Double‑braided cable‑core ropes from 12 to 48 strands can deliver breaking strengths from around 4.5 kN upward, depending on diameter, core type, and jacket material. Select construction to match load, flexibility, and handling requirements.
Key gains – ≈ 3 min read
- ✓ Match load and handling to strand count – 12, 16, 24, 32, or 48‑strand options for different bend profiles and cover smoothness.
- ✓ Optimise flexibility – lower strand counts generally feel softer and run freer through pulleys; higher counts give a smoother, more stable jacket.
- ✓ Streamline specification – a clear strand‑matrix helps you choose confidently and avoid over‑ or under‑engineering.
- ✓ Accelerate rollout – defined selection criteria reduce trial iterations and help teams move from prototype to production faster.
Some specifiers assume a 48‑strand build always performs best. In practice, more strands can add stiffness and cost without improving your specific application. If you understand how cable core rope construction works, you can choose the exact strand count and materials that meet your load, flexibility, and budget goals. This guide explains the trade‑offs and the simple steps to select the right 12‑to‑48 strand configuration for your job.
Cable Core Rope Definition and Core Types
When engineers speak of a cable core rope, they mean a rope whose inner core carries most of the tensile load while a braided jacket protects and stabilises it. Compared with a plain jacketed rope, this construction increases effective break strength, reduces stretch, and resists crushing in pulleys—key traits for applications such as flag‑pole halyards and telecom cable pulling.
Understanding the core is the first step to selecting the right rope. The three types of wire rope cores are:
- Fibre Core (FC) – natural or synthetic fibres that give the rope a softer feel and lower weight.
- Independent Wire Rope Core (IWRC) – a full‑size steel wire rope inserted as a separate element, offering higher tensile capacity and crush resistance.
- Wire Strand Core (WSC) – multiple steel strands bundled together, balancing strength and flexibility.
What is a cable rope called? In industry parlance, a “cable” is essentially a wire rope; many practitioners use the terms interchangeably, especially for diameters below about 3/8 in.
“Choosing the right core is like selecting the foundation of a building – it determines how much load the rope can bear and how it behaves under stress.” – Senior Rope Engineer, iRopes
Each core type influences the rope’s overall characteristics. A Fibre Core excels where a gentle grip is required, such as some marine tasks, while an Independent Wire Rope Core is often chosen for higher load and low‑stretch performance. The Wire Strand Core sits between them, providing enough rigidity for flag‑pole halyards yet retaining flexibility for pulleys that see frequent bending.
With the core taxonomy set, the next variable is the strand configuration of the braided cover. Strand count shapes handling, jacket smoothness, and bend performance. Understanding how 12, 16, 24, 32, or 48 strands behave will guide you to a well‑balanced specification.
Double Braided Rope Structures – 12 to 48 Strands
Having clarified the role of the core, consider how the outer construction is arranged. In common practice, a cable‑core rope uses a braided cover over a steel or fibre core. Where a true double‑braided build is required, an inner braid is added beneath the outer braid for extra stability and abrasion allowance. Either way, strand count in the cover affects handling and surface finish more than raw tensile strength, which is governed primarily by the core.
Common strand‑count options include 12, 16, 24, 32, and 48. Lower counts tend to be more pliable and forgiving over tight sheaves. Higher counts produce a smoother, rounder jacket that runs cleanly and resists snagging. Select a count that suits your safety factor, bend radius, and expected duty cycle.
- 12 strands – compact profile, high flexibility, easy handling.
- 16 strands – balanced handling with a slightly smoother jacket.
- 24 strands – versatile choice combining pliability and a cleaner surface.
- 32 strands – smoother feel and stable running over hardware.
- 48 strands – maximum jacket smoothness and dimensional stability.
A quick reference on typical breaking loads helps frame expectations. The figures below reflect indicative ranges for steel‑core cable core ropes with polyester jackets in common commercial sizes; actual capacities vary by diameter, core type, and construction. Always confirm with iRopes’ specification sheet.
| Strand Count | Indicative Breaking Strength (kN) |
|---|---|
| 12 | ≈ 4.5 kN for 1/4 in; higher for larger diameters |
| 16 | ≈ 5–7 kN depending on size and core |
| 24 | ≈ 6.5–9.5 kN (size‑dependent) |
| 32 | ≈ 8–12 kN (size‑dependent) |
| 48 | ≈ 10–15 kN (size‑dependent) |
The choice between flexibility and jacket stability becomes clearer with the end use. For instance, a 24‑strand cover often provides enough smoothness for telecom pulls while remaining supple for tight sheaves. For long pulls through multiple conduits, 32‑strand and above can run cleaner and wear more evenly.
Best rope for pulling cables
Blue polypropylene pull line is common for light to medium pulls. For higher tensile demands, a steel‑core (IWRC) cable core rope with a polyester jacket in 24–32 strands offers low stretch and durable handling.
