Wire Rope

Indusco is proud to bring a new line of Wire Rope products from Casar.

Please visit their site at the following link to browse our newly offered products for information and availabilty.

www.casar.de

Standard 6 x 19 & 6 x 36 Classification Ropes

The 6 x 19 classification of wire ropes includes standard 6 strand, round strand ropes with 16 through 26 wires per strand. The 6 x 36 classification of wire ropes includes standard 6 strand, round strand ropes with 27 through 49 wires per strand. Although their operating characteristics vary, all have the same weight per foot  and the same minimum breaking force, size for size.

While the 6 x 19 ropes give primary emphasis to abrasion resistance in varying degrees, the 6 x 36 ropes are important for their fatigue resistance. This fatigue resistance is made possible by the greater number of small wires per strand.

Although there are exceptions for special applications, the constructions in 6 x 36 classification are primarily designed to be the most efficient for each rope diameter. As the rope size increases, for instance, a large number of wires can be used to achieve required fatigue resistance, and still those wires will be large enough to offer adequate resistance to abrasion.

Rotation-Resistant Ropes

Rotation-resistant ropes can frequently provide the best and most economical service in specific applications when you choose, handle and use them properly.

Contra-helically laid, rotation-resistant ropes are different from standard ropes because they're designed to reduce rope torque. Modes of failure and wear for rotation-resistant ropes can differ from those for standard rope constructions. The very nature of these ropes requires special handling, selection and usage not encountered with standard constructions. They are susceptible to kinking, crushing and unbalancing in the form of "core pops" and "birdcages." Use extreme care to avoid operational practices that can possibly lead to these conditions.

There are different types of rotation-resistant ropes, categorized by their resistance to rotation. Category 1 rotation-resistant rope has at least 15 outer strands, has three layers of strands (over a center) and has little or no tendency to rotate, or, if guided, transmits little or no torque. Category 2 rotation-resistant rope has 10 or more outer strands, has two or more layers of strands (over a center) and has significant resistance to rotation. Category 3 rotation-resistant has no more than 9 outer strands, has two layers of strands (over a center) and has limited resistance to rotation. For best performance, Category 2 and 3 rotation-resistant ropes should not be used with a swivel. Category 1 rotation-resistant rope may be used with a swivel.

Rotation-resistant ropes should be replaced when you see two randomly distributed crown wire breaks in six rope diameters -- or four randomly distributed crown wire breaks in 30 rope diameters. If any significant reduction in diameter is found in a short length of a rotation-resistant rope, the rope needs to be replaced.

Because rotation-resistant ropes are special, there are separate design, maintenance, inspection and removal criteria established for them by applicable industry regulations and standards.

Premium Value Ropes

Flex-X® 6 wire ropes

Most applications for wire rope are extremely demanding. Wire rope must resist crushing, bending fatigue and abrasion. For example, clamshell closing lines must resist bending fatigue and boom hoists are subject to pressures that cause crushing. Overhead hoists test the stability and strength of a wire rope. All drum-related applications demand a rope that will spool and operate smoothly and dependably.

Flex-X 6 users receive superior performance and increased service life in many applications compared to the ropes they had previously employed. When compared to conventional 6 strand ropes, Flex-X 6 ropes provide greater surface area and more steel per given diameter, which increases rope stability and strength, too. This results in longer service life and less sheave and drum wear.

Minimum Breaking Force & Weights For Flex-X 6

Flex-X® 9 wire ropes

WireCo WorldGroup, Incorporated announces the newest addition to the Flex-X family, Flex-X 9.

Our research and field engineers have devoted a great deal of time and effort to design Flex-X 9, the very latest in compacted wire rope. Its high-density strands deliver extra strength, surprising bendability, a stubborn resistance to abrasion, and perhaps its greatest asset to users, a high resistance to drum crushing. Beyond the design, Flex-X 9 is manufactured with a dual compaction process to produce a compact cross-section with minimum voids and greater surface area on outer wires that contact drums, sheaves and the rope, itself, during operation. This process also results in high-density, compacted strands to minimize nicking at strand-to-strand contact points.

Now you can keep your crane up and running longer. Flex-X 9 has been designed to resist crushing. However, when rope deterioration inevitably occurs, Flex-X 9’s unique design greatly assists the operator with crucial rope inspections. Wire breaks with Flex-X 9 are typically found on the outside of the rope, making them much easier to identify. Any rope inspector can appreciate that.

TUF-KOTE® / PFV wire ropes

TUF-KOTE / PFV, the plastic-impregnated wire rope, has proven in many applications to give you longer service life and cleaner operation than conventional wire ropes.

On the inside, you'll find our top-of-the-line wire rope that effectively withstands the tough pressures of your demanding jobs. On the outside, you'll see a specially engineered polymer plastic designed to overcome even harsher conditions. This polymer is applied at high pressure to force the material into the rope, filling the valleys of the strands. TUF-KOTE / PFV cushions the strands, distributes internal stresses, keeps in wire rope lubricant and keeps out dirt and debris.

