02 Wire Rope Strand

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02 Wire Rope & Strand.qxd 15/2/12 5:13 PM Page 1
A. Noble & Son Ltd. has been stocking and distributing wire rope
almost since the inception of the company in 1911.
Apart from the distribution of wire rope Nobles personnel can
supply guidance on correct usage and selection of wire rope.
Nobles branches throughout Australia have swaging presses for
terminating wire rope and NATA accredited tensile testing
laboratories. The testing laboratories can be used for destruction
testing and proof loading of wire ropes and wire rope assemblies.
A. Noble & Son Ltd. represents a range of wire rope
manufacturers from all over the world who each have their own
specialities in mine winding, crane and general purpose ropes.
Description, Size & Construction
A wire rope is made up of the basic components illustrated.
The terms used to describe these component parts should be
strictly adhered to, particularly when reporting on the conditions
of ropes.
Describing wires as strands and strands as wire can be grossly
misleading. For example, a report that a rope has a broken strand
in most applications calls for immediate discarding of the rope,
and subsequent cessation of operation, while a report that a rope
has a broken wire in it should call for early inspection but seldom
for discarding the rope.
Wire Rope Description
The properties of a wire rope are derived from its size,
construction, quality, lay and type of core.
Size
Ropes are referred to by a diameter size. The correct way to
measure wire rope is shown below.
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Wire Rope & Strand
GENERAL INFORMATION
Construction
The main components of a wire rope are shown below.
In the above example, each individual wire is arranged around a
central wire to form a 7-wire strand. Six of these strands are
formed around a central core to make a wire rope. The rope is
specified as 6x7 (6/1) i.e. six strands each of seven wires.
The size and number of wires in each strand, as well as the size
and number of strands in the rope greatly affect the
characteristics of the rope. In general, a large number of small-
size wires and strands produce a flexible rope with good
resistance to bending fatigue. The rope construction is also
important for tensile loading (static, live or shock), abrasive wear,
crushing, corrosion and rotation.
Equal Laid Rope Cross Laid Rope
Correct Method Incorrect Method
Core
Strand
Wire
Wire Rope
Composition of Wire Rope
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Wire Rope & Strand
GENERAL INFORMATION
Multiple Operation: Individual strands are composed of
successive layers of wire laid up at different lay lengths.
This results in a cross laid rope.
This type of construction is now confined to a limited range of
products such as ropes below 8mm diameter, and large sling and
static ropes.
Single Operation: All wires in the strand are laid up in the one
manufacturing operation. This type of rope is standard production,
providing an equal laid rope that eliminates internal cross-mating
and forms a compact strand of high metallic content. There are
three main types: 6x9/9/1, 6x25 FW and 6x36 SW.
Rotation Resistant: The conventional rotation resistant wire
rope is composed of a number of strands that are laid up in
opposite directions to produce a non-rotating effect.
The 4 strand Mono Track is a complete departure from this
convention and is created through theoretical analyses of the
working torques.
Triangular Strand: The wires are specially formed to produce
a strand with a triangular section this type of rope is only
produced in Langs lay. This construction has improved wear and
crush resistance and has wide application in winding and haulage
systems.
Galvanised Strand: These are single strands of concentric layers
of wires, some of which are cross laid to produce a non-rotating
result.
Half Locked Coil: A strand with the outer layer composed of
alternate shaped and round wires covering one or two layers of
round wires laid in the opposite direction.
Full Locked Coil: A strand used as a rope and composed of one
or two layers of Z-shaped wires laid over layers of half lock coil
and/or layers of round wires.
Rotation Resistant Mining Ropes: A rope composed of
flattened strands of six or eight wires contra laid over a triangular
strand rope to produce a rotation resistant result.
Cores & Wire Tensile
A number of core types are available and each gives specific
properties to the rope:
1. Fibre Core (FC) sisal or polypropylene.
2. Wire Strand Core (WSC) strand usually of the same
construction as the outer strands.
3. Independent Wire Rope Core (IWRC) a wire rope usually of
6x7 (6/1)/1x7(6/1) construction.
Fibre Core (FC) in 6x7 rope
A fibre core, generally sisal, provides a
resilient foundation for the strands in the
rope structure. Fibre cores are used for
ropes that are not subjected to heavy
loading and where flexibility in handling is
required. Fibre cores are inadequate where
wire rope is subjected to heavy loading,
prolonged to outdoor exposure and
crushing on small drums and sheaves.
Wire Strand Core (WSC) in 6x7 Rope
These cores are used chiefly for standing
ropes (guys or rigging), and offer higher
tensile strength and, owing to the larger
wires in the core, greater resistance to
corrosion failure.
Independent Wire Rope Core (IWRC)
in 6x25 FW Rope
In many instances it is recommended to
use a wire rope with an independent wire
rope core (I.W.R.C). Such a core is usually
made up of 6 strands of 7 wires each plus
centre strand.
Multiple Operation
Single Operation
Rotation Resistant
Triangular Strand
Galvanised Strand
Full Locked Coil
Half Locked Coil
Non-Rotating Mining
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Wire Rope & Strand
GENERAL INFORMATION
The independent wire rope core provides:
1. Permanent support and uniform spacing of the strands laid
around it; it is not compressible and has greater wear
resistance than fibre core.
2. Permanent elastic stretch of the wire rope over a longer
period of time.
3. Increased resistance to deterioration and deformation.
4. Delay of internal corrosion; the lubricant is not squeezed out
of the core.
5. It increases the actual breaking load of the rope by at least
8% in the case of 6-strand ropes and about 25% in the case
of 8-strand ropes.
6. Better performance for operating in very high temperatures.
An independent wire rope core increases the weight of a 6-strand
rope by about 10%, and that of an 8-strand rope by approx. 20%.
Although a new rope with I.W.R.C. may be somewhat less flexible
than a new rope with fibre core, it retains its relative flexibility
whereas a rope with fibre core gradually loses its flexibility during
use. Having better resistance to deterioration and deformation, a
rope with I.W.R.C. is less susceptible to damage when used on
small sheaves and drums than a rope with fibre core, it will also
last longer before deterioration and deformation set in when
wound on a drum in multiple layers.
Tensile Strength Grades
Wire ropes are usually supplied in the following tensile ranges:
Rope Grade Range of wire tensile strength grades
N/mm
2
1570 1370 to 1770
1770 1570 to 1960
1960 1770 to 2160
2160 1960 to 2160
Rope Grade Equivalents
Rope Grade Designation Equivalent Rope Grade
IPS 1770
EIPS 1960
EEIPS 2160
Preforming, Postforming & Lay
Preforming
A preformed rope is one in which the component strands are
shaped to their final helical form before being laid into the rope.
Preforming can be applied to both Ordinary lay and Langs lay
ropes and, unless specifically ordered otherwise, all standard
ropes are supplied preformed.
The advantages of preforming are mainly:
1. Reduction of internal stresses in the rope. This makes the
rope easier to handle, install, reduces its tendency to kink
and gives better spooling onto drums.
2. Greatly improved resistance to bending fatigue particularly
in operation over small drums and sheaves.
3. Greater stability and better resistance to shock loading
and abrasion.
4. Improved rope life due to the better equalisation of loading
between strands in the rope and reduction of internal stresses
in the rope.
5. Greater safety in handling of ropes as broken wire ends do
not protrude. This factor also reduces wear on equipment in
contact with the rope.
Postforming
Postforming is a manufacturing process applied to ropes to
minimise stretch in service. It reduces the stretch caused by
"bedding-in" the wires and strands onto their respective cores.
In addition to controlling stretch, postforming produces results
closely related to those achieved by preforming.
Postforming is particularly useful in overcoming stretch in long
lengths of rope and where take-up adjustment is restricted. It is
commonly applied to ropes used in aerial ropeways, guying,
chairlifts and control cables.
Lay
This refers to the way the wires in the strands, and the strands in
the rope are formed into the completed rope. The wire strands
are essentially laid up in a planetary motion with controlled twist
being imparted to produce a tightly formed rope.
The term "lay" is used in three ways:
1. To describe the direction in which the strands are laid in the
rope, right or left. In a Right Hand lay strands are laid around
the rope core in a clockwise direction see illustration.
In a Left Hand lay, the strands are laid anti-clockwise
see illustration. Steel Wire Ropes are conventionally produced
Right Hand lay unless special circumstances require Left Hand
lay.
2. To describe the direction in which the wires are stranded in
relation to the direction of the strands in the completed rope,
e.g. Ordinary lay or Langs lay.
Ordinary lay means the wires in a strand are laid in a
direction opposite to the direction in which the strands are
laid in the final rope.
Langs lay is the reverse of Ordinary lay. That is, the wires are
laid in the same direction as the strands in the rope.
Langs lay ropes have superior properties in resistance to
wear, abrasion, fatigue and scuffing. This is illustrated on the
following page, where it can be seen that wear on an outer
wire is distributed over a far greater area than in Ordinary lay.
3. "Lay" is also a measure of the pitch of a strand in a rope.
With the increasing use of heavy-duty and more compact
equipment (e.g. power winches on mobile cranes and mine
winding) there is a gradual upward trend in the required rope wire
tensile range. However, as factors other than strength influence
the life of wire rope, the specific application must be kept in mind
when tensile strength of wire is selected.
Surface Finish
The most common are:
Galvanised wire rope - Zinc coated Class B is denoted
with B (formerly G).
Galvanised wire rope - Zinc coated Class A is denoted
with A (formerly G Class A).
Uncoated or Bright wire rope (Black) - is denoted
with U (formerly B).
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Wire Rope & Strand
GENERAL INFORMATION
Characteristics of Lay: The direction of rope lay does not affect
the Breaking Force of a rope. However, the combination of strand
lay and rope lay will greatly affect the rope characteristics and
this factor must be taken into consideration when choosing a
rope. Although the lay length can slightly affect rope behaviour
the dominant aspect that influences performance is the direction
of lay and whether it is Langs lay or Ordinary lay. For example,
the importance of rope lay is evident in a four-part highlift grab
where rotation of the grab is prevented by the use of alternate
right-hand and left-hand ropes.
Lubrication, Specifications, Testing
& Plastic Coating
Lubrication
When a rope is operated over a drum or sheave, the strands
and wires move relative to one another. To reduce the resultant
friction within the rope as well as the friction between the rope
and drum or sheave, ropes are lubricated in manufacture.
In addition this lubrication also retards corrosion and inhibits
possible rotting of the fibre core. In special applications a
combination of lubricants may be called for, e.g., the core and
inner wires of the strands may be heavily lubricated while the
lighter lubrication may be applied to outer wires and strands.
Wire rope cores are normally heavily lubricated irrespective of
the outer strand lubrication.
Specifications
All standard ropes are produced to generally comply with the
requirements of Australian Standards. However some of our
more technically advanced wire ropes have special characteristics
required to provide superior performance.
Testing & Inspection of Wire Ropes
Nobles can offer special services for rope users to assist in their
inspection of used ropes. Our personnel have in many cases had
a lifetime in the industry during which considerable experience
has been gained.
The NATA accredited tensile laboratories in the various Nobles
branches throughout Australia can provide tensile destruction
testing services, while the company is also accredited by NATA
to carry out non-destructive testing on wire ropes in situ.
Plastic Coated Wire Ropes
Plastic coatings are extruded onto a range of rope and stranded
products for applications requiring a high resistance to corrosion.
Plastic coated ropes are available in the following rope size and
construction range:
6x7 and 7x7 up to 8mm galvanised
6x19 and 7x19 up to 12mm galvanised
6x24 up to 12mm galvanised
Typical applications are rigging lines, handrails, steering lines and
holding lines in the shipping, pearling and fishing industries.
Plastic coated strands are also available in PVC and black
polyethylene.
Standard Blue PVC Coating on 6 x 19 FC B 1570 Wire Rope
Lay Directions & Types
z (right lay) s (left lay)
Lay direction of strands for stranded ropes are right (z) or left (s)
and correspond to the direction of lay of the outer wires in
relation to the longitudinal axis of the strand.
Lay direction of ropes are right (Z) or left (S) and correspond to
the direction of lay of the outer wires in a spiral rope, the outer
strands in a stranded rope or the unit ropes in a cable-laid rope
in relation to the longitudinal axis of the rope.
