TECHNICAL CONCEPT

WIRE ROPES
Wire Rope is a critical component in so many industrial
applications across the world.
Wire ropes simply comprise of continuous wire strands
wound around a central core & are commonly used in crane,
tower crane, surface and underground mining, excavation,
logging of any type of terrain, tramway, elevator, oil and gas,
drilling, marine and electrical constructions etc.

COMPONENTS OF WIRE ROPES

WIRES
Wires are the smallest component of wire rope and
they make up the individual strands in the rope. Wires
can be made from a variety of metal materials
including steel, iron, stainless steel and bronze. The
wires can be manufactured in a variety of grades that
relate to the strength, resistance to wear, fatigue
resistance, corrosion resistance, and curve of the wire
rope.

STRANDS
Strands of wire rope consist of two or more wires
arranged and twisted in a specific arrangement. The
individual strands are then laid in a helical pattern
around the core of the rope.

CORE
The core of a wire rope runs through the center of the rope
and supports the strands and helps to maintain their
relative position under loading and bending stresses. Cores
can be made from a number of different materials
including natural or synthetic fibers and steel.
 DESIGNATION OF WIRE ROPE
A typical strand and wire designation is 6x19. This
denotes a rope made up of six strands with 19 wires in
each strand..

CLASSIFICATION OF WIRE ROPES WITH RESPECT TO

APPLICATIONS
Wire ropes faces two types of the working conditions in
it's life span:

1. Static :

Static ropes are employed to support structures like

buildings, bridges etc.

As there is no movement, wire strands doesn't offer

friction to each other.

So there is little need of relubrication for this type of wire

ropes.

2. Dynamic:

Dynamic ropes are utilized in heavy equipment

applications for lifting or hauling purposes.  

In this type of applications wire ropes witnesses critical

working conditions like heavy load, temperatures etc.

Hence it is required to monitor & lubricate these type  of

wire ropes properly with frequent intervals with right
quantity.
COMMON TYPES OF WIRE ROPE FAILURE
Mechanical Damage due to
Lopped wires as a result of
rope movement over sharp
torsional imbalance or
edge projection while
shock loading
under load

Localized wear due to Multistrand rope Bird cage

Abrasion on supporting due to torsional imbalance 
structure

Narrow path of wear Protrusion of rope center,

resulting in Fatigue resulting from built up of
Fractures caused by tum 
working in a grossy
oversized groove or over
small support rollers

Severe wear associated High operating temperature

with High thread pressure results in wire strand
damage  

Primary stage of corrosion Two parallel paths of

& weakening of wire broken wires indicative of
strands results in failure of Bending Failure through an
wire rope undersized groove in the
sheave 

Severe Corrosion Typical example of localized

wear and deformation

Internal corrosion while

Wire fractures at a strand or
external surface shows
core interface as distinct
evidence of deterioration 
from 'crown' fracture.
LUBRICATION OF WIRE ROPES
Wire rope lubricants have two principle 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

DESIRED PROPERTIES OF WIRE ROPE LUBRICANTS

1. Should penetrate easily to the core of the wire rope

2. Should not contain grit, sand, other abrasives, water, chlorine, or similar impurities

3. Must be water-resistant and non-emulsifying

4. Should be free of additives and compounds which result in corrosive reactions or

degeneration

5. Should ensure flexibility of wire rope is maintained over a longer period

LUBRICATION METHODS TO BE ADOPTED
1. Penetrating type :

 Penetrating lubricants contain an evaporative solvent that facilitates migration of the lubricant
into the core of the wire rope, then evaporates, leaving behind a heavy lubricating film that
protects and lubricates each strand.

2. Coating type :

Coating lubricants penetrate slightly and seal the outside of the cable from moisture, reducing
wear, rust and corrosion.

3. Combination of Penetrating & coating type :

Depends upon requirements we can adopt combination of both to get required results 
MOSIL'S SOLUTION
PENETRATING TYPE WIRE ROPE LUBRICANT:
WR - 100 :   Lubricant fortified with high quality Molybdenum Disulfied for excellent lubrication effect

WR - 101 :  Quick & efficient way to lubricate wire rope

WR - 100P : Heavy duty adhesive type wire rope fluid (finished film)

KEY BENEFITS 
1. Penetrates into inner strands providing effective lubrication

2. Ensures long lasting thin water & corrosion resistant film on the rope

3. Extends re - lubrication interval

4. Withstands heavy load

CONCLUSION 
To sustain the life of wire rope, it is necessary to adequately relubricate them at regular intervals.
Rope tests show that the service life of a regularly relubricated wire rope is two to three times
longer than that of a dry rope.

MOSIL offers new generation wire rope lubricants that  provide efficient relubrication of the wire
ropes thus ensuring longer life of the wire ropes.

SATISFIED CUSTOMERS