This article takes an in depth look at wire rope.
You will learn more about topics such as:
Wire rope consists of several strands of wire intricately twisted and interwoven in a spiral or helix shape. By combining these individual wires into one cohesive form, they form a single, stronger wire. This arrangement allows the strands to distribute pressure evenly, providing enhanced flexibility compared to singular wires.
To further amplify the strength of wire ropes, they are assembled and entwined to create cables. This process significantly boosts their utility, making them more effective for tasks such as support, lifting, and ensuring structural stability.
A crucial aspect of wire rope construction is the lay of its strands, which can be categorized as either regular or lang. Regular lay, sometimes referred to as right or ordinary lay, features strands wound from left to right, with wires laid in the opposite direction of the strand’s orientation. Conversely, lang lay involves wires wound in the same direction as the strand’s layout.
The composition and design of wire rope result in a product that boasts remarkable strength, outstanding flexibility, and an impressive capacity to endure continuous bending stress. Additionally, wire rope's weather-resistant nature ensures its durability across various environments.
Wire rope is a highly versatile engineered product, essential in numerous industries due to its exceptional adaptability, tensile strength, and flexibility. Also referred to as steel cable, wire rope is manufactured from several strands of steel wires twisted into a helix, creating a robust, durable component. Its engineering makes it ideal for heavy lifting, load-bearing, motion control, and critical safety applications. From mining and marine to construction and aerospace, the diverse uses of high-performance wire rope ensure it remains an indispensable tool for operations demanding strength, endurance, abrasion resistance, and secure load handling.
In the aerospace industry, wire ropes—sometimes called Bowden cables or aircraft control cables—are used to connect cockpit pedals, levers, and flight control surfaces, transmitting mechanical power to critical systems. These aviation-grade cables are crucial for adjusting propeller pitch, cowl flaps, and throttle controls in airplanes. For optimal safety, aircraft wire rope systems are insulated to reduce vibrations and mitigate wear and tear. The high fatigue resistance and flexibility of galvanized or stainless steel aircraft cable ensure reliable performance under demanding operating conditions.
Wire rope and steel cables play an integral role in the automotive industry, thanks to their versatility and high load capacity. Typical applications include power window regulators, sunroof mechanisms, parking brake cables, and steering systems. Automakers also rely on wire rope for seatbelt retractors, suspension springs, exhaust components, and door engineering. During assembly and maintenance, heavy-duty wire ropes are used in hoists, automotive lifts, and cranes for safe vehicle movement and precise positioning of car bodies and parts. Their flexibility and consistent performance under repeated bending make them ideal for various automotive systems requiring reliable lifting and mechanical movement.
The construction industry depends significantly on industrial-grade wire rope for lifting, rigging, hoisting, and securing heavy materials. Construction wire rope is engineered for high tensile strength and resistance to abrasion and fatigue, ensuring safety and efficiency. Common uses include crane cables, winch lines, concrete column support, cable-stayed suspension bridges, elevator systems, and reinforcing temporary structures. Labor-intensive projects such as tower erection, steel framework placement, and pre-stressed concrete supports benefit from the unmatched durability and load-bearing capabilities of galvanized or stainless steel wire rope. Compliance with rigorous safety standards and regular inspections is critical in construction environments.
In the food processing industry, stainless steel wire rope is preferred for its sanitary properties, corrosion resistance, and durability during washdowns and frequent chemical cleaning. It is used in conveyor belts, hoisting meat or packaged products, overhead load handling, loading docks, and suspension of food-grade enclosures. Food-grade wire rope ensures compliance with strict hygiene standards while maintaining strength and flexibility for moving heavy loads efficiently within manufacturing or storage facilities.
The oil and gas sector relies on high-strength, corrosion-resistant wire ropes for offshore and onshore drilling operations. These wire ropes, often used as drilling lines, mooring lines, and riser tensioning cables, handle extreme loads while withstanding harsh conditions such as saltwater exposure, chemical contamination, and immense pressure. During ocean drilling, engineered wire rope is deployed for lowering subsea equipment, anchoring rigs, and securing drilling platforms. Advanced construction and coatings enhance resistance to corrosion, fatigue, and wire strand failure, ensuring greater safety and reducing operational downtime. Notably, oil rig wire ropes can extend over 10,000 feet and must meet stringent performance standards for safety and longevity.