RHOL / RHRL (sZ) LHOL /LHRL (zS) RHLL (zZ) LHLL (sS)
Ordinary lay Langs lay
Note: The first letter of the symbol denotes strand direction and the second letter denotes
rope direction.
Right hand ordinary lay (sZ)
Right hand langs lay (zZ)
Left hand ordinary lay (zS)
Left hand langs lay (sS)
Right hand alternate lay (aZ)
One rope lay
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Wire Rope & Strand
GENERAL INFORMATION
Ordering
The size, grade and construction of a rope must match the
specific application and design factors.
Rope Length
Wire rope is manufactured to length tolerances as follows;
Up to 400m = +5% - 0%
400 to 1000m = +20m
Over 1000m = +2% - 0%
When a closer length is required, this should be specified in the
order. In calculating rope length requirements, it is advisable to
consider the following practical points for economy in operation:
1. In most cases, mining regulations require a test length be cut
at specified periods. Sufficient extra length to cater for such
tests over the expected service life of the rope should be
added to the necessary operating rope length, plus a
minimum of 2 1/2 drum turns for anchorage.
2. It is also advisable to make allowance for "cropping" in
service as a consequence of wear or accidental damage at
the capel end.
3. In many rope applications, wear and other deterioration are
concentrated in spots along the length of the rope. It is often
possible to gain economies in the overall life of the rope by
providing additional length to enable feeding through of the
new rope from the drum to spread the area of wear. This
practice is regularly used to advantage on cable-operated
earthmoving equipment and oil-well drilling rigs.
4. Short lengths of special rope constructions, if ordered in
single units, can be costly to produce. Consideration of the
number of such ropes in use and their probable service life
can often make it more economical to order several such
ropes at one time. As a rule, this helps to expedite production
and lessens the possibility of delays in supply.
On existing equipment the rope size is generally fixed by the
grooving of the sheaves and drums. Larger ropes should never be
used without modification of drum and sheave grooving to suit
the new rope. It should be remembered that ropes 8mm and
above are made to a diameter tolerance of minus 0% to plus 5%
with the exception of 6x24 construction, which has a tolerance of
plus 7%.
Construction
The construction of a rope for any given application should be
suited to the equipment and to the conditions under which it will
operate. It is important to nominate the construction when
ordering. For example, the rope illustrated is ordered as 6x25
Filler Wire.
Rope Grade
The minimum tensile strength of the wire is expressed in
megapascals.
Lay of Rope
Lay affects behaviour and operating life of a wire rope. It is
important therefore to quote (a) the direction of lay, and (b) the
type of lay and details of the rope application and operating
conditions. The illustration shows a right hand langs lay (zZ) or
RHLL rope. Ropes are normally supplied right-hand lay.
Rope Core
The type of rope core must be specified because of the significant
differences in properties of a wire rope core and fibre core.
Ordering for Special Applications
To obtain the best rope recommended for particular equipment
and operating conditions, information should be supplied on
loading, sheave and drum diameters, speed of operation,
corrosive conditions and fleet angles etc. A simple sketch of the
rope rigging is a convenient means of showing this type of
information.
All orders should contain information on the above factors.
When purchasers are not sure of the exact requirements the
following particulars should be submitted:-
(a) Length and size.
(b) Load exclusive of mass of the rope.
(c) Dimensions of drums and sheave.
(d) Corrosive conditions.
(e) Sketch of the application.
Special aspects of rope supply may be necessary
The following check list is suggested:-
(a) Special length considerations such as minimum length,
exact length.
(b) Special diameter tolerance.
(c) Rope end preparation.
(d) End attachments to inside or outside end.
(e) Stretch considerations.
(f) Special lubricant type and amount.
(g) Special reel dimensions, strength, shaft sizes, anchorage
details and lagging.
(h) Despatch instructions.
EXAMPLE
A typical order for wire rope would read:
"500m 16mm 6x9/9/1 A, B or U 1770 Grade RHLL (zZ) IWRC."
Abbreviations, Prestretching & Seizing
Abbreviations
The following abbreviations have been standardised for ordering
and identification purposes.
Wire Qualities
1570 MPa
1770 MPa
1960 MPa
I.P.S. Improved Plough Steel
E.I.P.S. Extra Improved Plough Steel
Right Hand Langs Lay
6 x 25 FW Fibre Core
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Wire Rope & Strand
GENERAL INFORMATION
Constructions & Lays
RHOL Right Hand Ordinary Lay (sZ)
LHOL Left Hand Ordinary Lay (zS)
RHLL Right Hand Langs Lay (zZ)
LHLL Left Hand Langs Lay (sS)
RHAL Right Hand Alternate Lay (aZ)
Pref Preformed
Post Postformed
IWRC Independent Wire Rope Core
WSC Wire Strand Core
FC Fibre Core
FW Filler Wire Strand Construction
TS Triangular Strand Construction
W Warrington Strand Construction
S Seale Strand Construction
SW Seale Warrington Construction
SF Seale Filler Construction
D or d Diameter (in millimetres)
FS Flattened Strand
HLC Half Locked Coil
FLC Full Locked Coil
Prestretching
Is the loading of a rope or strand from 33.3% to 50% of its
breaking load to remove constructional stretch, and this allows for
the more accurate setting of lengths for guying and suspension
cables.
The initial stretch cannot be accurately determined by theoretical
means and will continue to take place until it has been completely
removed.
After this initial stretch (or constructional stretch) has been
removed the strand will have a truly elastic measure where
elongation is proportional to applied load.
Seizing
Either of the following methods of seizing will ensure that the
rope will later perform its job satisfactorily.
Long Seizing (for ropes over 26mm diameter)
1. Place one end of seizing wire in the valley between strands.
2. Take the long end of the wire and turn at right angles to itself
and wind back over itself and the rope in a close tight seizing
of the required length.
3. The amount of seizing should not be less than 6 to 8 times
the rope diameter.
4. Twist the two ends of the wire together. Alternate tightening
and twisting of the ends will draw the seizing up tight.
5. Cut the end of the twisted wires and knock down into a valley
between two strands.
The above method is best applied using a seizing mallet or bat.
Short Seizing (for ropes below 26mm diameter)
1. Wrap the seizing wire around the rope eight or ten turns.
2. Twist the two ends of the seizing wire together approximately
at the centre position of the seizing. Alternate tightening and
twisting of the ends will draw the seizing up tight.
3. Cut the end of the twisted wires and knock down into a valley
between strands.
The number of seizings required depends on the type and
diameter of the rope. The following minimum number of seizings
are recommended:-
Preformed or Postformed ordinary lay 1 seizing.
Langs lay rope with wire rope core and rotation resistant ropes
2 seizings.
Seizing Wire
Both soft annealed single wire and stranded seizing wires are
used in the seizing of steel wire ropes. Suitable sizes are listed
below:-
List of Seizings Recommended For Standard Ropes
Rope Diameter (mm) 7 wire seizing strand Single seizing wire
Up to 14 0.90
16 26 1.25
28 38 7/0.90 2.00
Over 38 7/1.25 2.75
Transport, Storage & Handling
Transporting
Ropes are supplied on reels or in coil form. When transporting,
care must be taken not to damage rope by contact with other
goods. Reels and coils should be lifted rather than dropped, tipped
or rolled, to avoid damage.
Ropes should be uncovered as soon as they are received and
checked for possible transit damage.
Storage
Ropes, whether on reel or in coils, should be stored on blocks off
the floor to prevent sweating and corrosion and under cover in
dry conditions free from possible attack by corrosive agents, such
as milldust, sulphur or acid fumes.
Long Seizing
Short Seizing
Seizing Mallet or Bat
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Wire Rope & Strand
GENERAL INFORMATION
If ropes are to be stored for any length of time in warm or hot
conditions likely to cause the lubricant to drain to the lower side
of the reel, the reels should be mounted on a horizontal shaft and
turned over periodically to maintain uniform lubrication of the
rope. Additional lubrication may be necessary.
Removed ropes awaiting further use, should be thoroughly
cleaned, inspected, lubricated and stored under the same
conditions as new ropes.
Handling
Incorrect handling of rope from reels and coils can result in
springing of wires and strands and kinking of the rope. This type
of damage can seldom be entirely corrected and can greatly
reduce the effective life of the rope.
The drawings show correct and incorrect methods of reeling a
rope from the transport reel onto a drum or another reel. The
transport reel should be firmly mounted and braked to prevent
overrunning and give tight rewinding. A suitable stand for the reel
is also shown.
Methods of removing rope from reels & coils
Turntables, preferably mounted on the floor, may be used for
unwinding ropes from reels stored on their sides. Care must be
taken to brake such turntables, as over-running could cause the
rope to slacken, fall off and foul under the turntable.
If a coil is too large to be handled manually it should be mounted
on a turntable or suspended by a spindle from a swivel crane
hook.
When coiling ropes down by hand on the floor, an occasional coil
wound underhand relieves torque and provides a more easily
handled coil. Right Hand lay ropes should be coiled down
clockwise, Left Hand lay ropes anti-clockwise.
Installation
Rope Equipment Checking
Improved rope performance can be obtained by paying attention
to the following areas:
Sheaves should be grooved to the nominal rope diameter plus
an allowance of 7% to allow for rope manufacturing tolerances
and should be re-machined when worn to nominal diameter
plus 3%. Sheaves must also be free from score marks, run
freely and be true.
Guides and rollers must be free from undersized grooving and
broken flanges, and should run free and true.
Drum grooves should be checked for size and riser plates
checked for effectiveness.
Displaced or damaged cheek plates in rope blocks or safety
guards should be repaired.
Grabbing clutches and brakes should be repaired and adjusted
to obviate impact loads on the rope.
End fittings, such as wedges, sockets and drums anchorages,
should be inspected for excessive wear.
The fleet angle has an important bearing on the winding of a
rope from sheave to drum, particularly at high operation speeds.
If winding is to take place smoothly, the fleet angles on both
sides of the drum will have to be kept within acceptable limits.
Excessive fleet angles can result in considerable abrasive damage
to both sheave flanges and rope and considerably reduce the life
of the rope and the equipment.
Fleet angles normally range to a maximum of 1.5 for plain
drums and to a maximum of 2.5 for grooved drums. Smaller
angles are required for high speed haulage such as mine
windings. Unless the head or guide sheave is centred with respect
to the drum, there will be different values for the left and the
right fleet angles.
Rope End Preparation
Normally wire ropes are delivered with seized ends. As a rule, no
further preparation is necessary, but in some cases where ropes
must be reeved through restricted openings, such as drum
anchorages and blocks systems, the rope can be supplied with
welded tapered ends or with links welded on the ends. The latter
enables the new rope to be installed by attaching it either to the
old rope or a tow rope and drawing onto the equipment.
Tensioning Rope
Wire rope for multi-layer drums must be installed under tension.
It is imperative that the bottom layer is tight with the exact
number of turns on the drum.
Correct method Incorrect method
Correct methods of taking ropes
from coils: Roll the coil along the
ground or use a turntable.
Incorrect method: Dont pull
the rope from a stationary coil.
Correct methods of taking ropes from reels: When a large
reel is used, it is recommended that a plank is used as a brake
against the reel flange or on the shaft or side plate.
WARNING
When releasing rope from coils or reels, care must be taken to
retard the violent release of the rope end which could cause
damage, serious injury or death.
Left Fleet Angle
Right Fleet Angle
Sheave
Drum
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Wire Rope & Strand
GENERAL INFORMATION
Wire Rope Life
The main factors, which affect rope life are:
1. Basic design of equipment or installation:
Sheave size, drum design and drum diameter can directly
affect wire rope life. For example, doubling the sheave size
can produce up to four times the rope life. The minimum
ratios in the following table should be adhered to:-
Recommended Minimum Ratio of Drum &
Sheave Diameter to Rope Diameter
Rope Construction Ratio
6 x 7 43
6 x 19S (9/9.1) 32
6 x 21FW (10/5 + 5F/1) 30
6 x 19W (6 & 6/6/1) 30
6 x 25FW (12/6 + 6F/1) 23
6 x 36SW (14/7 & 7/7/1) 22
6 x 26WF (7 & 7/7/4/1) 22
6 x 24 (15/9/F) 22
6 x 29FW (14/7 + 7F/1) 22
6 x 41SW (16/8/8 & 8/8/1) 21
6 x 37 (18/12/6/1) 21
19 x 7 23
35 x 7 20
4 x 39 Mono Track 20
2. Operating Environment:
Corrosion when corrosive conditions exist, regular rope
inspection, particularly of the IWRC, is essential. The effects
of corrosion can be partly offset by the use of galvanised
wire rope.
