WIRE ROPE PRODUCTS Guide
The Wire Rope Products Guide provides definitions and graphics for a comprehensive look at the industry’s most popular wire rope products. Our aim is to provide you with clear and concise explanations that will empower you to make informed decisions and confidently navigate the complexities of wire rope selection and usage.
A
AIRCRAFT CABLE (7×7, 7×19) — Stainless Steel & Galvanized
Definition:
Aircraft cable is a flexible cable construction made in 7×7 or 7×19 strand patterns, commonly used in mechanical, architectural, and industrial applications where flexibility and smooth handling are needed.
GAC: Galvanized Aircraft Cable
SSAC: Stainless Steel Aircraft Cable (typically stainless steel 302/304)
Key standards and specifications:
- Commercial grade: RR-W-410 Type VI, class 2 (7×7), class 3 (7×19)
- Commercial grade: ASTM A1023
- Military specification: MIL-DTL-83420 (required for critical aerospace use)
- Typical diameters: 1/32” through 3/8”
Important note:
The term “aircraft cable” does not automatically mean aerospace-certified. For critical aerospace applications, use MIL-DTL-83420 only.
Related terms: Wire Rope, Strand
B
BLACK AIRCRAFT CABLE
Definition:
Black aircraft cable is aircraft cable with a black surface finish applied for appearance, glare reduction, theatrical or architectural use.
How it’s made:
- Galvanized cable with a black finish (commonly powder coating or anodizing)
- Typically 7×7 or 7×19 stranding constructions
- Stainless steel cable may be finished with black oxide
Related terms: Nylon Coated Cable, PVC/Vinyl Coated Cable, Aircraft Cable
F
FIBER CORE (FC) WIRE ROPE
Definition:
Fiber core (FC) wire rope is wire rope with a center core made from fibers such as polypropylene material rather than steel. For elevator application sisal core may be used. For conveyor application polycore may be used.
Why it matters:
- More flexible than IWRC
- Lower strength than an equivalent IWRC construction
- Available Bright (plain with lube) or Galvanized (dry or lubed).
- Available in 6×19 class and 6×37 class
- Commercial grade: RR-W-410, ASTM A1023
Common applications:
General lifting, flex-focused applications; specialty polycore use cases such as some conveyors.
Related terms: Independent Wire Rope Core (IWRC), General Purpose Wire Rope
I
IMPREGNATED WIRE ROPE
Definition:
Impregnated wire rope has plastic (typically polypropylene) material surrounding individual wire strands to reduce internal friction and increase corrosion resistance Sometimes called PFV (poly filled valley).
Benefits:
- Reduces strand-to-strand rubbing
- Improves wear resistance
- Adds protection from condensation and moisture which is helpful in corrosive environments such as salt water and chlorinated water
Related terms: Compacted/Swaged Wire Rope, General Purpose Wire Rope
INDEPENDENT WIRE ROPE CORE (IWRC)
Definition:
Independent wire rope core (IWRC) is wire rope with a steel wire strand core (typically 7×7)running through the center, with outer strands laid around it.
Why it matters:
- Higher strength than FC constructions
- Better performance under heat and heavy load conditions
- Available in 6×19 class and 6×37 class
- Commercial grade: RR-W-410, ASTM A1023
Related terms: Fiber Core (FC) Wire Rope, General Purpose Wire Rope
N
NYLON COATED CABLE
Definition:
Nylon coated cable is cable with a nylon “jacket” that provides protection and improved performance in cycling and abrasion environments. For example, fitness cables cycling over pulleys or sheaves require nylon coating.
Common materials:
- Many nylon coatings use nylon 6
- Nylon 11 is used when higher cycling performance and friction resistance are required
- MIL-DTL-83420 Type 2 uses a clear/natural nylon 11 jacket
- Typically 7×7 and 7×19 constructions and less commonly 6×19 class and 6×37 class
Related terms: PVC/Vinyl Coated Cable, Black Aircraft Cable
P
PVC / VINYL COATED CABLE
Definition:
PVC (vinyl) coated cable is a cable with a PVC jacket designed to protect the cable and improve handling ergonomics and color appearance.
