Advantages of Fiber

Rope Over Wire Rope

GALE P. FOSTER*
Technical Director
Cordage Institute
2907, Hockley Drive
Hingham, MA 02043, USA

ABSTRACT: Over the years, fiber ropes have increased in strength to the point
where they began to replace wire ropes in some applications. The major factors have
been the development of high tenacity fibers and the advancements in fiber rope
constructions. This started with high tenacity nylon and polyester fiber ropes, ropes
combining both of those fibers, the combining of polyester and polypropylene ropes
and ropes combining polypropylene and polyethylene. This was followed by the
development of high-tech fibers, with the result that stronger and stronger ropes
could be produced to the ultimate where a fiber strength member can provide a 10–1
strength-to-weight ratio advantage over wire rope. At the same time, new finishes for
fibers were developed that improved durability and strength retention, new
constructions were able to provide increased translation efficiency, and better
inspection and testing methods were developed. Application advantages are
discussed, each having a number of factors that reduce costs, even though the
actual cost of the fiber strength member may be slightly higher than for wire. The
result is a rationale that when the cost of a flexible strength member is fully measured
there is a strong reason that a fiber strength member, when compared with a wire
rope, can save money and improve operations in an increasing range of applications.

KEY WORDS: fiber rope, cordage, para-aramid, high-modulus polyethylene, liquid

crystal polyester, LCP, PBI, HMPE, PBO, strength member.

*E-mail: Ropecord@aol.com

JOURNAL OF INDUSTRIAL TEXTILES, Vol. 32, No. 1—July 2002 67

1528-0837/02/01 0067–9 $10.00/0 DOI: 10.1106/152808302031656
ß 2002 Sage Publications
68 G. P. FOSTER

INTRODUCTION

HE NEED TO pull, haul, lift, hoist, hold, or otherwise control objects has
T been around since the beginning of civilization. In the earliest days it
was simply an assemblage of vines, which then developed into the use of
vegetable or natural fibers from plants, usually indigenous to a particular
region. The pyramids of Egypt and the Aztec dwellings of Mexico, among
others, could never have been built without these indigenous fibers, very
probably aided by some mechanical schemes which today would be
identified as block and tackle. The names for this assemblage of fibers
twisted together in strands to form a strong, flexible and round strength
member became cordage and rope.
As civilization became more progressive so did the ‘‘assemblage’’ of
fibers. Going a step further and checking Webster’s Third International
Dictionary we find an interesting analogy: a machine – ‘‘an assemblage of
parts that transmit forces, motion, and energy one to another in some
predetermined manner and to some desired end’’. The machine concept
suggests that in the 21st Century, fiber cordage and rope has progressed to
the point of being one of the most versatile and effective ‘‘machines’’ in the
world.

Fiber Development

The birth of nylon polyamide fiber in the late 1930s started the concept of
industrial-grade fibers. Fibers of higher-tenacity were developed, including
nylon, polyester, polypropylene and polyethylene, making it possible to
produce flexible tension members of much higher strength and durability.
Industrial nylon and polyester, originally offshoots of tire yarns, typically
500 denier or greater, began to be tailored with tenacities and properties
important to rope applications. Today, the industrial fibers are defined as
those with an average tenacity between 7.0 and 15 gpd.
The birth of the para-aramid KevlarÕ , and similar fibers, such as
TechnoraÕ and TwaronÕ , represented a quantum leap in fiber development
(see note in acknowledgements re trademarks and source of information).
The availability of such materials introduced the concept of high
performance, high modulus fibers that are considered to have tenacities
greater than 15.0 gms per denier. At the same time, industrial grades of
polyester were being improved. Although these fibers did not get into the
15 gpd range, they provided better quality, and the use of marine grade
overlay finishes significantly increased abrasion resistance. Other high
strength/low elongation fibers have come into the market, which include
HMPE (high modulus polyethylene) fibers such as DyneemaÕ and
 Advantages of Fiber Rope Over Wire Rope 69

Table 1. Fiber tenacities (grams/denier).

