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\\' ire Rope is an important engineering material which is being used in M ining & other engineering
indusLrics. lt is used for holding. li fting , mo vmg and pulling various Lhmgs.
In the lifting and rigging indusLries, wire rope is attached to a crane or hoist a nd fiLtcd with swivels,
shackles or hooks to attach to a load and move it in a control led maller. lL can also be (1sed to lift and
lov,·er elevators. or as a means of support for suspension bridges or towers.
Co mposition of Wire Rope:
Carbon - 0.5
Silicon - 0.1 I
M anganese - 0.48
Sulphur - 0.033
Phosphorous - 0. 0 14
- Rest

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 Dd~eu UII u:;ay e. TXPP~ OF WIRE ROPES
1. Standing Ropes: Carr/ fhe oadt"uH'emain stationary.
Examples: Guide ropes (e.g., in shafts) , Bucket support ing ropes (e.g., for rope excavators).
These ropes support a load i n a st at ionary posit ion without undergoing significant movement.

2 . Running Rop es: Frequently undergo running or coil ing, often with varying loads.
Examples: Winding ropes , Haulage ropes , Ropes used in excavators and cranes.
These ropes are designed lo move or coil frequently, often carrying varying loads during their operation.

Based on Construction:
1. Stranded Ropes: Consist of mul ti ple strands (layers of wires) twisted or brai ded together.
Enhanced flexi bil ity, strength, and durabil ity due to the structure of interwoven strands.
1-nmmnnl11 11c:orl i n ::I 11:::ir i oh, nf :::innlir:::it innc: rl 110 tn thoir strength and flexibility.

$ ,ct strands.
to st randed ropes.
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...._./ \\.ires for haulage ropes have a tensile strength more than fo ur Li mes Lhal of mi ld steel.
• The increased strength is obtained during manufac tu re, mainly by clraw1ng U1e wire several tim~s
through progrcssi,·ely smaller tapered holes in metal blocks or dies, steadi ly decreasing its cliamelcr
and increasing its length.
• This elongates the grains of steel within the wire inlo longer, fibre-likestructures, leading to an increase
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) i( its tens ile strength.

..___;, Tensile strength is measured in Newtons per square millimetre (N/mm 2) .
• Hanging a 1 kg weigh t on a wire would create jusl under IO N (J_ 0 Newtons) of tension in that wire. 1f
the wire had a cross-sectional area of I mm 2 then the tensi le force in that wire would be just under I0
N/mm2 . J
• The tensile strength of ,:vires in most general purpose haulage ropes is nonnally 1770 N/mm 2 (the so
called 1770 grade).
 STRANDED ROPES
Stra nded Rope Construction:
Strand Con1position: SLra ndcd ropes are rnade up Qf slra nds, and each stTand co nsists or· a central steel wire
known as the "king wire" covered by concenlri ca ll y laid wires ro rrning a helix arnoncn 11e ce ntral wrre.

2 Strand Types:
3. SeYen-\[Link] Strnnd: Consists ofa king wi re and six co nccnln ca ll y laid wires. Common ly used in haul age ropes.
4. Nineteen-Wire Strand : Crea ted by covering a seven-wire strand with a seco nd layer or 12 wires. Typ icall y u) d in winding ropes.

Strand Twisting : The strands twi st around th e co re, sim ilar Lo screw threads. The direction of this twisting
detemunes whether the rope has a right-hand lay or a lcrt-hand lay.

(:>) Lang nghl-Mnd

{b) Lang ,en-hand

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,,·tst1ng: s trande d rop es
The indi, 1dual ,,·ires wi Lhin Lhe strands also twist around the strands. and the d1rcc l1011 of lhis twisting is
termed as Lang's lay for the same direction or ordinary lay for the oppos ite direct ion.
Rope Designation:
\\'i re ropes :ire typically designated by specifying the number of strands foll owed by Lhe 11[11nber of wires in
each strand. For example, "6 x 7" denotes a wi re rope made up of 6 strands, with each stra m, comprising 7
wires.

Exan1ple: 6 x 7 Wire Rope :

Tv!ade up of 6 strands, each strand consisting of 7 wires.
Simplest construction, mainly used fo r haulage purposes.

