Wire ropes, essential components in industries such as mining, construction and transportation, require careful lubrication to ensure their longevity and safe operation. Ron Byrnes, senior technical sales representative and wire rope specialist at Lubrication Engineers (LE) South Africa, emphasizes that proper lubrication is crucial, emphasizing that wire ropes are complicated machines and not just cables. With over 30 years of experience in the field, including working with large mines in southern Africa and wire rope manufacturers, Byrnes explains that wear in wire ropes occurs not only between individual wires, but also between strands as they move against each other.
Byrnes emphasizes that without lubrication, wire ropes are susceptible to corrosion, which can lead to gradual loss of steel in the rope components. This internal wear is often difficult to contain and cannot be managed without sufficient lubrication. While rust corrosion is a problem, internal friction and wear are the main causes of rope failure. Proper lubrication helps mitigate these effects, extending the service life of wire ropes and improving operational safety.
Despite the importance of lubrication, Byrnes notes that many industries take an inconsistent approach to rope maintenance. Operations teams often rely on visual inspection and intermittent lubrication, with a more thorough assessment only occurring with non-destructive electromechanical testing. To improve these practices, Byrnes advocates for an “application theory approach” that focuses on understanding both the function of the wire rope in its specific application and the behavior of the lubricant in reducing wear and corrosion.
In South Africa, where both locally manufactured and imported wire ropes are used, lubrication practices vary depending on the type of lubricant used in manufacturing. A bitumen-based lubricant is commonly used on site, but Byrnes emphasizes that this does not necessarily dictate the best approach to maintenance. He recommends LE's Wirelife Monolec Penetrating Lubricant 2001 for imported heavy-duty wire ropes and LE's Wirelife Almasol Coating Grease 452 for round, non-spin and 6-strand triangular ropes. These lubricants are designed to penetrate into the spaces between the rope and remain effective even when applied to ropes with pre-existing bitumen-based coatings.
Byrnes also highlights the benefits of using a Viper rope lubricator, a device that ensures consistent lubricant application while cleaning the rope of old lubricants. The system helps massage fresh lubricant into the core of the rope, ensuring optimal lubrication and improved performance.
The benefits of these modern lubricants go beyond performance. Bitumen-based lubricants can become brittle in cold temperatures, throwing off the rope and causing damage. In contrast, Wirelife Almasol Coating Grease 452 remains effective in a wide temperature range from -20°C to over 120°C. In addition, LE's products meet strict environmental standards, produce fewer harmful emissions and reduce safety risks compared to bitumen-based lubricants.
Byrnes also emphasizes the importance of aligning lubrication practices with health and safety regulations such as the Mine Health and Safety Act and OSHA standards to protect workers and the environment. A more systematic and scientifically based approach to wire rope lubrication can significantly improve the safety, performance and sustainability of these important components in various industries.
