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Name: Wire Rope Manufacturer in China - SICHwirerope
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As a wire rope factory, Sichwirerope Manufacturer is dedicated to providing high-quality wire ropes for various industries. Our wire ropes are made using advanced production techniques and high-grade materials, ensuring exceptional durability and reliability. We specialize in manufacturing custom wire ropes to meet the specific requirements of each customer, with options including different wire configurations, coatings, and finishes. With years of experience in the wire rope industry, our team of experts is committed to delivering excellent customer service and technical support. Sichwire Rope Manufacturer is committed to providing our customers with the best possible wire rope solutions, at competitive prices.

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The Ultimate Guide Of Wire Ropes

Wire Rope Types, Breaking Strength, Cautions

Chapter 1

What is Steel Wire Rope?

- Wire Rope Production Process

The wire rope production process is an involved and intricate process that requires a great deal of skill and expertise to execute effectively. At Sichwirerope manufacturer, we take great pride in our ability to create high-quality wire ropes that are durable, reliable, and resistant to wear and tear.

The first step in the wire rope production process is to select the appropriate materials. We typically use high-strength metals such as steel to create our wire ropes, as these materials offer excellent strength and resilience.

Once the materials have been chosen, we begin the process of wire drawing. This involves pulling the metal through a series of dies of slowly decreasing sizes in order to create a wire that is uniform in shape and size.

The next step is to strand the wires together into a cable or rope. This process can involve anywhere from three to over two dozen individual wires, depending on the intended use and strength requirements of the final product.

After the rope has been formed, it is typically subjected to a series of heat treating and stress relieving processes in order to enhance its strength and durability. We will also conduct extensive testing to ensure that the rope meets our high standards for quality and performance.

Overall, the wire rope production process is a complex and detailed process that requires a great deal of expertise, experience, and attention to detail. At Sichwirerope manufacturer, we take great pride in our ability to create wire ropes that are reliable, durable, and versatile, and we are always looking for ways to improve our manufacturing processes in order to deliver the best possible products to our customers.

Chapter 2

Lay, Classification, Structure, and Construction of Wire Rope

- Wire Rope Core

The core of wire rope can be fiber core or steel core, choose which core depends on the end purpose of wire rope. The main purpose of the rope core is to support the strands so that each strand can also be kept in the correct position when in working condition. Steel wire rope core plays the role of supporting wire rope strand, divided into the fiber core and steel core.

Fiber Core

There are two kinds of fiber cores, natural fiber jute core or sisal core (NF) and synthetic fiber core (SF), and the fiber core is soaked with lubricating grease that has anti-corrosion and anti-rust properties.

Steel Core

Steel cores are classified as individual wire rope cores (IWR) and wire strand cores (IWS).

Individual wire rope cores (IWR): they are made up of individual wires twisted together to form a rope core. This core provides excellent crush resistance and is very durable, making it ideal for heavy-duty applications. However, it can be stiff and difficult to handle.

Wire strand cores (IWS): they are made up of multiple strands of wire twisted together to form the core. This core is more flexible and easier to handle than IWR, but it may not provide as much crush resistance. It is also less expensive than IWR and is commonly used in lighter applications.

- Lay of Wire Rope

The lay of a wire rope refers to the direction in which the individual wires and strands are twisted together to form the rope. There are 4 basic types of lay: right hand regular lay(RHRL), left hand regular lay(LHRL), right hand lang lay(RHLL), and left hand lang lay(LHLL).

The right hand regular lay (RHRL) wire rope has a right-hand twist in both the strands and wires, which means that the strands are twisted in a left-hand direction and the wires are twisted in a right-hand direction. It is the most common type of lay and is used in a wide range of applications.

The left hand regular lay (LHRL) wire rope has a left-hand twist in both the strands and wires, which means that the strands are twisted in a right-hand direction and the wires are twisted in a left-hand direction. It is less common than the RHRL wire rope but is used in specific applications where left-hand twist is required.

The right hand lang lay (RHLL) wire rope is similar to the RHRL wire rope, but the twist length in both the strands and wires is longer. This means that the wire rope is stiffer and more resistant to abrasion, making it suitable for applications with higher loads or more severe conditions.

The left hand lang lay (LHLL) wire rope is similar to the LHRL wire rope, but the twist length in both the strands and wires is longer. This means that the wire rope is also stiffer and more resistant to abrasion, making it suitable for specialized applications where left-hand twist is required.

The selection of the right type of wire rope lay depends on the application, load requirements, and environmental conditions. In general, RHRL and RHLL wire ropes are more common and versatile, while LHRL and LHLL wire ropes are more specialized and are used only in applications that require left-hand twists. If you are not sure which lay of wire rope to purchase, pls feel free to contact us.

- Construction of Wire Rope

Wire rope is made by rotating and twisting wires together and lubricating. Multi-strand wire rope is several wire rope (or strand) around a core rotating twisting and lubrication made. The core is also a wire rope, the center of which has a central wire parallel to the length of the rope.

The following figure is a very basic steel wire rope diagram. In the actual application, the increasingly high load design, the more demanding use of the environment are to the wire rope put forward higher requirements: requires the wire rope manufacturers have a lot of technical knowledge and advanced manufacturing capabilities to achieve the strength of the wire rope, flexibility, durability and other properties of the balance. This balance of performance can ensure that the wire rope in any application environment or industry sector can be safe and economic operation.

Rules for naming wire rope shown on the left：

6 × 36WS-IWRC-1960-Zs

6 = No. of strands
36 = Number of wires per strand
1-7-7+7-14 = Arrangement of each wire layer in the strand
IWRC = Type of steel core
1960 = Wire rope strength grade
Zs = Right hand regular lay

Wire rope is actually classified as mechanical. This is because the wire rope in the load, its internal components of the interaction is very complex, and wire rope bending will produce fatigue like machinery. In order to achieve better performance, synthetic materials are applied to the wire rope structure, which makes the internal interaction of the wire rope become more complex.

So you should choose the suitable wire rope according to the specific working environment or model so that you can take into account the safety at the same time, make the wire rope achieve the longest service life.

- Structure of Wire Rope

If you are unsure of which structure of wire rope to choose, you can consult our wire rope manufacturer who can help you assess your specific needs and recommend the best product for your applications. Sichwirerope as a knowledgeable and experienced supplier can help ensure that you select the right wire rope structure, size, and composition to meet your specific requirements and budget.

- Classification of Wire Rope

Chapter 3

Wire Rope Types

There are many types of wire ropes available, each with different characteristics suited to specific applications. At Sichwirerope manufacturer, here are some common types of wire ropes which we produce:

- Regular lay wire rope

The most common type of wire rope, regular lay wire ropes have a right-hand or left-hand twist and are typically used in a wide range of applications.

Regular lay wire rope is the most common type of wire rope, characterized by having a right-hand or left-hand twist in both the individual wires and the strands that make up the rope. The individual wires are twisted together in a helix pattern to form strands, and the strands are twisted together in the opposite direction to form the final wire rope structure.

Regular lay wire rope is highly versatile and is used in a wide range of applications, including lifting, rigging, and mooring operations. It is available in a variety of sizes and configurations to suit different load requirements, and can be manufactured from different materials, including carbon steel, stainless steel, and other alloys.

Regular lay wire rope is preferred in applications where flexibility and ease of handling are important, as it is more flexible and easier to manipulate than some other types of wire rope. However, it is not always as strong or abrasion-resistant as other types of wire rope, which can limit its suitability for use in more demanding applications.

Because regular lay wire rope is the most common and widely used type of wire rope, it is available from many manufacturers and suppliers in a wide range of configurations, making it easy to source and readily available for a variety of applications.

- Lang lay wire rope

Lang lay wire ropes have a longer twist length and are stiffer and more resistant to abrasion than regular lay wire ropes. They are often used for heavy-duty applications.

Lang lay wire rope, also known as long lay wire rope, is a type of wire rope that has a longer twist length than regular lay wire rope. Lang lay wire rope is made up of multiple strands, each composed of multiple wires twisted together in a helix pattern. The strands themselves are then twisted together in the opposite direction to the individual wires to form the final wire rope structure.

The longer twist length used in Lang lay wire rope results in a stiffer, more rigid rope than regular lay wire rope. This makes Lang lay wire rope highly resistant to abrasion and crushing, making it ideal for use in heavy-duty applications where the rope is under constant strain and subjected to punishing conditions, such as in mining, oil and gas drilling, and marine applications.

