The Hidden Craft

In aerial tramways and gondolas, the haul rope must form a continuous endless loop. But how do you join the ends of a massive steel wire rope without clamps or connectors?

The answer: the endless splice. A technique that’s equal parts craft and engineering.

Here’s how it works:

• Unlaying the Ends - Rope ends are unwound strand by strand, sometimes for 80–100 meters. So far, most codes world wide are 1200 times rope diameter.
• Interweaving - Each strand from one end is carefully woven into the other, tapering wires so the splice blends smoothly.
• Tension & Alignment - Winches keep the rope under controlled tension while splicers work the wires into place.
• Lubrication & Compaction - The splice zone is treated and compacted so it matches the rope’s original diameter.
• Final Inspection - Crews check the splice and run it slowly through sheaves and grips to ensure smooth passage.

The result? A splice is as strong as the rope itself, invisible in operation, and able to carry millions of passengers safely uphill.

It’s slow, meticulous, and done entirely by hand by skilled splicers. It is one of the most specialized jobs in ropeway construction.

Next time you ride a gondola or tram, remember: the whole system depends on a hidden splice that holds it all together.