In the marine and shipping industries, wire rope is critical for mooring, towing, anchor lines, and lifting applications aboard ships, fishing vessels, and offshore platforms. Marine-grade, galvanized, or stainless steel wire rope offers exceptional resistance to corrosion from saltwater and marine atmospheres. These ropes are used for securing and launching lifeboats, winching heavy cargo, rigging sails on sailboats, and stabilizing masts and booms. Their superior strength-to-diameter ratio and anti-corrosive properties make them ideal for marine engineering and shipbuilding, ensuring safety and reliability even in harsh ocean environments.
The ski and resort industry utilizes special high-tensile wire ropes for cable car systems, gondolas, chair lifts, and tramways. These lift cables are engineered to support heavy passenger loads and withstand dynamic tensions created by constant start-stop operation and extreme mountain climates, including severe cold, snow, and ice. The dependability, safety, and robust construction of ski lift wire rope directly contribute to passenger security and operational uptime. Routine inspection and proper lubrication are vital for extending lifespan and preventing catastrophic failure.
Since the advent of amusement parks, wire rope has been integral to ride construction, offering strength and flexibility for safe operation. From hoisting roller coaster cars and Ferris wheels to supporting ride swing systems and pulling vehicles on tracks, wire rope ensures both load management and passenger safety. Amusement ride manufacturers select wire rope based on tensile requirements, fatigue resistance, and compliance with rigorous safety guidelines. Regular maintenance is critical in these demanding, high-cycling environments to ensure lasting performance and minimize risk.
Wire rope is a safety essential in the entertainment and motion picture industry, primarily for high-risk stunt work and performer protection. Specialized, lightweight wire ropes are selected for their strength, flexibility, and nearly invisible profile in filming. These cables enable secure harnessing, controlled lifts, and stunt rigging for complex action sequences, ensuring both safety and creative freedom on set. Wire rope specifications for stunt applications prioritize ease of movement, minimal stretch, redundancy, and high endurance to ensure fail-safes during demanding shots.
In modern architecture and interior design, wire rope is widely used for decorative and structural purposes, including safety guardrails, cable balustrades, stair railing systems, tensile roof structures, green walls, and plant trellises. Cable railings, for example, are sought-after for their unobtrusive yet secure profile, blending aesthetic appeal with building safety requirements. Stainless steel wire rope resists both corrosion and visual degradation, making it ideal for outdoor balconies and terraces. In sustainable buildings, vertical gardens use wire ropes to support climbing plants, merging natural beauty with durable engineering. The discrete footprint and modern style of wire rope allow architects to achieve open, light-filled spaces while ensuring compliance with building codes for fall protection.
A common use of wire rope is in railings, which are not only safe and durable but also enhance architectural aesthetics. Wire rope railings provide vital protection on balconies, decks, and stairways without blocking sightlines, making them perfect for both residential and commercial projects. This design flexibility is one reason wire rope has been embraced in large-scale architectural projects, seamlessly integrating with interior and exterior structures.
Wire rope is also vital for mining, logging, and manufacturing industries. In mining, it serves as hoisting cable for elevators, draglines, and cranes, designed to handle abrasive environments and extreme loads. In material processing and manufacturing, wire rope is used in conveyor belts, material handling equipment, and process automation, valued for its wear resistance, flexibility, and consistent tension.
For users seeking wire rope suppliers, it's crucial to assess specifications such as wire rope diameter, construction (e.g., 6x19, 7x7), core type (fiber core vs. wire core), and breaking strength based on your application requirements. Reputable manufacturers offer technical guidance, quality certifications, and custom fabrication to ensure optimal product selection and safety compliance.
