Lexco Cable Used in Construction of Suspension Bridge

Posted by David Karbin | Mon, Jun 27, 2016 @ 01:08 PM | 0 Comments

Long Travelled and Treasured

Since the French explorer Samuel de Champlain first set foot in Vermont in 1609, the region has held its reputation as a land of natural beauty and rugged landscapes.  These features have been pondered on by luminaries such as Thoreau and Frost, and enjoyed by visitors from across the globe.

Vermont also features some of the best hiking in the country; it is crisscrossed by over 700 miles of trails and thousands of miles of paths and dirt roads. One of the state's most famous is known as The Long Trail. This aptly named route runs 273 miles from the Canadian border in Quebec to the Massachusetts border in North Adams, where it connects with The Appalachian Trail.

Hikers familiar with The Long Trail can attest to its ruggedness and spectacular vistas as it snakes its way north. It is also the oldest established hiking trail in the United States and was built and is maintained by Vermont’s Green Mountain Club. Construction of the trail began in 1910 and was completed in 1930; its trails and shelters are now maintained by an army of over 1000 volunteers.

Crossing the Winooski River

For over 100 years, the Winooski River crossing in Bolton has been an impingement to full completion of the trail. Crossing the river required the use of a ferry to allow passage from Mansfield to Camel’s Hump or a 3.5 mile road walk.


The idea of a footbridge has been in the works for many years; however, raising the funds needed for the 224 foot span would need contributions from a wide range of sources. Funding for the bridge was finally obtained in mid-2013, and a design was created by the renowned structural bridge engineers at the firm of Vanasse Hangen Brustlin, Inc. of Ferrisburgh, VT.

Construction was then carried out by Kleinhans Construction & Welding of Lebanon, NH.

Proper Use of Cables in a Suspension Bridge

Since this is a suspension bridge, its strength and durability would rely mainly on cabling and cable assemblies. These included cable components for the trusses, the deck, and the cross braces that would support the pedestrian walkway and handrails.

One of the major concerns in a project such as this is the environment. The bridge location is just over 70 miles from the Canadian border, and Vermont winters have a well-earned reputation as being long and harsh, especially in the higher elevations.

What Kleinhans Construction needed in this project was a partner that had broad experience in the fabrication and installation of cable assemblies.  For these reasons, they selected Lexco Cable of Illinois to provide all of the required cable and cable assemblies.

Lexco has over 30 years of experience designing and fabricated high strength cable assemblies for some very demanding industries. Their design expertise can be the difference between a good bridge and a great bridge, and their understanding of assembly and installation of structural elements makes the overall build process much easier.

After being contracted, the Lexco team performed a comprehensive review of the architectural drawings. In their study, they identified a number of clearance issues that would have impeded design functions of various support cable assemblies. Without altering the original design, they were able to develop alternatives that would not affect any aspect of the project.


During Lexco’s design process, they created individual engineering drawings for each of the numerous cable assemblies. Each assembly was unique and varied in length and diameter; in addition, each unit required a special turnbuckle.

 Lexco’s manufacturing operation relies heavily on quality control; all components were checked for dimensional accuracy, and each assembly was load tested to ensure a long trouble free service life.

In a short time, Kleinhans Construction had all the parts and components that they required to quickly build a suspension bridge that would provide safe crossing of the Winooski River for thousands of hikers every year.

Lexco Cable specializes in providing services that go far beyond just fabricating parts; they work closely with customers to obtain a full understanding of specifications, design intent, and what is really expected of the finished product.


Lexco Cable Joins Technology Manufacturing Association

Posted by David Karbin | Wed, Mar 04, 2015 @ 11:24 AM | 0 Comments

Lexco Cable joined the Association of Manufacturing Technology on Nov. 12, enabling us to offer customers unprecedented access to resources for almost any project.

Norridge, Illinois — Feb. 17, 2015 — Lexco Cable, manufactures a custom mechanical custom cable assembly. We distribute wire rope, aircraft cable, coated cable, and related fittings and hardware. We are proud to announce our membership in the Technology & Manufacturing Association (TMA). Through this membership, Lexco Cable can offer customers unparalleled access to resources for almost any project, regardless of level of complexity.

