced torque. Also known as standard wire rope. or eye in the end of a rope by tucking the ends of the
strands.
Peening Permanent distortion of outside wire in a rope
caused by pounding. Stainless steel rope Wire rope made of chrome-
nickel steel wires having resistance to corrosion.
Preformed wire rope Wire rope in which the
strands are permanently shaped before fabrication into standard wire rope See NON-ROTATION-
the rope to the helical form they assume in the wire rope. RESISTANT WIRE ROPE
Preformed strand Strand in which the wires are Strand An arrangement of wires helically laid about
permanently shaped before fabrication in the strands to an axis, or another wire or fiber center to produce a
the helical form they assume in the strand. symmetrical section.
Prestretching Stressing a wire rope or strand before Strength, breaking The load, applied through
use under such a tension and for such a time that the some type of tensile machine, that it takes to pull that
constructional stretch is largely removed. piece of rope apart. This is the load at which a tensile
failure occurs in the piece of wire rope being tested.
Reel The flanged spool on which wire rope or strand
is wound for storage or shipment. Strength, aggregate The sum of the breaking
strength in tension of all the wires of a wire rope when
Regular lay rope Wire rope in which the wires
the wires are tested individually.
in the strands and the strands in the rope are laid in
opposite directions. Swaged rope A wire rope that is rotary-swaged
after closing to produce a compact cross-section.
Reserve strength The percentage of the minimum
breaking force represented by the inner wires of the outer Warrington A strand construction in which
strands of a wire rope. the outer layer of wires is composed of
alternating large and small wires.
Right lay (1) Strand a strand in which the cover wires
are laid in a helix having a right-hand pitch or (2) Rope Wire A single, continuous length
a rope in which the strands are laid in a helix having a of metal cold-drawn from a rod.
right-hand pitch.
Wire rope A plurality of
Rotation-resistant rope A wire rope consisting of strands laid helically
at least two layers of strands where the lay direction of around an axis
the outer layer is opposite of its underlying layer. or core.
Sand line The wire rope that operates the bailer for
removing water and drill cuttings in drilling a well.

WARRANTY
Any warranty, expressed or implied as to quality, performance or fitness for use of WireCo WorldGroup products is always premised on
the condition that the published strengths apply only to new, unused products, that the mechanical equipment on which such products
are used is properly designed and maintained, that such products are properly stored, handled, used and maintained, and properly
inspected on a regular basis during the period of use.
Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including but not
Form No. 1001M
limited to personal injury, labor costs, a loss of profits resulting from the use of said products or from said products being incorporated
in or becoming a component of any other product.
816.270.4700
info @wirecoworldgroup.com
2016 WireCo WorldGroup
2400 West 75th Street

Prairie Village, KS 66208
fax: 816.270.4707
www.UnionRope.com

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Wire Rope Users

WIRE ROPE BASICS Page(s)

WIRE ROPE PRODUCTS

PROPER wire ROPE USE

2 Union A WireCo WorldGroup Brand

WireCo WorldGroup has manufacturing operations

Our manufacturing standards typically exceed

Union A WireCo WorldGroup Brand 3

Number of strands and The strands provide all the tensile

As a general rule, a rope that has

4 Union A WireCo WorldGroup Brand

Combined patterns When a strand

Union A WireCo WorldGroup Brand 5

Standard rope classifications > TUF-KOTE /PFV A plastic

> Stresses or environ- > 7-Flex A wire rope that offers

6 Union A WireCo WorldGroup Brand

Union A WireCo WorldGroup Brand 7

in approximately three times the amount EEIP XXIP 1960 N/mm2

8 Union A WireCo WorldGroup Brand

> Right lay Regular lay

> Left lay Regular lay

> Right lay Lang lay

> Left lay Lang lay

Union A WireCo WorldGroup Brand 9

No single wire rope The values in this handbook apply to

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Crushing resistance therefore is a ropes Peening causes metal fatigue, which

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Metric conversion and equivalents

units into SI International System of Units 1/4 6.5 2 1/8 54

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T he design factor is defined as the

it is expected to carry. How to use design factors

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Properties OF STANDARD 6 X 19 AND 6 X 36 WIRE ROPES

6 x 19 Class ropes 6 x 36 Class ropes

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Fiber core IWRC

3/16 0.059 1.55 1.71

Available galvanized at 10% lower strengths, or in equivalent strengths

Should not be used with a swivel.

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Contra-helically laid, rotation-resistant Category 3 rotation-resistant rope

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3/16 0.064 1.57

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Flex-X 9 should not be used with a swivel.

Smooth contact creates less

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3/8 0.32 8.8

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TUF-MAX shovel ropes plus, its greater surface area puts

With eight outer strands fortifying the

With eight outer strands, PowerMax

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