The types of wire rope are classified based on the number of wires in each strand and the total number of strands in the rope. This classification follows a two-number system: the first number represents the total number of wires, while the second number indicates the number of wires in each strand. For example, a 6x19 wire rope consists of 6 strands, each containing 19 wires.
The wire shown is a 7x7 stainless steel wire rope made from grade 302 stainless steel. As depicted in the diagram, it consists of seven wires and seven strands.
A wide variety of products are made using wire rope, driven by its strength, durability, and reliability. One of the most common wire rope products is the wire rope sling, which is primarily used for lifting and moving heavy materials and items.
While the basic construction of wire rope slings is similar across all types, there are variations tailored to specific applications. These variations, known as hitches, adjust the sling configuration to accommodate different types of loads.
Vertical Hitch: A vertical hitch involves attaching one eye of the wire rope to the hook and the other eye to the load.
Choker Hitch: In the choker configuration, one eye of the sling is attached to the lifting hook, while the second eye is looped over the first sling eye to create a noose or choke shape. The load is then placed within this choke loop.
Basket Hitch: The basket hitch is formed when both eyes of the sling are looped over the lifting hook, creating a sling that supports the load from both sides.
Bridle Hitch: The multiple leg or bridle hitch style involves more than one wire rope sling, which helps to equalize the load and maintain balance. This configuration minimizes load damage by utilizing fixed points on the load and facilitates easier rigging when connected to fixed lifting points.
Single Part Wire Rope Sling: In a single-part wire rope sling, the eye is created by looping the wire rope back onto itself. The end of the rope is secured using a clamp or by weaving it manually or mechanically into the rope body. This type of sling utilizes a single wire rope to form the complete sling.
Braided Wire Rope Sling: A braided wire rope sling is created by braiding multiple wire ropes together to form the sling. This process increases the strength and load capacity of the sling due to the greater number of strands involved. Braiding can be accomplished with three to nine wire ropes.
Cable Laid Wire Rope Sling: Cable laid wire rope slings are constructed by combining several smaller wire ropes to create a flexible, easy-to-handle, and kink-resistant sling.
Woven Eye Wire Rope Sling: In the woven eye version of a wire rope sling, the eye is created by weaving the wire rope into itself after forming the loop. This design helps reduce the likelihood of the sling catching or getting hung up during lifting.
Thimble Wire Rope Sling: To enhance the strength of wire rope slings and reduce stress on a small area of the eye, a thimble—a U-shaped piece that fits the wire rope� is placed in the eye. This helps the sling maintain its natural shape and prevents the hook or load from coming into contact with the wire rope.
Endless Wire Rope Sling:Endless wire rope slings, also known as grommet wire rope slings, are versatile slings without a fixed wear point. They can be made in various sizes and are useful in applications with limited headroom. These slings are created by splicing the ends of a piece of wire rope together or by tucking the strand ends into the body to form a core with the tucked position opposite to the core.
Coiled wire rope is created from bundles of small metal wires twisted into a coil. Available in various types, it is easy to store because it does not need a spool. Coiled wire rope is manufactured in coils and, when not in use, naturally springs back into its coiled shape, making it simple to handle.
Cable wire rope is a type of high strength rope, made of several individual filaments. These filaments are twisted into strands and helically wrapped around a core. One of the most common types of wire rope cable is steel cable.
Push pull wire rope assemblies are used to send force and are used in the aircraft, exercise, medical, automotive, and office equipment industries. Unlike using a single heavy wire, push pull assemblies made with wire rope are stiffer and have a larger bend radii for smoother motion of the wire.
Wire rope assemblies consist of the wire rope itself along with various added components that enhance its functionality. These assemblies include connectors designed to link the rope to hooks, equipment, machines, or other wire rope assemblies. The central element of a wire rope assembly is the wire rope, which defines the type and extent of work the assembly can perform.
Wire rope assemblies are utilized for:
Wire rope lanyards are a versatile wire rope product manufactured using the same process and numbering system as wire rope. They are designed to secure fasteners, hardware, or components, helping to prevent loss or reduce the risk of injury.
