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    Technical Information  
  Use and Care of Wire Rope  
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    Installation of Wire Rope:  
  Foreword, Measuring the rope diameter  
  If you have to cut a rope  
  Unreeling the rope  
  Connecting the old rope to the new rope  
  Rope lay direction versus Drum Grooving  
  Winding on to the drum  
  Installation of Wedge Sockets  
  Using your rope for the first time  
  Efficiency ratings of end terminations  
    Inspection of Wire Rope:  
  How to inspect Wire Rope  
  Crown- and Valley Wire Breaks  
  Number of broken Wire Discard Tables  
  Reduction of diameter, Rope Wear  
  Rope Stretch, Core Wire breaks  
  Mechanical damages  
  Corrosion, Rope Removal and Cause  
    Maintenance:  
  Inspection of Sheaves and Drums, Dimensions of Groove Radius  
  Cut and Slip Procedure, Lubrication  
    Rope Properties & Data:  
  Tensile Strength and Fill Factor  
  Strand- and Swage Compaction  
  Rotation Resistant and Non-Rotating Wire Rope  
  Sheave and Drum Dimensions  
  Relative Service Life, Loss of Strength over Pins, Why Multistrand Ropes  
Technical Information – Rope Properties & Data
 
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The breaking strength of wire rope can be increased in two ways: either by increasing the wire material TENSILE STRENGTH or by increasing the rope's FILL FACTOR.
     
Tensile Strength
The wires of wire rope are made of high-carbon steel. These carbon steel wires come in various grades. Wire ropes are usually made of Extra Improved Plow Steel (EIPS) or Extra Extra Improved Plow Steel (EEIPS) which roughly equivalents to a wire tensile strength of
1960N/mm and 2160N/mm.

As one can see from the tables, the difference in the rope's breaking strengths by increasing the material tensile strength is only about 10%.
 
     
Fill Factor
In order to further increase the breaking strength of wire rope one has to increase the rope's fill factor.

The fill factor measures the metallic cross section of a rope and compares this with the circumscribed area given by the rope diameter. Traditional rope constructions 'fill' the rope diameter only up to about 58% with steel. Python® and Compac® wire rope 'fill' the rope diameter up to 80% with steel. That is an metallic increase of about 38% which results in a similar increase in rope strength.

Two methods can be employed: Selecting a different rope CONSTRUCTION or COMPACTING/DIE DRAWING the rope/strands.

Many high strength rope constructions use both methods at the same time.
 
Fill Factor of different rope constructions
 
     
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