Wire Rope Specifications

TYPES OF CORES
An important point to consider is the selection of the proper type of core needed in the rope. Wire Ropes are made with either
fiber core or steel wire core.
1) Fiber Core (FC) This center is made of either natural fibers or polypropylene and offers greater elasticity than the
independent Wire Rope Core.
2) Independent Wire Rope Core (IWRC) This center is usually composed of a separate 7x7 wire rope designated as IWRC.
The steel core increases the strength by 7% and the weight by 10%. These steel cores provide more substantial support than
fiber cores to the outer strands during the rope's operating life. Steel centers resist crushing, are more resistant to heat and
increase the strength of the rope.

DESIGN FACTOR
The Design Factor being both the ratio between the minimum Breaking load of the rope and the
rated capacity (RC) tells at what percentage of its ultimate strength a wire rope is operating. The
Design Factor takes into consideration both normal rope wear and potential stresses in various
applications. The best practice in determining an adequate design factor is to analyze the specific
conditions involved inn each individual installation. The following example shows how to determine
the Design Factor: If a rope is working under a max. operating load of 10,000 lbs. and is having an
ultimate strength of 50,000 lbs., the factor is 5 which means it is operating at 20% of its ultimate
strength.
FLEET ANGLE
The fleet angle is the angle formed between the rope running to or from the extreme left or right
of the drum and a line drawn from the center of the sheave normal to the axis of the drum. For
optimum efficiency, the angle here should not exceed 1 1/2 degrees for a smooth drum, or 2
degrees for a grooved drum. If the fleet angle is larger than the recommended limits, it can cause
bad winding on smooth drums and rubbing against the flanges of the grooves. Too small a fleet
angle should also be avoided since it will cause the rope to pile up against the flange head.
Before installing any wire rope that winds onto a drum, the fleet angle should be checked
and if found improper, conditions should be corrected.

SHEAVE ALIGNMENT
Proper alignment of sheaves is essential. The main sheave should line up with the center
of the hoisting drum, otherwise both the rope and sheave flanges will be subjected to
severe and rapid deterioration will occur. If rope speeds are high, sheaves should also be
balanced.
NOTE:
Wire rope products will break if abused, misused or overused. Regular inspection and
maintenance are necessary. Consult industry recommendation and OSHA standards
before using.
OSHA SAY
In running wire ropes: Six randomly distributed broken wires in one rope lay or three
broken wires in one strand in one rope lay, where a rope lay is the length along the rope
in which one strand makes a complete revolution around the rope.
1926.1413(a)(2)(ii)(A)(2)In rotation resistant ropes: Two randomly distributed broken
wires in six rope diameters or four randomly distributed broken wires in 30 rope
diameters. 1926.1413(a)(2)(ii)(A)(3)In pendants or standing wire ropes: More than two
broken wires in one rope lay located in rope beyond end connections and/or more than
one broken wire in a rope lay located at an end connection. 1926.1413(a)(2)(ii)(B)A
diameter reduction of more than 5% from nominal diameter
More About 6x37 Bright Wire Rope EIPS IWRC (Steel Core) TEREX 2013 MODEL RT
6x37 wire rope is a more flexible cable wire than 6 x 19 wire rope, due to the higher
number of wires per strand. However, this configuration has less resistance to abrasion
than 6 x 19 wire ropes. The actual rope construction is 6x36, with 6 strands/35 wires per
strand. This type of steel cable is found in many industries, including crane work, dredging,
excavating, logging, oil fields, and marine environments. Common applications include
winch wire rope, choker and hoist ropes, boom lines, and trolley lines.
The grade of steel used in our 6 x 37 bright wire rope is known as EIPS, meaning Extra
Improved Plowed Steel. EIPS wire rope has roughly 10% more strength than regular
IPS. An independent wire rope core (IWRC) provides added strength and will also
reduce the amount of stretch. A 6 x 37 IWRC wire rope will also offer more resistance
to heat than a similar fiber core wire rope. The bright wire finish does not provide
corrosion resistance as well as wire rope with a galvanized or stainless steel finish.
 This type of wire rope using TADANO CRANE
While not as rotation resistant as 19x7 rope, 8x25 Spin Resistant rope is more stable. With its increased
resistance to bending fatigue and crushing, it is also used for general purpose on single-part crane lines and
sometimes multi-part wire rope systems.