Temperature excessively high operating temperatures can
lead to deterioration of the wire rope core, and thereby cause
rope fatigue.
3. Rope Maintenance:
End for ending and cropping in certain applications, e.g.,
drag ropes, it is possible to "end for end" the rope. This will
give longer rope life due to the wear points being re-located.
If additional rope can be accommodated on the drum, then
progressive cutting back (cropping) will bring "new" rope into
the system, and will re-locate wear points.
Treatment of broken wires broken wires affecting the life
of adjacent wires should be removed.
Discard practices - clear policies regarding discard should
be formulated. Rope Maintenance Schedules, based on
experience, should be drawn up to provide periodic
inspections and removal cycles for each rope as well as
inspections of individual components such as the sheaves.
Regular maintenance ensures optimum rope life, minimises
down time of plant and equipment and increases the
efficiency of the operation.
Broken Wires
General purpose ropes, crane ropes and hoist ropes should be
discarded whenever any of the types of degradation exceed the
limits given in the Table below. However, the rope life may be
ended before these limits are reached.
The table below allows for internal wire breaks and is valid for
all constructions of rope. In 6-strand and in 8-strand ropes, wire
breaks occur principally at the external surface. This does not
apply to wire ropes having a number of layers of strands
(typically multistrand constructions), where the majority of wire
breaks occur internally and are therefore non-visible fractures.
Limit of Degradation for Discard of General Purpose Lifting Ropes, Crane Ropes
& Hoist Ropes (see Notes 1 & 2)
Broken wires 6 x 19 (12/6/1) 5 10
6 x 19 S (9/9/1) 3 6
6 x 26 SW (10/5 and 5/5/1) 5 10
6 x 25 FW (12/6 and 6/1) 5 10
6 x 29 FW (14/7/7/1) 7 14
6 x 24 (15/9/F) 5 10
8 x 19 S (9/9/1) 5 10
8 x 25 FW (12/6 and 6/1) 6 13
6 x 36 SW (14/7 and 7/7/1) 7 14
6 x 37 (18/12/6/1) 10 19
6 x 41 SW (16/8 and 8/8/1) 9 18
18 x 7 NR 1 2
34 x 7 NR 2 4
4 x 48 2 4
Wear All types Outer wires are worn more than one third of their diameter
Loss of area All types The loss of metallic area due to visible combined wire wear and
broken or cracked wires exceeds 10%
Corrosion All types Corrosion is marked by noticeable pitting or loosening of outer wires
NOTES:
1. The number of wire breaks before discard in the above table is quite high, and if wire breaks are concentrated in one strand, lower levels for discard are appropriate. If more than
one third of the outer wires in a strand are broken over a length of six times the rope diameter, the rope shall be discarded.
2. Where ropes are used for lifts, AS 1735.2 applies, which is less stringent than the above table. The mining industry frequently requires more stringent discard criteria.
3. Rope of Langs lay construction other than rotation resistant ropes shall have no more than 50% of the above values.
4. Number of broken wires alone is not the only factor in discarding a wire rope.
Type of degradation Construction (see Note 3)
Limit of degradation for discard (see Note 4)
Maximum allowable number of
broken wires over a length of 6
times the ropes diameter
Maximum allowable number of
broken wires over a length of 30
times the ropes diameter
For Casar and 4 x 39 Mono Track wire ropes refer to A. Noble & Son Ltd.
For Casar Ropes refer to A. Noble & Son Ltd.
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32
Wire Rope & Strand
GENERAL INFORMATION
Care & Maintenance
Breaking in
A wire rope may be looked upon as a machine composed of a
large number of moving parts. As such it should be broken in as
soon as it is installed, by loading it very lightly for a few cycles
and then gradually stepping up the load, to enable both wires and
strands to bed down into the working positions, with the load
distributed as uniformly as possible.
With strand 6 and 8 stranded ropes, the torque can greatly
diminish after breaking in by releasing the connection and
allowing the torque to run out. This procedure may have to be
repeated until the constructional stretch has been worked out of
the rope and it has become neutral.
The use of spinners or swivels should be avoided whenever
possible. All ropes should be reeled onto winch drums as tightly
and uniformly as possible during the initial installation.
Inspection
Wire rope is tough and durable, but nonetheless expendable
and eventually reaches the end of its safe service life.
Rope deterioration becomes noticeable through the presence of
broken wires, surface wear, corrosion, wire or strand distortion
due to mechanical abuse, or drastic reduction in diameter and
lengthening of the lay. Also deterioration can be detected by the
use of non-destructive testing techniques. Wire ropes should
periodically be inspected for signs of deterioration.
While Statutory Regulations govern the inspection and discarding
of certain wire ropes, the same rules cannot be applied to all
ropes. The proper frequency and degree of inspection depends
largely on the possible risk to personnel and machinery in the
event of rope failure. The determination of the point at which a
rope should be discarded for reasons of safety requires judgment
and experience in rope inspection in addition to knowledge of the
performance of previous ropes used in the same application.
Where the Statutory Regulations are laid down for the inspection
and discarding of wire ropes and their attachments, wire rope
users should become fully acquainted with the regulations and
see that they are carried out.
Sufficient records should be kept to provide a reliable history of
the ropes under their control. Inspection of both operated and
discarded ropes frequently indicates equipment faults that have
a large bearing on the service life and safety of the rope. It is
therefore essential to inspect the equipment on which the rope
is used as well as the rope itself.
Non Destructive Testing
This method of inspection of wire ropes has become part of the
mining industries standard requirements for over 20 years.
An electromagnetic instrument is used to non-destructively
examine the rope. It incorporates a sensor head that is able to
induce a magnetic field in a section of rope that is located within
the instrument. Changes in the metallic field enable a chart to be
produced showing changes in metallic cross-sectional area and
any wire breaks or other anomalies. Life of costly wire ropes may
be extended by this sophisticated method.
Deterioration
Typical examples of wire rope deterioration
1. Mechanical damage due to
rope movement over sharp
edges whilst under load
2. Localised wear due to
abrasion on supporting
structure.
3. Narrow path of wire breaks
caused by working in a
grossly oversized groove or
over small support rollers.
4. Severe wear in Langs Lay,
caused by abrasion at cross-
over points on multi-layer
coiling application.
5. Corrosion of severe degree
caused by immersion of rope
in water.
6. Typical wire fractures as
a result of bend fatigue.
7. Wire fractures at the strand,
or core interface, as distinct
from crown fractures caused
by failure of core support.
8. Typical example of localised
wear and deformation created
at a previously kinked portion
of rope.
9. Multi-strand rope bird caged
due to torsional unbalance.
Typical of build-up seen at
anchorage end of multi-fall
crane application.
10. Protrusion of IWRC resulting
from shock loading.
- METALLIC AREA LOSS CHART - % REDUCTION
- LOCAL FAULT CHART -
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33
Wire Rope & Strand
GENERAL INFORMATION
Approximate Modulus of Elasticity for New Ropes
6 x 7 FC 96 GPa (0.0098 x 10
6
kgs/mm
2
)
7 X 7 117 GPa (0.0119 x 10
6
kgs/mm
2
)
6 X 19 FC 89 GPa (0.0091 x 10
6
kgs/mm
2
)
6 X 19 IWRC 110 GPa (0.0112 x 10
6
kgs/mm
2
)
7 Wire Strand 145 GPa (0.0148 x 10
6
kgs/mm
2
)
6
kgs/mm
2
)
6
kgs/mm
2
)
6 x 36 IWRC 82 GPa (0.0084 x 10
6
kgs/mm
2
)
6 x 36 FC 82 GPa (0.0084 x 10
6
kgs/mm
2
)
6 x 12/12/ FC 96 GPa (0.0098 x 10
6
kgs/mm
2
)
Locked Coil Winding Rope 125 GPa (0.0127 x 10
6
kgs/mm
2
)
Locked Coil Guide Rope 138 GPa (0.0141 x 10
6
kgs/mm
2
)
For used ropes 20% should be added to these figures.
Calculation of Cross Sectional Area of Wire Rope
A = F x d
2
A = Metallic area of rope with fibre core in mm
2
F = Compactness factor
d = Nominal diameter of rope in millimetres
For 6 strand rope with IWRC add 15%, with strand core add 20%
For flattened strand rope with IWRC, add 10%
For 8 strand rope with IWRC, add 20%
Compactness Factor F
Rope Construction Factor F
6 x 7 0.38
6 x 19/6 x 21 0.395
6 x 25 Filler Wire/6 x 36 Group 0.405
7 Wire Galvanised Guy Strand 0.596
19 Wire Galvanised Guy Strand 0.580
Stretch in Ropes
When load is first applied to a new rope it stretches due to the
individual wires settling down. This is referred to as the Initial or
Manufacturing Stretch. Subsequently a gradual stretch takes place
during the whole of the ropes life; the amount depends on many
variables such as length, type of construction, loading and the
modulus of elasticity of the particular rope.
T = (2W + Lw)
( )
L
2a E
Where T = Stretch in metres
W = Load in kgs
L = Length in metres
w = Weight of rope in kgs/ metre
a = Cross sectional area of rope in millimetres
2
E = Modulus of Elasticity, kgs/mm
2
To forecast the amount of stretch accurately for a rope under
a given set of conditions, calculations must be based on the result
of a load/extension test on a sample from the particular rope.
However, if the results of such a test are not available,
an indication of the increase in length can be obtained from
the formula.
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34
Wire Rope & Strand
GENERAL INFORMATION
Nominal Rope Diameter Tolerance as percentage of nominal diameter
d Ropes with strands that are exclusively of Ropes with strands that incorporate
mm wire or incorporate solid polymer centres fibre centres*
2 d < 4 +8 -0 -
4 d < 6 +7 -0 +9 -0
6 d < 8 +6 -0 +8 -0
8 +5 -0 +7 -0
* For example 6 x 24FC
Tolerances on rope diameter
Nominal Rope Diameter Tolerance as percentage of nominal diameter
d Ropes with strands that are exclusively of Ropes with strands that incorporate
mm wire or incorporate solid polymer centres fibre centres*
2 d < 4 7 -
4 d < 6 6 8
6 d < 8 5 7
8 4 6
* For example 6 x 24FC
Permissible differences between any two diameter measurements
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35
Wire Rope & Strand
BREAKING FORCE TABLES
The following tables show rope mass in "kg per 100 metres" and
breaking force in "kilonewtons" for the various rope groups.
It will be noted that the value varies from group to group since
the various constructions contain different steel areas and variable
losses are incurred as the result of the stranding of the wires.
Wire quality has been nominated in 1570, 1770 and 1960 grade
for the majority of wire ropes, the value 1570, 1770 etc.
corresponds to the minimum tensile strength of the wire
expressed in megapascals. Marine and General Purpose
galvanised ropes have been nominated in 1570 grade and are
confined to certain rope constructions. Other 6 strand
constructions in galvanised rope should be ordered in 1770 grade.
The breaking forces of rope of tensile grades other than 1770 can
be calculated by multiplying the value of 1770 grade by the ratio
of the grade number. The grade of 2070 is the preferred high
tensile grade for 6 strand ropes but 1960 is preferred for 19x7,
35x7 and most Casar ropes.
All ropes are in millimeter diameter. Only preferred sizes have
been included in the tables. Non preferred sizes should be the
subject of special inquiry. Special non preferred sizes to suit
existing deep mining and large excavator equipment are available
although new equipment should use only preferred diameters.
The breaking force unit is the kilonewton, this being the force
which, applied to a mass of one kilogram, produces an
acceleration of one metre per second. The minimum rope
breaking force required will depend on the factor of safety
covered by the application and in the case of a single supporting
rope where the rope mass is ignored will be equal to the
gravitational force multiplied by the factor of safety. Minimum
rope breaking force (kN) = Mass (tonnes) per rope part x factor
of safety required x 9.81.