Polyester Over 10
Para-aramids 18–29
LCP 22–27
HMPE 25–41
PBO Over 42

SpectraÕ ), LCP (liquid crystal polymer) fiber VectranÕ ), and PBO (poly-
para-phenylene bisoxazole) fiber ZylonÕ .
This gave the cordage and rope industry five low elongating fiber
types that could be used to build strength members that in turn made it
possible to expand the applications for fiber ropes, especially those that
previously used wire rope. These fibers and their respective tenacities are
shown in Table 1.
The physical and environmental properties of these fibers are extensive
and make it possible to tailor ropes to specific applications. The major
commonalities are high strength-to-weight ratios, low elongation, minimum
moisture regain and a high modulus. Specific gravity, creep resistance and
abrasion resistance are advantages available in some types. The Cordage
Institute in the United States provides Guideline CI 2003 that provides a
comparative listing and detailed information can be obtained from
individual fiber manufacturers.

DISCUSSION

Flexible Strength Members

The major difference between fiber rope and wire rope strength members
is the strength-to-weight ratio. For fiber ropes using the high-tech fibers
advantages up to 10–1 can be achieved over steel. This factor permeates
many of the advantages of a flexible fiber strength member, when compared
to a flexible wire rope. For example, comparing three ropes with the same
125,000 lb breaking strength, the density or weight per 100 feet between
fiber and steel, as shown in Table 2, are dramatic. These weight differences
become very important when you consider that the rope must support not
only the weight of the load, but its own weight as well.
Both fiber rope and wire rope depend on a variety of constructions to
translate the strength of the fiber or wire into a strength member. The
ultimate strength member needs to have good translation efficiency and be
suitable for a given application. The Wire Rope Users Manual, produced by
70 G. P. FOSTER

Table 2. Weight (lb) per 100 feet of rope.

Wt. (lb) Wt. (lb)

Material In Air In Water

Steel 185 161

Aramid 36 10
HMPE 26 0

FIGURE 1. Fiberlay/Cablelay Rope.

FIGURE 2. Three-Strand Rope.

the Wire Rope Technical Board (Tel. 410-461-7030), lists some 37 different
constructions for a wide range of applications, while fiber ropes are based
on a relatively few constructions. The original fiber ropes were three-strand
and stayed that way into the 1950s. As the variety of fibers expanded, new
constructions were developed to improve translation efficiency and to make
them more effective with new applications. The result has been that fiber
strength members can be designed for most applications based on eight
basic constructions: Twin-PathÕ Roundslings, 4-strand ropes, 8-strand
(plaited) ropes, single and double braided ropes, kernmantle ropes, cablelay
ropes, wirelay ropes and Coated/Jacketed/ParallayÕ ropes (Figures 1–4).
 Advantages of Fiber Rope Over Wire Rope 71

FIGURE 3. Eight-Strand Rope.

FIGURE 4. Double-Braided Rope.

These constructions can be 100% of a given fiber or use a combination of

fibers to provide specific properties and advantages for a given application.
There can also be various types of jackets and coatings to provide improved
durability and stiffness for a rope. In Twin-Path RoundslingsÕ , for example,
a combination of para-aramid and HMPE are combined for very heavy lifts.
In sailboat rigging, HMPE and polyester can be combined to achieve overall
lower cost along with lighter weight, good abrasion resistance and good
handling on winches.

Application Advantages

With a weight advantage of up to 10–1 compared to flexible wire, use of

fiber rope results in lower weight per foot, reduces the size of related
equipment and hardware and significantly reduces manpower requirements
and exposure to injury. Many applications, especially in the marine
environment, place great importance on the weight of a strength member,
especially in water. Compared to wire, para-aramid based ropes have a
density less than one-fifth (1/5) and HMPE ropes have a density less than
one-eighth (1/8).
72 G. P. FOSTER

