Extend the life of your Steel Wire Ropes

What happens inside the rope when it is loaded?

When a wire rope is working on a winch, crane or hoist, every wire and strand moves slightly in relation to the others to accommodate the load. This internal movement creates friction – steel against steel – which gradually wears both wires and strands.

In addition to this internal wear, the rope is also influenced by external conditions such as:

• Weather and moisture
• Variations in temperature
• Contact with sheaves, winch drums and other equipment
• Exposure to gases, chemicals or dust

All of these factors will affect the rope’s condition and service life.

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Applying lubricant to a steel wire rope

Most steel wire ropes leave the factory with a light protective oil intended primarily for storage and transport. This factory-applied oil is not the same as a dedicated service lubricant and does not offer optimal protection during actual operation. For that reason, the rope should be treated with a suitable wire rope lubricant before it is put into service.

Lubricant can be applied in several ways, depending on the product type and the working environment:

• Spraying (aerosol or portable sprayer)
• Dripping
• Scrubbing
• Brushing
• High-pressure lubricator / lubrication device

As a general guideline:

1. Thin, penetrating lubricants are typically sprayed or dripped onto the rope.
2. Grease-like or gel lubricants are usually applied by brushing, scrubbing or using a grease gun.

For the most effective treatment, a high-pressure lubrication system is recommended. This method helps drive the lubricant into the rope’s interior so it can reach the core (provided the rope is not plastic-coated).

Selecting the right lubricant

The most suitable lubricant is determined by the operating environment and how the rope is used. Different products are optimized for different conditions, such as:

• Indoor vs. outdoor operation
• Wet, humid or marine environments
• High or low temperatures
• High-speed or heavily loaded applications

Ropetex lubricants are designed specifically for steel wire ropes and are available in various grades so you can match the product to the application. For more detailed guidance, see our brochure “Extend the service life of your steel wire ropes”. On page 15 there is a selection table that shows which Ropetex lubricant is recommended for which rope type and operating condition.

All wire rope lubricants share two key functions:

• Reduce internal friction and wear
• Protect the rope from external influences such as corrosion and contamination

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How much lubricant should be applied?

Determining the correct quantity is just as important as selecting the right product. A common mistake is to apply far too much lubricant.

Using excessive quantities:

• Wastes product unnecessarily
• Can seal the rope so tightly that moisture is trapped inside, increasing the risk of internal corrosion
• May cause contamination of surrounding equipment when surplus lubricant drips or is flung off the rope

For these reasons, it is important to apply only as much lubricant as the rope actually needs.

As a general rule of thumb, the required amount can be estimated using a simple calculation formula based on rope diameter and length. This provides a starting point that can be adjusted according to experience and specific operating conditions.

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