To calculate approximate mass equivalent, at sea level,
divide kilonewtons by 9.81
Example: 12mm 6 x 7 Fibre Core G1570 grade
= 75 kN = = 7.65 tonnes
For most practical purposes, divide by 10 in lieu of 9.81
75
9.81
TYPICAL ROPE RECOMENDATIONS
Applications Size Range Rope Recommendations Lay Preformed Core Factors of Safety
Dia. (mm)
LOGGING Log Winch 13 - 28 19S RHOL IWRC Logging Skylines........3.5
32 - 36 25FW RHOL IWRC
Log Skidder 13 - 28 19S, 25FW RHOL IWRC
Yard Rope 16 - 20 25FW, 29FW RHOL FC
PILING Pile Driving Hammer 16 - 32 36 RHOL IWRC
Drop Hammer 16 - 32 25FW, 36SW, 4x39 RHOL FC
Pile Handling 13 - 24 25FW RHOL IWRC, FC
SLINGS Slings - Standard 9 - 32 24, 36SW RHOL FC, IWRC AS 1666 - 1995.......5.0
Slings - High Tensile 9 - 28 25FW, 36SW RHOL IWRC
32 - 104 36SW, 41SW RHOL IWRC
CRANES Tower - Hoist 20 - 42 Eurolift, 35x7, Powerlift, Starlift RHOL or RHLL For safety factors on cranes
refer to AS 1418.1:2002
Tower - Luffing 20 - 42 4x39, Stratoplast, Turboplast RHLL
Trolley Line 13 - 24 25FW, 36SW RHOL IWRC
Overhead 6 - 10 19x7, Starlift
1 - 3 Falls 12 - 18 35x7, Eurolift, 4x39 RHOL
Overhead Stratoplast, Turboplast RHOL or RHLL IWRC
4 Falls or more 25FW, 36SW, Betalift, Alphalift RHOL or RHLL IWRC
Mobile - Hoist 11 - 20 Eurolift, Starlift, 19x7, 35x7,4x39 RHOL or RHLL
22 - 32 Eurolift, Starlift, 19x7, 35x7,4x39 RHOL or RHLL
Mobile - Luffing 13 - 26 25W, Stratoplast, Turboplast RHLL IWRC
GRABS Grab - Holding 18 - 28 25FW, 36SW, 4x39 RHOL or RHLL IWRC, FC ................5.0
Closing 18 - 29 Stratoplast, Turboplast LHOL or LHLL
WATER DRILLING 14 - 18 24, 4x39 LHOL, RHOL FC
DRILLING Diamond 12 - 16 19x7, 4x39 RHOL FC
16 - 20 35x7, 4x39 RHOL* FC
SHIPPING Mooring 16 - 26 24, 36SW RHOL FC
26 - 40 36SW, 41SW RHOL FC
Towing 32 - 56 36SW, 41SW RHOL FC, IWRC
Loading Gear - Lashing 12 - 32 24 RHOL FC
Rigging 10 - 32 7x7, 7x19 RHOL IWRC
SLIPWAY 16 - 32 24, 36SW RHOL FC
32 - 56 36SW, 41SW RHOL FC, IWRC
WINCHES Trailer - Boat 5 - 8 19, 7x19 RHOL IWRC, FC
General Purpose 8 - 28 19S, 25FW, 36SW RHOL IWRC
32 - 64 25FW, 36SW, 41SW RHOL IWRC
Note: 6 Strand ropes except where otherwise stated.
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36
Wire Rope & Strand
GENERAL PURPOSE WIRE ROPES
Galvanised Wire Ropes for Marine and General
Purposes Round Strand 6 x 7
Nominal Approximate Minimum Breaking
Diameter Mass Force Grade 1570
Fibre Core Wire Rope Core Fibre Core Wire Rope Core
FC IWRC FC IWRC
mm kg/100m kg/100m kN kN
2 1.3 1.5 2.1 2.3
3 3.1 3.5 4.7 5.1
4 5.5 6.1 8.4 9.0
5 8.6 9.6 13.1 14.1
6 12.4 13.8 18.8 20.3
7 16.9 18.8 19.3 27.6
8 22.1 24.6 33.4 36.1
9 27.6 31.1 42.2 45.7
10 34.5 38.4 52.2 56.3
11 41.7 46.5 63.1 68.2
12 49.7 55.3 75 81.2
13 58.3 64.9 88.1 94.9
14 67.6 75.3 102 111
16 88.3 96.3 133 145
18 112 124 169 183
20 138 154 208 225
22 167 186 252 273
24 199 221 300 324
26 233 260 353 381
28 270 301 409 442
32 353 393 534 577
Diameter Mass Force Grade 1570
Fibre Core Wire Rope Core Fibre Core Wire Rope Core
FC IWRC FC IWRC
3.5 4.2 4.6 5.8 6.4
4 5.5 6.1 7.7 8.5
5 8.6 9.5 12 13.2
6 12.4 13.7 17.6 19.3
7 16.9 18.7 23.4 25.8
8 22.1 24.4 30.9 33.3
9 28 30.8 39.1 42.2
10 34.6 38.1 48.2 52.1
11 41.9 46.1 58.4 63.1
12 49.8 54.8 69.5 75
13 58.5 64.3 81.5 88.1
14 67.8 74.6 94.6 102
16 88.6 97.4 124 133
18 112 123 156 169
20 138 152 193 208
22 167 184 234 252
24 199 219 278 300
Purposes Round Strand 6 x 19
Purposes Round Strand 6 x 24 Fibre Core
Nominal Diameter Approximate Minimum Breaking Force
Mass Grade 1570
mm kg/100m kN
8 20.1 28.7
9 25.4 36.4
10 31.4 44.9
11 38.0 54.3
12 45.2 64.0
13 53.1 75.9
14 61.5 88.0
16 80.4 115
18 102 145
20 126 180
22 152 217
24 181 259
26 212 304
28 246 352
32 322 460
7 x 7 (6/1)
6 x 19
(12/6/1)
6 x 19S
(9/9/1)
6 x 19W
(6 & 6/6/1)
6 x 7 (6/1)
6 x 24 (15/9/F)
Diameter Construction Mass Force Grade 2070
Wire Rope Core Wire Rope Core
IWRC IWRC
mm kg/100m kN
4 7 x 19 6.1 11.9
5 7 x 19 9.5 18.7
6 7 x 19 13.7 27.3
6.3 7 x 19 15.1 33.4
8 6 x (9/9/1) S 24.4 47
10 7 x 19 38.1 68.6
11 6 x 25FW 50.6 89.4
16 6 x 25FW 107 188
7 x 19 WSC 6 x 25 FW
(12/6 & 6 F/1)
6 x 19 S
(9/9/1)
Galvanised Wire Ropes (Higher Tensiles)
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37
Wire Rope & Strand
GENERAL PURPOSE WIRE ROPES
Nominal Approximate Minimum Breaking Force
Diameter Mass
Grade 1770 Grade 2070
Polypropylene Wire Strand Polypropylene Wire Strand Polypropylene Wire Strand
Core Core Core Core Core Core
mm kg/100m kg/100m kN kN kN kN
3.35 4.4 8.5
5 8.6 9.6 16.1 17.1 18.8
6 12.4 13.8 21.2 22.9 24.6 27.1
7 16.9 18.8 21.8 31.1 37.1
8 22.1 24.6 37.6 40.7 47.4
9 27.6 31.1 47.6 51.5 60.2
10 34.5 38.4 58.8 63.5 74.1
6 x 7 (6/1) FC 7 x 7 WSC
Nominal
Approximate Mass
Minimum Breaking Force
Diameter IWRC
6 x 19 to 6 x 25 6 x 26 to 6 x 49 Grade 1770 Grade 1960
IWRC IWRC
8 25.6 26.2 40.3 44.7
9 32.4 33.1 51 56.5
10 40.4 40.9 63 69.8
11 48.4 49.5 76.2 84.4
12 57.6 58.9 90.7 100
13 67.6 69.1 106 118
14 78.4 80.2 124 137
16 102 105 161 179
18 130 133 204 226
20 160 164 252 279
22 194 198 305 338
24 230 236 363 402
26 270 276 426 472
28 314 321 494 547
32 410 419 645 715
36 518 530 817 904
40 640 654 1010 1120
44 774 792 1220 1350
48 922 942 1450 1610
52 1080 1110 1700 1890
56 2250 1280 1980 2190
58 1390 2200 2440
60 1440 1470 2270 2510
64 1730 2691
70 2080 3090
75 2360 3622
6 x 19 S
(9/9/1)
8 - 44mm
6 x 21 FW
(10/5 + 5 F/1)
8 - 60mm
6 x 25 FW
(12/6 & 6 F/1)
8 - 60mm
6 x 26 WF
(7 & 7/7/4/1)
9 - 16mm
6 x 29 FW
(14/7 + 7 F/1)
10 - 44mm
6 x 36 SW
(14/7 & 7/7/1)
9 - 60mm
6 x 41 SW
(16/8 & 8/8/1)
22 - 52mm
6 x 49 SFW
(16/16/8 + 8 F/1)
52 - 60mm
Travelling Irrigator Galvanised Wire Ropes
General Purpose Wire Ropes
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TO AS 3569.1
38
Wire Rope & Strand
Rotation Resistant 19 x 7 L
ROTATION RESISTANT WIRE ROPES
19 x 7 Construction Wire Ropes are not
recommended in diameters above 18mm.
35 x 7 ropes should be used above
12mm diameter.
Rotation Resistant 35 x 7 L Compacted
Nominal Approximate Minimum
Diameter Mass Breaking Force
Grade 1960
mm kg/100m kN
6 15 25.9
8 26.9 47.1
9 34.1 59.6
10 42.1 73.5
12 60.8 105.9
13 70 119.6
14 81.9 143.8
16 107 188.5
18 137 238.6
Nominal Approximate Minimum Minimum
Diameter Mass Breaking Force Breaking Force
mm kg/100m kN kN
13 87 157 -
14 100 182.3 -
16 132 237 251
18 167 301 308
19 184 335.8 344
20 206 373 382
22 247 450 466
24 294 535 555
26 343 627 660
28 398 694 758
30 463 797 -
32 527 908 980
34 594 1020 -
36 666 1147 1232
Rotation Resistant 35 x 7 L
Nominal Approximate Minimum Minimum
Diameter Mass Breaking Force Breaking Force
mm kg/100m kN kN
14 87 160.1 165
16 113 202.5 217
18 143 263.1 271
19 160 298.9 308
20 175 319.2 336
22 211 387.9 413
24 251 457.7 493
26 301 545.7 576
28 339 617.8 646
30 392 724.2 -
32 441 811.2 829
34 501 918.7 -
36 563 1029.7 1060
L = Langs Lay.
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L = Langs Lay.
L = Langs Lay.
39
Wire Rope & Strand
ROTATION RESISTANT WIRE ROPES
Nominal
Diameter
Approximate Mass
H Grade SH Grade
mm kg/100m kN kN
10 41 63.9 69.2
11.2 51 80.3 87
12 59 89 96.5
12.5 63 100 108.9
14 80 125.7 136.3
16 104 163.8 177.5
18 134 208.7 225.6
19 149 231.4 251.1
20 163 256 277.5
22.4 205 321.7 348.1
24 235 356 385.4
25 255 399.1 432.5
26 276 431.5 466.8
28 325 502.1 543.3
30 373 575.7 623.7
31.5 411 634.5 687.5
32 424 655.1 709
33.5 465 717.8 777.7
35.5 522 806.1 872.8
37.5 582 899.3 973.8
40 663 1000.3 1078.7
42.5 748 1127.8 1225.8
45 838 1255.3 1372.9
Rotation Resistant 4 x 39 (SES)
Mono Track
It is well known that wire ropes tend to spin or rotate under load.
This can cause damage to the wire rope or load, work delays and
4 x 39 (SES)
a hazardous environment. To overcome this problem a 4-strand
rope with a unique construction has been designed.
These rotation resistant wire ropes are commonly used in the
construction industry to minimise rotation in single and multi-part
hoisting systems.