Advantages of Lang lay wire rope over regular lay wire rope include higher resistance to abrasion and crushing, better fatigue resistance, and a longer service life. However, Lang lay wire rope is less flexible and more difficult to bend than regular lay wire rope, making it less suitable for use in applications that require high flexibility.

- Non-rotating wire rope

Non-rotating wire ropes are designed to minimize rotation during use. They are commonly used in applications where rotation could interfere with the operation of equipment.

A non-rotating wire rope, also known as rotation resistant wire rope, is a type of wire rope designed to reduce or eliminate the twisting and rotation that can occur when the rope is under tension. Rotational forces can cause problems in many applications by creating instability, decreasing operational efficiency, and causing wear and tear on the wire rope itself.

Non-rotating wire rope is made up of specialized construction that includes several layers of strands and wires twisted together in different directions. These layers work together to cancel out the rotational forces, keeping the wire rope stable and preventing unwanted twisting and rotation.

Non-rotating wire rope is commonly used in applications such as crane and hoist operations, where precise control of loads is required. It can also be used in a variety of other applications where rotational forces are a concern, such as in drawbridge operations and marine equipment.

There are two main types of non-rotating wire rope: bi-directional and uni-directional. Bi-directional non-rotating wire rope is designed to resist rotation in both directions, while uni-directional non-rotating wire rope is designed to resist rotation in one direction only.

Non-rotating wire rope is available in a variety of sizes and configurations to suit different load requirements. It may be made from various materials, including carbon steel, stainless steel, and other alloys. The choice of material and size will depend on the specific needs of the application and the load requirements involved.

- Round strand wire rope

Round strand wire rope, also known as round strand compacted (RSC) wire rope, is a type of wire rope that is made up of a single, large-diameter strand that is formed by compacting a series of smaller wires. The individual wires are laid in a spiral pattern around a center wire, which is then compacted using a special process that eliminates voids and air pockets between the wires.

The resulting strand has a circular cross-section that is denser and more uniform than traditional wire rope. This makes round strand wire rope stronger, more resistant to abrasion, and less prone to crushing or flattening under load.

Round strand wire rope is commonly used in applications that require high strength, durability, and resistance to abrasion, such as in mining, oil and gas, and construction industries. It is also used in elevator cables, hoist ropes, and other applications that require smooth operation and consistent performance.

- Compacted wire rope

Compacted wire ropes are produced using a special process that reduces the voids between wires, resulting in a denser and more durable rope.

Compacted wire rope is a type of wire rope that undergoes a special production process to decrease the space between wires in the rope, resulting in a denser and more compact structure. The compacting process reduces the voids and gaps between the wires in the rope, which makes the rope stronger, more durable, and more resistant to abrasion than traditional wire rope.

The compacting process also smooths the exterior surface of the rope, resulting in a more uniform, smoother finish. This provides additional benefits, such as improved fatigue resistance, resistance to crushing, and longer service life. Compacted wire rope can, therefore, handle a greater load capacity, and is less prone to breakage.

Compacted wire rope is commonly used in industrial applications where strength, durability, and resistance to abrasion and crushing are major requirements. It is also used in applications that require superior flexibility, such as in winch lines, crane cables, tow lines, and other rigging and mooring applications.

Compacted wire rope is typically more expensive than traditional wire rope due to the additional processing required, but the increased strength, durability, and resistance to abrasion make compacted wire rope a cost-effective option in many heavy-duty applications.

At Sichwirerope manufacturer, compacted wire rope of different diameters, construction, and materials are available. The selection of the appropriate compaction level, material, and size of compacted wire rope will depend on the specific needs of the application, the load requirements, and environmental factors, etc.

Chapter 4

Breaking Strength of Wire Rope

- Wire Rope Tensile Strength Grade

Wire tensile strength grade refers to the grade requirements for wire tensile strength and the corresponding range. It is defined according to the low limit of tensile strength and is often used to calculate the minimum breaking tension of wire rope or to calculate the sum of wire breaking tension in megapascals (Mpa) or Nm/square millimeter (N/mm).

- Wire Rope Breaking Strength Chart

· General purpose wire rope & Significant purpose wire rope

· Compact strand wire rope

Weight calculation： M=K*D²

M- Rope unit length of a reference weight, unit: kg/100m.
D- Wire rope nominal diameter, unit: mm.
K- Adequate oiling of a structure of steel wire rope unit length weight coefficient, unit: kg/100mmm'(see table).

Breaking Strength calculation： F₀=K’*D²*R₀/1000

F₀– Wire rope minimum breaking load, unit: kN.
D – Wire rope nominal diameter, unit: mm.
R₀– Wire rope nominal tensile strength, unit: MPa.
K’ – A specified structure of the minimum breaking load factor of the wire rope (see table).

Chapter 5

Wire Rope Surface Treatment

Wire ropes can be treated with a variety of surface finishes to improve corrosion resistance and overall durability. Here are some common surface treatment methods used for wire ropes:

Bright: Steel wire rope in the production process has been dipped in grease or spray grease treatment, steel wire rope oil can not only reduce the friction between the steel wire in the rope strand and the rope strand in the rope but at the same time can play the role of rust corrosion prevention. General purpose steel wire rope or indoor use steel wire rope does not need additional anti-corrosion measures, is the rope steel wire does not need galvanization and other surface treatment of twisted steel wire rope collectively known as the light surface steel wire rope.

Galvanization: Wire ropes can be hot-dip galvanized to create a protective layer of zinc that resists corrosion and extends the life of the rope. Wire rope twisted after hot or electroplating treatment is called galvanized wire rope, the galvanized layer can provide good protection against corrosion for the wire exposed to the environment of preservatives (salt, water, humid air, etc.). Depending on the application environment, the thickness and amount of galvanized layer varies.

Oil coating: A light oil coating can be applied to a wire rope to help prevent rust and protect the surface against environmental factors.

Plastic coating: A plastic coating can be applied to a wire rope to protect it from chemical exposure and environmental factors.

Black oxide coating: A black oxide coating can be applied to steel wire rope to provide a high degree of rust resistance and an attractive matte black finish.

Zinc-Aluminum coating (ZnAl): ZnAl is a newer coating method that combines zinc and aluminum to create a highly durable and corrosion-resistant surface.

Epoxy coating: An epoxy coating can be applied to the surface of a wire rope to provide a protective barrier against corrosion and abrasion.

Take 6×36 wire rope for example：

The selection of the appropriate surface treatment method for a wire rope will depend on many factors, including the intended use and the environmental conditions it will be exposed. Sichwirerope as a qualified and experienced wire rope manufacturer can help you guide the selection process and make sure that the chosen surface treatment method effectively meets the specific needs of your application.

Chapter 6

Wire Rope Thimbles

In SICHwirerope, a thimble is a metal that is placed inside the eye of a wire rope to protect and strengthen it. The thimble prevents the wire rope from being crushed or chafed and helps to distribute the load evenly across the rope. It also adds flexibility to the rope, making it easier to splice and bend.

If you want to ask “does wire rope need a thimble?” We think wire ropes do require a thimble to ensure that the rope maintains its strength and integrity. Without a thimble, the wire rope could become damaged and weaken over time, leading to potential safety hazards.

In our SichWirerope rigging hardware manufacturer, there are 3 types of wire rope thimbles:

standard wire rope thimbles
heavy-duty wire rope thimbles
solid wire rope thimbles

with GB, EN, and Federal standards. This section will list the different sizes, materials, and styles of thimbles.

- Standard Wire Rope Thimbles

If you have any questions about these standard wire rope thimbles, feel free to contact our team at any time.

- Heavy Duty Wire Rope Thimbles

If you have any questions about these heavy duty wire rope thimbles, feel free to contact our team any time.

- Solid Thimbles

If you have any questions about these solid thimbles, feel free to contact our team at any time.

Quality Requirements:

Thimbles should be smooth and flat, there should not be any damage to the wire rope cracks, defects, sharp edges and surface roughness, and inequality defects. The tip of the thimbles should be free to fit, and the tip part should be truncated to half of the groove depth.
The surface of the thimbles should be hot dipped galvanized, and the surface should be smooth and flat, there should be no defects such as leakage, zinc particles, bubbles, and cracks, and the galvanized layer should have sufficient adhesion strength in normal application.
The material of the thimbles can be A3 steel or 15, 35 high-quality carbon steel.
Thimbles’ safety load should not be less than 32% of the minimum breaking tension of the wire rope.
When using thimbles, the diameter of the shaft pin shall not be less than two times the diameter of the wire rope.

