SPECIAL STEEL WIRE ROPES LTD.

PROCESS

 

THE PROCESS

Making the best possible quality of steel wire ropes is a complex procedure. It requires expertise of a great degree to produce an international standard product of high grade performance and durability. At Special Steel Wire Ropes, we believe in leaving no stone unturned. Our high-tech production facility is fully equipped with all the machinery and production requirements to create world-class steel wire ropes and slings. We also have well qualified and well trained personnel who operate this advanced machinery. They include a judicious mix of both
skilled and unskilled talent. A detailed explanation of the complete steel wire rope making process is given below.

1. Primary Pickling:
   The raw batch of steel rods are generally unclean and sometimes slightly corroded. A primary pickling is done, in order to remove any corrosion and cleanse the rods of impurities. This is done by means of a wash cleansing of the rods in cold hydrochloric acid, and then rinsing them under a clean water jet.
2. Patenting:
   Special Steel wire ropes are made from high carbon steel rods. These steel wire rods are heat treated above their point of transformation wherein they gain a homogeneous granular structure. This process is called 'patenting'
3. Secondary Pickling:
   Oxide forms on the surface of steel wire rods after patenting and heat treatment. It is a due to a chemical reaction that takes place. This makes it important to cleanse the steel wire by immersing and treating it in a tank of cold hydrochloric acid, then rinsing it thoroughly well under a jet of water, and finally coating the wire surface with a layer of protective phosphate.
4. Drawing:
   Drawing is a cold process that involves plastic deformation of steel, which makes the wires acquire their eventual mechanical characteristics in the aspects of shape, size and basic fundamental physical properties.
5. Galvanization:
   To protect and secure the quality of the wire, especially in a corrective atmosphere, a coat of zinc is applied by the 'Hot Dip' process wherein the wire is passed through a molten zinc bath. This process is known to make the wire more corrosion resistant and more break-proof.
6. Inspection Post-Galvanization:
   A few random samples from the galvanized coil are inspected for extra amounts of zinc coating and uniformity of coating. Other physical properties are also checked, like the tensile strength, elongation, wrapping of the wire, etc.
7. Winding: Finished and ready wires in their coil form are wound onto bobbins to be fed into stranding machines. This is the process of winding the wire just before stranding
8. Stranding: Stranding is the process where a predetermined number of wires are helically laid around a center to form a structural unit called a 'Strand'
9. Inspection Post-Stranding: Strands samples are checked for all the properties stipulated in the standard, like breaking strength, resistance, flexibility, proof stress, lay length, etc.
10. Roping: A specific predetermined number of strands are laid helically around a steel or fiber core to make the final Steel Wire Rope. This procedure is known as 'Roping'
11. Lubrication: The process of lubrication is done along with roping. An optimal amount of lubricant is applied upon the steel wire rope, in order to ensure resistance towards abrasion, corrosion and other damage. It gives more flexibility to the wire rope. Different types of wire ropes need different types of lubrication depending upon the usage and composition
12. Packing: Single wire coil or strands are packed in a way such that the reel is maintained intact during transit or storage. Proper packing also ensures protection against rust and external damage