The degree to which a strength member is easy to handle is reflected in

both direct and indirect costs. Directly, a fiber strength member is much
easier for users to handle, lift and store. Indirectly, it requires less space to
store, pays out cleanly, has optimum flexibility, requires no need for grease
or contaminants, requires less manpower, and related handing equipment
can be downsized.
It is expected that any flexible strength member should be easily applied
to a wide variety of applications. Fiber ropes can provide a variety of
advantages that can reduce costs in operations. For instance, fiber ropes
allow faster, simpler change-outs on related equipment and machinery.
Long lengths are lighter and more manageable, and repairs and splicing can
be performed in the field. They work well on winches, are easier and faster
to rig, require fewer riggers and can utilize less costly handling equipment.
The result is productivity improvements. In many operations, such as
towing, lifting and moving, the faster that rigging and lifting can be done is
critical to completing a project or mission on time. Fiber strength members,
because of their lower weight and easier handling, increase productivity by
reducing both time on the job and the size of crew needed.
A significant amount of work has been done to improve the durability of
fiber strength members. This includes development of stronger construc-
tions, better rigging practices, guidelines for safe use, frequent inspection
and retirement criteria. The use of coatings and the use of special finishes
also improve fiber life cycles, especially in the marine environment. In
contrast to most wire rope, fiber ropes are noncorrosive, and, in most cases,
are not affected by UV, chemicals or environmental factors.
Factors that can be overlooked in evaluating the use of a strength member
are the overhead costs associated with any operation. Many of the
advantages given in the above paragraphs relate to overhead costs and
can have a significant impact on the bottom line. This includes reduced
injuries, lower insurance costs, reduced labor requirements, reduced out of
operation time and the lower cost of the capital required for heavier
equipment and its time in use.
A major consideration in virtually all applications of strength members is
the safety factor. The advantages of lower weight and reduction of risks to
personnel are basic to any operation. Information has been developed on
the safe use of rope and the importance of selecting Design Factors (DF)
and Working Load Limits (WLL) for optimum safety in a given application.
WLL is obtained by dividing the Minimum Breaking Strength (MBS) of a
rope by the selected DF. It is recommended that anyone involved with any
type of strength member should give high priority to safety considerations in
the selection of any fiber or wire rope.
 Advantages of Fiber Rope Over Wire Rope 73

Application advantages constitute the major factors that are present in

the selection and use of virtually all strength members. There is much
diversity in the degree in which factors are applicable to the selection
process, but the important consideration is that all factors need to be fully
measured in order to make a responsible decision. But there is also
another important consideration – the engineering support that is now
available for developing fiber strength members. For many years not much
data was developed, but as the higher tenacity fibers came into play, an
increasing amount of data has been generated and captured. This comes
from fiber producers, rope engineering professionals, joint industry
projects and the empirical and anecdotal information from many projects
such as the fiber rope deep-sea moorings being used in the offshore oil
fields. The Cordage Institute provides sources for rope engineering
professionals and member companies to improve the capability of fiber
rope strength members.

Application Examples

The trend where fiber rope has replaced wire rope for construction of
strength members are numerous, but it is worthwhile to give brief
descriptions of typical applications where the change has been made:
. Fiber winch lines, one of the earliest applications, replaced wire on boom
trucks used for power distribution and for stringing power transmission
lines. Benefits are lighter weight, better dielectric properties and ease of
handling. Fibers: Polyester and HMPE.
. Fiber RoundslingsÕ for lifting products and materials at construction
sites. Sling weight is reduced about 80% when compared to wire. Fibers:
Aramids and HMPE.
. Reduction of crane weight on heavy loads by using lighter Roundslings,
by an amount as much as 80%. Fibers: Aramid and HMPE.
. Increased safety, simplified inspection and precision spotting for
shipbuilding by using Roundslings with optic inspection and overload
tell-tales. Fibers: Aramid and HMPE.
. Facing ‘‘wire’’ (now fiber) ropes to simplify tug and barge operations.
Benefits include lower weight, easier handling, floatability, and con-
trolled elongation. Fiber: HMPE.
. Ship assist lines that allow more powerful and maneuverable tugs to meet
demands for better performance. Fiber: HMPE.
. Actuators for medical devices, replacing stainless steel by providing
lighter, more flexible and longer lasting service life. Fiber: LCP.
74 G. P. FOSTER

