wire rope inspection standards price

This safety saying from the early 1900s applies well to the lifting and material-handling industries. And that is especially true for the inspection of specialty ropes used in overhead lifts on your cranes.

Third-party crane rope inspections are a fairly new concept in the lifting and rigging industry. It’s a streamlined process where you will get some extra documentation and protection before your crane is put into service.

The lifting and rigging industry is dynamic, and price increases continue impacting vendors and customers alike. Because of that, it’s important for you to be as precise with your expenditures as possible, while still making sure everything with your crane and its ropes are in working order before it actually goes to a jobsite.

When the crane returns from the field, the rope may no longer be in good working order and should be inspected before going back into service on another job. This would be the time to bring in a third-party inspector to examine your rope, especially if your operators are unable to determine whether the rope should stay in service or be discarded.

If this process isn’t completed, and there is enough damage to meet removal from service criteria, the ropes must be replaced in the field. Replacing crane ropes in the field is much more complicated and costly, especially if a hot shot is required. In the crane ropes industry, a “hot shot” is an expedited order that is needed because an inactive crane is costing the renter thousands of dollars an hour in downtime.

First, you must find a company that has the correct rope for your crane. Then, there’s the matter of shipping and delivery, as well as finding an experienced technician who can remove the old crane rope and install new ones.

The moment a technician arrives on location, they’re going to set up the equipment. Then, they’re going to conduct and discuss the Job Safety Analysis (JSA) with everyone involved in the inspection.

Mazzella technicians will dictate how the inspection is going to occur, and explain whether we need access to the equipment all day, as well as provide a rough timeframe for completion of the process.

We require each technician to take between 20 and 50 pictures per inspection for documentation purposes. Everything we do in the field is going to be documented on a piece of paper and photographically. The report and photos will be given to you at the end of the inspection.

During the inspection, the technicians are tasked with conducting specific measurements. If they find damage, they’re noting damage in their report. They count the number of wire breaks and note other potential damage that was found. When they pull off the rope, they take rope diameter measurements every 500’ to make sure there is not less visible damage to the rope.

You do need to have a crane operator on site to help with the inspection. Also, if the crane requires a mechanic to reset some of the codes and indicators, then they need to be on location, too.

A properly trained inspection technician should be able to handle the majority of the inspection himself. However, with certain cranes, you really need to be on-site to support the technician. Additionally, you should designate an on-site person to handle the paperwork.

During a rope inspection, our technicians will communicate with the decision-maker throughout the entire process so there are no surprises at the end. If we do find broken wires, we let you know right away. If in the middle of a rope inspection, we find broken wires, we’re going to let you know we found damage.

A lot of the cost will be dependent on the location of the crane versus where our technician(s) and equipment are located at the time you need the inspection. When you consider the price of the rope, investing in an inspection could save you a significant amount of money from potential downtime after the crane is in the field.

The hourly rate for Mazzella crane ropes inspectors is between $195 and $250. That’s our technician’s rate from the time they leave the shop until they get back after the inspection is complete.

The overall length and time of the inspection also affects the cost. Weekends and holidays will come with higher rates for the technician’s services. Also, if multiple technicians are needed to service multiple cranes, that will add to the overall cost of an inspection.

We’re continually setting up training classes with manufacturers to make sure we’re following all of the ISO and ASME (American Society of Mechanical Engineers) standards, and making sure we’re doing everything at as high of a level as we possibly can.

Mazzella is a one-stop-shop for high-performance crane ropes, or any kind of specialty ropes. Also, we have fittings and sockets that we can install, and a large inventory of ropes in stock that allow us to help get you back up and running as quickly as possible.

We offer a new rope replacement off the same truck and trailer that we’re doing the inspection from. If it’s a rope replacement, that’s something we can typically get on a truck and on the way the same day if the order is placed by 2 p.m. EST. If that happens, we can get the rope on the road and conduct the install the next day.

