Product Information

Wirelife™ Almasol® Coating Grease (453-451)

Tacky Grease Resists Water, Protects Moving Parts

Wirelife™ Almasol® Coating Grease is a soft, semifluid

formulation designed to coat wire rope as well as moving
chain and cable parts to ensure long life and smooth, quiet
operation. Its tacky, water-resistant characteristics enable
it to adhere strongly to rapidly moving parts and to seal out
damaging moisture. Available in three NLGI grades, Wirelife
Almasol Coating Grease contains Almasol, LE’s exclusive
wear-reducing additive that protects against premature
wear and shields metal against corrosive attack.

Beneficial Qualities

Wear Reduction & Smooth, Quiet Operation

Corrosion Protection
• Lubricates and reduces wear
to wire rope and to all moving
parts, including chains (links, pins,
bushings) and cables (sheave
bushings and bearings, cable
strands)
• Protects wear-intensive areas
such as chain sprockets and
cable sheaves
• Lessens resistance when surfaces
slide over one another, ensuring
cooler operation
• Seals all surfaces, protecting against
rust and corrosion
• Shields against acid attack
Tackiness & Water Resistance
• Clings tightly to pin, bushing or
bearing surfaces
• Resists sling-off; keeps work area
clean
• Stays in place in presence of steam
and moisture for long service life
• Increases service intervals,
requiring less lubricant to be used
• Enables metal joints and strands to
move freely
• Softens shocks with its full-bodied,
semifluid properties
Versatility
• Excellent for wire rope, cables,
open or enclosed silent chains and
roller chains, as well as chain links,
pins, bushings and cable sheave
bearings
• Also works great for small, slow-
turning gearboxes in which
operating temperatures are
relatively low (less than 71°C/160°F)
and a semifluid grease is required
• Meets USDA H2 criteria for nonfood
contact areas of food processing
Available Grades
• NLGI 0 (453)
• NLGI 00 (452)
• NLGI 000 (451)
Proprietary Additive
LE’s proprietary additives
are used exclusively in LE
lubricants. Wirelife Almasol
Coating Grease contains
Almasol.
Almasol® wear-reducing
additive attaches itself to
metal surfaces in a single
microscopic layer, yet will
not build on itself or affect
clearances. It possesses
tremendous load-carrying
capacity, is impervious to
acid attack and minimizes
metal-to-metal contact
and the resulting friction
and wear. When added to
LE lubricants, it provides a
level of protection available
with no other lubricant.

www.le-inc.com
The Lubrication Reliability Source™ 800-537-7683
 Technical Data

Wirelife™ Almasol® Coating Grease

453 452 451
Thickener Type Calcium Calcium Calcium
Texture Stringy Stringy Stringy
Color Red/Gold Red/Gold Red/Gold
NLGI Grade 0 00 000
Unworked Penetration @ 25°C (77°F) 365 415 460
Dropping Point °C (°F) 82 (180) 82 (180) 82 (180)
Base Fluid Characteristics
Viscosity @ 100°C (212°F), cSt, ASTM D445 11.70 11.70 11.70
Viscosity @ 40°C (104°F), cSt, ASTM D445 144.0 144.0 144.0

Performance Requirements Met or Exceeded

• USDA H2

Recommendations
• Typical operating range is -29°C to 77°C (-20°F to 170°F)
• Not for high temperature use or when gear oil is specified

Typical Applications
• Wire rope
• Chain links
• Pins
• Bushings
• Cable sheave bushings
• Cables
• Open and closed silent and roller chains
• Small, slow-turning gearboxes that require a semifluid lubricant

Wirelife™ is a trademark of and Almasol® is a registered trademark of Lubrication Engineers, Inc.

LI30038 5-10

300 Bailey Avenue Fort Worth, TX 76107 Fax: 800-228-1142 www.le-inc.com

LE products manufactured under an ISO 9001:2000 Certified Quality System 800-537-7683
White Paper
LE WHITE PAPER
Lubrication Basics for Wire Ropes

Lubrication Basics for Wire Ropes

Written by
Jeffrey E. Turner
Executive Vice President
Lubrication Engineers, Inc.

