35WXK7
High performance steel wire rope from Aulone for cranes.
High Performance Steel Wire Ropes For Crane Industry
Aulone experts develop, manufacture, and provide innovative high-performance wire rope solutions for the global construction industry’s cranes.
For decades, the quality of our crane ropes has satisfied our customers because they meet the high demands of the construction industry. Direct and close collaboration with system and crane manufacturers is the cornerstone of our wire ropes, which possess all the technical characteristics required in the construction field. Our experts have extensive user knowledge and years of experience. Additionally, our wire ropes are designed to save our clients significant time and costs. By offering enhanced durability and reliability, our products reduce the frequency of replacements and maintenance, ensuring smoother operations and increased efficiency on all construction sites.
Tailored Wire Ropes to Suit Your Needs!
At Aulone, we specialize in providing high-performance crane wire ropes designed to support the critical demands of lifting and rigging operations. As your trusted partner in wire rope manufacturing, we offer products that are not only tailored to meet specific industry standards but also engineered to enhance the efficiency and safety of your crane operations.
Available Sizes: Ranging from 1mm up to 260mm.
Tensile Strength: 1570, 1770，1870, 1960, 2160, and 2260mpa.
Specifications on Offer: EN12385-4, GB 8918, YB/T5359 and specific customer requirements.
Surface Treatments: Options including hot galvanized, ungalvanized, and stainless steel.
Special technology: Including multi-strand ropes, plastic impregnated, compacted, galvanized.
Structure: 35WX7, 35WXK7, 19X7, 19XK7, 15XK7, 8X26, 8XK26WS-IWRC, 6X36WS,6XK36WS, 6X26, 6XK26, 4x39S+5FC etc
Lay types: RHLL, RHRL, LHLL, LHOL
Certifications: All our ropes come with BV and CE certifications, providing you with the assurance of quality and compliance with international standards.
Applications: Tailored for heavy lifting, crane operations, such us tower cranes, all terrain cranes,crawler cranes, rotary drilling rigs etc
Aulone is dedicated to delivering not just products but solutions that contribute to the success of your projects. We would be happy to discuss how our crane wire ropes can meet your specific requirements or arrange for samples to be sent to you for evaluation.
Let’s elevate your lifting solutions with Aulone’s reliability and strength.
Wire Rope Termination Options
Socketing:
- Wedge Sockets: Provide a quick and efficient means of attaching a wire rope to a fixed point. They are commonly used in crane and rigging applications.
- Open and Closed Swage Sockets: Offer a more permanent termination. The wire rope is inserted into the socket, and molten zinc is poured in to secure it, creating a very strong bond.
- Resin Socketing: Similar to swage sockets, but uses resin instead of molten zinc for securing the rope. It is suitable for both temporary and permanent applications.
Mechanical Terminations:
- Swaged Fittings: The end of the wire rope is inserted into a metal fitting and then compressed (swaged) onto the wire rope using a hydraulic press. This creates a strong and permanent termination.
- Swaged Eyes: These are loops made at the end of the wire rope, swaged with a fitting to create a strong, fixed loop.
Splicing:
- Flemish Eye Splice: Involves unlaying the strands of the wire rope, forming a loop, and then relaying the strands back into the rope body. It is usually secured with a metal sleeve or by swaging.
- Hand Splicing: Traditional method where the strands are manually woven back into the rope to create a loop or eye. It is labor-intensive but can be very strong and reliable.
Clips and Clamps:
- Wire Rope Clips (Clamps): Consist of a U-bolt and a saddle, which are used to clamp the rope back onto itself. This method is suitable for temporary or less critical applications and is easy to install and adjust.
Thimbles:
- Thimbles: Used in conjunction with splices and clamps to form a protective loop at the end of the wire rope. They help maintain the shape of the loop and reduce wear on the rope.
Each termination method has its specific applications and advantages, depending on the requirements for strength, permanence, and ease of installation. For crane applications, selecting the right termination method is crucial for safety and efficiency.
Beyond Simply Supplying Wire Ropes
At Aulone, we’re not just a wire rope supplier. We’re dedicated to superior quality, advanced manufacturing processes, and a team with deep industry expertise. That’s what sets us apart in the metal wire products space. Here are our core services:
Precision Manufacturing
Utilizing state-of-the-art equipment and stringent quality controls, we ensure every piece of wire rope meets the high standards of strength and durability required in demanding industrial applications
Customized Solutions
Understanding that each project has unique demands, Aulone offers customized wire rope configurations. Whether you need specific lengths, diameters, or strength parameters, our team is skilled in crafting solutions that align perfectly with your project requirements.