We have one of the largest crane ropes inventories in the United States…ready for immediate delivery! We provide wire rope assemblies, and manufacture bridge cables, crane cables, steel mill cables, and thousands of OEM assemblies:In sizes from ¼” to 3” diameter and 9mm to 52mm diameter

Any wire rope in use should be inspected on a regular basis. You have too much at stake in lives and equipment to ignore thorough examination of the rope at prescribed intervals.

The purpose of inspection is to accurately estimate the service life and strength remaining in a rope so that maximum service can be had within the limits of safety. Results of the inspection should be recorded to provide a history of rope performance on a particular job.

On most jobs wire rope must be replaced before there is any risk of failure. A rope broken in service can destroy machinery and curtail production. It can also kill.

Because of the great responsibility involved in ensuring safe rigging on equipment, the person assigned to inspect should know wire rope and its operation thoroughly. Inspections should be made periodically and before each use, and the results recorded.

When inspecting the rope, the condition of the drum, sheaves, guards, cable clamps and other end fittings should be noted. The condition of these parts affects rope wear: any defects detected should be repaired.

To ensure rope soundness between inspections, all workers should participate. The operator can be most helpful by watching the ropes under his control. If any accident involving the ropes occurs, the operator should immediately shut down his equipment and report the accident to his supervisor. The equipment should be inspected before resuming operation.

The Occupational Safety and Health Act has made periodic inspection mandatory for most wire rope applications. If you need help locating the regulations that apply to your application, please give our rigging experts a call.

This 12-page brochure presents important guidelines for inspecting wire rope systems or installations. It provides a clear and concise approach to assisting wire rope users" needs to comply with industry and governmental regulations that require inspections of individual ropes, fittings and attachments, as well as entire operating systems at regularly scheduled intervals. It is very useful for conducting safety meetings and training sessions. In addition to information and criteria, the brochure includes a blank Inspection Form, which may be easily copied for recording results of regular inspections for the permanent, written files required by many regulations.

A competent person must begin a visual inspection prior to each shift the equipment is used, which must be completed before or during that shift. The inspection must consist of observation of wire ropes (running and standing) that are likely to be in use during the shift for apparent deficiencies, including those listed in paragraph (a)(2) of this section. Untwisting (opening) of wire rope or booming down is not required as part of this inspection.

Significant distortion of the wire rope structure such as kinking, crushing, unstranding, birdcaging, signs of core failure or steel core protrusion between the outer strands.

In running wire ropes: Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay, where a rope lay is the length along the rope in which one strand makes a complete revolution around the rope.

In rotation resistant ropes: Two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters.

In pendants or standing wire ropes: More than two broken wires in one rope lay located in rope beyond end connections and/or more than one broken wire in a rope lay located at an end connection.

If a deficiency in Category I (see paragraph (a)(2)(i) of this section) is identified, an immediate determination must be made by the competent person as to whether the deficiency constitutes a safety hazard. If the deficiency is determined to constitute a safety hazard, operations involving use of the wire rope in question must be prohibited until:

If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

If a deficiency in Category II (see paragraph (a)(2)(ii) of this section) is identified, operations involving use of the wire rope in question must be prohibited until:

The employer complies with the wire rope manufacturer"s established criterion for removal from service or a different criterion that the wire rope manufacturer has approved in writing for that specific wire rope (see § 1926.1417),

If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

If the deficiency (other than power line contact) is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. Repair of wire rope that contacted an energized power line is also prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

Where a wire rope is required to be removed from service under this section, either the equipment (as a whole) or the hoist with that wire rope must be tagged-out, in accordance with § 1926.1417(f)(1), until the wire rope is repaired or replaced.

The inspection must include any deficiencies that the qualified person who conducts the annual inspection determines under paragraph (c)(3)(ii) of this section must be monitored.

Wire ropes on equipment must not be used until an inspection under this paragraph demonstrates that no corrective action under paragraph (a)(4) of this section is required.

At least every 12 months, wire ropes in use on equipment must be inspected by a qualified person in accordance with paragraph (a) of this section (shift inspection).