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40
Wire Rope & Strand
OLIVEIRA ROTATION RESISTANT WIRE ROPES
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NR Maxipact
Nominal Metallic Approximate
Grade 1960 Grade 2160 Diameter Area Mass
mm mm
2
kg/100m kN kN
13 94 81 156 164
14 109 94 182 191
15 124 107 207 217
16 143 124 239 250
17 160 139 267 280
18 178 154 297 311
19 198 171 330 347
34 x 7 20 220 190 367 385
21 247 214 412 432
22 267 231 446 467
23 295 255 492 516
24 320 277 534 560
25 353 306 581 617
26 379 327 632 663
27 407 352 679 712
28 436 377 728 763
30 507 438 846 887
32 575 497 959 1006
34 647 559 1079 1132
37 x 7 36 732 633 1221 1281
38 811 701 1352 1418
40 896 775 1495 1568
42 997 862 1664 1745
Non rotating construction with fully
compacted strands.
Available in Lang's Lay only
Can be used with a swivel
Can be used with a single fall
Also available with a Plastic
Protected Impregnated core (PPI)
Full size range available from 13mm to 52mm
NR Maxipact (34 x 7)
NR Maxipact
with optional PPI (34 x 7)
NR Maxilift
mm mm
2
kg/100m kN kN
13 90.9 79 152 159
14 105.5 91 176 187
15 122.3 106 204 214
16 138.8 120 232 243
27 x 7 17 155.5 134 260 272
18 175.0 152 292 306
19 193.9 168 324 340
20 215.7 186 360 378
21 241.7 209 403 423
22 266.5 231 445 -
23 290.4 252 485 -
24 315.9 274 527 -
25 344.6 298 575 -
26 369.9 320 617 -
27 395.5 344 660 -
28 437.1 379 729 -
31 x 7 28.6 451.8 392 754 -
30 496.0 430 828 -
32 560.5 484 935 -
34 628.0 545 1048 -
36 717.2 622 1197 -
38 797.3 693 1330 -
40 873.6 758 1457 -
42 981.7 853 1638 -
Non rotating construction with fully
compacted strands.
Can be used with a swivel
NR Maxilift
with optional PPI (27 x 7)
NR Maxilift (27 x 7)
Wire Rope & Strand
OLIVEIRA ROTATION RESISTANT WIRE ROPES
LT 24 K (24 x 7)
Minimum
Nominal Metallic Approximate Breaking Force
Diameter Area Mass Grade 1960
mm mm
2
kg/100m kN
7.2 26 23 43.7
8 33 29 55.1
9 41 37 69.6
10 53 46 88.2
11 65 57 108
12 77 68 128
13 89 78 149
24 x 7 14 104 91 173
15 119 104 198
16 137 121 230
18 177 155 295
19 194 170 324
20 212 186 354
22 259 227 432
24 311 274 519
Rotation Resistant (Low Torque)
construction with fully compacted
strands
Can be used with a swivel with a
minimum of 2 falls
Cannot be used with a single fall
LT 24 K (24 x 7)
LT 24 K (24 x 7)
with optional PPI
LT 24 K (24 x 17)
Minimum
mm mm
2
kg/100m kN
16 138 121 229
18 174 154 290
19 194 172 324
20 215 191 359
22 259 230 433
24 315 279 526
24 x 17 25.4 345 306 575
26 366 324 610
28 423 375 706
30 484 427 808
32 561 496 937
34 628 554 1047
36 699 617 1165
38 776 685 1295
Rotation Resistant (Low Torque)
construction with fully compacted
strands
minimum of 2 falls
LT 24 K (24 x 17)
LT 24 K (24 x 17)
with optional PPI
41
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OLIVEIRA WIRE ROPES
42
Wire Rope & Strand
HD 8 K
mm mm
2
kg/100m kN kN
8 33 29 - 58.0
8 x 12
9 42 36 - 73.6
10 53 45 - 92.4
11 64 55 - 112
12 75 65 125 131
13 90 77 150 157
8 x 17 14 103 89 172 180
15 120 103 200 210
16 134 116 224 234
18 172 149 287 300
19 191 165 318 334
8 x 26
20 214 185 358 375
22 257 223 430 451
24 308 266 513 538
26 359 310 600 629
28 415 358 692 725
30 479 416 800 859
32 549 475 916 961
34 620 538 1035 1086
8 x 31 36 689 595 1149 1205
38 771 666 1286 1349
40 852 736 1421 1480
42 938 812 1564 1640
44 1031 892 1721 -
46 1133 980 1891 -
48 1222 1057 2040 -
50 1327 1151 2214 -
8 x 36 52 1440 1253 2404 -
54 1565 1351 2611 -
56 1667 1442 2781 -
58 1794 1552 2993 -
60 1920 1661 3203 -
For when rotation resistant ropes
are not required
Sizes 8mm to 11 mm are an
8 x 12 construction with
compacted outer strands
Sizes 12mm and above are with
fully compacted strands
Available in Regular or Lang's Lay
Cannot be used with a swivel
HD 8 K (8 x 17)
HD 8 K (8 x 17)
with optional PPI
Towerlift
Minimum
mm mm
2
kg/100m kN
13 84.7 73 141
14 100.3 87 168
15 115.6 100 193
16 129.7 112 217
27 x 7 17 147.6 128 246
18 162.4 141 271
19 180.5 156 301
20 200.0 174 334
21 224.8 195 375
22 245.8 213 410
23 271.0 235 452
24 295.8 256 494
25 320.3 277 535
26 343.9 297 574
31 x 7
27 377.8 327 631
28 403.5 349 674
30 463.3 401 773
32 522.4 452 872
34 594.0 515 991
36 666.1 577 1111
38 738.4 640 1232
Non Rotating construction with
compacted outer strands.
minimum of 2 falls
Towerlift (27 x 7)
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43
Wire Rope & Strand
CASAR SPECIAL WIRE ROPES
Hoist rope for tower cranes, mobile cranes, electrical hoists
and other applications where rotation resistant ropes are required.
Diameter Area
Mass
Grade 1770 Grade 1960 Grade 2160
mm mm
2
kg/100m kN kN kN
16 145.6 126.7 209.4 230.6 249.1
17 163.3 142.1 235.9 257.9 280.6
18 183.7 159.8 266.9 293.9 317.5
19 204.0 177.5 297.1 329.0 352.8
20 227.5 197.9 329.3 362.2 391.7
21 249.0 216.6 362.3 396.1 430.9
22 273.9 238.3 398.5 441.4 472.0
23 299.6 260.6 431.5 471.8 513.2
24 326.8 284.3 474.3 524.3 564.1
25 348.8 303.5 512.8 567.9 609.4
26 377.9 328.8 555.0 614.9 657.4
27 410.5 357.1 598.3 654.2 711.7
28 442.5 385.0 643.7 712.9 765.6
29 473.4 411.8 690.2 754.6 821.0
30 505.4 439.7 738.1 817.4 877.9
32 579.4 504.0 843.4 930.0 1002.8
34 652.0 567.3 950.8 1045.0 1130.9
36 735.6 640.0 1070.0 1185.0 1262.3
38 815.3 709.3 1191.0 1319.0 1412.2
40 909.9 791.6 1360.0 1462.0 1560.4
42 1000.8 870.7 1455.0 1611.2 1667.4
Hoist rope for mobile cranes, electrical hoists and other applications where rotation
resistant ropes are required. Especially suitable for multiple layer spooling.
Is a rotation resistant, flexible
hoist rope with a compacted steel
core.
Is fully lubricated.
Has best-in-class breaking loads.
Has a core of unique design and
very high density, providing
excellent resistance to external
wear and crushing on drums.
Langs Lay only.
Is a rotation resistant, flexible
hoist rope made out of compacted
outer strands and a compacted
steel core.
Has an extremely high breaking
load and a very good resistance
against drum crushing.
Has a core of special design
avoiding crossovers between the
strands of the core which reduces
the danger of internal rope
destruction.
Regular Lay or Langs Lay.
Other diameters are available on request
Nominal Metallic Approximate Minimum
Diameter Area Mass Breaking Force
mm mm
2
kg/100m kN
16 149.1 126 272
19 210.2 182 382
22 281.7 246 509
25.4 370.4 326 675
26 393.5 342 705
28 456.3 394 815
30 523.9 458 934
32 596.0 521 1060
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44
Wire Rope & Strand
Hoist rope for electrical hoists and lifting devices with multiple part reeving, twin hoist
systems with left and right hand ropes, where rotation resistant ropes are not required.
Diameter Area Mass
mm mm
2
kg/100m kN kN kN
4 8.0 6.8 11.7 13.0 14.3
4.5 10.0 8.6 15.1 16.7 18.4
5 12.3 10.6 19.0 21.1 23.2
5.5 14.8 12.8 23.6 26.1 28.8
6 18.2 15.7 28.5 31.5 34.7
6.5 22.4 19.2 34.2 37.9 41.8
7 24.9 21.4 38.5 42.6 47.0
7.5 28.5 24.5 44.8 49.6 54.6
8 33.0 28.4 49.6 55.0 60.6
8.5 37.1 31.9 53.0 58.7 64.6
9 41.4 35.6 65.0 72.0 79.3
10 50.2 43.2 75.8 84.0 92.5
11 60.7 52.2 92.9 102.9 113.3
12 72.3 62.2 111.3 123.2 135.8
13 84.8 72.9 129.4 143.3 157.9
14 98.4 84.6 150.3 166.4 183.4
15 112.9 97.1 175.7 194.6 214.5
16 128.5 110.5 196.1 217.1 239.3
Is an 8 strand rope in parallel lay
construction made out of
conventional strands.
Is very flexible.
Has a high breaking load.
Alphalift should NOT be used with
a swivel.
Regular Lay only.
Hoist rope for electrical hoists and lifting devices with multiple part reeving and twin hoist
systems with left and right hand ropes, where rotation resistant ropes are not required.
Diameter Area Mass
mm mm
2
kg/100m kN kN kN
8 36.9 31.4 56.1 62.1 68.4
9 47.3 40.2 71.8 79.5 87.6
10 57.3 48.7 87.9 97.3 107.2
11 68.6 58.3 106.9 118.4 130.5
12 83.7 71.2 126.5 140.1 154.4
13 97.4 82.8 148.7 164.6 181.4
14 113.2 96.2 172.3 190.8 210.3
15 130.0 110.5 197.9 219.1 241.5
16 147.7 125.6 226.3 250.6 276.2
17 167.7 142.5 253.4 280.5 309.2
18 187.3 159.2 286.4 317.1 349.5
19 206.9 175.8 318.5 352.7 388.6
20 233.8 198.7 351.6 389.4 429.1
21 254.3 216.2 390.1 432.0 476.1
22 275.9 234.5 426.3 472.0 520.2
23 302.9 257.5 465.2 515.2 567.7
24 333.5 283.5 507.3 561.8 619.1
25 362.3 307.9 549.1 608.0 670.1
Is a 10 strand rope in parallel lay
construction made out of
compacted strands.
Is very flexible.
Has an extremely high breaking
load.
Betalift should NOT be used with
a swivel.
Betalift is NOT suitable for use on
overhead travelling cranes.
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45
Wire Rope & Strand
Pendant rope for tower cranes, mobile cranes, grabs, suspended structures etc, when
high breaking load is required.
Diameter Area Mass
mm mm
2
kg/100m kN kN kN
16 147.2 123.7 218.4 241.9 266.5
17 166.1 139.6 248.1 274.8 302.8
18 185.3 155.7 278.5 308.4 339.8
19 207.5 174.3 307.3 340.3 375.0
20 229.6 192.9 342.3 379.0 417.7
21 251.1 211.0 375.0 415.2 457.6
22 278.4 233.9 414.4 458.9 505.7
23 304.2 255.5 453.0 501.7 552.8
24 330.5 277.6 490.2 542.8 598.2
25 357.3 300.1 532.7 589.9 650.1
26 391.6 328.9 574.4 636.0 700.9
27 424.1 356.2 624.8 691.8 762.4
28 452.1 379.8 670.4 742.4 818.1
29 486.5 408.6 721.5 799.0 880.5
30 519.5 436.4 772.4 855.3 942.6
31 560.0 470.4 822.9 911.3 1004.3
32 593.4 498.4 874.4 968.2 1067.0
33 634.1 532.6 930.3 1030.2 1135.3
34 666.8 560.1 988.9 1095.0 1206.8
36 747.4 627.8 1101.7 1220.0 1344.5
38 836.5 702.7 1230.3 1362.4 1501.4
construction made out of compacted
strands.