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 \[Link] Rope Co11st rn c tionN on stranded ropes
Central Portion : Consists o r thick round" ires formed into strands.
O uter Layer :
The outer layer (or layers) consists of spccin ll~ cd wi res, often in I-sectio n, rail section, or trapezoidal section.
interlocking,, nh one another to create a smooth andpla ne rope surface. ._______. - -
The interlocking design helps in enhancing strength and preventing the wires from slipping, providing durability and
stability.
3 No Stran d Structure:
In a non-stranded rope, there arc no distinct strands as seen in traditional stranded ropes.
The rope is constructed v,·ith concentric sheaths, each composed of special ly shaped wires interlocking with one another.
Non -Spinni ng Properties: The arrangement of wires in opposite directions w ithin different sheaths imparts non-sp inning
properties to the rope.
Locked Coil R ope:
A prime example of a non-strnnded rope is the locked coil rope, often utilized for wi nding and hois ting appl1cations.
The design of a locked coi l rope invo lves spec ially s haped int erlocki ng wires, contributing to increased SlTength and reduced
spinning tendencies.
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C ompariso n witJ1 Sb·anded R <'".',
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',on-stranded ropes (e.g .. locked coil) arc heavi er and stronger than s tranded ropes of the same diameter.
 Types of Non-Stranded Ropes
FULL LOCKED COIL ROPES
Ful l locked coil ropes are a unique assembly of
a classic w ire rope core consisting of multiple
he lically tw isted wires, with on top of that on
the outs ide one or more layers of profiled, Z-
shaped wires that interlock with each other.

HALF LOCKED COIL ROPES

Tbe Half Locked Coil consh1.1ction
have shaped wires and round wires side by
sid e v,rhich Lock into position on the outer
cover giving a smooth ro e surface excellent
fo r [Link] th standing ,,vear.
 Ad, antages of Non-Sti-anded W ire Rope :
'--L,-I·ugh Tensile Strength: Non-stranded wire ropes exhibit high tensi le strength, maki ng them sui ta ble for applications where
srrong and durable ropes are required.
2. Higher Strength and Weight Ratio: Non-stranded ropes are heavier and stronger compared to stranded ropes of the same
diameter.,. offering an excellent stTength-to-weight ratio. \
J ,5fuoth Exterior and Less Abrasion: The ropes have a smooth exterior due to specially shaped interrocking wires, causing
less abrasion and wear on the surface.
J ..-[Link] Properties: Th_y wires in non-strnnded ropes are arranged in a manner that reduces spinn ing, enhancing safety
and stability during operation. - - - - - ------ \
5. Ability to Withstand Radial Pressure: Non-stranded wire ropes can handle higher radial pressure com pared to other rope
types, making them suitable for applications with significant pressure
Disadvantages of Non-Stranded Wire Rope:
._6,-Com plex Constructfon: The constrnction of non-stranded wire n ·d
knowledge and ski lls.
7. Difficulty in Lubrication: Lubrication of the interior of non-st, j,

preventing easy access for lubrication. Half Loci< Full Loclc Full L ock

8. Inability to Splice: Non-stranded ropes cannot be spliced, whicl

9. Limited Flexibility: Non-stranded wire ropes are less flexil •••
••••••
n
applications requi ring high flexibility . •••••••
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. Difficulty in Capping: Capping, the process of protecting the
.lenging in non-stTanded rope
• 1 X 37 1 X 61
 WIRE ROPE LAY
The lay of a \\'tre rope describes the manner in whi ch either the wires in a strand . or the strands in
the ro pe , are laid in a helix.

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RIGH'TI ND l!AY, [!§M[M.

The term lay used i n ect ton of laying of

vvi-ss in the strand.
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Regular ) Lang 's
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Left
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f Right
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Left Right II
hand hand