The inspection must be complete and thorough, covering the surface of the entire length of the wire ropes, with particular attention given to all of the following:

Exception: In the event an inspection under paragraph (c)(2) of this section is not feasible due to existing set-up and configuration of the equipment (such as where an assist crane is needed) or due to site conditions (such as a dense urban setting), such inspections must be conducted as soon as it becomes feasible, but no longer than an additional 6 months for running ropes and, for standing ropes, at the time of disassembly.

If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

If the qualified person determines that, though not presently a safety hazard, the deficiency needs to be monitored, the employer must ensure that the deficiency is checked in the monthly inspections.

All documents produced under this section must be available, during the applicable document retention period, to all persons who conduct inspections under this section.

Wire ropes are largely used in marine environment or for rigging purposes. They receive considerable loads and thus suffer a great deal of mechanical damage throughout their service life. Moreover, research has shown that the major cause of wire rope failure is excessive deterioration and corrosion, lack of maintenance and inspection, and wrong usage resulting in early discarding, reduced safety and replacement cost increase.

Sometimes damage can be easily detected, while in other cases fractured wires may occur on the inside. Hence, wire ropes should be inspected and maintained by the right person (competent person assigned by the company), to assure they’re in perfect condition. Regular inspectionsensure high rope performance, long service lifetime , safety of personnel and equipment, and reduced operating costs.

All ropes (synthetic, high modulus and wire ropes) should be inspected before and after an operation. This guideline ensures maximum safety for both a ship’s personnel and equipment. Even though it’s difficult to determine the exact service life span of ropes, there is a way to have a more precise estimation about their efficient lifecycle. Calculating the exact time ropes have been in use (e.g mooring time, mooring conditions, weather and tidal conditions) is the answer. All in all, rope inspections should occur at least once a year.

Inspecting wire ropes in particular, comes with great responsibility. Inspection results should be recorded, and any defects noticed have to be reported and addressed properly. Some defects can be repaired, while in some cases replacing a wire rope is inevitable.

Periodical inspections ofvessel deck equipment is also crucial for maintaining the good condition of wire ropes. The condition of the drum, chocks, bitts, rollers, sheaves, cable clamps and other end fittings, affect the rope’s performance, threads and cords. Make sure to mark these parts during your overall inspection.

In order to help marine officers and staff conduct successful wire rope inspections – and keep an up-to-date record of them – we have created an inspection solution that helps in maintaining and monitoring a ship’s ropes and deck equipment.

When calculating mass using F = Minimum Breaking Force, according to the wire rope’s diameter, you can determine the Minimum Breaking Massand therefore the wire’s max strength. When calculating mass using F = Safe Load according to the wire rope’s diameter, you can determine the Safe Load Mass,which is the advised load for this rope diameter.

The strands of a wire rope absorb the majority of the tensile force applied on the rope. Their design and manufacturing standards affect the level of fatigue resistance and resistance to abrasion. An easy way to understand which rope design is suitable for each purpose, is the wire rope classification.

Wire ropes are classified according to the number of strands in each construction and the number of wires in each strand. For example, a classification of 6X19 means that a wire rope of this type always has six strands, but its wires could be 15-26 per strand. This is because 19 is not the exact number of wires, but the classification of a wire number range.

Visual inspections are a common and fast way to assess wire rope condition. Both the standard and rotation resistant wire rope inspectionprocesscomply with the same four steps of examination. A ship’s crew can perform them as follows:

Steel wire rope distortion is obvious in most cases and can easily be identified by the inspector or the ship‘s crew. It usually occurs if load is suddenly applied or abruptly released (shock loading), or even if swift torque is forcefully induced.

Although not all of these deformations make the rope absolutely dangerous to use, they all may cause ropes to wear unevenly in time. This means inspections should take place more often, and distorted ropes should be handled with caution.

The rag and visual inspection is a good method for regular inspection intervals. The inspector pulls a rag along the rope trying to find broken wire cords. If the rug gets snagged by the rope, the inspector has to stop and assess the wire rope’s condition. Extreme caution should be exercised during the visual inspection, and under no circumstances should this method be the only one used to inspect wire ropes.

Tip: When you encounter a protruding wire end, bend it back and forth manually, until it separates from the wire. This will protect neighboring wires from wearing out.

