Unit 3
Wire Ropes
Types and Construction of Wire Rope
UNIT 3: Wire Rope
Types and Construction, Wire Rope Lays, Non- Stranded Ropes, Selection osf Wire Ropes, Ropes
used for different purpose, Mass & Strength of Wire Ropes.
• A wire rope is an important item of engineering materials in mining and many other
engineering industries.
• Wire ropes are made from steel wires and plain carbon steel having high tensile strength.
• the steel is as follows: (by welght, percentage). Carbon 0.5, silicon 0.11, manganese 0.48,
sulphur 0.033, phosphorus 0.014; iron rest.
• Wires for haulage ropes have a tensile strength more than four times that of mild steel. The
increased strength is obtained during manufacture, mainly by drawing the wire several times
through progressively smaller tapered holes in metal blocks or dies, steadily decreasing its
diameter and increasing its length. This elongates the grains of steel within the wire into
longer, fibre-like structures, leading to an increase in its tensile strength.
The ultimate tensile stength or breaking strength of the steel rods is about 65 kgf/mm2 (638 MN/m).
These rods undergo the process of patenting (or normalising), pickling and coating as well as
wire drawing. The ultimate tensile strength (breaking strength) of wires used for haulage/winding
ropes is generally between 140 kgf/mm2 and 170 kg/mm. (160 kgf/mm is equivalent to 1570
MN/m2).
The wire is subjected to the following tests carried out according to the standards prescribed by
I.S. specifications.
1. Tensile test.
2. Torsion test.
3. Bending test.
4. Wrapping test.
5. Looping test.
Some wire ropes are required to carry the burden or load bur more or less stationary, e.g. guy
ropes, guide ropes in shats blucker-supponting ropes in bicable aerials ropeways. Such ropes are
classified as standing rope Other types of ropes, classilied as running ropes, have to undergo
frequent movement, running or coiling often with varying loads and they have, therefore to be
flexible. The ropes used for winding, haulage, coal-cutting machines winches, excavators, cranes
are running ropes and compared to them the wires in the standing ropes are usually more robust in
section and fevwer in number as flexibility is not a major consideration with the latter.
On the basis of construction wire ropes are classified as:
(a) stranded ropes, and
(b) non-stranded ropes.
• A stranded rope is built up of strands and each strand consists of a number of concentrically
twisted wires laid in the form of a helix round a central steel wire. A seven wire strand consists
of a single centre wire, called king wire, covered by 6 concentrically laid wires and is common
in the ropes used for haulages.
• If the wires of such strand are covered with a second layer of 12 wires the resultant strand is a
19-wire strand which is normally used for windng ropes.
• In the flattened strand rope, described later, the king wire in the strand is of triangular cross-
section.
• Wire ropes are designated usually by stating the number of strands, followed by the number of
wires in each strand.
• For instance 6 x 7wire rope means that it is made up of 6 strands, and each strand is made up
of 7 wires. Such rope is the simplest construction and is used mainly for haulage purposes.
• For winding and hoisting 6 x 19 or 6 x 37 construction is preferred.
diagram of Wire Ropes
HAULAGE ROPE CHARACTERISTICS
1 A steel wire rope consists of many individual wires laid into a number of strands which are, in
turn, laid around a centre core.
2 The characteristics and strength of a wire rope of any given diameter and the uses for which it is
suitable are determined by:
a. type and size of wire;
b the number of wires in the strands;
c the type of core;
d the rope's construction.
3 The wire shapes used in the manufacture of haulage
ropes are as follows:
a. round - ie circular in cross section
b. triangular - ie triangular in cross
section, as used for the centre wires of
some strands
Stranded Ropes
A strand is formed by laying up or spinning one or more layers of wires around a strand centre. A
strand centre is either a single wire or is built-up of a group of wires (known as a built-up centre,
or BUC). The types and shapes of strands are as follows:
a. round
b. triangular
Stranded Ropes
• In a stranded rope the strands twist around the core like screw threads. If they twist in the same
direction as a right-hand thread then the rope is in right hand lay (Figures 5a and c). If the
strands twist in the opposite direction it is in left-hand lay (Figures 5b and d).
• The individual wires also twist around the strands. If the wires twist in the same direction as the
strands, then the rope is in Lang's lay (Figures 5a, b and 6a).
• If the wires twist in the opposite direction to that of the strands, then the rope is in ordinary lay
(Figures 5c, d and 6b).
• A stranded rope may be in Lang's right-hand lay (Figure 5a) or in one of the other three lays
shown in Figure 5. In most cases it does not make any difference whether right-hand or left-hand
lay is used (but see Technical Annex 2 on rope
diagram of laying in Wire Ropes
Wire rope lays
• The term lay used in relation to a strand indicates the direction of laying of wires, in the strand.