Lexco TMA Membership

With 900+ members in North Eastern Illinois, TMA is a non-profit that brings together leading precision manufacturers and suppliers of precision items. The Association is committed to manufacturers of recognition as the value aggregates producers of goods and services and to create high-quality jobs for all citizens of Illinois. It also promotes a strong sense of mutual support among members and throughout the industry in general. With this, finally, the Association advocates on behalf of the interests of its members to generate growth and offer positive benefits to TMA members and communities in Illinois. Finally, the Association advocates on behalf of the interests of its members to generate growth and offer positive benefits to TMA members and communities. 

"Joining TMA was a natural fit for Lexco," said David Karbin, Product Manager at Lexco Cable. "One of the pillars of our quality policy is 'continuous improvement'." Sometimes, these ideas of improvement come internally, but participating in events of TMA, we open ourselves up to a vast wealth of practical ideas that will help us to speed up the improvements of our company." 

TMA offers a variety of services ranging from media relations to leadership training and education. It also provides access to employee training for new skills, seminars, networking opportunities, and guest speakers.

“Lexco Cable joined TMA and immediately did what most members should do—raise their hands and ask a question,” said Kent Gladish, Senior Marketing and Sales Director at TMA. “TMA connects members to others who have solved that problem. David Karbin’s questions are excellent, challenging, and needed by others. In one case, the TMA Marketing committee will be asked to assist with a comprehensive answer.”

Lexco Cable offers a variety of wire rope, aircraft cable, bungee, fittings and other related services. Visit Lexco's website to learn more about their capabilities.

About Lexco Cable:

Lexco has capacity domestically and abroad. We have a network of providers of coated cable, aircraft cable, wire size micro, bungee, accessories and services related to provide your specific custom assembly of cable or rope. We run vinyl coated cable and plastic coated cable. We have hydraulic presses and automatic wire cutters. We have test capabilities for your test and tensile test requirements related to provide your specific custom assembly of cable or rope.  

Lexco Cable is a family-owned and operated business. It began as a hardware store and Schwinn franchise on the west side of Chicago in the 1950s. We continued as a Schwinn bicycle shop on the city’s north side in the 60s. In the 70s, Lexco began using aircraft cable and making bicycle and retail security cables. During the 1980s and 1990s, industrial applications for cable and wire rope assemblies were developed, and capabilities supporting applications fleshed out. In the 2000s, bungee assemblies, push-pull controls, and their unique elements were developed.

We have been ISO 9001:2008 certified since 2009.

We enjoy the challenges of new applications and welcome your inquiries.


Lexco Cable is Proud to Announce the Winners of Our Photo Contest

Posted by David Karbin | Tue, Feb 24, 2015 @ 09:54 AM | 0 Comments

In November, Lexco Cable held a contest for best photo featuring a Lexco product in the picture.

The rules were quite simple. Each entry had to feature a project integrating any product from Lexco Cable, whether it was a cable assembly with aircraft cable or wire rope hardware and snap hooks.

The goal was to connect with current and past Lexco Cable customers and see how they are using Lexco products in their applications. This call to submit entries went out in the fall and at the end of the year we started reviewing to determine which photographs were the most attractive, fun, and the best examples of Lexco Cable products in action.

There was a large range of photos submitted to the contest. Many of the photos were of very high quality and clearly showed the Lexco Cable product in action.

The applications ranged from marine to canopy support, to mechanical linkage, to architectural.

It was exciting to see how all of these products and projects integrated Lexco’s products with such beautiful photographs.

The Winners

Now, we are pleased to announce the winners of Lexco’s photo contest.

Our first winning photo comes from Blue Water Furnishings with this beautiful architectural cable railing shot:  

Cable Railing from Blue Water

Blue Water Furnishings ( is based in Phoenix, Ariz. They have been a Lexco customer since 2010.

Blue Water Furnishings makes architectural features for homes and businesses in the serene southwest. Lexco is privileged each time we have the pleasure to supply cables to Blue Water Furnishings. The clean lines of stainless cable rails against the backdrop of the desert and beautiful infinity pool (looks like Blue Water lives up to its name!) always make for a visually stunning contrast.

Our second winning photo comes from Jed Smith Construction’s fantastic work, which can be seen in the below architectural railing shot:

Jed Smith Construction cable photo

Jed Smith Construction ( is based in Aquinnah, Mass. Aquinnah is surrounded by the Vineyard Sound and the Nantucket Sound in Dukes County on the U.S. eastern seaboard.