Diameter reduction is a critical factor in steel wire rope wear and if not properly taken care of, it can result in rope breakage. Excessive abrasion, loss of core mass, corrosion or inner wire failure are all factors that contribute to diameter reduction.

To get an accurate measurement of the rope’s diameter, measure the rope at three different points at least 5 feet apart. Take the average of these three measurements to determine the true diameter.

Any measurements showing a reduction of ⅓ or more, indicate that a replacement should follow without delay. A diameter reduction of less than 1/3 still requires attention, and the inspector or the ship’s crew should be on guard in the next scheduled wire rope inspection.

Failure from abrasion or corrosion is a result of deficient deck equipment inspection or insufficient wire rope lubrication respectively. Internal corrosive damage is more difficult to identify than any other types of degradation. In most cases, the damage has progressed more than the external signs suggest.

Wire rope storage plays a significant role in the rope’s operation life.Wire rope corrosion and pitting can be avoided if ropes are safely stored in a clean, cool, dry and well-ventilated place. Steel wire ropes should not by any means rest on the floor, and should be protected from water, dust or any chemical fumes. Long term storage requires periodic greasing, turning the reel upside down for preventing grease dripping and possibly re-winding to another reel with larger inner tube diameter.

Wire ropes should be maintained with periodical lubrication. In order to prevent internal corrosion, a pressure lubricator is suggested to be used. In this case, a small amount of grease is used to lubricate the rope internally, while the deck stays grease-clean. Pressure lubricators clean the rope before they grease it so that the new grease enters a clean rope. The type of grease used is very important for maximum protection and greasing efficiency.

Steel wire ropes exposed to dirt, grime and other contaminants, have to be cleaned with a wire brush and petroleum (unless a pressure lubricator is used). Optimal cleaning of wire ropes can extend their service life and guarantee safe operations.

The reeling process is of high importance for the longevity of wire ropes. To protect them from being damaged, it is important that the surface of the drum is clean, smooth and dry. Improper reeling may cause wire-rope strands to spread or get flattened, when in contact with one another, as successive layers are being spooled and upper layers apply pressure on the lower ones.

Katradis S.A. offers a wide range of top quality wire ropes for shipping (mooring and hoisting operations), fishing and construction purposes. Our wire ropes have greater resistance to fatigue, and they distribute tension force equally among the rope strands. They are less likely to kink, providing higher staff safety and assuring operation success.

If required UNIROPE® provides ON SITE INSPECTION SERVICE. Our factory trained inspection personnel will provide you with a full WRITTEN inspection report and a complete LISTING of all inspected slings in service at your plant or construction site. Where necessary we will proof-load the slings and issue a PROOF TEST CERTIFICATE. This service not only covers slings made from wire rope, but also slings made from chain and synthetic fibers.

The goal of a sling inspection is to evaluate the remaining strength in a sling, which has been used previously, to determine if it is suitable for continued use.

Specific inspection intervals and procedures are required by local safety regulations (e.g. in Ontario see OHSA) and by ASTM B30.9. The responsibility for having the inspection done is placed upon the SLING USER.

As a starting point, the same work practices which apply to all “working” wire ropes also apply to wire rope slings. Therefore, a good working knowledge of wire rope design and construction will not only be useful but essential in conducting a wire rope sling inspection.

Since a wire rope is a rather complex “machine”, no precise rules can be given to determine exactly when a wire rope sling should be replaced. There are many variables, and all must be considered.

Broken Wires: For 6-strand wire rope slings, 10 randomly distributed broken wires in one rope lay, or five broken wires in one strand of one rope lay. For Gator-Flex® and Tri-Flex® slings these same rules apply to each of the component ropes.

Metal Loss: Wear or scraping of one-third the original diameter of outside individual wires. This is quite difficult to determine on slings and you require some experience to perform this evaluation.

Distortion: Kinking, crushing, birdcaging, or other damage which distorts the rope structure. The main thing to look for are wires or strands that are pushed out of their original position in the rope. Slight bends in a rope where wires or strands are relatively in their original position would not be considered serious damage. But good judgment is indicated.