As shown in the image below, lanyards are available with a range of connectors tailored to specific applications. Custom-designed lanyards are created for unique or specialized functions where standard lanyards may not be suitable. The variety of connectors ensures easy and secure attachment.
When deciding to purchase a lanyard, consider the following factors:
In many respects, wire rope functions like a machine with multiple moving parts. Although it lacks traditional components like motors, drives, and gears, wire rope fits the definition of a complex mechanism due to its intricate design. Its various elements work in unison to handle and transport heavy materials and loads.
The primary function of wire rope is heavy lifting, which relies significantly on wire rope slings. The type of sling used depends on the quality of the wire rope and whether multiple ropes have been braided or wound together.
The components of wire rope include the wire itself, a core, strands, and lubricant.
Wire is the fundamental component of wire rope, forming the strands. It can be made from steel, iron, stainless steel, copper, or other metals and comes in various grades. Wires may be coated or left bright (uncoated).
Strands are groups of wires twisted together and arranged in a helical pattern around the core. The size of the wires affects their abrasive qualities, with larger wires being more abrasive and less flexible compared to smaller ones.
The core is the central component of the wire rope, providing support for the strands and maintaining the rope's shape under stress or when bearing a load.
Lubrication is applied during manufacturing to minimize friction between the wires and strands, and to protect against corrosion and rust. The tight winding of the wires helps the wire rope retain this lubrication, which is crucial for its durability and longevity.
Lubricant is applied to wire ropes to reduce friction between the cables, thereby extending their lifespan. However, in specific applications, such as space travel, where lubricants can pose risks or cause equipment malfunctions, non-lubricated wire ropes—known as dry wire ropes or cables—are used instead.
Among the various products made from wire rope, slings are the most prevalent and widely used. These looped wire ropes come in different varieties and grades based on the type of wire used. To enhance performance, multiple wire ropes can be wound together, creating a sturdier and more reliable sling.
For processing and delivery, wire rope is spooled. The production of wire rope slings starts with unspooling this wire rope.
The wire rope is cut to the required length to create the sling.
Flemish splicing is a technique used to repair wire rope. It involves cutting the rope in half and then rejoining it. In this method, the wire rope is doubled back on itself, and a sleeve is swaged over the unbroken section to form a new eye.
Before inserting the wire rope into the holding device for shaping the eye, a steel compression sleeve is placed onto the rope. This sleeve is used to secure and hold the eye in place.
To create the correct eye size, the rope is unwound to the number of lays needed for the specific eye configuration.
Once the correct size is reached, the unwound strands are rewound in the reverse order of their original arrangement. If the wire rope has a right-hand lay, it is rewound using a left-hand lay, and vice versa. This technique creates a friction mold necessary for splicing the sling.
Anti-rotational wire rope is designed to resist rotational forces by incorporating opposing layers of helical strands. This construction prevents the rope from unwinding in either clockwise or counterclockwise directions. The effectiveness of anti-rotational wire rope relies on maintaining a static outer diameter.
In the production of anti-rotational wire rope, the filaments are counter-stranded with intentional gaps between them. To achieve anti-rotational properties, the rope is tightly twisted counterclockwise, closing these gaps and creating a spring force when the rope is rotated in that direction. This design ensures that the strands tighten around each other, preventing unwinding.
Before applying the compression sleeve, the tails and stray wires of the wire rope must be straightened and properly aligned. After placing the sleeve, it is crucial to verify that it is correctly positioned and fully engaged to ensure a secure and effective splice.
Before inserting the wire rope sling into the swaging die, ensure that the die is thoroughly lubricated. Once the die is prepared, the wire rope's compression sleeve and the wire rope are subjected to several hundred thousand pounds of pressure. This swaging process modifies the dimensions of both the wire rope and the compression sleeve to create a tight, precise connection, ensuring the correct diameter for the sling. During compression, the sleeve is rotated to ensure even application of pressure.
The final step in manufacturing a wire rope sling is to test it to verify that it meets its load specifications and performs reliably under the intended conditions.