There are two types of lays, the right hand lay, and the left hand lay In a right hand lay the wires
sprial ound the core in thesame direction as the threads anght hand screw The opposite is
known asthe left hand lay. The length of lay is the distance measured along a straight line
parallel to the strand in which the individual wire forms one complete spiral round the strand.
• In the right hand lay the rope resembles a multi start right screw thread. The right hand lay is a
standared construction unless ordered otherwise by the user The laft hand lay construction is
not common for haulage ropes or winding pes used on drum winders but scmetmes
adoptedfor i.e. one rope with rightg hand lay and the adjacent rope of left hand lay. this prevent
untwisting of strands.
Lang's lay and ordinary lay Ropes
• A rope is of ordinary lay construction if the wires in the strand and the scrands in the rope are
laid in opposite directions. Ordinary lay is also known as regular lay.
• A rope is of Lang's lay construction if the wires in the strand are laid in the same direction as
the strands are laid in the rope Such construction causes the rope to spin. for this reason for
this reason lang's lay rope must never be used if there is free end to rotate. The advantage of
this lay is that the rope offers a also more resistant to bending fatigues. lang's lay rope are
favoured for windng and haulage purposes,not only because they present a much greater
wearing surface than the ordianary lay. but also because of they are not liable to break on the
crown of the strand unlike in ordinary lay.
• Lang's lay ropes have to be used carefully and are preferably operated with both ends of ropes
anchored. Regular lay ropes have the advantage that they are non-rotating since the strands
and wires, being laid in opposite directions, tend to balance each other's rotating tendency
They are ideal for use in places where they are freely suspended, such as in cranes.
Non Stranded or Locked coil Ropes
An example of this category is the locked coil ropes. The cross-section of lock coil rope shows
that the central portion consists of strands of thick round wires; only the outer layer (or two outer
layers) consists of round wires placed between specially shaped wirs of I section, rail section or
trapezoidal section so that the wires lock with one another and the rope surface is smooth and
plane compared to stranded ropes. By laying up the outer wires in the direction opposite to that of
the inner wires, locked coil ropes are made non- spinning and this is a major advantage in sinking
shafts where guide ropes are not installed.
The ropes are of full-lock or [Link]. The locked coil ropes are heavier and stronger
but less flexible than the stranded of the same dia. For winding and hoisting purposes a locked
coil rope is sometimes preferred because of Its high capacity factor which permits a high factor of
safety. A broken wire in a locked coil rope lies flat and it is possible to braze the ends together in
situ. The disadvantages of locked coil ropes are:
1. its construction is somewhat difficult,
2. its interior cannot be lubricated from outside.
3. it cannor be spliced,
4. it is not so flexible,
5. It is somewhat difficult to cap as compared with the stranded ropes.
Locked coil Rope
Factors affecting Selection of Wire Ropes
1. Watery place and corrosive atmosphere : Agalvarnised rope should be used in such places to
prevent rusting and effect of corrosive fumes.
2. High temperature : Rope with fibre core should be avoided in such places e.g. in foundries,
steel melting shops.
3. Stationary or running coiling rope : Stationary ropes can be large diameter rods or strands eg.
guide ropes in a shaft. Running or coilling ropes require flexibility and smaller the drum/pulley,
more is the flexibility required, eg. rope of a coal cutting machine which has to coil on a small
drum should consist of a large number of thin wires and the lay of rope should be "regular as it
give more flexibility.
4. Splining or rotating quality : In a crane rope, one end is free to rotate and a non-spinning rope
or one with ordinary lay should be used. In a sinking shaft, the sinking bucket is not travelling on
guides, therefore, a non-spinning rope of locked coil construction or a rope with ordinary lay
should be used.
5. Shock loads : Where a rope has to withstand shock loads, the core should be of steel e.g. coal
cutting machine rope crans, AFCs.
6. Resistance to wear: Ropes for haulages and winders have to be flexible and resistance to
abrasive wear. Such ropes should be of Lang's lay construction as they offer more weoring surlace.
7. Tensile strength and factor of safety Ropes used:- for winding of men should have high tensile
strength and high factor of safety than those used for winding of materials only. Rope of the
Lang'a lay construction stretches under load more than the rope of rogular lay construction.
stand.
8. Bending fatigue : Repeated bending of a wire over sheves or drums cases fatigue fallure of the
wires. The rope should be flexible which is possible in a rope having large number of rope smaller
wires.