Notes:
- “PVC” and “vinyl” refer to the same jacket material in this context..
- Typically 7×7 or 7×19 and less commonly 6×19 class and 6×37 class
- Commercial grade: RR-W-410, ASTM A1023
Related terms: Nylon Coated Cable, Black Aircraft Cable
S
STRAND
Definition:
In wire rope terminology, a strand is a single structural element made of multiple wires (for example, 1×7 or 1×19) and is not the same as a complete wire rope construction.
Key specifications:
- Low flexibility ideal for straight applications where rigidity and low stretch are helpful such as messenger wire and guy wire
- 1×7: Commonly ASTM A475 galvanized EHS (extra high strength) used for guying towers, barriers, and related applications. Also available in galv per ASTM A363 or stainless per ASTM A368
- 1×19: Common in architectural cable railing
- Mil spec strand: MIL-DTL-87161
Related terms: Aircraft Cable, Wire Rope (General Purpose)
W
WIRE ROPE — COMPACTED / SWAGED
Definition:
Compacted wire rope is wire rope with strands that have the outer wires mechanically flattened to increase breaking strength and abrasion resistance.
Swaged wire rope is wire rope that’s mechanically compressed to a smaller (denser) diameter which increases breaking strength and abrasion resistance.
Common notes:
- Often available in bright (plain steel with lube)
- Typical applications include logging
- Galvanized compacted is less common but may be used for commercial zip lines
- Available in general purpose 6×19 class and 6×37 class
- Available in rotation resistant constructions including 8×19 class (8×25) 19×7 class (19×19), 35×7 class
Related terms: General Purpose Wire Rope, Impregnated Wire Rope
WIRE ROPE — GENERAL PURPOSE (6×19 CLASS / 6×37 CLASS)
Definition:
General purpose (GP) wire rope refers to common wire rope constructions built with six outer strands around a core, typically in the 6×19 class or 6×37 class. 6×37 class is approximately twice as flexible as 6×19 class.
Plain-language guidance:
- RR-W-410 Type I, Class 2, 6×19 class:
- includes Construction 4, 6×25 Filler Wire
- includes Construction 5, 6×26 Warrington-Seale
- RR-W-410 Type I, Class 3, 6×37 class:
- includes Construction 6, 6×36 Warrington-Seale
Related terms: IWRC, Fiber Core (FC) Wire Rope, Rotation Resistant Wire Rope
WIRE ROPE — ROTATION RESISTANT
Definition:
Rotation resistant wire rope is designed with alternating strand layers to reduce twisting and rotation under load.
- RR-W-410, Type I, Class 4, 8×19 class
- RR-W-410, Type II, Class 2, 8×19 class for elevator application
- RR-W-410, Type III, Class 4, 8×19 class
Examples (in increasing rotation resistance):
8×19 class (8×25), 19×7 class (19×19), 35×7 class
Related terms: General Purpose Wire Rope, Compacted/Swaged Wire Rope
Guides And White Papers
Want to learn more about Lexco’s wire rope specifications, or see
them in action yourself? Get started with some of our guides:
Discover an extensive range of cutting-edge products and components by exploring Lexco’s impressive line card, designed to meet the diverse needs of nearly every industry.
Make informed decisions and select the perfect products tailored to your specific requirements by exploring Lexco’s carefully crafted spec sheet.
Make informed decisions and select the perfect products tailored to your specific requirements by exploring Lexco’s carefully crafted spec sheet.
Discover an extensive range of cutting-edge products and components by exploring Lexco’s impressive line card, designed to meet the diverse needs of nearly every industry.
Make informed decisions and select the perfect products tailored to your specific requirements by exploring Lexco’s carefully crafted spec sheet.
Get an inside look at Lexco Cable-who we are, what we do, and why we’re the best cable manufacturer in the industry.