. Elevator Cables providing a range of benefits such as easier change-out,

longer endurance with higher bending efficiency and clean, lubricant-free
surface. Fiber: Aramid.
. Restraints for wheels on NASCAR racers, providing lighter and stronger
performance. Fiber: LCP.
. Trolley lines for target drones, providing a lighter, stronger and smaller
catenary, and longer lasting operation. Fiber: Aramid.
. Protective netting for baseball stadiums to provide easier installation,
better see-through visibility and longer life. Fiber: HMPE.
. Tethers for Eye-in-the-Sky balloons used for border control and other
surveillance projects. Lower weight, easier handling, and simpler stow-
age. Fiber: Aramid.
. Spokes for racing bike wheels where lighter weight and less windage are
critical to improve speed. Fiber: LCP.
. Running rigging for yachts, including the America’s Cup, where wire has
been replaced with multi-fiber ropes that offer lighter weight, easier
handling, smaller sizes and less windage. Fibers: LCP and HMPE.
. Fiber cable for Heavy-Lift Helicopters used in military and commercial
operations. Lighter, reduced snap-back, easier to handle. Fibers: Aramid
and LCP.
. Reduced snap-back ropes for the US Navy ships and commercial vessels.
Fibers: Aramid and HMPE.
. Deep water moorings to replace wire and chain for offshore oil
exploration and drilling. Benefits are lighter weight, no corrosion, easy
to splice, easy to inspect, easy to repair. and overall easier management of
long lengths. Fiber: High-tenacity polyester.
. Anti-collision nets to protect drill strings on offshore structures from
debris and off-course vessels. Fiber: High-tenacity polyester.
. Docking and mooring lines for commercial vessels reduce crew injuries,
speed tie-up and departure time, lighter to handle and smaller crews.
Fiber: HMPE.

SUMMARY AND CONCLUSIONS

There has already been significant progress in the rationale of fiber

strength members being able to replace wire, based on the cost/benefits
approach, in a wide range of applications. Given the technology and
flexibility available with the high-performance fibers, there are many other
applications where fiber strength members are being investigated. For
instance, crane ropes will follow the route of the elevator cables, using
special designs and terminations. Cargo dirigibles to move super-large
 Advantages of Fiber Rope Over Wire Rope 75

freight would use fiber strength members to support the envelope and
handle the lifting. Parachutes for commuter airplanes will require material
reinforcement and suspension lines. Application of ropes to reduce
earthquake damage is the subject of a study on using the dynamic action
within the cable to dissipate energy and constrain movement within the
building. The first higher tenacity polyester taut mooring has been installed
in the Gulf of Mexico operating at a depth of 6385 ft.
What more does the future hold? A new fiber-based product has recently
been developed to replace the age-old steel rebar for use in reinforcing
concrete construction. It is called TechnoraÕ Rod and it is made of para-
aramid fiber reinforced plastic (AFRP). It has been successfully demon-
strated in such applications as bridges, buildings, marine piers, revetments,
nonmagnetic structures, antighosting walls, and viaduct construction. As
technology advances, new materials become available, and new applications
are conceived. Fiber rope reinforcements will continue to find new
applications, in some instances by continuing to replace steel, but they
will also find unique applications where neither has been used before.

ACKNOWLEDGMENT

The Cordage Institute is a not-for-profit trade association founded in

1920 to represent the cordage, rope, twine and netting industry in the USA.
Over the years, the Institute has expanded to include raw material and
machinery suppliers, fabricators and intermediaries and technical and
testing companies, and now has members worldwide. Members of the
Cordage Institute (CI) can be contacted to provide detailed information
on the engineering and manufacturing of fiber strength members. Guideline
CI 2003 provides data on all the properties for fibers to be used in fiber
cable, cordage and ropes and is available at no charge the CI Web site at
www.ropecord.com. Members are listed in the RopeCord Directory,
available from Email: info@ropecord.com.
Editor’s note: While this is not a technical paper, it gives insight on the
evolution of technical textile products with the availability of new materials.
As such, we feel it provides important information and adds to the body of
knowledge of the industry.