Cable railings built by Jed Smith Construction compliment the architectural style and views of homes built on the Atlantic.

And finally, our third photo winner features cables installed on a speedboat named the "Barefoot Sanger."

Barefoot Sangover

The water skiing boat belongs to Dave Steffes of Saint Paul, Minn. Dave used plastic-coated stainless steel aircraft cable to support an extended height tow pylon for barefoot water skiing. According to Dave, "it's been used several summers now and is still rock solid."

The photo winners will now receive a free digital caliper, a very useful tool for measuring dimensions in applications needing wire rope products.

Winners of the contest also have the option of having their project featured on Lexco Cable’s profile on Houzz, the online architecture, interior design, landscaping, and home improvement network.

Congratulations to our winners! And thank you to everyone who participated. Feel free to continue sending us photos of your wire rope projects.

Submit Your Photo


Download Important Documents from Lexco’s Technical Resource Library

Posted by David Karbin | Mon, Jan 19, 2015 @ 08:06 AM | 0 Comments

Get useful conversion charts, guides, and much more.

Lexco Cable presents our Technical Resource Library, a range of documents related to the wire rope and cable industry. These are offered as references to easily consult when purchasing wire rope, specifying a new project, or checking measurements.

Procurement Guides and Detailed Charts

Technical Resource Library

Our Resource Library is dedicated to helping you at various stages of any wire rope, or cable application. As a result, we have documents such as the Decimal/Metric Chart, side-by-side comparisons of measurements of wire rope and cable diameter in inches and millimeters.

Also available in our Resource Library is the Wire Rope Diameter and Construction Design Guidelines. This chart recommends the minimum bend required to maximize wire rope life and strength for cycling applications. The document includes various wire rope and cable profiles, helping you find the products compatible with your project requirements.

Customers can also find our Push/Pull Replacement Guides. Each of are quick references on replacement cables in a variety of vehicles and applications, including:

  • Tractors
  • Excavators
  • Cabover Engine Trucks
  • Tow Trucks
  • Generators
  • Work Boats

There are nine replacement guides included in our resource library to help you find the right cable for your specific application, including aircraft cable, vinyl coated cable or plastic coated cable just to name a few.

A Range of Comprehensive Wire Rope and Cable Considerations

Additional documents in the Lexco Cable Resource Library include:

Each of these documents is designed for proper procurement, installation, and care of your wire rope and cable products. Most importantly, these documents can be printed out and hung up in the office, letting you easily check them for quick reference.

Click here or the button below to visit our Technical Resource Library and download any of the above listed documents:

Access Our Resource Library

For all additional questions, including any questions on topics not covered in our library, contact us today. We hope these resources are exactly what you are looking for.


Submit Your Photo of a Lexco Product for a Chance to Win

Posted by David Karbin | Thu, Nov 20, 2014 @ 10:38 AM | 0 Comments

Do you own or work with a Lexco Cable product? If you do, then you are eligible to win a prize just by submitting a photo.

All you have to do is snap a quick picture of your Lexco item that has been used in one of your projects or products. As you know, we are one of the largest wire rope manufacturers with our products such as the wire rope, aircraft cable, and the bungee cord!

describe the imageFor example, our products have been used is within the brewing industry. Hops, which give beverages their tangy taste, is grown very similar to grape vines.  Utilizing strings that are tied to a Lexco-produced cable, the growers can keep their hop plants off the ground via the wires, saving it from harmful bacteria and spoilage.

So, now is your chance to become the photographer and capture one of your products in action. If you win, it could become as well-known as the cables that assist the Skycam in its vital Super Bowl work. Who knows? 

The photos can be taken anywhere, whether it’s at the car dealership holding the spare tire into place, or even you playing at a slot machine, where it is in use. The more creative you get, the better!

Here's one idea — capture one of our products by hanging from an anchor of a boat.  In many anchors, the cable used to help raise and lower it is a product of ours. The possibilities are endless!

Once you take your photo, be sure to go to to fill out the form and submit your photo! May the best photo win.