Chapter 7

Wire Rope Ferrules

Wire rope ferrules are used to secure the ends of wire ropes for added safety and strength. They are available in a wide variety of materials and sizes, depending on the type of wire rope and the application.

There are various types of wire rope ferrules in our SICHwirerope rigging hardware manufacturer:

Oval ferrules: These are the most commonly used type of wire rope ferrule. They are shaped like a narrow oval and are suitable for general-purpose applications.
Stop ferrules: These have a narrower profile than oval ferrules and are used to create a stop on the end of a wire rope.
Duplex ferrules: These have a double oval shape and are used for heavy-duty applications where additional strength is required.
Hourglass ferrules: These are shaped like an hourglass and are used in applications that require a very strong, wear-resistant connection.
Specialty ferrules: There are various other specialty ferrules available, including swage ferrules, hand-spliced ferrules, and thimbles.

To work, the ferrule is first attached to the wire rope. Once securely fitted, the eyelet is crimped or swaged shut using a hydraulic tool. The set screw is then tightened to secure the sleeve in place. After the sleeve is secured, the eyelet is then connected to a hook or shackle.

Wire rope ferrules are commonly used in a variety of applications including lifting, rigging, hoisting, and marine. They are an essential component for ensuring a safe and secure connection between the sling and the load. Additionally, they are used to extend the life of the wire rope sling, as they protect it from abrasion, wear, and fatigue.

Sichwirerope manufacturer provides a wide variety of ferrules for wire ropes, for example, flemish eye steel swaging sleeves(S 505), Aluminum ferrules(DIN 3093), round sleeves, oval sleeves, hourglass sleeves, stop buttons, etc. You can also contact us for OEM / ODM at any time.

- Flemish Eye Steel Swaging Sleeve (S-505)

Sichwirerope S 505 sleeves are equivalent to the Crosby S-505. The SichWirerope is a recognized manufacturer and supplier of wire rope slings in China, offering low-price but high-quality products.

If you have any questions about these Flemish Eye Steel Swaging Sleeves (S-505), feel free to contact our team at any time.

- Aluminum Ferrules (DIN 3093)

The Sichwirerope Aluminum Ferrules are produced in strict accordance with EN13411-3 (DIN3093) standards, and their material composition and mechanical properties fully meet or exceed the EN requirements.

If you have any questions about these aluminum ferrules, feel free to contact our team at any time.

- Aluminum Ferrules Form C

Sichwirerope Aluminum ferrules form C is placed over the ends of the wire rope and then crimped in place. It is made from aluminum, which is a strong yet lightweight metal.

If you have any questions about these aluminum ferrules form C, feel free to contact our team at any time.

We can also supply other types of ferrules, so please feel free to contact us if you need to wholesale them.

The choice of ferrule type depends on the application and the size and type of wire rope being used. It is important to select the right ferrule for the job to ensure a strong, safe, and durable connection.

Chapter 8

Wire Rope Clamps

A wire rope clamp, also known as a wire rope clip, is a type of fastener used to create a loop on the end of a wire rope cable. The clamp is designed to hold the cable securely in place and ensure a strong connection.

Wire rope clamps are typically made of metal and consist of two pieces: a U-shaped bolt and a saddle. The saddle is placed over the rope and the bolt is threaded through it to create a loop. The assembly is then tightened using a nut to securely hold the cable in place.

Wire rope clamps are available in different sizes to accommodate various wire rope diameters, and they are commonly used in applications such as rigging, fencing, and suspension bridges.

To clamp a wire rope cable, follow these steps:

Measure and mark the point where you want to form the loop.
Place the saddle over the rope at the marked point, making sure that the U-shaped bolt is on the side opposite the load.
Insert the U-shaped bolt through the saddle, ensuring that the saddle is seated properly.
Install a nut on the threaded end of the bolt and tighten securely using a wrench.
To provide additional security, add at least one more clamp, depending on the size of the cable and the load.

In our SICHWirerope manufacturer, we mainly provide 2 types of wire rope clamps:

Galvanized wire rope clips
Drop forged wire rope clips

You can choose the above two types of wire rope clamps, and we provide OEM and ODM services.

You may ask “How many cable clamps are on the wire rope?”

The number of cable clamps required on wire rope depends on the diameter of the rope and the application. Generally, the American Iron and Steel Institute (AISI) recommends the use of three clamps for wire ropes with diameters up to 1 inch, and four clamps for diameters of 1-1/8 inch and above. However, it is important to consult with the manufacturer’s recommendations and/or industry standards for the specific application to ensure the proper clamping procedure.

It is important to note that the clamps should be spaced out evenly along the wire rope to ensure optimal grip and load distribution. The first clamp should be placed approximately 6 rope diameters from the end of the rope, and the remaining clamps spaced at intervals of approximately 3 to 4 rope diameters. After clamping, the wire rope should be carefully inspected for damage or wear, and the clamps should be periodically inspected and tightened as necessary to maintain a secure and safe connection.

Chapter 9

Wire Rope Fittings & Accessories

Wire rope fittings are components used to secure the ends of a wire rope to an item being lifted or moved. They are designed to provide a secure and safe attachment of the sling to the item being lifted or moved. End fittings come in a variety of designs and materials, including mechanical clamps, swaged fittings, and even forged components.

At Sichwirerope manufacturer, we mainly provide the following types of wire rope sling end fittings:

Shackles
Hooks
Master Links
Wire Rope Sockets
Wire Rope Clips
Lifting Points

They are all with EN, ASME, ASTM, or Federal standards. If you want to custom other end fittings, we can support you, just contact us!

- Lifting & Rigging Shackles

At Sichwirerope manufacturer, there are 3 main common types of rigging shackles available to choose from:

Anchor shackles
Chain shackles
Wide body shackles

If you have any questions about any types of rigging shackles, feel free to contact our team at any time.

- Hoist Hooks, Rigging Hooks, Sling Hooks & Lifting Hooks

In our 40 years SichWirerope manufacturer, in China, we provide 4 common rigging hook types:

Hoist hooks
Sling hooks
Self-locking hooks
Grab hooks

If you are unsure about which rigging hook is right for your application, please contact our specialist for assistance.

- Master Links & Rigging Rings

There are 4 types of Sichwirerope master links & rings in our wire rope manufacturer:

Blong master links
Master link assembly
Pear links
Weldless rings

If you want to choose the right master links or rigging rings for your project, you can contact us at any time and our experts will help you.

- Wire Rope Sockets

There are 3 main common types of wire rope sockets in our wire rope manufacturer:

Open spelter sockets
Closed spelter sockets
Short bow sockets

Of course, there are 4 customized styles of sockets available: open swage sockets, closed swage sockets, wedge sockets, and threaded swage thuds.

If you want to choose sockets for your project, you can contact us and our experts will help you.

- Wire Rope Clamps

In our SichWirerope manufacturer, we provide 2 types of wire rope clips:

Galvanized wire rope clips
Drop forged wire rope clips

You can choose the above two types of wire rope clamps, and we provide OEM and ODM services.

- Lifting Points

In our China 40 years rigging hardware manufacturer – SichWirerope, we mainly have 4 common types of lifting points:

Swivel hoist ring – Grade 80
Shoulder eye bolt – Galvanized
Weld On D Ring – Grade 80
Shipping container hook – Grade 80

If you want to wholesale lifting points, you can contact us for OEM / ODM, and our experts will help you at any time.

Chapter 10

Considerations When Buying Wire Ropes

- Wire Rope Selection Consideration

When choosing wire rope for a particular purpose, the following aspects of performance should be considered:

Strength
Resistance to rotation
Resistance to fatigue
Resistance to abrasion, friction
Resistance to pressure
Anti-corrosion

· Strength

The minimum strength of wire rope used in a particular system is determined by the equipment, machine or lifting facility manufacturer. The general procedure is equipment, machine or lifting facilities manufacturers need to know the local regulations, standards or operating rules, these will affect the design factor of the wire rope (now usually called use factor), other factors may affect the design of the pulley and reel, the shape of the rope groove surface and the related radius, drum center distance, release angle, all of these have an impact on the performance of the wire rope.

When the strength of the wire rope (minimum breaking tension or minimum breaking load) is determined, it is necessary to consider which kind of wire rope is suitable for the application. It is very important that the designer needs fully understand the performance, and characteristics of various optional wire ropes and various different wire ropes in the use of limitations.