Approx. Nominal
Diameter Weight Breaking
Per Foot (lbs) Strength (lbs)
3/8" 0.26 13,260
7/16" 0.36 17,940
1/2" 0.47 23,200
8X25 Filler
9/16" 0.6 29,400
Wire IWRC
5/8" 0.73 36,200
3/4" 1.06 51,800
7/8" 1.44 70,000
1" 1.88 91,000
 While not as rotation resistant as 19x7 rope, 8x25 Spin Resistant rope is more stable. With its increased
resistance to bending fatigue and crushing, it is also used for general purpose on single-part crane lines and
sometimes multi-part wire rope systems.
 TEREX-RT555-1

Convert to There are 25.4 mm in each inch. 5/8 inch = 0.625 inch So, 5/8 inch = 0.625 *
25.4 = 15.875 mm- (Note:-This wire rope look like that ordinary wire rope TADANO but
compacted)
Main Applications: Should Reade
http://www.unirope.com/wireropes/wr_compac_18.shtml
Python® Compact 18 is recommended for both multipart load and single part
applications where a medium rotational stability is needed. Use as main- and auxiliary
hoist line on GROVE, LINK BELT, MANITOWOC, TEREX and other US made mobile- and
truck cranes. Large lifting heights will require a tag line to prevent spinning of the load.
Filler wire compacted
TEREX-RT555-1
Auxiliary hook original spin resistance Main hook not original (Rotation
wire rope right regular lay (strand 6 ) resistance -non rotating)
19mm right regular lay (strand 12 ) 19mm
NEED GREASE OTHER WAYS
DAMAGE
6x19 Class Wire Rope

T he 6x19 Classification of wire rope is the most widely used in the

industry. Because of its effective combination of flexibility and wear resistance,

rope in this class is well-suited to meet the specific needs of diverse kinds of
machinery and equipment.
The 6x19 Seale construction – with its large outer wires – provides exceptional
ruggedness and resistance to abrasion and crushing. However, its resistance
to fatigue is somewhat less than that offered by a 6x25 construction. The 6x25
possesses the best combination of flexibility and wear resistance in the 6x19
Class due to the filler wires that provide support and impart stability to the
strand. The 6x26 Warrington Seale construction has a high resistance to
crushing. This construction is a good choice where the end user needs the
wear resistance of a 6x19 Class rope and the flexibility of a 6x37 Class rope.
6x37 Class Wire Rope
The 6x37 Classification of wire rope is characterized by the relatively large number
of wires used in each strand. Ropes of this class are among the most flexible
available due to the greater number of wires per strand – however, their resistance
to abrasion is less than ropes in the 6x19 Class.

The designation 6x37 is only nominal, as is the case with the 6x19 Class. None of
the ropes actually has 37 wires per strand. Improvements in wire rope design, as
well as changing machine designs, have resulted in the use of strands with widely
varying numbers of wires and a smaller number of available constructions. Typical
6x37 Class constructions include 6x33 for diameters under ½”, 6x36 Warrington
Seale (the most common 6x36 Class construction) offered in diameters ½” through
1-5/8” and 6x49 Filler Wire Seale over 1-3/4” diameter.