Is very flexible.
Has an extremely high breaking load.
Turbolift should NOT be used with a
swivel.
Boom hoist rope for mobile cranes and grabs, hoist rope for container cranes,
floating cranes etc. In multiple part reeving for smaller lifting height.
mm mm
2
kg/100m kN kN
10 53.0 46.1 88.7 114.5
11 63.8 55.5 107.5 137.8
12 75.7 65.8 127.4 163.5
13 89.5 77.8 151.3 193.3
14 103.1 89.7 174.8 222.7
15 119.0 103.5 202.7 257.0
16 135.5 117.9 229.4 292.7
18 168.9 146.9 288.2 364.8
19 189.0 164.4 323.5 408.2
20 210.7 183.3 355.5 455.1
22 251.9 219.1 433.7 544.1
24 299.5 260.6 514.3 646.9
26 352.4 306.6 607.8 761.2
28 405.2 352.5 697.3 875.2
32 533.7 464.3 911.0 1152.8
36 670.5 583.4 1129.2 1448.3
38 753.1 655.2 1262.6 1626.7
40 837.9 729.0 1395.5 1809.9
42 914.7 795.8 1543.8 1975.8
44 1010.7 879.3 1687.4 2183.1
48 1201.1 1044.9 2018.0 2594.4
Is an 8 strand rope made out of
Has a plastic layer between the
steel core and the outer strands
giving the rope a high structural
stability. The plastic layer also
assists in avoiding internal rope
destruction and protecting the
core against corrosive
environments.
Has a very high breaking load
and good resistance against drum
crushing.
Turboplast should NOT be used
with a swivel.
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46
Wire Rope & Strand
mm mm
2
kg/100m kN kN
8 30.6 27.3 47.2 52.3
9 38.8 34.5 60.0 66.4
10 48.8 43.4 74.0 82.0
11 59.6 53.0 88.5 98.0
12 68.3 60.8 106.6 118.0
13 81.7 72.7 125.5 138.9
14 95.1 84.6 144.6 160.1
16 125.4 111.6 189.0 209.3
18 157.7 140.4 239.8 265.5
19 178.6 159.0 264.5 292.9
20 198.2 176.4 295.3 327.0
22 245.4 218.4 356.2 394.5
24 280.0 249.2 423.4 468.9
26 326.8 290.8 504.7 558.8
28 375.2 333.9 576.2 638.0
30 435.8 387.9 666.3 737.8
32 495.4 440.9 756.7 837.9
34 556.8 495.6 853.7 945.3
36 626.5 557.6 952.4 1054.7
38 705.1 627.5 1071.1 1186.0
40 770.1 685.3 1181.1 1307.9
42 859.3 764.8 1308.5 1448.9
44 942.5 838.8 1430.1 1583.7
Hoist rope for container cranes, floating cranes, harbour cranes, portal cranes etc.
In multiple reeving for smaller lifting heights. Holding rope and closing rope for grabs.
Is an 8 strand rope made out of
conventional strands.
environments.
Stratoplast should NOT be used
with a swivel.
Hoist rope for electrical hoists and lifting devices with multiple part reeving, where a
rotation resistant rope is not needed due to great lifting heights, low number of falls or
non guided loads. High breaking load.
Diameter Area Mass
mm mm
2
kg/100m kN kN kN
6 19.0 16.1 29.5 32.7 35.2
7 26.3 22.4 41.0 45.4 48.9
8 34.8 29.6 54.2 60.0 64.6
9 44.1 37.4 68.6 76.0 81.8
10 54.2 46.1 84.5 93.5 100.7
11 65.7 55.9 102.4 113.4 122.1
12 79.6 67.6 123.9 137.2 147.8
13 92.6 78.7 144.2 159.7 172.0
14 107.1 91.1 166.9 184.8 199.0
15 123.1 104.6 191.7 212.3 228.6
16 139.4 118.5 217.1 240.4 258.9
17 158.5 134.7 246.8 273.3 294.4
18 176.4 150.0 274.8 304.3 327.7
19 198.3 168.6 308.9 342.0 368.4
20 220.1 187.1 342.9 379.7 408.9
21 240.4 204.3 374.5 414.7 446.6
22 264.8 225.1 412.5 456.8 491.9
23 299.8 254.8 467.0 517.1 556.9
24 325.7 276.9 507.3 561.8 605.0
25 353.1 300.1 550.0 609.0 655.9
26 383.9 326.3 598.0 662.2 713.1
construction made out of compacted
outer strands.
Has a plastic layer between the steel
core and the outer strands.
Has a very high breaking load.
Paraplast should NOT be used with a
swivel.
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47
Wire Rope & Strand
Boom hoist rope for mobile cranes and grabs, hoist rope for container cranes, floating
cranes, portal cranes etc. In multiple part reeving for smaller lifting heights.
Diameter Area Mass
mm mm
2
kg/100m kN kN kN
16 137.0 117.8 205.7 226.5 248.1
17 156.6 134.7 236.2 260.0 284.8
18 176.0 151.4 266.0 292.8 320.8
19 194.0 166.8 291.0 320.4 351.0
20 215.4 185.3 326.5 359.4 393.8
21 237.7 204.4 360.4 396.8 434.7
22 260.0 223.6 392.6 432.2 473.5
23 286.4 246.3 429.7 473.0 518.2
24 312.2 268.5 470.0 517.4 566.9
25 336.5 289.4 516.0 585.0 613.4
26 363.7 312.8 549.5 604.9 662.7
27 390.7 336.0 587.6 646.8 708.6
28 420.3 361.4 654.0 720.0 822.0
29 445.8 383.4 670.2 737.8 808.3
30 480.5 413.2 723.8 796.8 872.9
31 509.3 438.0 769.1 846.7 927.5
32 560.3 481.8 841.0 925.9 1014.3
33 585.1 503.2 879.7 968.4 1060.9
34 630.2 542.0 950.2 1046.0 1145.9
36 704.1 605.5 1065.1 1172.5 1284.5
38 774.3 665.9 1165.1 1282.5 1405.0
40 861.9 741.2 1298.3 1429.3 1565.8
42 949.8 816.8 1436.7 1581.5 1732.6
44 1038.3 892.9 1567.8 1725.8 1890.7
Is a 10 strand rope made out of
environments.
Has a very high breaking load
and good resistance against drum
crushing.
Superplast 8 should NOT be used
with a swivel.
mm mm
2
kg/100m kN kN
12 81.8 72.0 118.2 130.8
13 97.2 85.6 139.0 152.7
14 111.7 98.3 161.7 179.1
15 127.6 112.3 184.5 204.0
16 147.0 129.4 209.4 230.6
18 186.7 164.3 266.9 293.9
19 207.2 182.4 297.1 329.0
20 227.7 200.4 329.3 362.2
22 276.2 243.0 398.5 441.4
24 326.3 287.2 474.3 524.3
25 358.3 315.3 512.8 567.9
26 389.2 342.5 555.0 614.9
28 446.6 393.0 643.7 712.9
30 514.4 452.7 738.1 817.4
32 584.9 514.7 843.4 930.0
34 656.9 578.1 950.8 1045.0
36 738.6 650.0 1070.0 1185.0
38 826.4 727.3 1191.0 1319.0
40 926.6 815.4 1360.0 1462.0
42 1013.4 891.8 1455.0 1611.2
Hoist rope for deck cranes, offshore cranes and other applications in the marine
environment, where rotation resistant ropes are required.
Is a rotation resistant hoist rope
made out of compacted strands.
environments.
Has a high breaking load and
good resistance against drum
crushing.
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Caculating the MBL in kN for a given rope diameter and a given tensile strength
MBL 1770 [kN] = 1.77 FF SF II (d[mm])
2
/ 4 or MBL 1770 [kN] = BLF 1770 (d[mm])
2
MBL 1960 [kN] = 1.96 FF SF II (d[mm])
2
/ 4 or MBL 1960 [kN] = BLF 1960 (d[mm])
2
Caculating a minimum rope diameter in mm for a given MBL and a given tensile strength
dmin 1770 [mm] = 4 MBL 1770 [kN] / (FF SF II 1.77) or
dmin 1770 [mm] = MBL 1770 [kN] / BLF 1770
dmin 1960 [mm] = 4 MBL 1960 [kN] / (FF SF II 1.96) or
dmin 1960 [mm] = MBL 1960 [kN] / BLF 1960
Caculating the outer wire diameter of the rope for a given rope diameter
= DF d
Caculating the rope mass for a given rope diameter
Rope mass [kg/m] = MF d
2
48
Wire Rope & Strand
CASAR SPECIAL MINING WIRE ROPES
Hoisting ropes in underground mining operations play a
vital role in the production cycle, not only to hoist
minerals but also to transport men and materials safely
and efficiently. Winding ropes are therefore clearly
safety critical throughout their operating life.
Casar specialises in this technology and is a world
leader in the manufacture of sophisticated wire rope
products for a broad range of lifting applications. In
Australia Casar has established a strong position in the
mining industry.
Quality and high tech design
Every effort is made to maintain and improve the
quality of Casar wire rope products for the mining
industry. Careful attention to quality and engineering
design details ensures that a Casar rope will routinely
outperform conventional six strand and rotation
resistant ropes. Special features of Casar mining ropes
include galvanising, compacted strands and a plastic
layer between steel core and the outer strands. The
internal plastic layer stabilises the construction and
experience has shown that Casar winding ropes are less
prone to torsional distortions like waviness and slack
outer strands.
Reliability and value for money
Casar Special Mining Ropes offer benefits such as
increased reliability of the hoisting system and reduced
downtime due to less servicing and fewer rope changes.
The higher breaking strengths of Casar Special Mining
Ropes allow for an increase of payload for the same
diameter. The increased capacity of the shaft will lead to
increased profitability of the mine.
How to select the most suitable design
This catalogue sets out a range of different mine
hoisting applications that Casar ropes can be used for
and identifies which rope construction should be used in
particular circumstances.
In order to assist you in rope selection, tables that
follow give factors that can be used to calculate for
example the rope minimum breaking loads (MBL) and
masses for a given rope diameter. This allows for
automated rope diameter selection given basic winding
system parameters. The detailed specifications of
various Casar mining ropes are given in 1mm diameter
increments, but with rope factors it is also possible to
calculate the rope specifications for intermediate
diameters, e.g. 42.5mm or 53.5mm, which Casar can
manufacture on request.
Tailor made rope construction
Within a particular rope construction family Casar are
able to deliver a wide range of fill factors and strength
to mass ratios. An example of this is the comparison
between Starplast M (with no compacted strands) and
Starplast VM (with fully compacted strands). By varying
the degree of strand compaction, Casar can
manufacture ropes with every metallic cross sectional
area, any breaking strength or any specific weight
between the figures of Starplast M and Starplast VM.
We are therefore able to adapt the rope specifications to
the exact requirements of your shaft. This is the core
competence of Casar.
Fill Spin Weight Wir Dia. Cross MBL MBL Mass
Factor Factor Factor Factor Section Factor Factor Factor
Factor
FF SF WF DF CF BLF 1770 BLF 1960 MF
[-] [-] [-] [-] [-] [-] [-] [-]
0.6590 0.68459 0.8700 0.0630 0.5176 0.7749 0.8581 0.00450
0.6517 0.8372 0.8700 0.0748 0.5119 0.7585 0.8399 0.00445
0.6571 0.8415 0.8900 0.0546 0.5161 0.7441 0.8239 0.00459
0.6746 0.8200 0.9100 0.0545 0.5298 0.7690 0.8515 0.00482
0.67238 0.7938 0.8800 0.0500 0.5685 0.7987 0.8845 0.00500
Casar Mining Rope Factors
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49
Wire Rope & Strand
TYPICAL MINE WINDERS
Koepe friction winders are either installed in a
ground or tower mounted configuration. The number
of head and tail rope pairs can vary between 1 and 10
depending on the hoisting duty of the winder. In general
the combined unit mass of the head and tail ropes are
equal to ensure balanced winding. Single layer rope
constructions are widely used for shallower shaft Koepe
winders, but for depths exceeding 900 m it is critical
that non-spin or rotation resistance constructions are
used. For free looping tail ropes, non-spin ropes with
swivels under both conveyances are recommended.