What are the different types of metal wires used to produce wire rope?
Wire ropes are made from uncoated bright wire, which is high-carbon steel. The specific type of steel used depends on the wire’s requirements for tensile strength, fatigue resistance, and wear resistance.
Galvanized wire rope is treated with zinc to prevent corrosion and can be used in harsh conditions and environments. It is a cost effective alternative to stainless steel but does not have the same corrosion resistance. Galvanized wire rope is stronger than stainless steel of the same grade and size. Vinyl coated galvanized wire rope is easy to handle and flexible.
Stainless steel wire rope is known for its corrosion and rust resistance, making it suitable for challenging environments. It is available in two main types: 316 and 304, with 316 offering superior corrosion resistance. This type of wire rope is ideal for marine applications, acidic conditions, and other demanding environments. It is manufactured to precise tolerances and composition to meet the specific requirements of its intended use.
Copper wire rope is crafted by braiding multiple strands of copper into a round hollow shape, which is then pressed to achieve the desired width and thickness. Known for its exceptional flexibility and durability, copper wire rope is often utilized in electrical components and applications requiring reliable, long-lasting performance.
Bronze wire rope is designed to inhibit sparking and resist corrosion. It is manufactured from preformed wire to maintain its shape and prevent unraveling when cut. This type of wire rope offers excellent abrasion resistance, flexibility, and features a crush-resistant core.
Inconel wire is suitable for applications with temperatures up to 2000°F and offers resistance to oxidation and corrosion. It is non-magnetic and highly resistant to chloride-based corrosion cracking. Inconel wire rope is commonly used in nuclear generators as well as in chemical and food processing industries.
Titanium wire rope is available in various grades, with Grade 2 being 99% pure. It is known for its excellent formability and weldability. Titanium wire rope is widely used in chemical processing and marine hardware applications.
To ensure optimal performance, wire rope requires proper care. As an essential tool for various lifting and moving tasks, it is crucial to handle, treat, install, store, and maintain it correctly to extend its lifespan and ensure it performs at its best.
Seizing should be applied to both ends of the wire rope to prevent it from loosening. Improper seizing can lead to distortion of the wire rope. Properly seized wire rope ensures an even distribution of the load.
Wire rope should be stored on reels or coils and handled with care during removal. To maintain its performance, avoid dropping the wire rope. If the reel or coil is dropped or damaged, handling the wire rope can become challenging. Ensure that the reel rotates smoothly as the wire is being removed.
Wire rope is crucial for heavy lifting and ensuring the safety of both loads and people. Like all heavy-duty equipment, it must be regularly inspected and visually assessed during use to maintain its reliability and safety.
What to Check for During a Visual Assessment:
To ensure optimal performance, wire rope should be stored in a well-ventilated, dry, and covered environment, keeping it off the floor. It’s essential to avoid high moisture or damp conditions. While in storage, the wire rope should be moved periodically to prevent the lubricant from wearing off.
Although lubricant is applied during the manufacturing process, it diminishes with use. Regular lubrication is crucial for maintaining wire rope performance, as it prevents abrasion from the wires rubbing against each other. Relubrication should be done after the initial lubricant has worn off to ensure continued effective operation.
Wire rope, like any machinery, needs regular cleaning to maintain its effectiveness. This can be done using petroleum solvents and a wire brush. Mechanical cleaning methods, such as compressed air or a steam cleaner, can also be employed. After cleaning, it's essential to apply lubrication to protect the wire rope and ensure its longevity.
Wire ropes can be damaged by substances such as salt water, brine, acids, gases, and humidity. To prevent damage, clean and lubricate the wire rope after use and store it properly in a dry, covered environment.
When removing or spooling wire rope, ensure the operation is smooth and that the spool rotates steadily at a constant speed. This practice helps to prevent kinking and binding.
If a wire rope exhibits reduced diameter, broken wires, kinks, nodes, flattened surfaces, displaced outer wires, heat damage, corrosion, or unexpected loops, it should be removed and either repaired or replaced.