Important tips for crane operators：

Recommended machines, equipment, and lifting devices put into use, in case of doubt, used to replace the wire rope to meet at least the minimum guaranteed breaking tension declared by the equipment manufacturer.

· Resistance to rotation

The first thing to do is to determine whether you need to use low-rotation or non-rotation wire rope, such wire rope is often called multi-strand rope. Generally choose six or eight strands of wire rope, unless the single rope system produces low rotation, or the multi-rope system twists the knot, causing operational problems.

It will be produced when the wire rope is load-bearing.

“Twist” if both ends are fixed
“Rotation” if one end is fixed

Twist:

When both ends of the wire rope are fixed, the applied tension produces twisting at the two fixed ends.

Rotation:

When one end of the wire rope is free to rotate, the tension produces rotation.

When the load increases, the twist or rotation will also increase accordingly. The degree of twisting or rotation depends on the structure of the wire rope. Awareness of the wire rope after the load will be what, then you have to choose the right type of wire rope. It is worth noting that: all wire rope in the load will produce some degree of rotation.

When the wire rope lifting height increases, the tendency of rotation will also increase. In the multi-rope system, the distance between the wire rope decreases will also lead to an increase in the tendency of mutual twisting knot. Selecting the correct wire rope can help prevent the wire rope knotting as well as lifting items rotating.

We are happy to advise on any questions regarding wire rope rotation for you.

We verify the rotational performance of our ropes by using our own designed twist/rotation testing equipment. All products for hoisting applications are subjected to a “twist and pass” inspection procedure.

The following chart shows the rotational characteristics of the four basic strands of wire rope.

· Resistance to fatigue

When the wire rope is bent around the pulley or reel may lead to damage due to bending fatigue. The degree of damage depends on the number of pulleys in the system, the diameter of pulleys and drums and the load-bearing situation.

When choosing the wire rope, know that bending fatigue becomes the main reason of wire rope damage, we should choose the wire rope composed of small diameter wire, police such as choose 6x36WS(14/7+7/7/1) instead of 6×19 S(9/9/1). If you need further fatigue resistance to achieve the role of cost savings, you can choose “compacted strand” series of wire rope.

The smooth surface of “compacted strand” product reduces the friction between pulley and wire rope surface, thus reducing the abrasion of wire rope and pulley. Cross-sectional steel area increases, the inner layer of wire friction is reduced so that the internal pressure level of the wire rope in use is reduced, so the bending fatigue life is longer and the operating cost is lower.

· Resistance to abrasion, friction

Friction damage usually occurs in the wire rope and pulley, wire rope and drum but the biggest friction is usually because in the drum of mutual “interference”.

If wear and tear is the main reason for damage to the wire rope, you should choose the outer wire larger wire rope.

Diameter 22mm single layer wire rope outer wire size comparison:

6×7：6 outer wires 2.20mm
6x19S：9 outer wires 1.83mm
6x25F：12 outer wires 1.47mm
6x36WS：14 outer wires 1.29mm
6x41WS：16 outer wires 1.16mm

The point friction between two adjacent circles of wire rope in the roller will accelerate the wear.

The non-compacted strand wire rope produces point friction between two adjacent turns in the drum, accelerating wear.

Choosing a compacted strand wire rope will reduce friction by improving contact.

The smooth surface of the compacted strand wire rope makes good contact and extends the life of the wire rope.

· Resistance to pressure

In a multi-strand rope winding system, back tension needs to be applied when installing the rope because more than one strand of wire rope is wound on the drum. It is recommended to apply the installation tension of 2%~10% of the minimum breaking tension of the wire rope. If can’t reach, or some bottom strand wire rope that bears high pressure is unavoidable use occasions, such as suspension wall wire rope from the horizontal position to raise the suspension wall, in this case, the bottom layer wire rope will be seriously crushed.

Choosing the steel core of the wire rope is better than the effect of the hemp core. To further improve the compression resistance function, need to use compacted strand wire rope because it has more steel filling area.

In multi-strand rope winding operation, the extrusion of the bottom strand is inevitable, so the use of compacted strand wire rope is recommended.

Rotating hammer head beaten wire rope is especially suitable for reducing the problem of crushing produced by drum winding.

· Anti-corrosion

When the steel wire rope is used in a very corrosive environment, it is recommended to choose galvanized steel wire rope. If the corrosion is less big, then choose the bright surface steel wire rope.

If the water vapor can penetrate into the wire rope corrosion core, then choose the plastic-coated core (PI) wire rope.

In order to minimize the impact of corrosion, choosing the appropriate grease is very important. Steel wire rope used in the process of regular lubrication can bring more benefits.

- Wire Rope Selection & Recommendation

1. Use galvanized wire rope in corrosive environments.
2. In conditions where the installed wire rope should not rotate. or should not entangle with each other(driven by a backwash force), Lang’s lay wire ropes are recommended.

Chapter 11

Guidelines for the Use of Steel Wire Rope

For each customer of our factory, a usage guide is prepared after shipment, with the purpose of providing you and your employees with guidelines for product safety. Please read and follow these instructions and precautions carefully, Or it could lead to injurious or destructive consequences.

“Caution” indicates that there is a potential hazard that may seriously damage the performance of the wire rope or directly or indirectly threaten the safety or health of personnel working in the hazardous area where the wire rope and related equipment are located.

1 - Store in a Warehouse

1.1 When you receive the wire ropes, you should open the package immediately to check its marking and condition, and verify whether it meets the description on the certificate or related documents.

You should measure the diameter of the wire rope, check the end treatment of the wire rope to ensure that the wire rope is suitable for the equipment or machine that will be installed on it. (Figure 1)

1.2 You must pick a place that is clean, ventilated, dry, and covered. If it is not an indoor storage, cover it well with waterproof material.

Long-term storage of wire rope to be rotated regularly, especially in a warm environment to prevent the flow of lubricant accumulation.

Make sure the wire rope is not in direct contact with the ground and that air is circulating under the reel.

Place the A-frame or other support for the wire rope in a place sufficient to support the rope and reel (Figure 2). Ensure that the wire rope is kept in a place where it is not susceptible to chemical fumes, steam or other corrosive agents.

ATTENTION

Don't store the wire rope in the place of constantly rising temperature, because this may affect its future use. Seriously will greatly reduce the original strength of the wire rope, making it unsuitable for safe use.

ATTENTION

If not in accordance with the requirements of the operation, the wire rope may be contaminated by external substances and began to corrode before use.

ATTENTION

Otherwise, it may seriously affect the wire rope to make it unsuitable for safe use.

1.3 Inspect the wire rope regularly and apply grease when needed that is compatible with the lubricant used in production. Contact the wire rope supplier, or consult the equipment manufacturer’s instructions to obtain information on the type of lubricant available to ensure the information on greasing methods and greasing tools for different types and different uses of wire rope.

Re-wrap the wire rope, unless doing so would be detrimental to the preservation of the rope.

Ensure that the wire rope is not vulnerable to accidental damage either in storage or when entering or leaving the warehouse.

ATTENTION

Wire oil use error will lead to the original wire rope factory wire rope oil failure and seriously affect the performance of the wire rope.

ATTENTION

If you do not pay attention to the above matters, it may reduce the strength of the wire rope and weaken its performance. Seriously will make the wire rope is not suitable for safe use.

2 - Certificate and Marking

Before using the wire rope lifting must ensure that the relevant certificates have been obtained.

Check and verify that the marking on the rope or its packaging matches the relevant certificate.

Note: It is the responsibility of the designer of the machine or hoisting system to grade the components of the machine or hoisting system. Re-classification should also be approved by the joint venture.

Store the certificate in a safe place for periodic inspection during future use.

3 - Handling and Installation

3.1 The handling and installation of the wire rope need to be carried out according to a detailed plan and supervised by a qualified person.

ATTENTION

Improper handling and installation of wire rope may cause serious injury to personnel in the operating area and to those directly involved in handling and installation.

3.2 Wear appropriate protective clothing such as coveralls, industrial gloves, helmets, eye protection and safety shoes (and respirators, especially in areas where fumes are emitted in the presence of heat)

ATTENTION

Not wearing proper protective clothing and equipment may cause skin problems due to excessive contact with some kind of wire oil and protective oil; cutting wire rope or cleaning rope section for recycling by sparks, rope end, melted wire oil or metal burns;cutting wire rope or cleaning rope section for recycling when inhaling fumes cause respiratory or internal organs problems; cutting wire rope when sparks splash eyes; wire rope end cuts. Body bruises or hand and foot injuries caused by wire rope bounce, backward draw or other deviation from the original running track of the silver wire rope.

