wire rope inspection standards in stock

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.

(1) 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.

(A) 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.

(1) 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.

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

(3) 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.

(i) 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:

(B) 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.

(ii) 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:

(A) 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),

(C) 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.

(B) 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.

(iv) 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.

(2) 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.

(3) 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.

(1) 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).

(ii) 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:

(iii) 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.

(B) 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.

(ii) 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.

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

Do you know who is supposed to be inspecting your lifting slings? More importantly, do you know how often they’re inspecting them? OSHA and ASME have different inspection requirements, frequencies, and removal criteria for each type of sling—including alloy chain slings, synthetic slings, metal mesh slings, and wire rope slings.

At Mazzella, we understand the amount of effort and coordination it takes to stay current on industry standards and to develop an inspection program that keeps your business in compliance. Because of this, we have a dedicated business unit made of up highly-trained and qualified inspectors and technicians that focus only on rigging equipment inspections, industry compliance, and sling testing and repair.

In this article, our goal is to help you understand what is required to inspect wire rope slings to meet ASME standards, which in turn, will help to ensure the safety of the users,help extend the service life of the slings, and help reduce unnecessary equipment repair costs and loss of production due to equipment downtime.

As a starting point, the same work practices which apply to all “working” wire rope apply to wire rope which has been fabricated into a sling. 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.

There are two industry standards that exist to provide the end-user with guidelines for inspection and criteria that warrants removal from service: OSHA 1910.184 and ASME B30.9.

Initial Inspection (prior to initial use): Best practice is to inspect the wire rope sling upon receiving it from the manufacturer. Double-check the sling tag to make sure it’s what you ordered and that the rated capacity meets all of your project specifications and lifting requirements.

Frequent (daily or prior to use): Designate a Competent Person to perform a daily visual inspection of slings and all fastenings and attachments for damage, defects, or deformities. The inspector should also make sure that the wire rope sling that was selected meets the specific job requirements it’s being used for.

Users can’t rely on a once-a-day inspection if the wire rope sling is used multiple times throughout the day. Damage to wire rope can occur on one lift and best practice is to perform a visual inspection before any shift change or changes in lifting application. Because shock loads, severe angles, sharp edges, and excessive heat can quickly cause damage to a lifting sling, the user should inspect the sling prior to each lift.

Periodic Inspection: A periodic inspection is performed by either a professional service provider, or by a Qualified Person, every 12 months (at a minimum) and monthly to quarterly in more severe service conditions. The following are all determining factors in scheduling the frequency of a periodic inspection:Frequency of use

Depending on the severity of the operating environment and frequency of use, your business may decide to inspect wire rope slings more often than the minimum yearly requirement.

Per ASME B30.9, the wire rope sling tag on all new slings shall be marked by the manufacturer to include:Rated load for the types of hitches (single-leg vertical, choker, and basket) and the angle upon which they are based

The goal of a sling inspection is to evaluate remaining strength in a sling which has been used previously to determine if it is suitable for continued use. When inspecting wire rope slings, daily visual inspections are intended to detect serious damage or deterioration which would weaken the sling.

This inspection is usually performed by the person using the sling in a day-to-day job. The user should look for obvious things, such as broken wires, kinks, crushing, broken attachments, severe corrosion, etc. Any deterioration of the sling which could result in appreciable loss of original strength should be carefully noted and determination made on whether further use would constitute a safety hazard.

2. Broken Wires: For strand-laid grommets and single-part slings, ten randomly distributed broken wires in one rope lay, or five broken wires in one strand in one rope lay. For cable laid, cable laid grommets and multi-part slings, use the following:

3. Distortion: Kinking, crushing, birdcaging or other damage which distorts the rope structure. The main thing to look for is wires or strands that are pushed out of their original positions in the rope.

7. Corrosion: Severe corrosion of the rope or end attachments which has caused pitting or binding of wires should be cause for replacing the sling. Light surface rust does not substantially affect strength of a sling.

9. Unbalance:A very common cause of damage is the kink which results from pulling through a loop while using a sling, thus causing wires and strands to be deformed and pushed out of their original position. This unbalances the sling, reducing its strength.

10. Kinks: Are tightened loops with permanent strand distortion that result from improper handling when a rope is being installed or while in service. A kink happens when a loop is permitted to form and then is pulled down tight, causing permanent distortion of the strands. The damage is irreparable and the sling must be taken out of service.