Submit Your Photo

The Beauty of Flaming Hula-Hoops (Accomplished Using Wire Strand)

Posted by David Karbin | Tue, Oct 14, 2014 @ 09:36 AM | 0 Comments

We at Lexco Cable are always excited and amazed to find a new or unique use for many of our cable assemblies.  One customer, Synergy FlowArts came to us to help them supply cable in keeping with safety and integrity requirements of their products.

quick wick resized 600

Synergy FlowArts manufactures products that encourage the growth of this unique art form that combines exercise, performance, and spirituality.  Flow Arts include a wide range of movement styles, forms & rhythms, often incorporating performance props.  Many of these props come in “fire-form” for fire spinning performance. Synergy FlowArts fabricates hoops and other tools such as their Quick Wick for use in firehooping. The Quick Wick is a clamp-on wick for a flame or multiple flames, turning an ordinary hula-hoop into a “firehoop.”  Each of the Quick Wicks clamps onto the circumference of the hoop.

The company has been utilizing Lexco’s wire strand to mount the flame wicks about 5 inches away from the plastic hoop tubing. During the performance, each wick is ignited. Due to the properties of the stainless steel wire strand, the rapid temperature changes that occur when lighting the wicks do not affect the hoop or damage it while under the intensity of the fire. Due to wire strand’s desirable rigidity for this application, 1x19 was supplied. Lexco also provides 1x7 wire strand for this client for whenever greater rigidity is desired.  

With help from our wire strand Synergy FlowArts is able to provide their customers with the safe and reliable performance equipment to make their art extraordinary. Many of their customers are multi-hoop fire spinners and they even have some Vegas style performers. Here at Lexco Cable, we help make that possible with our dependable and diverse selection of wire rope products. You may not find us spinning fire, but we continue to innovate, support and collaborate with clients, helping to create unique products for unique markets.


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Lexco Cable and Pull Testing for Wire Rope Assemblies

Posted by David Karbin | Mon, Sep 15, 2014 @ 09:24 AM | 0 Comments

Pull testing is an effective means of testing the strength of wire rope assemblies to ensure they meet the specific requirements of the customer’s application. That’s why Lexco Cable offers these services for our customers. We can proof load to a percentage of the break strength or we can perform a fully destructive pull test to determine at what point a cable assembly meets its limits.

Pull Testing in Action

In the video below, you will see a cable construction of 5/8” diameter, 7x7 galvanized wire rope being pull tested to verify the swage sleeve would hold to 100% strength efficiency. When completed, this type of test indicates the break strength of a cable assembly based on a gradual linear pull.

In the test shown in this video, the cable assembly met the nominal break strength required by the customer, exceeding it by more than 10%. While this particular test was done to destruction, there are other tests performed to measure a percentage of that break strength requirement.

Pull testing as shown in this video is a vital part of the quality control process. The machine used is a 55 foot long pull tester, calibrated for testing up to 50,000 lbs against a cable assembly, allowing Lexco to perform extensive tests for our customers, whatever their requirements might be.

Contact Lexco for More Information About Pull Testing

If you need to learn more about pull testing and its benefits, contact the experts of Lexco Cable. We can discuss with you how best to match the break strength requirements of your cable assembly and then perform the necessary testing to ensure this is the case.

Click the button below to fill out a form or call us directly and speak with an expert who can help you with your custom cable assembly, cable assembly pull testing, or general wire rope needs. 

Consult a Cable Expert


Laser Marking and Traceability for Cable Assemblies

Posted by David Karbin | Wed, Aug 20, 2014 @ 03:05 PM | 0 Comments

According to ISO 8402, traceability in manufacturing represents "the ability to trace the history, application, or location of an entity by means of recorded identifications." Our customers sometimes require the added peace of mind that this capability provides. It’s for this reason that Lexco Cable actively utilizes a variety of technologies including laser marking to ensure its parts can match the requirements of customers.

When Traceability Is Vital

Some products require much higher levels of traceability than others. This can include specific data such as the date an item was manufactured, the lot number, the product number, or the specific part number. Traditional methods were limited in providing these benefits. The best way to mark a product is with a permanent marking, which more recent advancements make possible.

In the video below, you can see a conduit being marked with a laser marking system utilized by Lexco Cable for just this purpose.

This conduit will be used in a push pull control assembly, and each of these components will be carefully marked with the data required by the customer, a service Lexco is proud to offer to any who require it.

Utilizing Laser Marking for Your Project

If your next project requires high levels of traceability, or if you need to discuss the specific benefits that such a system can offer your company, call Lexco Cable and ask about laser marking as a value added service for our cable assemblies.

Click the button below and fill out the form or call Lexco directly and speak with one of our cable assembly manufacturing experts. 

