wire rope maintenance pdf quotation

Wire rope slings have played a critical role in applications like lifting, rigging, and hoisting. They are usually made from galvanized or un-galvanized steel wire strands, which are woven into ropes with end terminations. The end terminations can be loops or hooks.

Several industries, such as mining, manufacturing, shipping, and power generation, use wire rope slings because they are easy-to-use, cost effective, and reliable. Depending on the type of load and crane, you can use an assembly of wire rope slings for lifting, rigging, and hoisting.

Although they are extremely strong and durable, wire rope slings require regular maintenance and inspection. They must be inspected to ensure safety and prevent economic losses. In this short guide, we will take a look at wire rope sling inspection, maintenance, and replacement.

As mentioned before, the purpose of wire rope sling inspection is to identify any damage or excessive wear before it leads to a disaster. Two leading organizations in the US, OSHA, and ASME have published inspection and maintenance guidelines to ensure wire rope slings safety and functionality.

The two standards governing the criteria and guidelines of wire rope sling inspection are OSHA 1910.184 and ASME B30.9. As per these guidelines, there are three types of inspections.

This inspection should be carried out immediately after receiving the wire rope slings. During this inspection, make sure to check the sling identification tags. These tags will bear the product information, its rated load capacity, and other specifications. Check if they are what you ordered and what you need.

The second type of wire rope sling inspection is to be carried out daily or prior to use. As wire rope slings are used in a wide range of applications, it is always better to inspect them before each use. In other words, if you are going to use a sling three times a day, you should inspect it three times.

As wire rope slings can get damaged during a loading or rigging application, this inspection is extremely critical. You can have designated personnel, usually a competent crew member, to inspect wire rope slings before each use.

Only a certified professional or service provider can carry out periodic inspections. You also need to document each periodic inspection and maintain records, as per the ASME B30.9 guidelines. The schedule of periodic wire rope sling inspection depends on factors like frequency of use, the severity of work conditions, type of lifting or rigging, and experience gained on the service life of wire rope slings used in similar applications.

Even though it’s usually a visual inspection, you have to be thorough with it. Neither OSHA nor ASME has specified any fixed sling inspection process. You need to set up a process of your own based on your requirements, rope sling usage, and other factors.

Usually, a proper wire rope sling inspection process should include the following steps:Make sure to lay down the sling on a flat surface in such a way that all its areas are visible and easily accessible.

While the structure and specifications of wires vary greatly, wire rope slings often have the following four key components:Core: The core is made from steel, synthetic, or natural fibers. The function of the core is to provide strength and support to the wires.

Wires: Wires are made from materials like steel, iron, bronze, and stainless steel. Wires surround the core, and they come in different sizes and strengths.

The guidelines for allowable broken wires are as follows:Single Part Body Slings and Strand Laid Grommets:5 broken wires in one strand in one rope lay

Distortion constitutes damages like kinking, crushing, and birdcaging, among others. If you see any such damage or wires and strands pushed out of their original positions, you need to replace the wire rope sling immediately.

Wire rope damage due to heat results in metallic discoloration, fusing of wires, or loss of lubricant. Make sure to replace the sling if there is heat damage.

While light surface rust will not affect the strength of wire rope slings, you will need a replacement if the corrosion has caused pitting or binding of wires.

When using wire rope slings, pulling through a loop can push out wires and strands from their original positions, pushing the slings out of balance. If you see this damage, replace the slings immediately.

Kinks are nothing but loops with permanent wire and strand distortions. As this type of damage is irreparable, you need to replace the slings right away.

Improper use of wire rope slings can cause doglegs, which are permanent bends. If the slings have minor doglegs with no strand distortion or if you can’t see them when the sling is under tension, you can continue using the sling. However, replacement is necessary if the doglegs are severe.

Make sure to discard the damaged wire rope slings in an eco-friendly manner. You should label the slings “Do Not Use” to avoid accidental use. Then, you should cut the eye and fittings from the rope, cut the rope into 3’ to 4’ sections, and send them for recycling.

The third most important step is wire rope sling maintenance. You should keep the following points in mind to ensure regular and comprehensive maintenance:Always keep the slings off the ground, in hanging position, and in a dry and cool environment.

Wire rope slings play a critical role in a wide range of industries such as mining, manufacturing, and shipping, among others. Although they are strong and have a long lifespan, rope slings do need regular inspection and maintenance to ensure safety and longevity. Hopefully, this guide will help clear all your doubts regarding wire rope sling inspection, replacement, and maintenance. If you need help with any rigging equipment inspection, maintenance, and replacement, feel free to reach out to our team at Holloway Houston Inc.

Before use: Look for rope distortion, kinks, cut or broken strands, corrosion, heat damage, birdcaging, or crushing. Look at the end attachments for cracks, wear or deformation, hooks with twists or a throat opening increase. Look for broken or missing wires.

For cable laid and braided broken wire inspection criteria, consult the manufacturer. If an inspection reveals that such wear or damage is present, replace the sling. Frequent inspection is done by the person handling the sling before each use and must include all of the Before use Periodic inspections must be recorded at least annually for normal service, quarterly or more frequently if in severe service or nearly constant use. Periodic inspections are performed by a designated person who records the observed condition and determines when further use would be hazardous.

Any hazardous condition disclosed by an inspection shall require replacement of the wire rope sling. Repair is not an option when damage/wear seriously reduces the sling’s capacity.

The Viper MKII Wire Rope Lubricator range provides fast and effective cleaning and lubricating of wire ropes. Wire ropes from 8 mm (5/16” ) to 165 mm (6-1/2”) in diameter can be automatically greased at speeds up to 2,000 mt per hour.

The Viper MKII with the new cast Aluminium collar is 32% lighter and combined with the unique inbuilt carry handles and shoulder strap enables single person wire rope lubrication. Ideal for use on all cranes, towing lines and mooring lines, the Viper MKII eliminates the HS&E risks associated with manual lubrication. Use of the Viper MKII provides improved wire rope lubrication by forcing wire rope lubricant under pressure into the wire rope.

Other lubricators just coat the surface of the ropes but the unique seal design of the Viper wire rope lubricator means the “wire dwell time” in the pressure chamber is up to 80% longer. This longer dwell time means greater lubricant penetration which leads to increased rope life and extended re-lubrication intervals.

Non rotating rope 18 mm Dia x 265 mtr( Ungalvanized, 35x7, WSC, 2160N/mm2, RHLL) C/wBOTH end plain. MBL of the rope is 29.5 ton,Actual breaking load= 30 tonWire rope brand DSR Korea

The lay of strands (wire rope) can be twisted either to the left or to the right. To determine whether the lay is left or right handed, look along the rope and see whether the wires appear to turn anti-clockwise (let handed) or clockwise (right handed) as they get further away from you.

Note: Regular rope inspection and maintenance shall be carried out according to the guideline instructions provided by the manufacturer and according to international standard ISO 4309:2009.

Note: Mechanical and electrical maintenance work requires special skills and tools to ensure safe and reliable operation of the product. Maintenance work shall be carried out only by authorized service personnel or an experienced service technician authorized by the product"s manufacturer or manufacturer"s representative.

Note: The internal examination of wire rope shall not be done as part of regular maintenance, unless the person is trained for that examination (ISO4309 Annex D).