Advanced Manufacturing
Our manufacturing processes are at the forefront of the industry, transforming high-quality steel into exceptionally strong wire ropes. This process ensures that our products can handle significant loads and stresses, providing you with reliability when it matters most.
Partner in Progress
More than just supplying products, Aulone believes in building relationships. We work alongside you to understand your challenges and provide continuous support, from initial consultation to after-sales services. Our goal is to contribute to your success, ensuring that you receive the best in both product and service.
Your Ultimate Guide to Acquiring Compacted Strand Wire Rope
Acquiring the right wire rope for crane operations is critical for ensuring safety, efficiency, and longevity of equipment. Here’s a comprehensive guide to help you make informed decisions when selecting wire rope for the crane industry.
Table of contents
Chapt 1
Key Properties of Wire Rope for Crane Industry
Chapt 2
Construction of Wire Rope for Crane
The construction of wire rope is a crucial factor in determining its performance and suitability for crane applications. Here are the key elements involved in the construction of wire rope:
Core:
- Fiber Core (FC): Consists of natural or synthetic fibers, such as sisal or polypropylene. The fiber core provides flexibility and cushioning, making it suitable for applications where bending fatigue is a concern.
- Wire Strand Core (WSC): Comprises a single strand of wire laid in the center of the rope. WSC cores offer more resistance to crushing and deformation compared to fiber cores.
- Independent Wire Rope Core (IWRC): Made of a separate wire rope with its own strands and core. IWRC cores provide the highest strength and resistance to crushing, making them ideal for heavy-duty lifting operations.
Strands:
- Regular Lay: In this construction, the wires within the strands are twisted in one direction, while the strands themselves are twisted around the core in the opposite direction. This arrangement balances the rope’s properties and provides good resistance to crushing and deformation.
- Lang Lay: Both the wires within the strands and the strands themselves are twisted in the same direction. Lang lay ropes offer better resistance to abrasion and fatigue but may be more prone to untwisting under load.
- Alternate Lay: This construction alternates between regular and Lang lay in adjacent layers or strands, combining the advantages of both types.
Wires:
- Wires are the individual filaments that make up the strands. They are typically made of high-carbon steel for strength and durability.
- The diameter and tensile strength of the wires vary depending on the rope’s design specifications and intended application.
Wire Rope Lay:
- Regular Lay: The wires in the strands are twisted in one direction, and the strands are twisted around the core in the opposite direction.
- Lang Lay: Both the wires and strands are twisted in the same direction.
- Alternate Lay: Combines elements of both regular and Lang lay, alternating between strands or layers to balance the rope’s properties.
Preforming:
- Preforming is a process where the strands and wires are shaped before being assembled into the final rope.
- This helps the wires and strands maintain their positions, reducing the risk of unraveling and improving the rope’s handling characteristics.
Compaction:
- Some wire ropes undergo compaction, where the strands or the entire rope are compressed to increase the contact area between wires.
- Compaction enhances the rope’s strength, wear resistance, and fatigue life.
Coating:
- Wire ropes may be coated with materials such as zinc (galvanized) or plastic to enhance corrosion resistance and reduce friction.
- Coatings also provide additional protection against abrasion and prolong the rope’s service life, especially in harsh environments.
These structures interact to determine the wire rope’s overall performance characteristics, such as strength, flexibility, abrasion resistance, and fatigue resistance, making them critical considerations in crane applications.
Specific Types of Wire Rope Construction for Cranes
Rotation-Resistant Wire Ropes
Main type: 35WXK7, 35WX7, 15XK7, 37XK7, 24WXK7,24X7, 40XK7, 19X7, 19XK7 etc
Construction: These wire ropes feature multiple layers of strands laid in opposing directions to resist twisting under load, They typically consist of an inner layer with a left-hand lay and an outer layer with a right-hand lay, or vice versa.
Advantage:
1. Enhanced Safety: Minimizes load spin during lifting.
2. Improved Load Control: Provides better positioning and stability.
3. Extended Service Life: Reduced wear and abrasion.
4. Versatility: Suitable for various crane types and applications.
5. Regulatory Compliance: Meets safety standards and regulations
Purpose: Rotation-resistant ropes are essential for crane applications where load rotation could be hazardous, such as in lifting operations involving sensitive or delicate loads.
Flattened Strand Wire Ropes:
Main type: 4VX39S+5FC, 4VX48S+5FC etc
Construction: Flattened strand wire ropes are engineered with strands that have a flattened cross-section, providing a smoother surface compared to traditional round strands.The flattened strands are often arranged in a helical pattern around the core.