For multi-rope winders, rope load balancing and equal
driving sheave/drum circumferences are critical to
ensure good rope life.
Double drum and BMR winders are almost always
ground mounted. For these winders, single layer rope
constructions can be used even in very deep shafts in
even in excess of 3000 m. However, in such cases the
lay length changes from the manufactured state would
be significant. Rope load balancing and accurate drum
spooling between rope pairs are critical on BMR
winders. Ropes which offer high drum crushing
resistance are preferred for these applications as the
ropes normally deteriorate first at the _ turn and layer
crossovers on parrellel grooved drums. In cases where
the ropes are free to rotate during the winding cycle
(e.g. kibble winders) or where the shaft uses rope
guides, non-spin or rotation resistant constructions
are used.
Ground mounted
Koepe friction
winder single rope
Ground mounted
Koepe friction winder
multi-rope
Tower mounted
single-rope no
deflection sheave
Tower mounted
multi-rope no
deflection sheaves
Tower mounted Koepe
friction winder single-
rope with deflection
sheave
Tower mounted
multi-rope with
deflection sheaves
Double drum
winder
Blair mult-rope
(BMR) winder
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50
Wire Rope & Strand
MINING WIRE ROPES
Is an 8-strand rope made out of compacted outer strands.
Has a plastic layer between the steel core and the outer strands, giving the rope
a high structural stability, avoiding internal rope destruction and protecting the
core against corrosive environments.
Has a very high breaking load and a good resistance against drum crushing.
Duroplast should NOT be used with a swivel.
Is an 8 strand rope made out of compacted outer strands.
Has a plastic layer between the steel core and the outer strands giving the rope
a high structural stability. The plastic layer also assists in avoiding internal rope
destruction and protecting the core against corrosive environments.
Has a very high breaking load and good resistance against drum crushing.
Turboplast should NOT be used with a swivel.
Nominal Diameter Metallic Area Approximate Mass
mm mm
2
kg/100m kN kN
28 401.3 349 594.7 658.5
30 460.7 401 682.6 755.9
32 524.1 456 776.7 860.1
34 591.7 515 876.8 970.9
36 663.4 577 983.0 1088.5
38 739.1 643 1095.3 1212.8
40 819.0 712 1213.6 1343.9
42 902.9 786 1338.0 1481.6
44 990.9 862 1468.4 1626.1
46 1083.1 942 1605.0 1777.3
48 1179.3 1026 1747.6 1935.2
50 1279.6 1113 1896.2 2099.8
mm mm
2
kg/100m kN kN
32 530.0 461 793.5 878.7
33 563.7 490 843.9 934.5
34 598.3 521 895.8 992.0
36 670.8 584 1004.3 1112.1
38 747.4 650 1119.0 1239.1
40 828.1 720 1239.9 1373.0
42 913.0 794 1367.0 1513.7
44 1002.1 872 1500.3 1661.3
46 1095.2 953 1639.8 1815.8
48 1192.5 1038 1785.5 1977.1
50 1294.0 1126 1937.3 2145.3
52 1399.6 1218 2095.4 2320.4
54 1509.3 1313 2259.7 2502.3
56 1623.2 1412 2430.2 2691.1
58 1741.2 1515 2606.9 2886.7
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Wire Rope & Strand
MINING WIRE ROPES
Is a rotation resistant hoist rope made out of compacted outer strands.
a high structural stability, avoiding internal rope destruction and protecting the core
against corrosive environments.
Has a high breaking load and good resistance against drum crushing.
mm mm
2
kg/100m kN kN
30 464.5 413 669.7 741.5
32 528.5 470 761.9 843.7
34 596.6 531 860.1 952.5
36 668.9 595 964.3 1067.8
38 745.3 663 1074.4 1189.8
40 825.8 735 1190.5 1318.3
42 910.4 810 1312.5 1453.4
44 999.2 889 1440.5 1595.1
46 1092.1 972 1574.4 1743.5
48 1189.1 1058 1714.3 1898.4
50 1290.3 1148 1860.2 2059.8
52 1395.6 1242 2012.0 2227.9
54 1505.0 1339 2169.7 2402.6
Is a rotation resistant hoist rope made out of compacted strands.
mm mm
2
kg/100m kN kN
30 476.8 434 692.1 766.4
32 542.5 494 787.5 872.0
34 612.5 557 889.0 984.4
36 686.7 625 996.6 1103.6
38 765.1 696 1110.4 1229.6
40 847.7 771 1230.4 1362.5
42 934.6 851 1356.5 1502.1
44 1025.8 933 1488.8 1648.6
46 1121.1 1020 1627.2 1801.9
48 1220.7 1111 1771.8 1962.0
50 1324.6 1205 1922.5 2128.9
52 1432.7 1304 2079.4 2302.6
54 1545.0 1406 2242.4 2483.1
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Wire Rope & Strand
MINING WIRE ROPES
mm mm
2
kg/100m kN kN
20 227.4 200 319.5 353.8
22 275.1 242 386.6 428.1
24 327.4 288 460.1 509.4
25 355.3 313 499.2 552.8
26 384.3 338 539.9 597.9
28 445.7 392 626.2 693.4
30 511.6 450 718.8 796.0
32 582.1 512 817.9 905.7
34 657.2 578 923.3 1022.4
36 736.7 648 1035.1 1146.3
38 820.9 722 1153.3 1277.2
40 909.6 800 1277.9 1415.1
42 1002.8 882 1408.9 1560.2
Is a rotation resistant hoist rope made out of compacted strands.
Has a plastic layer between the steel core and the outer strands giving the rope
a high structural stability. The plastic layer also assists in avoiding internal rope
destruction and protecting the core against corrosive environments.
Is a 12 strand rope made out of compacted strands.
Langs Lay only.
mm mm
2
kg/100m kN kN
30 465.1 414 683.3 756.6
32 529.2 471 777.4 860.9
34 597.4 532 877.7 971.9
36 669.8 596 983.9 1089.6
38 746.3 664 1096.3 1214.0
40 826.9 736 1214.8 1345.1
42 921.1 811 1371.0 1500.9
44 1000.5 891 1469.8 1627.6
46 1093.5 973 1606.5 1779.0
48 1190.7 1060 1749.2 1937.0
50 1292.0 1150 1898.0 2101.8
52 1397.4 1244 2052.9 2273.3
54 1507.0 1341 2213.9 2451.5
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Wire Rope & Strand
MINING WIRE ROPES
Nominal Approximate Mass Minimum
Diameter Breaking Force
6 x 19 to 6 x 25 6 x 27 to 6 x 28 Grade 1770
mm kg/100m kg/100m kN
16 105 164
18 132 206
20 164 255
22 200 312
24 237 369
26 276 432
28 320 500
32 420 655
36 530 825
40 653 637 1020
44 800 782 1250
48 945 923 1475
52 1080 1730
56 1250 2000
60 1440 2300
Triangular Strand
6x8 to 17 Outer Wires - Fibre Core
6x19 (8/10/)
6x22 (9/12/)
6x23 (10/12/)
6x25 (12/12/)
6x27 or 28 (14 OR 15/)
6 x 12/12/3TS
6 x 10/12/3TS
6 x 15/12/9TS
Full Locked Coil Winding Ropes
Nominal Approximate Nominal
Diameter Mass Breaking
Load
mm kgs/m kgs
32 5.78 88,800
33 6.14 94,400
35 6.91 106,000
37 7.72 119,000
38 8.14 125,000
40 9.02 139,000
41 9.48 146,000
43 10.4 160,000
44 10.9 168,000
46 11.9 184,000
48 13 200,000
49 13.5 208,000
51 14.7 226,000
53 15.8 244,000
54 16.4 253,000
56 17.7 272,000
57 18.3 282,000
59 19.6 298,000
61 21 319,000
62 21.7 329,000
64 23.1 351,000
Up to 57mm Nominal B.L. x 1.197 = Aggregate B.L.
Over 57mm Nominal B.L. x 1.212 = Aggregate B.L.
These ropes conform to N.C.B. Spec. 186
Half Locked Coil Guide Ropes
Nominal Approximate Nominal
Diameter Mass Breaking
Load
mm kgs/m kgs
29 4.63 42,900
32 5.63 52,200
35 6.74 62,500
38 7.94 73,900
41 9.25 85,700
45 11.1 103,000
48 12.7 117,000
51 14.3 133,000
Nominal Breaking Load x 1.082 = Aggregate Breaking Load
These ropes conform to N.C.B. Spec 388
Full Locked Coil Half Locked Coil
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Wire Rope & Strand
AMERICAN WIRE ROPES
Hoist and Luffing Ropes for Lattice Boom Cranes (American Manufacture)
6 x 25 FW or 6 x 31 WS IWRC
Nominal Diameter Approximate Mass Nominal Strength in kN
Inches mm kg/100m Extra Extra Improved Extra Improved
Plough Steel Plough Steel
5/8 15.9 107 202 183
3/4 19.1 155 288 262
7/8 22.2 211 390 354
1 25.4 275 506 460
1
1
/8 28.6 348 636 578
1
1
/4 31.8 430 782 711
Nominal Strength is an American term.
Minimum Breaking Force is 2 1/2 % lower than the Nominal Strength.
OIL INDUSTRY WIRE ROPES
Drilling Lines 6 x 19 SEALE
Nominal Diameter Approximate Mass
IPS Grade EIPS Grade
Inches mm kg/100m lb/ft kN 1000 lb kN 1000 lb
7/8 22 211 1.42 308 69.2 354 76.6
1 26 275 1.85 399 89.8 460 103.4
1
1
/8 29 348 2.34 503 113 578 130
1
1
/4 32 430 2.89 617 138.8 711 159.8
1
3
/8 35 521 3.5 743 167 854 192
1
1
/2 38 619 4.16 880 197.8 1014 228
1
5
/8 42 726 4.88 1023 230 1174 264
1
3
/4 45 844 5.67 1183 266 1361 306
Alternate Lay for Luffing Ropes Right Hand Ordinary Lay for Hoist Ropes
Right Hand Ordinary Lay, Ungalvanised
IWRC to API Spec 9A
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55
Wire Rope & Strand
ONESTEEL FISHING WIRE ROPES
The OneSteel range of fishing ropes are characterised by the very
high levels of galvanising achieved in the high strength 1770 MPa
grade wire. Galvanising levels at 25% above Class A (now Class
W10Z to AS/NZS 4534) are targeted in manufacture.
OneSteel refer to these as marine grade galvanised wire products.
This along with the special treatment that ropes receive in
manufacture to prevent nicking and marking the zinc ensures
a product that is highly resistant to corrosion. The product is
popular for warps and bridles in trawling.
Rope cores are lubricated laid polypropylene for best results.
Also the rope strands are lubricated in manufacture using a wax
base lubricant with extreme pressure additives and corrosion
inhibitors. In accord with occupational health and environmental
principles the use of bitumastic based lubricants has been
discontinued.
Note:
Information on other rope sizes, constructions and compak
fishing ropes are available on request.
There is a limit to the wire size available with the marine grade
levels of galvanising in high strength 1770 MPa grade. In larger
sizes these may need to be of 1570 grade tensile wire to obtain
the same high levels of galvanising.