3.3 Check whether the description on the certificate is consistent with the description on the purchaser’s order to ensure that the supplied wire rope is correct.

3.4 Measure the nominal diameter of the wire rope to ensure that it conforms to the nominal diameter described in the certificate.

For verification purposes, the width of vernier calipers used to measure the diameter must be at least wide enough to span the two adjacent strands. Measure at least two sets of data at two points at least one meter apart to ensure that the value is taken at the largest cross-sectional dimension and that the angle is correct at these two points.

The average value of these four data should be within the corresponding standard or the specified error range. For the general measurement of the diameter of the wire rope, just use calipers to measure the line. (Look at Figure 1)

3.5 Visually inspect the wire rope to ensure that there are no signs of damage or obvious damage during storage or when transported to a safe location.

3.6 Check the working area around the equipment to eliminate potential hazards affecting the safe installation of wire rope.

3.7 Check the condition of the equipment related to the wire rope according to the manufacturer’s instructions, including:

* Reel

Check the basic condition of the reel.

If the reel is slotted, then check the radius of the rope groove, and the center spacing, to ensure that it meets the requirements and can accommodate the size of the new rope. ( Figure 3)

* Pulleys

Make sure that the sheave shape of the pulley matches the size of the new rope.

Check that all pulleys are rotating properly and in good condition.

* Wire Rope Guards

Check that wire rope guards have been installed and are working properly.

Check the condition of the wear plates and rollers, which protect the whole structure.

ATTENTION

Otherwise, it may affect the effectiveness or safety of the wire rope.

Note: The sheave groove must provide enough support for the wire rope ,and there must be a certain space for the wire rope to move freely and facilitate bending. When the sheave groove wears out, the wire rope tends to accumulate in the side of the groove, so the rope strand and the wire activity is restricted, and the bending ability will be weakened. (Figure 4)

Install new wire rope will find, the new rope size and has damaged the old rope a big difference, so the new rope does not necessarily fit has worn the rope groove, which may therefore lead to the wire rope unnecessary wear and deformation. You can polish the sheave groove before installing the new rope, but check the sheave or reel first to see if the strength of the remaining material after processing is enough to support the wire rope safely.

A qualified person should be familiar with the corresponding device/machine standards

Note: ISO4309 <wire rope selection, maintenance, and care> provide users with comprehensive guidance.

Carefully move the wire rope from the storage area to the installation site.

* Collect and Release the Wire Rope

Put the rope reel on the ground, and roll the wire rope reel in a straight line to release the rope, but make sure the wire rope will not be eroded by dust, sand, moisture, or other harmful substances. (Figure 5)

If the wire rope coil is too big to handle easily, you can put him on a rotatable seat, pull out the outer end of the wire rope then pull the rope to make the spool rotate to release the rope.

ATTENTION

Do not pull the rope out from the fixed rope coil, this will make the rope twist to produce twist knot, seriously affect the performance of the wire rope. (Figure 6)

* Wheel

Put a shaft through the roll reel and place it on a suitable support so that it can rotate and also brake to prevent over-releasing the rope during installation. When multiple layers are involved, the reel needs to be placed on a device that creates a backward tension when the rope is wound from the reel to the roll. This is to ensure that the bottom layer (and the backward layer) of wire rope is tightly wound onto the drum. (Figure 7)

When placing the rolls and brackets ensure that the angle of the release rope does not exceed 1.5°. (Figure 8)

If the wire rope produces a soft loop, make sure this soft loop will not tighten and twist into a knot

ATTENTION

The production of knot will seriously affect the strength of 6 strands of rope, make the non-rotating or low rotation of the rope deformation, which will lead to the rope immediately scrap.

Fix the bullwheel bracket to prevent reverse bending when passing the rope (i.e., when the wire rope overlaps on the winch’s roll brief, take the wire rope away from the top of the roll. (Figure 7)

3.9 Before loading the rope, make sure all the machines and equipment for loading the rope have been correctly and safely placed and stopped normal use. Check the manufacturer’s manual and the relevant practical regulations.

3.10 When releasing the outer end of the rope from the roll or coil, make sure that the whole process happens under controlled conditions. When removing the wire rope package, the wire rope has the inertia of straightening, if the control is not good, it will be a very violent action, so clear the field beforehand.

ATTENTION

Poor control may cause injury.

Ensure that the wire rope installation process can maintain the condition of the wire rope when it was produced.

One of the ways to use the old rope to guide the installation of the new rope is to use the wire rope short sleeve (or long sleeve) to connect the ends of the two ropes. Ensure that the ends of the short set of wire rope (or long set) tied wire or wire clips tied well (see schematic 9). Connecting the two ropes with a strong enough fiber rope can avoid transferring the torque on the old rope to the new rope. Similarly, a section of fiber rope or wire rope with sufficient strength can be coiled into the system as a guide rope. Do not use the swivel when installing the wire rope. (Figure 9 )

3.11 When the wire rope is pulled into the system please control it carefully, do not let any parts in the system obstruct the wire rope, which may make the wire rope loose.

ATTENTION

Failure to control the process may result in injury.

The entire operation should be carried out carefully under the supervision of a qualified person.

3.12 Special care must be taken when cutting wire rope and following the manufacturer’s guidelines. Tie wire is tied on both sides of the cut. (Figure 10 shows a typical lashing method for a multi-layer wire rope)

Make sure the length of the tie is at least twice the diameter of the wire rope. (Note: Spiral wire rope, such as spiral single strand wire rope and sealed wire rope, need special lashing)

Diameter less than or equal to 100mm wire rope, at least two ties on one side are generally sufficient (see Figure 10), the diameter of a little larger, at least four ties on one side. In order to keep the wire rope does not loose, use the correct size of the tie wire or strand (Figure 10a) in the tying process applying sufficient force is especially important, especially not after the pre-tensioned wire rope, multi-strand anti-rotation wire rope and parallel twist wire rope. Not to do the above requirements may affect the wire rope breaking the tension and the performance during use. In the tying process, can use the mallet and manual tying machine to help tie the wire rope firmly.

SICHwirerope On-site tying guidelines：

Put the wire rope well, after cutting the rope end position can be maintained, to avoid the back draw or other movement.

Use high speed abrasive wheel cutter to cut the wire rope. When the wire rope end need to burn or braze, although not recommended, but still can use other suitable mechanical or hydraulic equipment to cut.

ATTENTION

When using the wheel cutter, please be aware of the dangers posed by sparks, grinding wheel chips, and the smoke and ash generated by cutting. (See 3.2)

Maintain ventilation to avoid the accumulation of ashes from the wire rope and its other constituent components, including hemp core (natural or synthetic) grease and synthetic filler and/or other wrapping materials.

ATTENTION

Some special steel wire ropes contain synthetic substances that decompose when heated to a temperature higher than the normal production processing temperature and may produce some toxic fumes.

ATTENTION

Wire rope twisted with carbon steel wire in the transport state does not pose a health hazard. The dust and fumes that may be generated during subsequent processing (e.g., cutting, burning, grinding, cleaning) may cause the operator to be affected.

The substances used to manufacture the lubricating and protective layer of wire rope are hardly harmful to the end user under normal conditions. But the user still should take appropriate measures to minimize skin and eye contact and avoid inhaling the vapors or fumes of these substances.

Non-pre-tensioned wire rope, multi-layer rope, and parallel sealing rope in the cross-section after cutting must be burned, brazed, or melt pulling taper to ensure that all the wire and rope strands in the rope are completely fixed.

3.13 Accessories used to secure the rope end such as rope clips are clean and undamaged before use. Make sure that the fixing is done according to the OEM’s instruction or manufacturer’s guidelines, paying special attention to special safety requirements such as torque values (and frequency of torque adjustment).

When using a wedge joint to connect a rope, secure the end of the rope with a rope clamp or follow the manufacturer’s guidelines to ensure that the end of the rope cannot be pulled out.

(Figure 11 for two ways to secure the end of a rope connected by a wedge joint. )

The backbend method uses wire rope clips and uses soft tie wire or tape to tie the loophole to the moving part of the rope to prevent the rope from flexing during use.

When the loop eye will touch the machine or structure is not suitable to use the back bend method.

3.14 When reeling the rope onto the smooth reel, make sure that each loop is tightly next to the next. Applying the right amount of force can greatly assist in reeling the rope.