Wire rope is regulated by the Occupational Safety and Health Administration (OSHA) under the regulations for cranes and derricks in construction, specifically in 29 CFR 1926.1413, which has been in effect since November 8, 2010.
Wire rope inspections occur at three levels: shift, monthly, and annually. Shift and monthly inspections can be carried out by an approved operator, whereas the annual inspection must be performed by certified personnel.
Shift inspections are conducted at the start of each shift and involve a visual check for the following factors:
Monthly inspections follow the same guidelines as shift inspections, with the addition of:
As with the shift and monthly inspections, the annual inspection follows the same guidelines but must be completed by certified personnel. This inspection requires a thorough examination of the entire surface of the wire rope, with particular attention to:
Annual inspections can be waived if the wire rope's setup, configuration, or work site location makes it impossible to perform. However, the inspection must be completed within six months. If any deficiencies are discovered, the wire rope must be repaired or removed. In some cases, if the deficiencies do not compromise safety, the wire rope may continue to be used but must be monitored regularly.
An aircraft cable is a style of highly durable cable that is used for aircraft flight controls and other applications and is differentiated from normal cables by its diameter, stranding, and wires, which provide...
A push pull cable control is used for the transmission of multi directional precision control of mechanical motion. The many varieties of push pull cables or controls are adaptable to a wide range of applications and...
Stranded wire refers to thin bundled up wires that are compressed and covered up in insulating material. Stranded wires are more flexible thus making them very ideal for joining electronic circuit components in confined spaces where their bending...
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...
A wire rope assembly is composed of wire rope and end fittings, terminals, or lanyards that are attached to various parts of the wire rope such that the assembly can be used to lift, hoist, and move loads. The various types of...
A bungee cord is a rope that is composed of two or more elastic strands coated with a woven fabric. It has hooks that are placed on both ends. A bungee cord is also known as shock cord and elastic cord...
Cordage is a series of intertwined fibers, strands, strings, or fabric that are joined by twisting or braiding to form a larger more formidable whole. The combination of the materials makes the final, larger strand stronger than its individual pieces...
Electric hoists are material handling equipment used for lifting, lowering, and transporting materials and products. They are powered by an electric motor and have a controller to adjust the lifting parameters...
A gantry crane is an overhead crane that has an overhead beam supported by freestanding legs and moves on wheels, a track, or rail system carrying a bridge, trolley, and hoist. Workshops, warehouses, freight yards, railroads, and shipyards use gantry cranes as their lifting solution as a variation of overhead or bridge cranes...
Rope is a collection of strands, fibers, piles and yarns joined together to form a strong and a large structure. These strands or fibers are either twisted or braided with one another to give high tensile strength to the rope...
A hydraulic lift is a device for moving objects using force created by pressure on a liquid inside a cylinder that moves a piston upward. Incompressible oil is pumped into the cylinder, which forces the piston upward. When a valve opens to release the oil, the piston lowers by gravitational force...
A jib crane is a lifting device with an arm or boom that extends off the main body of the crane to provide extra reach and has a lattice design to lower the weight added to a load. The design of jib cranes allows them to work...
A lift table is a platform capable of holding materials and raising, lowering, and adjusting them to any height to meet the needs of an application and the user’s requirements. Lift tables are supported by a strong, rigid, and stable base frame placed flat on the floor, in a pit, or equipped with casters or wheels...
An overhead crane is a type of heavy duty machinery that is capable of moving extremely heavy loads and equipment from one location to another in a safe and precise manner using the overhead space of a manufacturing facility. Due to the nature of the work they perform...
Scissor lifts are a type of manlift that is commonly used in construction and facility maintenance to raise employees and their tools to working heights. A power system and a control system make up the scissor lift...
A hydraulic system is based on Pascal‘s principle of fluid pressure, which hypothesizes that a change in pressure in a fluid is transmitted to all points of the fluid in all directions. With a hydraulic lift, an electrically powered pump pushes fluid into a cylinder at the base of a lifting jack system that lifts the platform up and down...