© 2002 Lubrication Engineers, Inc. 

www.le-inc.com
The Lubrication Reliability Source™ 800-537-7683
LE WHITE PAPER
Lubrication Basics for Wire Ropes

Wire rope forms an important part of many machines and structures. It is comprised of continuous
wire strands wound around a central core. There are many kinds of wire rope designed for different
applications. Most of them are steel wires made into strands wound with each other. The core can be
made of steel, rope or even plastics.

Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or
not it is preformed, by its lay, the number of strands and the number of wires in each strand.

Figure 1. Comparison of Typical Wire

Rope Lays:
A) Right Regular, B) Left Regular,
C) Right Lang,
D) Left Lang, E) Right Alternate

A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires
in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and
resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small sheaves
(pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through abrasives.
There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with
a 1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking
strength than a fiber core rope and a high resistance to crushing and deformation.

A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope core.
WSC ropes are high strength and are used mostly as static or standing ropes.

 © 2002 Lubrication Engineers, Inc.

LE WHITE PAPER
Lubrication Basics for Wire Ropes

Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also
be made with plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core
ropes are quite flexible and are used in many overhead crane applications.

The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are
four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope, the strands twist to the
right as it winds away from the observer. A left lay rope twists to the left. A regular lay rope has the wires
in the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist
of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to have
better fatigue resistance due to the flatter exposure of the wires.

Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability and
for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used and are
described in Table 1.

Table 1
Grade Tensile Strength (psi)
Extra improved plow steel 245,000 to 340,000
Improved plow steel 220,000 to 300,000
Plow steel 195,000 to 258,000
Mild plow steel 168,000 to 225,000
Iron 100,000

Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will straighten
and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires that are
shaped so that they lie naturally in their position in the strand, preventing the wires from protruding and
potentially causing injury. Preformed wire ropes also have better fatigue resistance than nonpreformed
ropes and are ideal for working over small sheaves and around sharp angles.

Wire Rope Lubrication

Lubricating wire ropes is a difficult proposition, regardless of the construction and composition.

Ropes with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials.
For this reason, it is important to consider carefully the issue of field relubrication when selecting rope for
an application.

Wire rope lubricants have two principal functions:

1. To reduce friction as the individual wires move over each other.
2. To provide corrosion protection and lubrication in the core and inside wires, and on the exterior surfaces.

© 2002 Lubrication Engineers, Inc. 

LE WHITE PAPER
Lubrication Basics for Wire Ropes

There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain
a petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving
behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants
penetrate slightly, sealing the outside of the cable from moisture and reducing wear and fretting corrosion
from contact with external bodies.

Figure 2. Foam Penetrating Type Wire Rope

Both types of wire rope lubricants are used. However, because most wire ropes fail from the inside, it
is important to make sure that the center core receives sufficient lubricant. A combination approach in
which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect the
outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease, petroleum oils
or vegetable oil-based (Figure 3).

Figure 3. Grease Lubed Wire Rope

Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In
addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection.
Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold
temperature conditions.

Asphaltic compounds generally dry to a very dark hardened surface, which makes inspection difficult.
They adhere well for extended long-term storage but will crack and become brittle in cold climates.
Asphaltics are the coating type.

Various types of greases are used for wire rope lubrication. These coating types penetrate partially
but usually do not saturate the rope core. Common grease thickeners include sodium, lithium, lithium
complex and aluminum complex soaps. Greases used for this application generally have a soft semifluid
consistency. They coat and achieve partial penetration if applied with pressure lubricators.

 © 2002 Lubrication Engineers, Inc.

LE WHITE PAPER
Lubrication Basics for Wire Ropes

Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design
of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil
type lubricants helps to wash the rope to remove abrasive external contaminants.

Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber
will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and
function as a reservoir for prolonged lubrication while in service.
If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of
the die that twists the wires into a strand. This allows complete coverage of all wires.

After the cable is put into service, relubrication is required due to loss of the original lubricant from
loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from
evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect
and preserve the rope core and wires, and thus extend the service life of the wire rope.

If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be
cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication.
The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be
applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave where
the rope strands have a tendency to separate slightly due to bending to facilitate maximum penetration to
the core. If a pressure boot application is used, the lubricant is applied to the rope under slight tension in
a straight condition. Excessive lubricant application should be avoided to prevent safety hazards.

