1. What Is Full Locked Coil Cable?

Welcome to Aulone, where our commitment to quality and customer satisfaction drives every product we offer. Our wire ropes and sling solutions are designed to deliver unparalleled strength, flexibility, and reliability, making them ideal for critical applications in diverse industries.

Explore our extensive range of product forms, including customized wire ropes, slings, shackles, and hooks, all tailored to meet the specific needs of your projects. Our solutions are particularly suited for applications requiring high load-bearing capacity and corrosion resistance, ensuring optimal performance under tough conditions.

At Aulone, we are dedicated to providing products that represent the highest standards of quality and safety. Our wire ropes and socket are your partners in lifting and construction tasks, designed to ensure success and excellence in your operations

This rope is commonly used in:

• Suspension bridges and stay cables

• Elevator hoisting

• Ropeways and cable cars

• Crane hoist and boom ropes

• Lifting in nuclear and hydropower plants

• Marine and offshore platforms

• Theater and stage rigging

• Structural tension elements

2. Construction and Structure

2.1 Multi-Layer Construction

Full Locked Coil cables are typically composed of:

• A central core, usually a round or compacted strand, which bears the primary load.

• One or more intermediate layers of Z-profile wires or shaped wires to improve strength and resistance to deformation.

• An outer layer of specially shaped Z-locked wires that interlock with each other, forming a smooth, sealed surface.

2.2 Common Configurations

The number of layers and wires per layer can vary. Some common configurations include:

• 1+6+12+18+24, etc., depending on diameter and application

• Outer layers with Z-shaped wires, providing the ‘locked’ effect

• Inner wires made of high-tensile steel (1770–2160 MPa)

2.3 Coating and Corrosion Protection

To meet long-term durability demands, FLC cables often feature:

• Galvanized wires (zinc or zinc-aluminum alloy coated)

• Polyethylene (PE) or HDPE sheathing

• Grease-filled interlayers to prevent water ingress and reduce internal friction

3. Key Advantages of Full Locked Coil Cable

3.1 High Breaking Force

Due to its compact structure and use of high-strength wire, FLC cable offers superior tensile performance, making it ideal for applications requiring maximum load-bearing with minimum elongation.

3.2 Excellent Corrosion Resistance

With tightly interlocked outer wires and additional galvanizing or polymer coatings, FLC cables provide outstanding protection against corrosion, even in marine or industrial environments.

3.3 Smooth Surface

The sealed outer layer prevents debris or ice from penetrating the cable core, reducing internal damage and wear.

3.4 Low Stretch and High Stability

Its design ensures minimal elongation under load, critical for precision lifting or tension applications such as bridges and elevators.

3.5 Rotation Resistance

Full locked coil cables are naturally rotation-resistant, which is essential for lifting mechanisms where load spin must be avoided.

4. Applications in Detail

4.1 Bridges and Civil Structures

FLC cables are widely used in cable-stayed and suspension bridges. Their low sag, long span capability, and resistance to weathering make them ideal as main cables or suspenders.

• Example: In long-span suspension bridges, hundreds of full locked cables are used to suspend the main deck with accurate load distribution.

4.2 Ropeways and Aerial Transport

In cable cars, funiculars, and ski lifts, FLC cables are employed as track ropes or traction ropes. Their rotation resistance and consistent diameter provide smooth and safe operation.

4.3 Elevators and Lifting Systems

Full locked coil ropes are used in high-speed elevators, especially in high-rise buildings and underground mining hoists. Their dimensional accuracy and minimal stretch are critical for passenger safety and operational precision.

4.4 Marine and Offshore Applications

On offshore oil platforms, FLC cables are used for tension leg platforms, riser systems, and mooring applications. Their sealed surface and corrosion resistance ensure performance in salt-laden air and splash zones.

4.5 Theatrical and Stage Rigging

Used in stage machinery for precise lifting and suspension of lighting, curtains, or scenery, FLC cables help achieve silent, smooth, and secure movements.