Advantage:
1. Reduced Wear: Minimizes wear on sheaves and drums.
2. Smooth Operation: Ensures smoother movement and reduced snagging.
3. Enhanced Flexibility: Better for frequent bending and wrapping.
4. Improved Load Distribution: More even stress distribution.
5. Noise Reduction: Quieter during operation
Purpose: These ropes are designed to reduce wear on sheaves and drums, making them suitable for applications where smooth, consistent movement is essential, such as in overhead crane systems.
Compacted Wire Ropes:
Main type: 35WXK7, 15XK7, 37XK7, 24WXK7, 40XK7, 19XK7, 8XK26WS-IWRC, 8XK36WS-IWRC, 8XK19S-IWRC, 6XK26WS-IWRC, 6XK36WS-IWRC etc.
Construction: Compacted wire ropes undergo a special manufacturing process where the strands or the entire rope are compressed to increase wire-to-wire contact and reduce void spaces. The compaction process results in a denser, more compact rope structure compared to standard wire ropes.
Advantage:
1. Increased Strength: Compaction increases the rope’s strength and load capacity.
2. Enhanced Abrasion Resistance: The denser structure provides better resistance to wear and abrasion.
3. Improved Fatigue Life: The compacted design reduces internal friction, enhancing fatigue resistance.
4. Greater Stability: Reduced stretch and deformation under load ensure more stable lifting operations.
5. Longer Service Life: Enhanced durability leads to a longer service life and lower maintenance costs..
Purpose: Compacted wire ropes offer enhanced strength, wear resistance, and fatigue life, making them well-suited for high-load crane applications where durability and longevity are paramount.
Plastic insert wire rope
Main type: 35WXK7-EP, 8XK26WS-EPIWRC, 8XK36WS-EPIWRC, 8XK19S-EPIWRC, 6XK26WS-EPIWRC, 6XK36WS-EPIWRC.
Construction: Plastic insert wire ropes, also known as plastic-coated wire ropes, feature a layer of plastic material inserted between the outer strands and the core. The plastic insert acts as a barrier between the steel core and the environment, providing enhanced resistance to corrosion. This is particularly beneficial in outdoor or marine crane applications where exposure to moisture and saltwater is common.
Advantage:
1. Corrosion Resistance: Protects against moisture and chemicals.
2. Reduced Wear: Minimizes friction and abrasion between strands.
3. Noise Reduction: Quieter operation compared to traditional ropes.
4. Improved Flexibility: Enhanced bending performance.
5. Increased Durability: Longer service life and lower maintenance costs.
Purpose: They are particularly well-suited for marine cranes, harbor cranes, offshore oil and gas platforms, and other outdoor or corrosive environments where traditional wire ropes may suffer from accelerated corrosion and wear.
Round strand wire rope
Main type: 6X19,6X26,6X36, 6X37,8X26, 8X36 etc.
Construction:Round strand wire ropes are composed of individual wires that are helically wrapped around a central core or around a fiber or wire strand. The wires are arranged in a circular pattern, giving the rope a rounded cross-section.
Core: Round strand wire ropes can have various core configurations, including fiber cores (FC), independent wire rope cores (IWRC), or steel cores (WSC). The core provides support and stability to the strands and helps maintain the rope’s structural integrity.
Advantage:
1. High Strength: Excellent tensile strength for heavy loads.
2. Flexibility: Good bending performance for various applications.
3. Durability: Resistant to wear and abrasion.
4. Versatility: Suitable for a wide range of crane and lifting applications.
5. Cost-Effective: Generally more economical than specialized rope types.
Purpose: Round strand wire ropes are widely used in various crane applications, including overhead cranes, gantry cranes, tower cranes, and mobile cranes.
Each type of wire rope construction offers unique advantages and is tailored to specific crane applications, allowing operators to select the most suitable rope for their needs based on factors such as load capacity, operating conditions, and safety requirements.
Chapt 3
Factors Affecting Wire Rope Performance in Crane Applications
Several factors affect wire rope performance in crane applications. Understanding these factors helps ensure the rope’s longevity, safety, and efficiency. Here are the key factors:
Load Capacity: Ensure the wire rope’s working load limit (WLL) is suitable for the application to prevent overloading and potential failure.
Bending Radius: Use sheaves and drums with appropriate diameters. Larger bending radii reduce stress and extend the rope’s lifespan.
Environmental Conditions: Consider temperature, humidity, and exposure to corrosive substances. Use ropes with suitable coatings or materials for harsh environments.
Lubrication: Maintain proper lubrication to reduce friction and prevent wear and corrosion. Regularly apply the recommended lubricant.