TUF-KOTE / PFV doesn't melt or soften from the heat of your normal operating temperatures. It's also virtually unaffected by sunlight and cold weather. The result is longer service life from your wire rope.

TUF-KOTE / PFV also helps shed water and dirt, giving you a clean, smooth surface to make it easy to pass over sheaves and onto drums. This smooth surface works to clean and polish as it extends the service life of your sheaves and drums. That reduces your cleanup requirements and your maintenance costs.

Space Lay Ropes

A unique plastic impregnated wire rope designed specifically for severe corrosive conditions.

Ordinary plastic-coated wire rope vs. SPACE-LAY

With ordinary plastic-coated wire rope, the individual metal strands are in direct contact with each other at many points. As a result, the metal-to-metal contact causes internal friction and wear. Even more important, with conventional constructions, there is no interlocking bond. If the outer cover (blue) becomes cut or abraded, it is easily peeled off, exposing the bare metal strands to corrosion.

In SPACE-LAY construction, each individual strand is separated from all the others by one or more extra-large “spacer-wires.” This design serves two important functions: (1) It enables the extruded plastic (yellow) to form a wall of protection around EACH strand. (2) It also assures a tight, interlocking bond between the inner plastic filler and the outer plastic jacket.

No peeling or leaking. PLUS, in SPACE-LAY construction, each individual wire is galvanized for additional corrosion protection.

For many applications, the SPACE-LAY design has proven far superior to all other known types of plastic coated wire rope. It has also outlasted bright, galvanized and stainless steel ropes – especially where submersion or abrasion prevents formation of a protective oxide film, which these metals require to resist corrosive elements. Under such conditions, SPACE-LAY plastic-impregnated and coated galvanized wire rope offers important advantages to users.

Flattened Strand Ropes

Also called triangular strand, flattened strand ropes perform exceptionally well on certain installations, especially those involving heavy loads where the speed of operation is slow, where adequate diameter sheaves and drums are used, or where a crush resistant rope is required. Typical installations include skip hoists, large overhead cranes, boom hoist ropes and mine shaft hoists.

Their distinguishing physical feature is their relatively flat exposed surfaces of strands. As a result, the rope exterior is more nearly a smooth, continuous circle than that of regular round strand wire rope. Flattened strand ropes are made with two layers of 12 wires around a triangular-shaped center. We offer a 6x30 Style G using a six-wire center as the standard construction.

The advantages of flattened strand ropes

The flattened shape forms a bearing surface with more contact points on each strand than a round strand rope. With more sheave contact, weight and wear on the rope are distributed more uniformly than on a typical round strand rope. The triangular strand structure also results in more steel in the cross-section than a standard round strand rope of equal size.

Minimum breaking force and weights for flattened strand XIP® ropes

EXTREMELY LOW TORQUE—EXTREMELY HIGH STRENGTH.

TOMORROW’S CRANE ROPE, TODAY.

What sets XLT4 apart is its unique design. Our PowerSteel Technology double packs more high-tensile steel wire into the rope’s diameter, giving XLT4 one of the highest strength-to-diameter ratios ever achieved — with a minimum breaking force 33% higher than standard 6-strand XIP ropes.

Under load, XLT4 generates near-zero torque, matching or surpassing the stability of Category 1 35x7 class rotation-resistant ropes. Yet, thanks to its unique design, XLT4 is not classified as a “rotation-resistant” rope. You can use it with or without a swivel as a mobile crane hoist rope at design factors as low as 3.5 to 1.

And for value, nothing performs like XLT4. Not only does it cost less than a 35x7 classification rope, its compact construction keeps more steel in contact with sheaves and drums for unmatched resistance to crushing and wear — for lower maintenance, less downtime and longer service life.

Flex-X 7® CC (LoadStar)-a crane rope that guarantees a lift in productivity.

Flex-X 7® CC (LoadStar) extended duty crane and hoist ropes were developed primarily for the container crane industry where repetitive, continuous operations are a fact of life. Subsequent research and extensive testing have shown that Flex-X 7® CC (LoadStar) delivers the same exceptional fatigue resistance and service life to other applications where bending fatigue is a problem.

Already a preferred rope for container cranes, Flex-X 7® CC (LoadStar) is now providing extended service life in carriage operations and other applications where multi-sheave equipment and rigorous duty cycles induce fatigue stresses. Almost any application currently using a 6x36 construction can gain an increase in service life with Flex-X 7® CC (LoadStar).

Flex-X 7® CC (LoadStar) STARTS OUT STRONGER.

Take a look at the strength comparison and you'll see that Flex-X 7® CC (LoadStar) provides a significant increase in initial strength. Actual test results show this differential increases throughout the fatigue life of the rope. In fact, Flex-X 7® CC (LoadStar) rope still has 103% of the standard rope's original strength at the point the standard rope experiences complete fatigue failure.

Flex-X 7® CC (LoadStar) LASTS LONGER.