3.15 Before use, check the size, strength, defects, and cleanliness of the rope tail treatment that can be recycled, depending on the material and application, a non-destructive test may be required. Ensure that the rope tail treatment complies with the equipment manufacturer’s instructions or the manufacturer’s guidance.

When recycling the rope section, depending on the type and size, the filling material inside the cone can be squeezed out, otherwise, use heating to melt out the filling material inside.

When installing treated wire rope ends into fixed equipment, find and fix the connecting pins or rigging correctly, referring to the manufacturer’s guidelines.

ATTENTION

When heating the solitaire, if the solitaire is originally filled with molten metal, there is a risk of releasing toxic gases. The white metal has a high lead content.

3.16 It must be checked if the speed limit button is installed in the system. After the wire rope is installed, readjust it if needed.

3.17 After completing the installation of the wire rope, record the following information on the certificate, type of equipment, location, factory reference code, purpose and date of installation, and any adjusted information/signature of a qualified person. Then store this certificate in a safe place.

3.18 Operate the equipment slowly to make the new rope “warm up”. It is best to run a few turns of low load. This can make the new rope gradually adapt to the working environment.

Note: Unless required by the inspection department, the rope should be kept in this condition until the machine and equipment are tested in tension.

Make sure the new rope is correctly wound on the drum, and no loose and overlapping phenomenon occurs.
When needed, apply as much tension as possible to the rope to make the rope roll tightly and evenly, especially the first layer.
When multiple layers must be rolled, the latter layer of rope should be evenly rolled on the former layer of rope.

3.19 Ensure the wire rope handling and installation process, the performance of the wire rope will not be affected.

3.20 Need to intercept samples from the wire rope for testing and / or evaluation, the most important thing is that the performance of the wire rope is not affected. According to the rope type and structure of the manufacturer’s guidelines, see the guidance notes in 3.12.

4 - In Use

4.1 At the beginning of each work cycle, especially the accident that has almost damaged the wire rope or device, check the wire rope and related equipment.

Check the whole wire rope, and pay special attention to those who know by experience easy to damage the part. Excessive wear, broken wire, deformation, and corrosion are the more common signs of damage. A detailed inspection will use special tools ( Figure 13 ) to assist in the internal inspection of the wire rope. (Figure 14)

When the rope is working on the drum, when it has been subjected to very heavy load (such as impact load), pay special attention to check those areas into the groove or away from the groove, or those places that are exposed for a long time, such as the sky wheel.

For some running ropes, especially the running ropes associated with fixed ropes (such as guide ropes), pay special attention to the places close to the tail treatment. (Figure 14)

Note: Shorten the wire rope to change the position of those most vulnerable to deterioration, if the situation allows, use a longer wire rope at the beginning, so as to make regular shortening later. Shorten periodically.

When there is no pre-tensioned wire rope, multi-layer wire rope, or parallel sealing rope connected to the wedge-shaped rope joint used and needs to shorten, must be used to burn or copper welding method to stabilize the end of the rope before pulling the rope through the body of the rope joint until it reaches the new position. Loosen the wedge, pull out a small section, or sample the required length of wire rope. Note that the original bent part of the rope should remain in the wedge. Reinstall the wedge and tighten it. Prepare and cut the rope according to 3.12. Make sure the end of the rope can not be pulled back from the knot, see 3.13.

ATTENTION

Failure to comply with the above guidelines will seriously affect the performance of the wire rope and make it unsuitable for further use.

Appears the wire rope one end occurs the serious wear situation, may through the conversion rope end method to extend the life of the wire rope, namely when the situation is not very bad, the wire rope to stay in the roll simple end into the end of the load.

4.2 Bend the broken wire back and forth with pliers and break it in the deep valley between the two outer strands (Figure 15). Wear one-piece overalls, industrial gloves, helmet, goggles, and safety shoes when operating.

ATTENTION

Do not use pliers to cut off the broken wire, because this will leave jagged edges to injure other wires and make the wire rope scrapped in advance. Not wearing enough protective clothing can lead to injury.

Note: Broken wire is a normal phenomenon in the use of copper wire rope, especially in the late use of wire rope, and is caused by bending fatigue and friction. Broken wire concentrated in some areas of the city can indicate the mechanical failure of the equipment.

4.3 Do not start any machine if the rope and its tail treatment are considered unsuitable for the operation to be carried out because of rope diameter, tested breaking tension, rope structure, rope length or strength, rope tail treatment type, etc.

4.4 If the installed wire rope has been deformed, destroyed or deteriorated to the extent of scrap, or according to the historical data, the wire rope to reach the extent of scrap earlier than expected, please do not start the machine.

ATTENTION

Wire rope deformation is usually mechanical damage caused by, can seriously reduce the strength of the wire rope.

4.5 Authorized qualified person must inspect the wire rope in accordance with the relevant provisions.

4.6 Unless the equipment manufacturer’s manual or other documents have provisions, can’t the wire rope load situation carry on the wire rope inspection, check, oiling, adjustment, or other maintenance work?

Unless the surrounding area has been isolated or has been posted in the vicinity of the adequate notice, otherwise, do not in the case of unmanned machine inspection wire rope or maintenance.

If the machine is operated, the qualified person authorized to inspect must have immediate and effective access to the machine driver or controller during the inspection.

4.7 Do not clean the wire rope without realizing the potential danger of operating on a moving wire rope.

When cleaning with cloths/rags, the cloths/rags may get caught on damaged wire rope and/or broken wires on the surface. Wear eye protection when cleaning with brushes. When cleaning with liquids be aware that some products are very flammable. Wear respiratory protection when cleaning with pressure spray systems.

Use only those liquid cleaners that will not damage the original wire oil and affect the wire rope related equipment.

ATTENTION

Insufficient attention or inadequate precautions can result in personal injury.

ATTENTION

Insufficient attention or inadequate precautions can result in personal injury.

4.8 Oiling in use must refer to the equipment manufacturer’s instructions or other equipment all approved documents to select a wire oil compatible with the wire oil used in production. In case of doubt, please contact us.

4.9 Special care should be taken when oiling in use. An oiling system involving pressure should be operated by a trained and qualified person, and strictly follow the manufacturer’s instructions.

In order to prolong the life of wire rope, many wire ropes should be oiled (including cleaning) at the beginning of use, and then oiled regularly afterward.

If the equipment requires to keep dry, do not lubricate the wire rope. (Refer to the equipment manufacturer’s manual)

When the wire rope must keep dry and in use without adding lubricating oil then to shorten the inspection cycle.

If the wire rope stained with a lot of external substances such as sand, dust, etc., before re-oiling the wire rope must be cleaned first.

ATTENTION

Oiling in use must refer to the equipment manufacturer's instructions or other 4.8 equipment all approved documents to select a wire oil compatible with the wire oil used in production. In case of doubt, please contact Sich.

ATTENTION

The life of a "dry" rope which is not subject to corrosion but affected by bending fatigue may only be 30% of the life of a regularly "lubricated" wire rope.

Note: The senior who carries on this test must realize that compared with the lubricated wire rope, the safety of this kind of wire rope operation must be reduced.

4.10 The person authorized to be responsible for the maintenance of the wire rope must ensure that the end of the wire rope is secure. The inspection of one end of the coil on the drum involves a comprehensive check of the starting point to ensure that there are at least two and a half turns of fixed wire rope wrapped tightly around the drum. The inspection of the other end involves a comprehensive check of the end treatment to see if it complies with the equipment manufacturer’s instructions or other documents approved by the machine and equipment owner.

Adjust the length of the wire rope in the multi-rope system to make each rope (within the permitted range) the force balance.

Need to cut wire rope see 3.12.
Need to fix the wire rope see 3.13.
Reuse the rope tail treatment see 3.15.
Reattach the rope tail treatment to the fixed equipment, see 3.15.

4.11 ATTENTION

Due to abnormal contact with the wire rope and lead to component (mechanical components or structural components] damage or scrap will endanger the safe work of the machine and equipment and / or affect the performance of the wire rope. Such as roller groove damage will make the winding rope instability and / or the upper layer of the rope is pulled to the lower layer, which will occur dangerously or make the rope damage concentrated in the intersection point, and eventually seriously affect the performance of the rope; missing / remove the protective structure of the grinding disc can cause mechanical fracture, further cause parts to cut the rope and / or rope scrap thus leading to serious structural damage.

4.12 Regular inspection as required, daily or after special inspection, any corrective measures taken should be reflected in the certificate, record the defects found, the degree of change, and the condition of the wire rope.

