Cleaning is integral to maintaining galvanized wire rope as it prevents internal and surface corrosion while significantly extending its operational life. This guide is of a general nature and does not delve into highly specialized areas such as maintaining elevator cables or crane ropes.
Always wear heavy-duty leather-faced gloves and safety glasses when handling wire ropes to protect against sharp, broken wires and cleaning chemicals. To clean and maintain it properly, follow a simple three-step regimen:
- Carefully inspect the rope for signs of wear or abuse,
- Thoroughly remove all old grease, grit, and contaminants, then
- Lubricate to protect and maintain the integrity of the wire rope.
How to Inspect Galvanised Wire Rope
Once the product is installed and subjected to use, an inspection will give you feedback on the sort of maintenance schedule you may want to consider.
- Inspect Routinely: Regularly inspect the rope along its length for broken wires, deformation, or changes in the rope’s diameter. Pay special attention to areas that cross sheaves, drums, or anchorage points. Also examine any terminations that are used on the wire rope and their continued existence is often critical.
- Assess Installation Location: If you need to store the wire rope, place it in a cool, dry, well-ventilated indoor location. Never leave coils resting directly on the ground; elevate them on pallets or racks. Cover outdoor storage with breathable waterproof fabrics rather than plastic foil, as plastic can trap condensation and cause rust.
- Assess Corrosion Factors: Where possible, reducing or eliminating factors that can cause of accelerate corrosion can make your life MUCH easier.
- Chemical Contact – exposure to oxidation accelerants – especially salt, chlorine, aggressive cleaning agents (acid or alkali) cause problems
- Atmospheric Conditions – high temperatures and high humidity are undesirable conditions.
- Surface Exposure – open surface exposure to the weather may reduce product longevity.
- Surface Finish – a smoother finish is better as it will accumulate fewer surface deposits (electroplate may perform better than a hot-dipped finish in some circumstances).
- Inappropriate Grade Selection – materials with a lower grade than G2070 (Marine Grade) are more susceptible to corrosive degradation.
- Poor Cleaning – the accumulation of deposits in the wire strand spaces hastens corrosion.
How to Clean Galvanized Wire Rope
Before applying any lubricant, clear accumulated dirt and hardened grime from the valleys (the small grooves between strands) to prevent it from grinding away the wire. Adding lubricant without proper cleaning simply creates a ‘cutting compound’
- Scrape First: Intent is to remove any thickened hardened grime or deposits. Use a synthetic putty knife, scraper, or a specialized wire rope cleaner tool to gently scrape off thick, hardened layers of old grease.
- Brush Next: Scrub the rope using a hard plastic bristle brush or a spiral Wire Rope Cleaning Brush. Note: Avoid both brass and steel bristle brushes on galvanized wire rope, as they can damage the zinc coating and cause discoloration.
- Wash Last: Use light solvent or soap in fresh water to remove the remnants. For heavy contamination, spray the rope with a compatible petroleum solvent, a low-pressure steam cleaner, or use warm water with a mild, non-alkaline laundry soap.
- Dry Completely: Allow the rope to dry completely before attempting to lubricate or use it.
How to Maintain Galvanised Wire Rope
Although galvanized wire is coated in zinc to resist rust, it still relies on internal lubrication to minimize friction between the moving steel strands. Strangely, it can be very instructive to think of wire rope as a machine unto itself. You can swab, drip, or spray the lubricant onto the rope. For large-scale maintenance, automatic wiper/lubrication systems (like a Viper lubricator) pump lubricant efficiently into the core and valleys.
- Use the Right Lubricant: Choose a high-quality wire rope lubricant that does not contain harsh acids or alkaline materials.
- Penetrate the Core: Start by applying a penetrating lubricant that can saturate the core of the rope.
- Apply Surface Coating: Follow up with a thicker coating lubricant to seal the outer surface and protect it from moisture.
- Wipe Excess: Wipe away any excess surface lubricant so it does not attract unnecessary dirt and grit.