Flex-X 7® CC (LoadStar)'s longer service life results in lower maintenance costs due to fewer rope changes. In addition, fatigue tests have shown that Flex-X 7® CC (LoadStar) will outperform competitors' premium 8-strand compacted, coated core ropes by 60% or more. These tests have also shown that Flex-X 7® CC (LoadStar) outlasts standard ropes by up to 88%.

7 & 8 Strand Wire Ropes

7-Flex® wire ropes

We offer 7-Flex ropes for many applications that currently use 6 x 19 or 6 x 36 classification ropes. Their operating characteristics are similar in many ways to 6 x 36 classification ropes. Typical applications such as container cranes, logging portal cranes and sawmill carriages have reported increased service life with the 7-Flex.

The 7-strand construction offers improved resistance to bending fatigue compared to a 6 x 26 due to a combination of the outer wire size and the seventh strand. These products are also available in a TUF-KOTE® / PFV option to further enhance their service characteristics.

8 x 19 classification

Standard constructions are regular lay and either 19 Seale or 25 Filler Wire. The size relationship between strands and core gives these ropes increased bendability over 6 strand ropes of the same diameter. It has less crushing resistance than a 6 strand rope.

6 x 7 classification sand lines

Once the rod and tubing have been pulled from the well, the sandline is used to lower tools down into the well for repair or for swabbing out the well. In these processes the sandline is exposed to chemical solutions in the well that can lead to corrosion of the wire rope.

6 x 7 classification sand lines. The vast majority of this market utilizes a 6x7 Bright Fiber Core. In a 6x7 rope, the wires are larger than those of other constructions of the same diameter. Wires of a 6x7 are approximately twice the diameter of outer wires of a 6x25 FW rope. The large size of the outer wires gives this class excellent abrasion resistance -at great sacrifice of bendability and resistance to fatigue. The standard 6x7 rope construction is made with fiber core and right regular lay.

6 x 7 Galvanized sand line. Designed for harsh conditions.

Where extremely corrosive conditions shorten the service life and effectiveness of bright sand lines, the WireCo WorldGroup 6x7 galvanized delivers the goods. Zinc-coated to perform better in hostile down-hole conditions, our 6x7 galvanized sand line reduces rope changes, downtime, and increases productivity.

6X7 GALVANIZED

• Provides longer service in hostile down-hole conditions
• Excellent abrasion resistance
• Operates smoothly and cleanly

5 x 7 classification sand lines.

Under normal conditions our 5 x7 Fiber Core (FC) lines have proven to be an economical tool for extending service life. These workhorses of the well servicing industry are available in both standard and swaged construction.

STANDARD 5x7 FC

• Designed specifically for sand line and swabbing operations
• Excellent handling and performance
• Very economical

SWAGED 5x7 FC

• Compacted swaged design provides greater strength per diameter
• Smaller diameter allows more rope to be spooled on the drum
• High density construction for greater crushing and abrasion resistance
• Compact cross section for greater surface area, less scrubbing, longer wear

Swaged Wire Ropes

6 x 19 and 6 x 36 classification swaged rope

These ropes offer greater strength than standard ropes of the same diameter while providing greater resistance to drum crushing, scrubbing and similar surface wear. To enhance the performance of our swaged ropes in the field, we utilize a special wire chemistry in the outer wires of the strands. Then during production, the rope is rotary swaged to produce a compact cross-section with minimum voids and greater surface area on outer wires. In addition to reducing rope surface wear, this compact design helps reduce wear to sheaves and minimizes crushing of the rope on the drum. These ropes are stiffer and less fatigue resistant than standard ropes.

Power-Swage™ logging ropes

If your application requires an even stronger rope, Power-Swage rope's have a 30% higher minimum breaking force. These ropes are designed to resist abrasion and drum crushing in logging applications. The compact design with smoother wire surfaces allows you to spool a greater length of rope onto drums than an unswaged rope of comparable strength.

3 x 19 and 3 x 36 classification swaged wire rope

These 3 strand ropes are ideal for pulling lines in electrical transmission line construction. Rotary swaging the rope results in an exceptionally compact rope cross-section. This increases surface area, which improves rope contact with sheaves and on drums, thereby providing greater resistance to surface wear and abrasion while reducing wear on sheaves. The smooth surface also helps reduce wear on underground conduits. Lengths may be fitted with flemish-eye ends. Please specify whether eye is to be on inside or outside of the reel, or at both ends.

Specialty Small Ropes

This category includes wire ropes in sizes as small as 1/32" in diameter. They're used in a variety of applications, including control cables, window and door closures, different kinds of remote control systems, boat rigging and many others.

They can be made of galvanized or stainless steel wire.

Each of these products is carefully engineered and fabricated to uniform size and quality. For example,1/16" 7 x 19 contains 133 separate wires, making the wires approximately the diameter of a human hair. Yet the rope has high strength, bendability and fatigue resistance.

These ropes are produced for the most common applications in the market. Utility grade is made to RR-W-410. These cables have historically been called"aircraft" cable. Since most applications do not require that designation, we are changing the name to "utility" cable. We can provide these ropes to MIL-DTL- 83420 "aircraft" specifications on request. They require special lubrication during manufacture, internal marking and fatigue testing.