4.13 Whether for inspection purposes or for destructive testing, select and intercept wire rope samples from new or old ropes in accordance with the following procedures.

Check whether the rope end of the sample to be intercepted has been burned, brazed, or tied wire binding. If not, we must intercept from the rope end far away, intercept before bundling with new tie wire. (See 3.12)

Handle the wire rope according to the guidelines in part 3, tie the wire rope using the buried wire technique (see Figure 10), and fit a wire rope chuck or wire rope clip as close to the cut drawing line as possible. Do not securely tie the wire by welding.

Make sure the sample is kept straight throughout the process. The sample of wire rope with a diameter of 76mm or less is 4 meters, and the sample of more than 76mm is 8 meters.

Oxyacetylene flame or cut the wire rope with a high-speed abrasive cutter. According to the description of 3.12 welding the sample rope end, and then remove the wire rope chuck or wire rope clip.

Wire rope information must be well documented and properly marked and packaged in samples. For 3 meters long sample, we recommend fixing it straight on a piece of wood for transportation. For 12 meters long sample, the diameter of the bend should be as big as possible when rolled up, not less than 2 meters.

Note: Wire rope samples used for destructive testing require end treatment according to recognized resin-filled rope joint standards (e.g. BSEN13411-4).

ATTENTION

Not to implement the above instructions can lead to the measured wire rope breaking tension value and the real strength of the wire rope have a difference.

5 - Wire Rope Scrapping

5.1 Scrap wire rope according to the current regulations and equipment manufacturer’s instructions.

Note: The authorized qualified person must be familiar with the latest version of the international standard SO4309 in the “crane – wire rope – inspection and scrap use number” and B.S.6570 in the “selection, care, maintenance of wire rope” provisions. These two standards cover more details than the other provisions. Other provisions of the wire rope end-of-life standards also apply. About the synthetic rope sheave (or synthetic village mat) please contact the synthetic rope sheave (or synthetic mat) manufacturer.

5.2 When the wire rope is scrapped, its use is very different from the historical use data, and no obvious reason can be found, please contact with SICHwirerope and its distributor.

5.3 Only qualified and experienced personnel who have taken appropriate safety protection measures and are wearing appropriate protective equipment can carry out the work of wire rope removal.

Be very careful when removing damaged/failed ropes from drums and sheaves, as they may be severely deformed and loosely wrapped around the drum or sheave.

5.4 Put the end-of-life wire rope in a safe and stable place or store it in a specific area. And it should be marked that this is a scrap wire rope, and can not be used again.

5.5 Record the date and reason for wire rope scrapping on the certificate, and then file the certificate for future reference.

5.6 Pay attention to the regulations about the safe handling of steel wire rope.

ATTENTION

Take special care when removing wire rope with mechanical damage, because the wire rope may suddenly fail during the removal process.

ATTENTION

Failure to take adequate measures may result in injury.

ATTENTION

If not handled correctly, scrapped wire rope (such as protruding broken wire, excess grease/lubricant, weight of wire rope) will pose a threat to both personnel and equipment.

6 - How to Select Wire Rope

Refer to the equipment manufacturer’s manual or other relevant documents to ensure the selection of the appropriate equipment wire rope. If you have any questions, please contact us.

6.1 Wire rope strength

Refer to the relevant regulations and/or applicable standards when required. Calculate the maximum tension that the wire rope will be subjected to.

The calculation should take into account the lifting or moving weight, impact load, the impact of high speed, acceleration, sudden start or brake, operating frequency and friction with the rope sheave bearing, etc.

After deciding the relevant use factor (i.e. safety factor), the strength of the wire rope tail treatment, and the minimum breaking tension of the wire rope can be set, these data can be found in the relevant national, European, and international standards or specific catalogs. If you have any questions, please consult SICHwirerope.

6.2 Bending Fatigue

The size and number of rope sheaves in the system will have an effect on the performance of the wire rope.

6.3 Friction

Subject to the friction of the wire rope will be because of the following reasons performance decline very quickly: External reasons – super heavy load, pulling through the sand or other abrasive material, through the rope sheaves, spool, roll simple. Internal reasons – load or bending.

6.4 Wire Rope Chattering

Wire rope fluttering will also make wire rope damage. The obvious sign is to absorb the trembling wire rope area appears broken wire.

6.5 Deformation

The steel wire rope will be deformed because of excessive pressure on the rope sheave, incorrect sheave groove size or multi-layered coiled rope on the rolling brief. Steel core wire rope has stronger resistance to extrusion and anti-deformation performance.

ATTENTION

Wire rope passing through a sheave, spool or drum can be damaged by bending fatigue. Reverse bending and high speed will speed up this process. Therefore, in this case, choose the wire rope with high resistance to bending fatigue. Check the product data information, if you have any questions, please consult the relevant experts.

ATTENTION

Friction makes the wire rope weaker by grinding off the metal of the outer and inner wires of the wire rope. Therefore, in this case, usually choose the wire rope with larger diameter of the outer wire.

ATTENTION

These broken wires may only occur in the inner part of the wire rope, the surface can not be seen.

6.6 Corrosion

A contains a large number of small diameter wire rope than a contains a small amount of large diameter wire rope is more likely to be corroded. Therefore, when corrosion is the main factor affecting the performance of wire rope, choose galvanized outer wire diameter as large as possible, but also take into account other factors in the operating environment of the wire rope (such as bending and friction).

6.7 Wire Rope Twist Knot

Sheave rotation causes the wire rope twist situation is usually the selection of rope error caused by (Figure 16). The lifting height of the large lifting operation is especially easy to occur, so must choose to resist the rotation design of the wire rope.

When the length of the wire rope kink is short, it can be solved simply by removing both ends of the wire rope and laying it flat to the ground. This can release the stress gathered in the wire rope before re-installation to the crane. When the length of the kink is longer, it must be corrected by releasing or increasing the stress at the point of support resistance leaving the system. If the left twist kink is created in the rope system, usually releasing the stress at the support resistance point (rightward twist of the wire rope, see Figure 16) can correct it. Release the stress from the whole rope or introduce the stress by lifting the rope to the highest height under light load, this procedure may have to be repeated several times to completely eliminate the stress. Right kink is usually corrected by introducing stress at the point of branch resistance.

6.8 Wire Rope End Fixed

Unless both ends of the wire rope are fixed or the weight will not rotate, you can not choose a high degree of rotational properties of the wire rope (such as a single layer of the same twist wire rope and multi-layer parallel twist wire rope).

6.9 Wire rope connection

Need to connect the wire rope to use the case, must ensure that they have sufficient strength, are the same type, and twist direction consistent (that is, “right twist to” right “twist).

6.10 Wire Rope Length

Wire rope length and/or the difference between two or more wire rope lengths in a set system can be an important factor in wire rope selection.

ATTENTION

Neglecting to do so can lead to catastrophic damage, especially if the joint is pulled apart due to loose strands.

ATTENTION

Wire rope will elongate under the force. Other factors such as temperature, rope rotation and internal wear have influence. Consider these factors when choosing the wire rope.

6.11 Pre-tensioned and non-pre-tensioned wire rope

Single-layer strand into wire rope is usually pre-tensioned. But if you choose a rope without pre-tensioning, responsible for the installation and/or maintenance of personnel in handling, especially when cutting pay special attention. Multi-layer rope, parallel sealing rope, and spiral rope are not pre-tensioned wire ropes.

6.12 Working Temperature
When the core of the wire rope can not give enough support to the outer wire and/or the working environment temperature exceeds 100 ° C, we should choose steel core wire rope.

When the working temperature exceeds 100°C, if needed, the minimum breaking tension of the wire rope can be adjusted down (such as 100°C -200°C between 10%; 200°C -300°C between 25% lower; 300°C -400°C between 35% lower).

Operating temperatures more than 400 ° C can not use high carbon steel wire rope.

ATTENTION

Failure to follow this guideline may result in the wire rope not being lifted.

ATTENTION

In some extreme low or high temperature environments, wire rope lubricants, synthetic fillers and/or wrapping materials may fail.

When the working temperature exceeds 400℃, we should consider using other materials, such as stainless steel or another special alloy.

Some wire rope tail treatment also has working temperature limitation, if you have doubts, you should consult Sich. The wire rope with an aluminum cover can not work in an environment of more than 150℃.