19x7 Rotation-Resistant Wire Rope

The 19x7 Classification of wire rope is recommended for hoisting unguided loads
with a single-part line. The rotation-resistant properties of this rope are secured by
two layers of strands. The inner strands are left lay, while the 12 outer strands are
right lay – which enables one layer to counteract the other layer's rotation. The
rotation-resistant characteristics of the 19x7 Class wire rope are superior to those of
the 8x19 Class wire ropes.
.
8x19 Rotation-Resistant Wire Rope
The 8x19 Classification of rotation-resistant wire rope is recommended for
hoisting unguided loads with a single-part or multi-part line. The eight outer
strands are manufactured in the right lay, with the inner strands being left lay.
These ropes are slightly stronger and significantly more rugged than the 19x7
construction. However, the rotation-resistant properties of the 8x19 rotation-
resistant ropes are much less than those of the 19x7 construction. These ropes
are manufactured in right regular lay in the 8x19 Seale and 8x25 Filler Wire
constructions.
WIRE ROPE
The strength, quality, and integrity of wire rope define the level
of safety for any lift at all construction sites. Each lift is only as
safe as the wire rope being used on the crane. Wire rope should
be inspected prior to each shift for damage. There are many
different types of wire rope used on cranes. The wire ropes used
in on cranes will either be a standing wire rope (such as a
pendant line) used mainly on lattice boom cranes, or running
wire rope (runs over a sheave) used as hoist line or boom hoist
reeving. For running wire ropes, there are dozens of types to
choose from for the hoist line on a crane. However, out of the
dozens of wire ropes available, similar characteristics for
inspection and removal criteria are shared by all.
The most common wire rope used on cranes is right regular
lay, which usually has a safety factor of 3.5 and must be removed
from service when there are 6 broken wires in one rope lay or 3
broken wires in one strand of one lay. Left lay and long lay share
similar criteria for removal from service.
Rotation resistant :
wire rope has different criteria for removal from service. Rotation
resistant wire rope is removed when there are 2 broken wires in 6
rope diameters or 4 broken wires in 30 rope diameters. Rotation
resistant has a safety factor of 5. Special attention should also be
given to any reduction in rope diameter, such as kinking, bird
caging, or crushing with rotation resistant. Find stainless steel
cable, galvanized cable, and wire rope providers at
CraneHunter.org
 7.4 REMOVAL OF BROKEN WIRE ENDS
Protruding wire ends may damage neighboring wires and affect the normal travel of the
wire
rope. They should be removed. It is not advisable to nip ends off with pliers but to grip
them,
bending them backwards and forwards until the wire breaks in the valley between two
strands.
Some rotation may occur in the initial cycles of operation. This rotation may result in the
twisting of the parts of rope forming the reeving or from the following features:
Turn induced during installation of the rope.
Turn induced by the operating arrangements of reeving.
Turn induced by the drum.
 WIRE ROPE PROBLEM AND SOLVED

CORE PROTRUSION:
Cause / action
1. Shock loading - review operating conditions
2. Too large fleet angle - control reeving
3. Change rope immediately
WAVINESS:
Cause / action
1. Too small groove radius - check all grooves
with gauges
2. Too large fleet angle - control reeving
3. Untwisting during installation
4. Check flange of the sheaves for damage areas
BASKET DEFORMATION:
Cause / action
1. Untwisting during time in service - mark the rope and search for influences in
the reeving
2. Shock loading - review operating conditions
3. Too small groove radius - check all grooves with gauges
EXTERNAL WEAR:
Cause / action
1. Too small groove radius - check all grooves with gauges
2. Sliding on edge(s) - search for abrasion on the crane
3. Check if all sheaves in the reeving are free to rotate
4. Heavy line pull - fatigue wear of a result of long time operation
EXTERNAL CORROSION:
Cause / action
1. Consider selection of galvanized rope
2. Review frequency, amount and type of service dressing
CROWN WIRE BREAKS:
Cause / action
1. Too small groove radius - check all grooves with gauges
2. Sliding on edge(s) - search for abrasion on the crane
3. Check if all sheaves in the reeving are free to rotate
4. Review operating conditions
MECHANICAL DAMAGE:
Cause / action
1. Generally results from operating conditions
2. Check if all sheaves in the reeving are free to rotate
3. Review operating conditions
4. Check sheave guards and support rollers to ensure that the rope does not jump
out of intended reeving system
ROPE CRUSHING:
Cause / action
1. not installed under tension
2. lose structure while installation
3. lose first layer / wraps on the drum
 One of the most common signs of rope deterioration is broken wires, normally the
outside wires at the crowns of the strands. During your inspection, it’s very important
to search for broken wires, especially the areas of the rope in contact with sheaves
and drums when loads are picked up.

1. The first step is to relax your rope to a stationary position, move the pick-up points off
the sheaves. Clean the grease from the rope with a cloth – a wire brush, if necessary – so
you can see any breaks.2. Flex the rope to expose any broken wires hidden in the valleys
between the strands.3. Visually check for any broken wires. One way is to run a cloth
along the rope to check for possible snags.4. With an awl, probe between wires and
strands and lift any wires that appear loose. Evidence of internal broken wires may
require a more extensive rope examination.
 Four Basic Strand Patterns

7 WIRE ORIDINARY 19 WARRINGTON 19 SEALE 25 FILLER WIRE

Combination Strand Patterns