KISWIRE FISHING WIRE ROPES
Diameter Mass Load 1770
mm kgs/100m kN
12 54.5 84.3
14 70.7 113.7
16 92.9 149.1
18 119.5 189.0
20 144.8 234.5
22 173.2 283.0
Galvanised - 6x9/9/1 Fibrillated Poly Core RHOL
mm kgs/100m kN
20 163.8 252.0
22 198.3 305.0
24 240.9 363.0
Galvanised - 6x9/9/1 Wire Rope Core RHOL
mm kgs/100m kN
8 24.4 37.4
9 30.8 47.3
10 38.0 58.4
11 46.0 70.7
12 54.7 84.1
14 74.5 114.0
16 97.3 149.0
18 123.0 189.0
20 152.0 234.0
Galvanised - 6x9/9/1 Poly Core RHOL
mm kgs/100m kN
10 41.8 63.1
11 50.6 76.3
12 60.2 90.8
14 82.0 124.0
16 107.0 161.0
18 135.0 204.0
20 167.0 252.0
Galvanised - 6x9/9/1 Wire Rope Core RHOL
1770 Grade Wire is standard, 1570 may be available upon request.
Kiswire fishing ropes are available in both A & B galvanising and
ALUMAR. ALUMAR fishing ropes have 5% aluminium in the zinc
galvanising mix with the inclusion of the aluminium ensuring
superior resistance to corrosion and a longer working life.
ALUMAR ropes have performed extremely well in laboratory
Salt Spray (NaCI) and SO2 Atmosphere humidity tests.
These test indicate that ALUMAR technology improves corrosion
resistance by approximately 3 times. ALUMAR fishing ropes are the
end product of many years of testing in regard to the correct level
of aluminium to be included in the zinc mix. The level of 5%
provides the optimum balance of corrosion resistance, durability
and working life.
1770 Grade Wire is standard, 1570 may be available upon request.
AB Galvanised fishing ropes also available upon requests.
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56
Wire Rope & Strand
STAINLESS STEEL WIRE ROPE
7 x 19
7x19 is the most common and versatile construction of stainless
steel wire rope. It consists of 7 strands each with 19 wires and
is the most flexible and the easiest construction to work with
particularly where the rope needs to turn corners, change
directions or where ferrule secured thimble eyes and wire rope
grips are used. 7x19 can be used in either fixed rigging or for
limited working rope applications such as on a boat winch.
7 x 7
7x7 consists of 7 strands each with 7 wires and is not as flexible
as 7x19. 7x7 is an excellent choice for fixed rigging applications
such as balustrading and safety barrier rails. Although 7x7 is
stiffer than 7x19 it is still capable of limited angles and can be
used with thimble eyes or swage fittings. 7x7 has very limited
applications as a running or working rope.
1 x 19
1x19 consists of a single strand with 19 wires. 1x19 is very stiff
and is suitable for fixed "straight line" rigging only such as mast
stays, guy ropes and structural applications. It cannot be used
with thimble eyes and is best utilised and looks very effective with
machine swaged end fittings.
There are three common constructions of stainless steel wire rope
used in fixed rigging applications. Nobles stock stainless steel wire
rope mainly in 316 grade but some 304 grade product is
available.
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Wire Rope & Strand
Nominal Diameter
Approximate Minimum
Stock Code Grade & Construction
mm
Mass Breaking Load
kg/100m kg
AS0201196 2 2.1 340
AS0301196 3 4.6 760
AS0401196 4 8.2 1,340
AS0501196 5 12.8 2,000
AS0601196 6 18.4 2,880
AS0801196 316 Grade 1x19 8 32.0 4,810
AS1001196 316 Grade 1x19 10 51.0 8,400
AS1101196 11 73.4 12,092
AS1301196 13 86.2 13,991
AS1401196 14 100.0 16,189
AS1601196 16 131.0 20,386
AS0207076 2 1.7 232
AS0307076 3 3.7 520
AS0407076 4 6.7 1,000
AS0507076 5 10.3 1,620
AS0607076 6 14.9 2,060
AS0807076 316 Grade 7x7 8 26.2 3,670
AS1007076 10 41.0 5,750
AS1107076 11 59.0 8,594
AS1307076 13 80.4 11,492
AS1407076 14 105.0 14,690
AS1607076 16 133.0 18,587
AS0207194 2 1.7 295
AS0307194 3 3.7 540
AS0407194 4 6.7 1,089
AS0507194 5 10.3 1,820
AS0607194 6 14.9 2,480
AS0807194 304 Grade 7x19 8 25.8 4,082
AS1007194 10 40.0 5,980
AS1107194 11 69.3 12,591
AS1307194 13 80.4 16,089
AS1407194 14 105.0 20,386
AS1607194 16 133.0 24,883
AS0207196 2 1.7 212
AS0307196 3 3.7 780
AS0407196 4 6.7 910
AS0507196 5 10.3 1,490
AS0607196 6 14.9 1,910
AS0807196 316 Grade 7x19 8 25.8 3,450
AS1007196 10 40.0 5,310
AS1107196 11 69.3 10,093
AS1307196 13 80.4 11,692
AS1407196 14 105.0 14,461
AS1607196 16 133.0 18,088
316 Grade ropes are preferred but 304 Grade is also usually available. Please nominate grade required at time of order.
White is the standard colour for PVC covered ropes but other colours may be available.
Reels are available in 305m, 500m or 1000m lengths.
Other constructions and sizes available on request.
STAINLESS STEEL WIRE ROPE
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Wire Rope & Strand
GALVANISED STRAND
Nominal Construction
Minimum Breaking Force, kN
Nominal Nominal
Diameter (abbreviated 380 820 1320 Mass Area
mm form) Grade Grade Grade kg/100m mm
2
4.2 1 x 3 11.7 7.6 9.43
5.7 1 x 3 21.4 13.4 17.17
2.5 1 x 7 1.4 3 3.2 3.97
3 1 x 7 2 4.3 4.4 5.56
3.5 1 x 7 2.8 6.2 9.9 6.3 7.92
4 1 x 7 3.5 7.6 12.2 8.7 10.8
5 1 x 7 5.4 11.7 18.8 12.8 15.9
6 1 x 7 7.9 17 27.4 17.7 26.6
7 1 x 7 10.7 23.1 37.2 25.5 31.7
8 1 x 7 14.6 30.2 48.6 32.3 40.1
9 1 x 7 17.8 38.4 61.8 39.8 49.5
10 1 x 7 21.9 47.3 76.1 51.2 63.6
11 1 x 7 26.6 57.4 92.4 60.6 75.3
12 1 x 7 31.6 68.2 109 75.4 88
10 1 x 19 46 74 50.4 60.3
12 1 x 19 63.2 101 72.6 87.2
14 1 x 19 86 137 98.8 119
16 1 x 19 182 129 144
Galvanised Strand is commonly used for guys on communication
towers, broadcasting towers, power poles and as load carrying
members in building structures.
Characteristics
Galvanised Strand is less flexible than wire rope, it is stronger
and has a higher modulus of elasticity. It is furnished with Class A
galvanised finish.
1 x 7 1 x 19
Galvanised Strand for
General Purpose Applications
1 x 37 Galvanised Strand
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59
Wire Rope & Strand
GALVANISED STRAND
Nominal Construction* Minimum Breaking Nominal Nominal Young
diameter (abbreviated form) Force Grade 1570 Mass Area Modulus**
mm kN kg/100m mm2 GPa
10 1 x 19 88 50.4 60.3 166
12 1 x 19 126 72.6 87.2 166
13 1 x 19 144 82.7 98.4 166
14 1 x 19 172 98.8 119 166
16 1 x 19 210 129 145 166
18 1 x 19 265 163 183 166
20 1 x 19 368 212 254 166
22 1 x 19 442 255 305 166
24 1 x 19 518 299 357 166
26 1 x 37 580 348 400 166
28 1 x 37 713 427 491 166
32 1 x 37 897 538 618 166
36 1 x 61 1150 687 789 166
40 1 x 61 1420 848 975 166
44 1 x 61 1800 1080 1240 166
48 1 x 91 2050 1260 1450 166
52 1 x 91 2400 1480 1700 166
54 1 x 91 2610 1610 1850 166
58 1 x 127 2850 1760 2020 158
64 1 x 127 3640 2250 2580 158
70 1 x 169 4450 2750 3150 158
76 1 x 169 4850 2990 3430 158
82 1 x 217 5560 3520 4050 158
86 1 x 217 6040 3830 4400 158
90 1 x 271 6940 4400 5050 158
95 1 x 271 7550 4790 5500 158
102 1 x 271 8850 5610 6440 158
* For strand 70mm diameter and greater, the number of wires may vary from that shown in the table provided that the other physical properties are in
accordance with those shown in the table.
** The values shown are indicative of values obtained after removal of constructional stretch. If a precise value is required, it should be determined by experiment.
Galvanised Strand for Guying Purposes
1 x 19 1 x 61 1 x 37
TO AS 2841
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Wire Rope & Strand
WIRE ROPE LUBRICANTS
Nobles Wire Rope Lubricant
Suitable For:
Running and standing wire ropes in Mining, Marine, Oil & Gas,
Construction and Industrial environments
Benefits:
An exceptional wire rope lubricant formulated with anti-drip wax
polymers to reduce drip and fling off.
Fortified with penetrating anti-rust and lubricating additives to provide
complete internal and external protection.
Easy to apply by brush, drip or spray can.
Available in 400g spray can, 4L and 20L pails, or economical 205L drums.
Stock Codes:
DRTSWR004N - 400g Spray Can
DRTSWR040N - 4L Pail
DRTSWR020N - 20L Pail
DRTSWR205N - 205L Drum
Nobles HD Wire Rope Grease
Suitable For:
Suspension ropes, running and standing ropes in extreme environments,
and also suitable for sheaves.
Benefits:
Contains no bitumen or wax
Exceptional corrosion resistance
Formulated with extreme anti-wear and pressure additives, combined
with unique penetrating oils to retard internal fretting
Available in 20kg pails or 180kg drums (supplied in 205L drum)
Stock Codes:
DRTHDNB020N - 20kg Pail
DRTHDNB205N - 205L Drum
Nobles EF Wire Rope Lubricant
Suitable For:
All wire ropes, sheaves and drums where environmentally friendly lubricants
are required. Available in 220 Grade for cool conditions or smaller diameter
ropes, and 460 Grade for hot conditions or large diameter ropes.
Benefits:
Contains all the performance of Nobles standard Wire Rope Lubricant,
while minimising the impact on the environment.
Specially formulated from ultra pure mineral oils of pristine quality
High resistance to oxidation
Can be used in food processing environments
Available in 20L pails or 205L drums
Stock Codes:
DRTEF220020N - 20L Pail 220 Grade
DRTEF220205N - 205L Drum 220 Grade
DRTEF460020N - 20L Pail 460 Grade
DRTEF460205N - 205L Drum 460 Grade
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Wire Rope & Strand
WIRE ROPE LUBRICANTS
Lanotec
Where environmental considerations are paramount Nobles
recommends the use of Lanotec sealants and lubricants. Nobles
are a leading stockist and distributor of Lanotec products and like
Nobles, Lanotec is a 100% Australian-owned and operated
company. By using Lanotecs naturally based products Nobles can
provide lubrication, corrosion protection and degreasing solutions
that are friendly for the environment and safe to use.
Lanotec Heavy Duty Liquid Lanolin
Lubrication and corrosion protection of wire ropes where
spraying is necessary
Penetrates to the core of the rope, providing long lasting
protection
Perfect for mobile cranes where lubrication needs to be
applied while rope is still on the spool
Non-fling and non-webbing
Suitable for all environments, including mining and marine
Stock Codes:
DRLHD21400 - 400g Spray Can
DRLHD21750 - 750ml Spray Bottle
DRLHD2105 - 5L Container
DRLHD2120 - 20L Container
Lanotec Wire Rope Lube
Can be sprayed or manually applied to ropes
Penetrates to the core of the rope, providing long lasting
protection
Semi fluid grease containing natural lubricant and corrosion
inhibitors
Ideal for marine cranes and ropes working in the splash zone
Lubrication of ropes in environmentally sensitive areas where
salt water is an issue
Suitable for all environments, including mining and marine
Stock Codes:
DRLHDWRL20 - 20L Container
DRLHDWRL2120 - 20L Pail
Lanotec Citra-Force
Biodegradable, water soluble degreaser concentrate
Easily removes tar-based wire rope coatings (blackjack)
Easily removes thread dope
Cleans stainless steel, metal surfaces, wire rope, safety
harnesses & webbing
Perfect for environmentally sensitive areas
Stock Codes:
DRLCF400 - 400g Spray Can
DRLCF750 - 750ml Spray Bottle
DRLCF05 - 5L Container
DRLCF20 - 20L Container
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