Consult a Cable Expert


New Cable Replacement Guides from Lexco

Posted by David Karbin | Wed, May 21, 2014 @ 12:33 PM | 0 Comments

At Lexco, we firmly believe that a little bit of knowledge can go a long way. That is why we are excited about the release of our latest set of guides to various industrial cable replacements. 

When you are on the worksite, the last thing you want to worry about is a faulty or low-quality cable. Not only can it put you behind schedule, it also can be a major safety issue. For decades, leaders in a wide variety of industries have relied on Lexco for their custom cable assemblies.


Through the years, we have received many questions about the correct replacement cable for very specific applications. It is for this reason that we are offering our latest set of cable replacement guides.

Guide to Excavator Cable Replacement

Excavators are a critical piece of equipment on any construction site. Our guide breaks down the different cables you many need to replace and the Lexco products that fit the bill perfectly.

Guide to Oil Pump Jack Cable Replacement

This guide identifies common cables used on oil pump jacks and the Lexco replacement products.

Guide to Log Skidder Cable Replacement

Like all of our guides, this one points out the most common cables used on a log skidder. It also charts the five different types of cables Lexco offers for replacement.

Guide to Tow Truck Cable Replacement

No one wants to worry about their tow truck due to a faulty cable. This guide identifies the most common cables and also offers a reference guide to replacement cables from Lexco.

Guide to Garden Tractor Cable Replacement

This guide provides a good overview of the most common cables and Lexco replacements for your garden tractor.

Guide to Work Boat Cable Replacement

Work boats have a number of different vital systems that must work at all times. This guide points out the cables used and the replacements offered by Lexco.

Guide to Generator Cable Replacement

A failed generator can mean slowed production or worse. This guide will point out the key cables and replacements from Lexco.

Guide to Cabover Engine Truck Cable Replacement

Lexco identifies the critical cables and their replacements for cabover engine trucks. Failures in these cables can cost you money and time.

To get or learn more about these critical guide, please visit our website or contact Lexco today.




Getting Wire Rope over a Barrel

Posted by David Karbin | Wed, Apr 23, 2014 @ 03:07 PM | 0 Comments

( customer spotlight)

Barrel Enterprises is a Canadian craft manufacturer of high-quality personal facilities made from very large wooden barrels. These unique offerings include saunas, hot tubs, wine cellars, dog houses, bath tubs, play houses, and even above-ground pools. Their products are made from Western Red Cedar staves fitted tightly together and bound by tightened wire rope. The cables maintain the structure of the units while under internal pressure, keeping them from expanding.When you think of wire-rope products, you’d probably never expect to hear about custom-made saunas and hot tubs made out of oversize barrels, as well as their new line of campground yurts. Well, it’s one of the many, many uses we find all the time for our line of cables. Here’s how these ones work. 


inside 1

According to the company, “it was the wooden hot tub that began the experience of social bathing in North America.” Barrel Enterprises’ hot tubs and other personal entertainment products are shipped to customers as kits requiring assembly, including the cabling. No special tools or skills are required for their assembly, and a detailed installation manual is included with every unit sold.

scenicviewsauna4The company’s unique saunas come equipped with polymethylmethacrylate bubble windows to enhance the user’s experience. As the company’s website explains, “Sauna is the Finnish word for ‘bath’. Finns who immigrated to North America brought with them a unique bathing custom, which has become popular here over the past decade.

Often confused with a steam bath, a true sauna bath is very different, even though both types of baths offer the same therapeutic benefits.” Solid wood is the only choice for true sauna construction. Although the steam room enclosure must be non-porous and steam tight, the opposite is true of a sauna room. A sauna must be constructed of porous materials (meaning some type of wood), and it depends on air circulation through intake and outlet vents.

The wood actually “breathes” absorbing and purging moisture. Many varieties of wood are acceptable for sauna construction, but care must be taken when selecting the type and grade due to leaching of pitch or slivers, according to Barrel Enterprises. You can learn more about Barrel Enterprises on their or you can call toll free with any questions 1 877 866 5151.

Whether manufacturing cable for specialized projects or working with more traditional applications, Lexco Cable sets a high standard for quality and on-time delivery. Lexco Cable is an ISO 9001:2008 certified factory and warehouse located in Norridge, Illinois (minutes from O’Hare Airport, Chicago). Learn more about Lexco Cable or contact us today if you have any questions. 

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