5. Manufacturing Process

Producing full locked coil cables requires high precision and technical expertise. The manufacturing process involves:

5.1 Wire Drawing

High-carbon steel rods are cold drawn through dies to reach the required diameter. Tensile strength and dimensional tolerance are strictly controlled at this stage.

5.2 Heat Treatment

The wires undergo patenting and annealing processes to achieve the desired mechanical properties (strength, ductility, toughness).

5.3 Shaping

Z-shaped wires for the outer layer are precisely shaped using rolling or extrusion, ensuring interlocking fit and alignment.

5.4 Galvanizing or Coating

Galvanization (hot-dip or electroplated) is applied to enhance corrosion resistance. Some wires are coated with Zn-Al alloy, known for superior marine protection.

5.5 Stranding and Closing

The layers are wound under tension around the core using state-of-the-art stranding machines. The outer Z-wires are pressed into a locked formation, resulting in a dense, smooth-surfaced rope.

5.6 Greasing and Sheathing (Optional)

To further protect the internal layers, high-performance lubricants or grease is injected. For bridge and offshore use, a plastic HDPE sheath may be extruded around the finished rope.

6. Inspection and Quality Control

Ensuring safety and longevity of FLC cables requires rigorous quality inspection protocols, including:

6.1 Dimensional Checks

Every batch undergoes measurements for:

• Diameter tolerance (±0.05 mm or stricter)

• Roundness

• Wire alignment

6.2 Mechanical Testing

Tensile strength, elongation, and breaking force are tested using universal testing machines (UTMs) according to standards like EN 12385 or ASTM A586.

6.3 Fatigue and Bend Testing

Full locked cables are fatigue-tested over pulleys to simulate real-world conditions. Bending fatigue is a critical indicator of lifespan.

6.4 Corrosion Resistance Tests

Salt spray testing, humidity testing, and accelerated weathering tests are performed to evaluate long-term protection.

6.5 Non-Destructive Testing (NDT)

Magnetic flux leakage (MFL) or eddy current testing may be used to identify internal defects without destroying the rope.

7. Technical Specifications

While specifications can vary by manufacturer, typical ranges include:

8. International Standards and Compliance

High-quality FLC cables are manufactured in compliance with international norms:

• EN 12385-10 (Steel wire ropes for general use)

• ISO 2408

• ASTM A1023/A1023M

• BS 302

Bridge and structural cables may also require:

• CE certification

• EN 1993-1-11 (Eurocode for structural cables)

• Third-party approval from bodies like Lloyd’s Register, BV, or DNV

9. Customization and Services

Leading manufacturers provide tailor-made solutions, including:

• Special diameter or breaking load requirements

• Pre-formed rope lengths

• End fittings: socketing, clamps, eye-splicing

• Installation and tensioning assistance

• Cable inspection and replacement consultation

10. Comparison: Full Locked Coil vs. Other Ropes

11. End-of-Life and Recycling

FLC cables, being composed almost entirely of steel, are 100% recyclable. At the end of their service life, they can be processed as scrap for reuse in steelmaking, contributing to a more circular and sustainable material lifecycle.

Inspection Criteria for Retirement:

• Number of broken outer wires per unit length (EN 12385-1 guide)

• Corrosion penetration of the core

• Excessive elongation or permanent deformation

• Reduced breaking force below 85% of nominal

12. Conclusion

Full Locked Coil Cables represent the pinnacle of wire rope technology, combining mechanical excellence with durability and customizability. Their sealed, high-strength structure and superior performance in rotation-sensitive or corrosion-prone environments make them a trusted solution for bridges, cranes, ropeways, and industrial lifting applications.

If your project demands a high-performance cable with proven engineering, long life, and safety compliance, Full Locked Coil Cable is the top choice. At Aulone (or your company name), we offer custom FLC cables tailored to your requirements, backed by strict quality control and expert technical support.