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Untma r y Lay or Kegular Lay:
· Constr uctio n: Individual w ires within a strand and the stra nds themselves a re laid m opposite directions,
resu lting in a non-spinning rope.
• The opposite constructiona l characteristics prevent the rope from rotating.
•A dvantages : Non-rotating property makes them ideal for applications w here rotation is undesirable, such as in
cranes or other free ly suspended uses.
• Often utilized in shaft sinking operations.
Lang's Lay:
•Construction:
• In Lang's lay, both the individual wires within a strand and the strands themse lves arc laid in the same
direction, resulting in a more compact rope. \
•A dvantages:
· Compactness: Lang's lay ropes are more compact due to the same constructional cba rac teri s ics of wires
and strands laid in the same direction.
• Durability: Wear due to friction is even, contributing to the durability of the rope.
• Suitability for Haulages: Often used in rope haulages due to their durability and com pac tn ess.
•L imitations :
• Spinning Tendency: Lang's lay ropes have a spi nning tendency, making them un su it ab le for applications
v-,,here sp in11ing is undesirable, such as in shaft sinking or hoist drums.
• Free E nd Rotation: Sh ,, . . . ' - - o the sp inning tendency.
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1ens:ively used fo r mine v-._1indin g and hmil age duty due to their durabi lit y and compact nature.
Ordinary La y or Regular Lay :
•Constr·uc tion: Individua l w ires within a strand and lhe strands th emse lves are la id in opRosite j_irection
resulting in a non -spi nnin g rope. ---
• The opposite constructional characteris tics prevent the rope from rota tin g . \
·Advant~ s: Non-rotati ng property mcrkes 1fiemidea l for applicat10ns where rotation is u r1~esirable , such as
cranes or othe¼ [Link].s.p ended uses. ----- :.:::::=.:::::.
• Often utilized in shaft sinking operations .
Lang's Lay:
•Construc tion:
• In Lang's lay, both the individual wires within a strand and the strands themselve s are laid in the sa
~ ' resulting in a more compact rope. ~
·Advantag es: \ . !
Compactness: Lang's lay ropes are more compact due to the same cons tructio nal characteri stics of wi
and strands laid in the same directiori. -
· Durability: ~ e to friction is even, contributin g to the durabili.ty_o.Ltb.e---rope .
Suitability for Haulages: Often used in 1 ~ u e to their durabili ty and com pactness.
·Limitatio ns:
\__,Y""Spin ning Tendency : Lang's lay ropes have a spi1ming tendency, ma ki ng them uns uita bJ e for applic ~
~
where spim1ing is undesirabl e, such as in shaft si nking or hoist drums.
· Free End Rotation: Sh
·AppJkati ons:
o Lhe sp rnning tende· "
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 A ,vire is to be selected on following con sid eraLi ons
1 Corrnsive Enviro [Link] : ln walery and corrosive atmospheres, opl for ga lva nized ropes Lo pre vent rust and corrosion .
.., High Temp eratures: Avoid ropes with fiber cores in high-temperature settings, such as fou ndries or steel melting
facilities.
3. Stationary or Running Ropes:
• For stationa1y appl ications , use large diameter rods or strands, such as gu ide ropes in shafts .
• In s ituatio ns requiring running or coilin g ropes, prioriti ze flexibility achieved throug h a high nu m
with a regular lay for small drum coiling.
-1. Spmning or Rotation:
• Select non-spinning ropes or those with an ordina1y lay when one end is free to rotale, as seen in cra ne o
For sinking shafts, choose non-spinning ropes v,,ith locked coil co nstruction or ordi nmy lay.
1
5. Shock Load Resistance: Ropes dealing with shock loads should have a steel core, suitable for applica ti on liRe coal
cutting machine ropes.
6. Abrasive Wear Resistance: Ropes used for haulage and winders should be flexible and resis tant to abrasive wear.
Consider Lang's lay construction for improved wearing surface.

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«< 11149 >» I ~ □ <A A> I 63 X 8
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 A wi re is to be se lected on following co nsiderati ons

- Tensile Strength and Safety Factor:

Ropes fo r winding 1naterials 1nust possess high tensile strength and a suitable safety
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factor. ~

Lang's lay constTuction ropes offer greater stretch under load compared to regular lay
ropes.
8. Bending Fatigue: Choose flexible ropes with numerous s1nall wires to address the issue of
fatigue caused by repeated bending over sheaves or drums.
7 Groove Fit: Ensure that ropes fit neither too loosely nor too tightly in the groove of pulleys
or drnms. /
D Crushing and Distortion Resistance: Consider flattened strand ropes and lock~d coil
·opes, with a steel wire core for enhanced strength and resistance to crushing and distortion.
Regulatory Compliance: Ensure that the selected wire rope comp lies with relevant
sb.-y and safety regu] icabl e to the application.
 A w ire is to be selected on fo llow ing cons ideratio ns
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U::,---1'2. Budget Constraints: Take into account budget limitations and select a w ire
rop e that offers the required perfom1ance w ithin the allocated budget.
13. Compatibility: Ensure that the chosen w ire rope is compad ble with the 1

associated hardware, such as pulleys, sheaves, and connectors, t'\guaranteE

sm ooth operati on.
• 14. Maintenance Requirements: Factor in the ma intenance needs o\ the w irG
rop e, including insp ection, lubricati on, and replacen1ent schedules, ancl choose
ropes that align with maintenan ce capabilities. 1
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 Applicatio11 of wire ropes in tl1e [Link] round
The main application areas of the wire ropes in the und erground m·e :
, . Haulage ropes
" \iVinding ropes
~ Balance ropes
-4. Guide and rubbing ropes