Corrosion: Severe corrosion of the rope or end attachments which has caused pitting or binding of wires should be cause for replacement. Light rusting usually does not affect the strength of a sling.

Mechanical Damages: One of the most common causes of damage is the kink which results from pulling the sling body through the loop (choker hitching), thus causing wires or strands to be deformed and pushed out of their original position. This unbalances the sling, reducing its strength.

Disposition: The best inspection program available is of no value if slings, which are worn out and have been retired, are not disposed of properly. Retired slings should be tagged DO NOT USE to prevent any further usage. The sling should be destroyed as soon as possible by cutting the eye and fittings from the rope.

Inspect the bearing point of the eye. Check for deformation and wear of sleeve, thimbles, and all attached hardware. Check for broken wires where the rope enters the sleeve or socket.

Both ASTM B.30.9 and most Provincial Regulations require that wire rope slings receive two types of inspections: a PRIOR TO USE visual inspection, and additional inspections where severe conditions warrant.

Daily inspections are intended to detect serious damage or deterioration which would weaken the sling. Look for obvious things, such as broken wires, kinks, crushing, broken attachments, severe corrosion.

Additional inspections must be carried out by a designated person who must have good knowledge of wire rope. The frequency of these regular inspections should be based on:

Wire ropes undergo constant stress and wear through daily use. So, wire rope requires monthly inspection in accordance with this section to reduce the risk of failure and potential resulting injury or property damage. In addition, this section covers criteria to use in determining when to replace rope, and requires inspection of rope on equipment that has been idle for a month or more, before the rope and equipment can be returned to service.

A thorough inspection of all ropes shall be made at least once a month and a certification record which included the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes which were inspected shall be kept on file where readily available to appointed personnel. Any deterioration, resulting in appreciable loss of original strength, shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following:

All rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. This inspection shall be for all types of deterioration and shall be performed by an appointed person whose approval shall be required for further use of the rope. A certification record shall be available for inspection which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the rope which was inspected.

Wear and damage to wire rope can’t always be seen on the surface. Konecranes RopeQ Magnetic Rope Inspection pairs visual inspection with non-destructive testing to detect internal broken wires that may escape detection through traditional inspection methods.

*The foregoing OSHA regulations are not intended to be a comprehensive overview of all applicable regulations pertaining to the designated topic. State laws may mandate different safety and maintenance standards. Accordingly, please consult applicable state laws as well as original equipment manufacturer specifications for further guidance. The statements and descriptions contained herein constitute the opinion/recommendation of the seller and are not intended to create any express warranties.

The MOL, CSA, OHSA and ANSI, AMSE and OSHA are North American governing bodies which legislate that inspections be performed at regular service intervals.

Immediately after the inspections are complete you will receive your certifications and will be in compliance with the Ministry of Labor and Government Law & Regulations

In 2019, Dosco partnered with Anthis, an NDT Inspection Company based in Italy, to develop a new technology that makes remote and digital wire rope inspection possible. A much more reliable and effective way than the visual inspection that is still the current standard while saving cost, time, and optimization of inspection criteria in environments with critical liftings.

Visual wire inspection only looks at the outside of wire rope, having a look at the inside is of course impossible without the use of technology. That leaves a lot of room for errors.

Inspection with MRTThe standard ISO 4309:2017 established the general principles for the care and maintenance, inspection and discard of steel wire ropes used on cranes and hoists. Although Wire rope slings do not belong to any of the categories where the Standard applies, we believe that any wire rope used in the lifting sector should be analysed and inspected with MRT technology to guarantee safety while lifting.

Dosco and Anthis have developed e-LIM (electric Line Integrity Monitor) and s-LIM (slick line Integrity Monitor) to be able to inspect electric lines and slick lines. The Wire Rope test bench for inspection of lifting ropes is equipped with that same state-of-the-art equipment. Unique in its kind and the first ever in the panorama of inspection of lifting accessories.

Wire line failures are classified either mechanical or electrical, while slick line failures are only mechanical. The mechanical ones can now be detected with e-LIM and s-LIM to avoid unnecessary downhole problems or to determine the reason of failure.