KSS on Wire Ropes

IMS-FRM-029-01 Nirantar Project Charter

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Wire Rope

Points to be covered
• Advantage of using wire rope
• Construction and Specification
• Inspection of wire rope
• Replacement of wire rope
• Lubrication of wire rope
• Storage of wire rope
• Safety

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Wire Ropes

• Wire rope is a flexible cable or rope made by number

of wires helically laid about an axis.
• Improved plow steel as material, gives huge strength,
so that we can use for power transmission.
• Power transmission in critical structure due to
flexibility of wire rope.
• Wire rope power transmissions use for short distance
as well as running over hundreds and sometimes
thousands of metres, where wire rope is only option
to transmit power.
• Very less amount of loss due to conversion of energy
like heat.
Construction of Wire Ropes

Wire rope composed by three parts

• String (wire)
• Strand (Lay)
• Core
Specification of Wire Rope

Typical order or technical enquiry should comprise of the

following :
a) Dimensions- Diameter and length of rope
b) Details of construction - Number of strands
Number of cores
Number of strands per core,
Direction and type of Lay
Type of core
Type of construction
Tensile designation
c) The intended purpose of use
d) The fittings required
e) Coating on rope
Types of Core

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Types of Strand Construction

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Types of Strand Construction

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Grade of Wire Rope

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IWRC (Inner Wire Rope Core)

• This center is usually composed of a separate 7x7

wire rope designated as IWRC.
• The steel core increases the strength by 7% and the
weight by 10%.
• These steel cores provide more substantial support
than fiber cores to the outer strands during the
rope's operating life.
• Steel centers resist crushing, are more resistant to
heat and increase the strength of the rope.

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STRAND CORE

• It Consists of a strand of steel wires, nominally 7, 19

or 37 in number.
• It is used occasionally in running ropes of smaller
diameters rather than IWRC.
• It may also be used in standing ropes, guys,
suspender ropes, etc. where extra strength,
reduced stretch and maximum resistance to
weathering are required.

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Right Lay Regular Lay

• The strands in the wire

rope are laid to form a
helix about the core
similar to the threads in
a right-hand screw.
• When viewed
lengthwise, the strands
are wound helically away
from the observer in a
clockwise direction.

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Regular Lay and Lang Lay
In this construction, the wires and strands spiral
in opposite directions.
In right-hand ordinary lay, the wires spiral to the
left and the strands to the right.
These ropes are easily handled and can be used
with one end left free to rotate, but they wear
quickly because only a few crown wires are in
contact with the bearing surface at one time
In this construction, the wires and strands spiral
in same directions.
Right –hand lay is usual, but it can be supplied in
left-hand lay.
6- and 8 stranded Lang’s lay rope has better
wearing properties than ordinary lay, but it is
harder to handle. Both ends must be secured to
prevent twisting or the load has to be guided
(i.e. not free to rotate). Not normally used for
slings.
Has better wear resistance when running over
sheaves because a longer part of the wire is in
contact with the sheave.
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Wire rope Types

According to lay
• “Z” lay Starts from right to left
• “S” lay Starts from Left to right
• RRL Right Regular Lay
• LRL Left Regular Lay
• RLL Right Lang Lay
• LLL Left Lang Lay
• RAL Right Alternate Lay
• LAL Left Alternate Lay

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Multi Strand Wire Rope

Multi-Stranded Rope
Both Lang’s lay and regular/ ordiary lay are used, with a double-layer (or triple layer)
construction.
If the inner rope is lf-handed, then the outer covering will be right-handed, or vice versa.
Occasionally used for crane pennants.
It is a rotation- resistant rope-has a steel core which is an independent rope, closed in the
opposite direction to the outer strands. Under load the core tries to twist the roe in the one
direction, the outer strands try to twist it in the opposite direction. The moments I the core and
the outer strands compensate each other. Over a wide load-spectrum, so the even with great
lifting heights no rope twist

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Wire Rope Lay

• This type lay rope is of course

just opposite of right lay

• The wires in the strands

and strands in the rope
are laid in same
direction.
Cross Section of Wire Rope

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Cross Section of Wire Rope

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Usha Martin Wire Rope

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Plastic Coated Inner Core Wire Rope

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Plastic Coated Inner Core Wire Rope

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Measurement

The correct diameter is the greatest

diameter of the rope or strand.

The correct diameter of a wire rope is the

diameter of a circumscribed circle that will enclose
all the strands. It's the largest cross-sectional
measurement. You should make the
measurement carefully with calipers

Figure shows the correct and incorrect

ways of measuring wire rope.
Allowance for
Rope Rejection

• Wear Limit : 7 % of the Nominal

Diameter
(Main Hoist - 30mm * 0.07 = 2.1 mm
(30 mm – 2.1 mm = 27.9 mm)
• 10 % of wires/strings broken in one
lay / stand according to the diameter
of rope
(6 x 36 = 216 string x 0.10=21.6
strings)
(36 * 10 % = 3.6 (Aprx. 4 strings per
strand)
Type of Wire Rope Socket

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Inspection of Wire Rope

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Inspection of Wire Rope

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Inspection of Wire Rope

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Inspection of Wire Rope

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Normal Wear and Tear of Wire Rope

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Corrosion of Wire Rope

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Wire Rope Wear

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Abrasion of Wire Rope

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Mechanical Damage of Wire Rope

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Thermal Damage of Wire Rope

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Malformation of Wire Rope

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Torsional Damage of Wire Rope

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Fatigue Damage of Wire Rope

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Termination Failure of Wire Rope

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Termination Failure of Wire Rope

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Termination Failure of Wire Rope

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Where to inspect

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Where to inspect

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Examination of Sheaves

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Looper Wire Rope

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Replacement of Crane Wire Rope

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Wire Rope Lubrication

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Wire Rope Lubrication

• The lubrication treatment during rope manufacture provides

the finished rope with protection for a reasonable period of
time which sustains for the early stages of the rope's working
life. However this lubrication has then to be supplemented, at
regular intervals depending upon the type of rope application.

• In most cases it thus becomes necessary to either thoroughly

clean the rope or to use a high pressure lubrication device which
forces new lubricant into the rope

Wire rope lubricants should perform 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. 47
Wire Rope Cutting

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Wire Rope Storage

• Don’t put in Concrete floor

• Don’t put Direct to sunlight
• Arrange ventilation
• Placed above the wooden
platform
• Take care from Rust by gas,
water
• Rotate its direction 180 degree
at every 3 month
• Every 3 month lubrication on
the top of rope
• Lay ropes in a dry storage

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Wire Rope Handling

• Never laying the coil flat and pull out

• Right way to unreel wire rope is to use a
vertical unreeling stand.
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• It prevents kinks, bend, rendering a rope