Sheave and Drum Condition: Inspect and maintain sheaves and drums to prevent uneven wear and stress on the rope.
Installation and Handling: Follow correct procedures to avoid kinks, twists, or other damage during installation and handling.
Load Cycles and Tension: Minimize shock loads and ensure gradual loading to extend the rope’s fatigue life. Monitor the frequency and magnitude of load cycles.
Alignment and Rigging: Ensure proper alignment and rigging to achieve balanced load distribution and prevent uneven wear.
Inspection and Maintenance: Conduct regular inspections for wear, corrosion, and broken wires. Perform timely maintenance and replace ropes when necessary.
Storage: Store ropes in a dry, cool, and well-ventilated area to prevent degradation from moisture, heat, or other environmental factors.
By addressing these factors, crane operators can ensure optimal performance, safety, and longevity of wire ropes in crane applications.
Chapt 4
Best Practices for Inspecting Wire Rope in Crane Operations
Chapt 5
How do you control the quality and min breaking force of the crane wire rope?
Controlling the quality and minimum breaking force of crane wire rope involves several key steps throughout the manufacturing process and during use. Here’s how Aulone typically done:
1.Raw Material Selection:
- Choose high-quality raw materials, typically high-carbon steel wires with precise chemical composition and mechanical properties. The quality of the steel directly affects the wire rope’s strength and durability.
- Conduct thorough inspections of incoming raw materials to verify compliance with specifications and standards. This may include chemical analysis, mechanical testing, and visual inspection.
2.Manufacturing Process:
- Wire Drawing: Start with wire drawing, where steel rods are drawn through progressively smaller dies to reduce their diameter to the desired wire size. This process ensures uniformity and consistency of the wire’s diameter and mechanical properties.
- Stranding: The wires are then twisted together to form strands using specialized machinery. Proper stranding ensures the integrity and strength of the wire rope.
- Closing: Strands are helically wound around a core to form the final wire rope. The closing process must be carefully controlled to achieve the desired lay length, lay direction, and pitch, which affect the rope’s flexibility and strength.
3.Quality Control Measures:
- Implement strict quality control measures at each stage of the manufacturing process. This includes regular inspections of equipment, process parameters, and product dimensions.
- Conduct non-destructive and destructive testing on samples of wire rope to verify compliance with specifications. Non-destructive tests may include visual inspection, magnetic particle inspection, and ultrasonic testing, while destructive tests may include tensile testing to determine breaking strength.
- Establish quality control checkpoints to ensure that only wire ropes meeting specified criteria are released for further processing or shipment.
4.Testing and Certification:
- Perform mechanical tests, such as tensile testing, to determine the breaking strength of wire ropes. The breaking strength must exceed the minimum specified value to ensure safety in crane operations.
- Obtain third-party certification from accredited testing laboratories or certification bodies to validate the quality and performance of wire ropes. Certification provides assurance to customers and regulatory authorities that the wire ropes meet industry standards and specifications.
5.Traceability and Documentation:
- Maintain detailed records of raw material sources, manufacturing processes, test results, and quality control measures. This enables traceability of wire ropes throughout their lifecycle and facilitates identification of any issues or non-conformities.
- Document all relevant information, including material certificates, production records, test reports, and certifications, to demonstrate compliance with quality standards and regulatory requirements.
6.Regular Inspection and Maintenance:
- Implement a comprehensive inspection and maintenance program for crane wire ropes in service. Regularly inspect wire ropes for signs of wear, corrosion, damage, or fatigue.
- Conduct periodic load testing and non-destructive testing to assess the condition and performance of wire ropes and ensure they remain within acceptable safety limits.
7.Training and Certification:
- Provide comprehensive training for personnel involved in wire rope manufacturing, inspection, maintenance, and operation. Training should cover relevant topics such as material properties, manufacturing processes, quality control procedures, and safety practices.
- Ensure that personnel responsible for wire rope inspection and maintenance are certified and competent to perform their duties effectively and safely. Ongoing training and professional development are essential to keep employees up-to-date with the latest industry standards and best practices.
By following these detailed steps, manufacturers and users of crane wire ropes can effectively control quality and ensure that wire ropes meet minimum breaking force requirements, thereby enhancing safety, reliability, and performance in crane operations.
Chapt 6
What role does wire rope lubrication play in crane operations, and how often should it be performed?
Wire rope lubrication plays a crucial role in crane operations by reducing friction between wires and strands, preventing corrosion, and extending the service life of the wire rope. Here’s why lubrication is essential in crane operations:
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