9. Groove size : The rope should not be loose or too tight in the groove of the pulley or drum.
10. Crushing and distortion : A flattened strand rope and locked coll rope ts better able to withstand
crushing than a round strand rope. The core should be of steel wire.
Ropes used for different purposes
Generally ropes of the following construction are used in mines for different jobs.
Winding ropes : 6x 7 Lang Lay, EC.
6 x 19 Seale Regular or Lung Lay, RC.
6 x 21 Filler Wire Regular or Lang Lay, EC.
6 x 25 Filler Wire Regular of Lang Lay RC.
6 x 27 Flattened Strand Lang Lay, RC.
6 x 30 Flattened Strand Lang Lay, R.C.
Locked coil hoist Rope.
Winding ropes for shaft sinking :
19x7 Non-rotating Regular lay or Locked Coil Hoist Rope
Guide Ropes :-
Half locked coil guide ropes.
Haulage Ropes :
6×7 and 6 x 19 Seale Construction in cither Regular or Lang Lay,
FC., depending upon operating conditions.
Coal Cutting machine ropes :
6 x 37 Regular Lay with IWRC or 6 x 31 regular lay, IWRC,
Dipper Shovel Ropes :
(a) Dipper Hoist Ropes :
For 32mm and smaller size, 6 x 25 Filler Lang Lay with IWRC.
For 35mm to 68mm size, 6 x 41 Seale Filler Lang Lay with IWRC
(b) Crowd and Retract Ropes :
For 58mm and Smaller size, 6 x 41 Seale Filler Wire Lany Lay with IWRC.
(c) Boom Holst Ropes :
For 30mm size, 6 x 25 Filler Wire Lang Lay with IWRC.
Dragline Hoist Ropes:
For 32mm to S8mm size, 6 x 25 Piller Wire Lang Lay with IWRC on
6x41 Seale Piller Wire Lang Lay with IWRC.
Dozers:
6 x 25 PIller Wire Regular Lay with IWRC (Blade hoist ropes)
Aerial ropeways:
Bicable ropeway
Track Cables : Lock Coil, Full Locked or Half Locked,
Traction Rope : 22mm and Larger, 6 x 19 Seale Lang Lay EC, or 6×25 Filler
wire Lang Lay with IWRC
Monocable
6x7 Lang Lay, FC
6 x 21 Filler Wire Lang Lay FC.
Mobile Cranes :
Main Hoist Rope
6x 25 Filler Wire Regular Lay with Fibre Core.
(Use IWRC Ropes to take care of crushing of the rope on the drum).
Boorm Hoist Rope
6 x 25 Filler Wire Regular Lay with IWRC
Mass and Strength of Wire Ropes
The space factor of a rope is the ratio of aggregate cross sectional area of the wires to the area of
a circle drawn around the rope. For a six standed rope the space factor is between 50 & 60
depending on the design but it is about 75% for a locked coil rope.
The mass of a rope depends upon the quantity of steel in it, i.e. the space, factor, and the design of
the rope.
Mass of Rope = k*d2
where k is a constant depending on rope design
d is diameter of rope in cm
Mass of rope is in kg/m length of rope.
Breaking Strength of Rope = s*d2
where s is a constant depending on rope design and quality of steel
Breaking Strength of rope in KN.
Mass and Strength of Ropes
Type of Ropes Value of k Value of s
Round strand with fiber core rope 0.36 52
Round strand with wire core rope 0.40 56
Flattern strand with fiber core rope 0.41 55
Flattern strand with wire core rope 0.45 58
Locked coil rope 0.56 85
Question based on Wire Ropes
SHAFT A SHAFT B
Length of rope 4000m 5000m
Cage Load on rope 200 te 180te
Diameter of rope 0.5m 0.6m
Take the value of k and s is 0.36 and 52 respectively. Assume that there are 2 shafts
Find the followings
a. Maximum Life of rope and which authority decides the same?
b. Factor of safety of rope in shaft A and shaft B.
If the diameter of winding drum is 100 times the diameter of rope and distance between head
Pulley and winding drum is 200 m.
calculate the length of drum required for shaft A and Shaft B.
Question based on Wire Ropes
Solve the problem and calculate
a. FOS
b. Life of rope
c. Weight on rope
d. Breaking strength of rope
In a direct rope haulage system having lead distance of 990m from the loading point and dumping
point total number of tubs are 10. Each bucket having tare of 0.5 tonne and capacity of 2 tonnes.
The size of each tub is 2.5 m length and 1.2 m wide. The rope using in haulage is round strand
with fiber core of 60 mm diameter.
Question based on Wire Ropes
Wire Rope Question of GATE 2020