ATTENTION

Wear and tear, shock load, overload load, wrong use, damage, improper maintenance or abuse will lead to the failure of the wire rope. Wire rope must be inspected before use to determine whether there is wear, damage or abuse of the situation; Never use wear, damage or abuse of the wire rope; Never overload the rope or apply shock loads; Remind yourself: read and understand the instructions in this catalog about the safety of the product; and read and understand the instructions of the machinery manufacturer; Find directives, regulations, standards and codes for inspection, examination and scrapping standards for wire rope。

ATTENTION

Caution a large diameter multi-stranded wire rope use restrictions. When the heavy load, if not get proper support, all wire rope are easy to damage. Large diameter multi-stranded wire rope is particularly vulnerable to damage in this regard, because they use larger wire to manufacture, make its structure inflexible. There have been such examples, wire rope in the flat drum on the heavy load, although the strength is only about half of the wire rope breaking load, but the wire rope is still scrapped in advance.

Chapter 12

Wire Rope Manufacturers & Suppliers in China

Wire rope manufacturers and suppliers in China offer a wide range of high-quality wire ropes for various applications. China has become a major producer of wire ropes, exporting to many regions of the world due to its world-class manufacturing capabilities, advanced technologies, and competitive pricing.

One of the leading wire rope manufacturers in China is SICHwirerope(Sich Technology Co., Ltd.), founded in 1982. SICHwirerope has more than 40 years of experience in manufacturing high-quality wire ropes and related products. We offer a wide range of wire ropes in different materials, including steel wire ropes, stainless steel wire ropes, galvanized wire ropes, and PVC-coated wire ropes. You can purchase wire ropes in various constructions such as 7×19, 6×36, 6×19, and 1×19 at factory price.

SICHwirerope is dedicated to providing you with top-quality products and services. We have advanced manufacturing equipment and a team of skilled technicians and engineers to ensure the highest level of precision and quality in their products. We follow strict quality control measures to ensure that all our products meet or exceed international standards such as ASTM, EN, and GB.

Apart from wire ropes, SICHwirerope also manufactures and supplies wire rope fittings and accessories such as thimbles, shackles, turnbuckles, wire rope grips, and pulleys. We consider your requirements a top priority and provide customized wire ropes to suit your specific needs and applications.

In summary, wire rope manufacturers and suppliers in China, such as our SICHwirerope are renowned for producing high-quality wire ropes and related products to meet the diverse needs of customers worldwide. With our state-of-the-art manufacturing facilities and expertise, we are well-placed to cater to various industries’ wire rope requirements, including transport, construction, marine, and oil and gas sectors.

As a wire rope manufacturer, there are many things we can do for our clients. Here are just a few examples:

Provide customized wire ropes: We can create bespoke wire ropes to meet our clients’ exact specifications, including specific diameters, lengths, materials, and constructions.
Offer a wide range of wire ropes: We can provide a broad selection of wire ropes, including steel wire ropes, stainless steel wire ropes, galvanized wire ropes, and PVC-coated wire ropes, as well as a variety of constructions such as 7×19, 6×36, 6×19, and 1×19.
Advise on the best wire rope for the application: With decades of experience in the wire rope industry, we can offer expert advice on the most suitable wire rope for a specific application based on the client’s requirements such as load capacity, durability, and environmental factors.
Provide ongoing support: We can offer long-term support to our clients, including maintenance of wire rope equipment, and ensuring adherence to the industry’s safety standards.
Fast and efficient delivery: We can guarantee quick and reliable delivery of our products to any location, ensuring that our clients can rely on receiving their orders on time.

Why choose us?

Quality products: We manufacture high-quality wire ropes that meet and exceed international standards.
Customized solutions: We provide tailored wire rope solutions to our clients’ specific needs and requirements.
Competitive pricing: Our products and services are competitively priced, ensuring that our clients receive high-quality products at an affordable price.
Experienced team: Our team has extensive experience and expertise in the wire rope industry, ensuring that we provide the highest level of service and support to our clients.
Reliable delivery: We guarantee reliable and efficient delivery of our products to our clients, ensuring that their operations run smoothly and without any delays.

In summary, as a wire rope manufacturer, SICHwirerope can provide customized solutions, high-quality products, expert advice, and ongoing support to our clients. By choosing us, clients can be assured of the best possible service, reliability, and value for money. Feel free to contact us!

Why Choose the SichWirerope Wire Rope Sling Manufacturer?

Found

1982

Acres

Employees

1600 +

Yearly Output

80000 tons

Testing Center

Cases

Global Contract Suppliers

> SichWirerope manufacturer the wire rope slings have been exported to more than 60 countries and districts such as Europe, Australia, South America, Japan, Southeast Asia, and the Middle East in the past 40 years.

> We attend the exhibition every year, such as the USA (Houston) International Petroleum Exhibition (OTC), and Guangzhou International Exhibition in China. So, we have signed contracts with various customers from different countries.

Certification

> The SichWirerope wire rope slings applicable standards: GB, EN, BS, DIN, AS, JIS, ASME, and WSTDA standards.

> We have got a CCS type certificate, DNV type certificate, CE certificate, GS certificate, CNAS national laboratory accreditation

> Supply CCS, DNV, ABS, BV, and other third-party testing services, issue certificates, and have many invention patents.

Testimonials

We are a trading company that deals with many suppliers on the B2B marketplace. It's hard to find right products for our customers, but SichWirerope had offered us high-quality goods and helped increase revenue in past years. We have been using their services since they opened up shop because there is no one else around here who can provide what we need at such great prices!

I found SichWirerope from their website. After confirming the customizable needs about the wire rope slings, they replied they can do modification as I request. I flew to China and met them, they were very patient to explain all different models and professional suggestion based on my idea, finally, I chose them to be my reliable suppliers to help me extend my business in lifting solution field.

When I first started working with SICHWIREROPE, they were one of the most professional companies that i had come across in recent years. They always seemed to have their customers' best interests at heart and went out of there way not only provide me great customer service but product quality as well!

I have had many contacts and cooperated with them. But from the wire rope slings filed, they've given me a lot of professional supports especially in model choice which helped improve my local market so much! They are really very trustful partner who always answer all questions quickly without being too pushy or overbearing.

Non Rotating Wire Rope

Round Strand Wire Rope

Compacted Strand Wire Rope

DNV, CCS, ABS, BV | EN, GB | OEM/ODM

DNV, CCS, ABS, BV

EN, GB

Factory Price

| Wire Rope Manufacturer

Non Rotating Wire Rope

Round Strand Wire Rope

Compacted Strand Wire Rope

Choose More Wire Rope Types

Can't Find What Your Looking For?

We Know Wire Ropes

The Ultimate Guide Of Wire Ropes

Wire Rope Types, Breaking Strength, Cautions

What is Steel Wire Rope?

- Wire Rope Production Process

Lay, Classification, Structure, and Construction of Wire Rope

- Wire Rope Core

- Lay of Wire Rope

- Construction of Wire Rope

- Structure of Wire Rope

Seale Wire Rope

Warrington Wire Rope

Filler Wire Rope

Warrington-Seale Wire Rope

Compact Strand Wire Rope

Special Strand Wire Rope

- Classification of Wire Rope

Wire Rope Types

- Regular lay wire rope

- Lang lay wire rope

- Non-rotating wire rope

- Round strand wire rope

- Compacted wire rope

Breaking Strength of Wire Rope

- Wire Rope Tensile Strength Grade

- Wire Rope Breaking Strength Chart

· General purpose wire rope & Significant purpose wire rope

· Compact strand wire rope

Wire Rope Surface Treatment

Wire Rope Thimbles

- Standard Wire Rope Thimbles

- Heavy Duty Wire Rope Thimbles

- Solid Thimbles

Quality Requirements:

Wire Rope Ferrules

- Flemish Eye Steel Swaging Sleeve (S-505)

- Aluminum Ferrules (DIN 3093)

- Aluminum Ferrules Form C

Wire Rope Clamps

Wire Rope Fittings & Accessories

- Lifting & Rigging Shackles

- Hoist Hooks, Rigging Hooks, Sling Hooks & Lifting Hooks

- Master Links & Rigging Rings

- Wire Rope Sockets

- Wire Rope Clamps

- Lifting Points

Considerations When Buying Wire Ropes

- Wire Rope Selection Consideration

· Strength

· Resistance to rotation

· Resistance to fatigue

· Resistance to abrasion, friction

· Resistance to pressure

· Anti-corrosion

- Wire Rope Selection & Recommendation

Guidelines for the Use of Steel Wire Rope

1 - Store in a Warehouse

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2 - Certificate and Marking

3 - Handling and Installation

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