Do you know how to store the tower crane wire rope after you buy it?

Proper storage of tower crane wire rope is one of the most critical yet frequently overlooked steps in ensuring safe lifting operations. Even the highest-quality wire rope can lose strength, corrode prematurely, or become permanently deformed if stored incorrectly. To maximize service life and maintain safety, it is essential to understand the correct storage, handling, inspection, and usage requirements.

Below, we will first explain how to store tower crane wire rope, followed by key rules for usage, inspection, and maintenance.

1. How to Properly Store Tower Crane Wire Rope

Ideal Storage Conditions

Tower crane wire ropes should be stored in a dry, enclosed warehouse, preferably with an asphalt or concrete floor. This prevents moisture absorption and slows down corrosion.

If temporary outdoor storage is unavoidable:

Place wooden sleepers on the ground to elevate the wire rope.

Cover the rope with waterproof material to prevent rain exposure.

Ensure good ventilation to avoid condensation buildup.

Maintaining Lubrication During Storage

Wire ropes must remain well-lubricated during storage.

If the wire rope is stored for more than six months, it should be re-lubricated.

Before relubrication:

Clean the surface thoroughly—remove dust, dirt, rust, and old grease.

Use a galvanized steel wire brush for best cleaning results.

Only then apply fresh lubricant so it can properly penetrate the strands.

Recommended Lubrication Methods

Brush Coating Method

A heated (about 60°C) wire rope grease is manually brushed on using a specialized brush.

Immersion Method

The rope is passed through a container filled with lubricant heated to about 60°C to ensure deep penetration.

Recommended grease: High-quality calcium-based graphite grease, free of acid or alkaline substances.

2. Specifications and Markings: Why They Matter

Each tower crane wire rope must have clear specifications and markings, including:

• Rope structure

• Diameter

• Tensile strength

• Rated breaking force

The breaking force is a key safety parameter and determines:

• Safety factor

• Allowable working load

Breaking force depends on the rope diameter, structural design, and wire strength. It is typically calculated by multiplying a conversion coefficient by the total breaking force of the individual wires.

3. Determining the Allowable Load of a Wire Rope

Wire ropes are subjected to:

• Bending forces

• Tensile forces

• Friction

• Occasional shock loads

Therefore, a safety factor must be applied.

Safety Factor = Actual Breaking Force ÷ Allowable Working Load

Once the safety factor is known, the maximum allowable load can be calculated:

Allowable Load = Total Breaking Force ÷ Specified Safety Factor

Choosing the correct allowable load is essential for preventing wire rope failure during lifting operations.

4. Wire Rope Inspection and Discarding Standards

How Often Should You Inspect a Tower Crane Wire Rope?

• Weekly: Routine visual inspection

• Monthly: Detailed inspection according to crane maintenance standards

Wire ropes undergo:

• Stretching

• Bending over sheaves

• Compression

• Friction

As the number of bending cycles increases, wires begin to break. Corrosion and wear accelerate this process.

When to Discard a Wire Rope

A wire rope must be removed from service when:

• The number of broken wires in one lay length exceeds the specified limit

• Severe wear, corrosion, birdcaging, or deformation is found

Minor broken-wire burrs should be removed with pliers to prevent hazards.

Detailed discard criteria can be found in relevant national and crane safety standards.

5. Usage Guidelines for Tower Crane Wire Ropes

Handling and Uncoiling

Wire ropes are usually supplied on reels.

To avoid twisting, kinking, or looping, never pull the rope off the side of the reel.

Correct method:

• Place the reel on a rotating stand

• Ensure the rope pays off in the same direction it will be wound onto the drum

Winding Onto the Drum

• Use a rotating support stand to keep tension consistent

• Ensure the drum’s groove direction matches the rope’s lay

• Check pulley edges for cracks before threading the rope

If a rope contacts a sharp structural edge, always place wooden padding underneath to prevent damage.

Storing a tower crane wire rope correctly after purchase is the first and most essential step in ensuring safety, performance, and long service life. Proper storage prevents corrosion, deformation, and lubrication loss—problems that can later cause serious safety risks.

Combined with correct usage, regular inspections, and compliance with safety standards, these practices help ensure reliable and safe lifting operations for any construction project.