Key Lubricant Performance Measures

Some key performance attributes to look for in a wire rope lubricant are wear resistance and corrosion
prevention. Some useful performance benchmarks include high four-ball EP test values, such as a weld
point (ASTM D2783) of above 350 kg and a load wear index of above 50. For corrosion protection, look for
wire rope lubricants with salt spray (ASTM B117) resistance values above 60 hours and humidity cabinet
(ASTM D1748) values of more than 60 days. Most manufacturers provide this type of data on product
data sheets.

Factors that Influence Wire Rope and Cable Performance

Cable life cycle and performance are influenced by several factors, including type of operation, care
and environment. Cables can be damaged by worn sheaves, improper winding and splicing practices,
and improper storage. High stress loading, shock loading, jerking heavy loads or rapid acceleration or
deceleration (speed of the cable stopping and starting) will accelerate the wear rate.

Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If a
machine is to be shut down for an extended period, the cables should be removed, cleaned, lubricated
and properly stored. In service, corrosion and oxidation are caused by fumes, acids, salt brines, sulfur,
gases, salt air, humidity and are accelerated by elevated temperatures. Proper and adequate lubricant
application in the field can reduce corrosive attack of the cable.

© 2002 Lubrication Engineers, Inc. 

LE WHITE PAPER
Lubrication Basics for Wire Ropes

Abrasive wear occurs on the inside and outside of wire ropes. Individual strands inside the rope move and
rub against one another during normal operation, creating internal two-body abrasive wear. The outside
of the cable accumulates dirt and contaminants from sheaves and drums. This causes three-body abrasive
wear, which erodes the outer wires and strands. Abrasive wear usually reduces rope diameter and can
result in core failure and internal wire breakage. Penetrating wire rope lubricants reduce abrasive wear
inside the rope and wash off the external surfaces to remove contaminants and dirt.

Typical Rope Applications

Many types of machines and structures use wire ropes, including draglines, cranes, elevators, shovels,
drilling rigs, suspension bridges and cable-stayed towers. Each application has specific needs for the type
and size of wire rope required. All wire ropes, regardless of the application, will perform at a higher level,
last longer and provide greater user benefits when properly maintained.

Through years of field experience, Lubrication Engineers has found that longer wire rope life can be
obtained by using penetrating lubricants, either alone or when used in conjunction with a coating
lubricant. Practical experience at a South African mine suggests that life cycles may be doubled with this
approach. At one mine site, the replacement rate for four 44-mm ropes was extended from an average
18.5 months to 43 months. At another mine, life cycles of four 43-mm x 2073 meter ropes were extended
from an average 8 months to 12 months.

In another study involving 5-ton and 10-ton overhead cranes in the United States that used 3/8-inch and
5/8-inch diameter ropes, the average life of the ropes was doubled. The author attributes this increased
performance to the ability of the penetrating lubricant to displace water and contaminants while
replacing them with oil, which reduces the wear and corrosion occurring throughout the rope. A good
spray with penetrating wire rope lubricant effectively acts as an oil change for wire ropes.

In these examples, the savings in wire rope replacement costs (downtime, labor and capital costs) were
substantial and dwarfed the cost of the lubricants. Companies who have realized the importance of
proper wire rope lubrication have gained a huge advantage over those who purchase the lowest priced
lubricant, or no lubricant at all, while replacing ropes on a much more frequent basis.

About Lubrication Engineers

A leader in lubricants since 1951, Lubrication Engineers, Inc., manufactures and markets premium
lubricants formulated from highly refined base oils. Enhanced with proprietary additives, LE oils and
greases provide unmatched performance in nearly any application operating in normal-to-severe
conditions. All Lubrication Engineers® lubricants are manufactured in an ISO 9001:2000 certified quality
system at LE’s state-of-the-art plant in Wichita, Kan., and are available worldwide. With its comprehensive
offering of lubricants and related reliability products, LE provides its customers with increased profitability
through longer equipment life, extended service intervals, reduction in energy use, fewer repairs and less
need for inventory.

References
1. American Iron and Steel Institute. (1985). Wire Rope Users Manual, Second Edition. p. 5-17, 67-68.
2. (1983). CRC Handbook of Lubrication, Volume 1. p. 193-201.
3. Brewer, A. (1974). Effective Lubrication. p. 236-242.
 © 2002 Lubrication Engineers, Inc.