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 Haulage ropes

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 Cl1oosing the right rope for haulages
For a \Yirc haulage rope to be suitable it has to be:
Strong enough and flexib le enough fo r the work it will have to do.
Matched as c losely as possible to the conditio ns in w hich it wi ll have to operate.
The work a haulage rope has to do and the cond itions in w hich it does it are known as its duty . There are a number o
factors to consider when selecting a suitable wire haulage rope of the right duty:
■ Length and ty pe of haulage;
■ Existing or planned layout of the rope haulage system;
■ Size and power of the haulage engine;
■ Gradients and bends;
■ Loads to be transported;
■ Frequency of use;
■ Conditions in w hich it is to be used;
■ Rope maintenance skills avai lable to the mine.

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 Choosing the right rope for haulages
T he failure of a steel wire hau lage rope whi le in se rvi ce is potenti a ll y d is~ p a d j,s1 il_!lr.l ~ ben being
used on a haulage _§..,~S tem . A ~pe failure during maleria1sfi1flTS]5ortcanaT fovl vehi c les to, run ou t of_controL
pu tting at risk any people in the roadway and potentially causing dam age to haula ge"'eqoipment, vehicles, the
track and even the roadway itself.
Failme of any rope w hile under tension results in the release of stored energy in the rope \ which usually
causes tbe broken rope ends to whiplash violently, resulting in dan ger to any people in th e 1111 1 ediate vicinity
of the breakage.
 Rope and strand constr uction for haulag e
· Only tw o rop e constructio ns , round stTand and triangular strand, are normall y used as ~aulage ropes.
• T he choice between a round sh·and rope or a triangular strand rope will cl epenc\ on whether
fle xibility or strength and resistance to external wear is the mos t important for a particular
application .

Rope Types
Rope Characteristics "UJ
Advantages Disadvanta ges W
Round sb·and • Fairly wide range of • Weaker than a triangular strnnd ro~
flexibility of equivalent diameter.
• More vulnerable to external
wear than a tTiangular strand rope
Triangular strand • Stronger than a round strand • Less flexible than round stra nd rope
rope of equivalent diameter.
• Withstands external wear
better than a round strand
rope

«( 24/49 ) )) J ~ 0 ¢,_ A> I Ei3 X 8

l 1 pe a nd direction of lay

There arc two mai n types of lay, Lang's lay and ord111a1y lay. The best lay for normal haL1lage purposes is
Lang's n ght-hand lay

Lang's lay rs better than ord111ary lay for withstand ing wear.

In ordmary lay, the w1res arc bent ve1y sharply around the strand on the outside of the rope . .tnd wear 1s
therefore concen trated on a short length of wire and rs likely to be deeper

Lays other than Lang's lay should be used only when there rs a special reason for domg so.

S urface finish
Gah amsed ropes are Sll!table for use 111 cond 1t1ons which are known to be wet or co1Tos1, c

Non-gah an ised ropes are suitable only where conditions arc dry
 Important points to reduce wear in haulage rope
..J PrO\·ide a smomh and steady haul.
-1 A. void all unnecessary bends in the rope .
\' ..J Plan road\\'ays \\'hich are as straight as possible .

..J Maximize [Link] radius of any bend around which the haulage rope must travel.
_J Guide the rope smoothly around bends on large wheels or on arcs consisting of a number of smaller pul leys.
_J Use large haulage engine drums or surge wheels.
:...J Use the largest pul leys or wheels practicable. If the rope has to change directi on by more than 1O''
wheel Lhe pu lley or wheel should be at least 48 x diameter of the rope.
:11

-1 Control the rope so that it runs between the rails on well -maintai ned and free-runn ing roller::- nHH1n1cd ,
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1ne pull.:: or
1ockets
wl11ch are clear of water;
..J Ensure that there are no obstructions, abrasives or water elsewhere in the path o f the rope.

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