Understanding how strand count influences handling and durability sets the stage for the next discussion: material selection, performance metrics, and the sizing checklist engineers rely on when specifying a cable core rope for a particular project.
Material Selection, Performance Metrics, and Sizing Guide
With strand configuration clarified, consider the outer jacket—the layer that protects the core and shapes the rope’s behaviour under load. Selecting the right jacket material balances durability, stretch, and cost for a given cable core rope.
The performance profile of a cable core rope hinges on three measurable traits: breaking strength, elongation under load, and resistance to UV and abrasion. A polyester jacket typically delivers outstanding UV resistance (around 90%) and good abrasion life. Nylon offers greater elasticity and shock absorption. Kevlar and Dyneema push tensile performance and heat tolerance for extreme environments.
Standard Jackets
Balanced performance for most uses
Polyester
High UV resistance, strong abrasion performance, low stretch.
Nylon
Higher stretch, excellent shock absorption, cost‑effective.
Polypropylene
Lightweight, floats, but with lower UV protection.
High‑Performance
Specialised options for extreme demands
Kevlar
Exceptional tensile strength, minimal stretch, heat resistant.
Dyneema
Ultra‑light, high‑strength, excellent abrasion resistance.
Hybrid
Combination of fibres tailored for stiffness and durability.
What is the best rope for a flagpole? For a tamper‑resistant, low‑stretch halyard, a cable core rope with an IWRC steel core and a polyester jacket is a strong option. A 24‑strand or 32‑strand cover offers a good balance of smooth running and pliability. Compared with solid‑braid nylon, this setup stretches less and endures UV exposure better.
Sizing Checklist
Determine required breaking strength; calculate Safe Working Load (SWL = Breaking Strength ÷ Safety Factor) using an appropriate factor (e.g. 4:1–6:1 by application); match diameter to pulley groove; add ≈ 10 % length for knots/terminals; verify UV/chemical exposure; and confirm compliance with relevant standards.
With the material matrix and sizing checklist in hand, you can translate requirements into a manufacturable specification—then leverage iRopes’ OEM/ODM capabilities through our customization services to deliver the exact diameter, colour, accessories, and packaging your project demands.
iRopes Customization, Pricing, and Buying Tips
After you’ve sized the rope to match the required load and length, the next step is to turn that specification into a product that fits your brand and budget. iRopes’ OEM and ODM services let you define every detail—from the core type to the colour of the outer jacket—so the final cable core rope arrives ready for installation.
Our engineering team works with you to select the exact core (Fibre, IWRC, or WSC), strand count, and jacket material. You can request accessories such as loops, thimbles, or custom terminations, and we’ll apply your logo or colour scheme to the packaging—whether that’s a branded bag, a colour box, or a plain pallet.
Design Flexibility
Choose core type, strand count, diameter, colour, and add loops or thimbles to suit any project.
Material Choice
From polyester to Kevlar, we source proven fibres that meet UV and abrasion requirements.
Competitive Pricing
Typical commercial‑grade starts from about $0.54 per foot for 1/4 in polyester‑jacket, steel‑core builds, with tiered discounts for bulk orders.
Fast Delivery
Factory‑direct shipping from our Chinese facility reaches major global ports typically within 7–14 business days.
Pricing is transparent: a 1/4‑in steel‑core rope with a polyester jacket typically costs about $0.54–$0.60 / ft depending on volume and specification. Orders of ≥ 500 ft commonly receive around 10 % bulk savings, and additional efficiencies apply when you combine colours or lengths in one production run.
We safeguard your designs and proprietary specifications throughout the process, and our manufacturing quality is backed by ISO 9001‑certified systems.
The ordering workflow is straightforward. First, submit a brief outlining your technical requirements. Our engineers return a CAD‑ready drawing for your approval. Once you sign off, we produce a short sample batch for field testing. After the sample passes, the full run begins, and we coordinate palletisation, customs documentation, and door‑to‑door delivery.
Ready to see a prototype that matches your exact dimensions and branding? Request a quote, learn more about diamond braid polyester rope structure, or compare Kevlar and polyester breaking strengths to understand how we turn a technical brief into a reliable cable core rope.
Need a personalised solution for your rope project?
This guide has shown how the core—whether fibre, IWRC, or WSC—sets the foundation, and how braided covers can be configured from 12 up to 48 outer strands. Each step affects jacket smoothness and flexibility, while the core and diameter drive tensile capacity. By matching strand count, jacket material (polyester, nylon, Kevlar, etc.), and safety factors, engineers can specify the optimal cable core rope for applications from flag‑pole halyards to heavy‑duty cable pulling.
If you’re ready to translate those calculations into a rope that meets your exact dimensions, colour scheme, and accessory requirements, simply complete the form above. Our specialists will provide personalised recommendations and a quote tailored to your project.