11. Doglegs: Are permanent bends caused by improper use or handling. If the dogleg is severe, the sling must be removed from service. If the dogleg is minor, (exhibiting no strand distortion) and cannot be observed when the sling is under tension, the area of the minor dogleg should be marked for observation and the sling can remain in service.

The best lifting and rigging inspection program is of no value if slings, which are worn out and have been retired, are not properly disposed of. When it is determined by the inspector that a sling is worn out or damaged beyond use, it should be tagged immediately DO NOT USE.

If it’s determined that the wire rope will be removed from service, we suggest cutting it down into more manageable sizes before discarding. This extra effort will help to accommodate the needs of most recycling facilities that will accept the damaged wire rope and also help to make sure that it cannot be used any further. Keep the following in mind when disposing of wire rope slings and wire rope cable:Cut into approximately 3’ to 4’ sections

OSHA does not provide clear guidelines on how to properly and adequately inspect wire rope slings. It is up to the designated inspection personnel to know the requirements of the sling inspection standards, and to develop a comprehensive inspection protocol. Wire rope inspection should follow a systematic procedure:First, it is necessary that all parts of the sling are readily visible. The sling should be laid out so every part is accessible.

Next, the sling should be sufficiently cleaned of dirt and grease so wires and fittings are easily seen. This can usually be accomplished with a wire brush or rags.

The best way to help extend the life of a wire rope sling, and help to ensure that it stays in service, is to properly maintain it during and in-between each use. Inspections are easier to perform—and probably more thorough—when slings are easily accessible and organized, kept off of the ground, and stored in a cool and dry environment.Hang slings in a designated area where they are off of the ground and will not be subjected to mechanical damage, corrosive action, moisture, extreme temperatures, or to kinking.

Like any other machine, wire rope is thoroughly lubricated at time of manufacture. Normally, for sling use under ordinary conditions, no additional lubrication is required. However, if a sling is stored outside or in an environment which would cause corrosion, lubrication should be applied during the service life to prevent rusting or corroding.

If lubrication is indicated, the same type of lubrication applied during the manufacturing process should be used. Your sling manufacturer can provide information on the type of lubricant to be used and provide the best method of application. We recommend a wire rope lubricant that is designed to penetrate and adhere to the wire rope core.

Proper inspection of your wire rope slings for damage or irregularities, prior to each use, is the best way to help keep everybody on the job site safe. Keep in mind that you’re planning to lift valuable and expensive equipment, and if a failure were to occur, it would not only cause unnecessary equipment repair costs and costly downtime, but also potentially jeopardize the lives of workers on site.

At Mazzella, we offer a variety of services including site assessments, rigging and crane operator training, sling inspection and repairs, overhead crane inspections and so much more. Our rigging inspection program is its own dedicated business unit with a team of inspectors that are certified through Industrial Training International to meet OSHA 1910.184 and ASME B30.9 requirements for sling inspection.

Guidelines for inspecting a wire rope system or installation are available in this brochure. The publication 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.  In addition to information and criteria, the brochure includes a blank Inspection Form, which may be copied for recording results of regular inspections for permanent, written fires required by many regulations.

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.

Maintain a record for each rope that includes the date of inspection, type of inspection, the name of the person who performed the inspection, and inspection results.

Use the "rag-and-visual" method to check for external damage. Grab the rope lightly and with a rag or cotton cloth, move the rag slowly along the wire. Broken wires will often "porcupine" (stick out) and these broken wires will snag on the rag. If the cloth catches, stop and visually assess the rope. It is also important to visually inspect the wire (without a rag). Some wire breaks will not porcupine.

Measure the rope diameter. Compare the rope diameter measurements with the original diameter. If the measurements are different, this change indicates external and/or internal rope damage.

Visually check for abrasions, corrosion, pitting, and lubrication inside the rope. Insert a marlin spike beneath two strands and rotate to lift strands and open rope.

Assess the condition of the rope at the section showing the most wear. Discard a wire rope if you find any of the following conditions:In running ropes (wound on drums or passed over sheaves), 6 or more broken wires in one rope lay length; 3 or more broken wires in one strand in one rope lay. (One rope lay is the distance necessary to complete one turn of the strand around the diameter of the rope.)

Corrosion from lack of lubrication and exposure to heat or moisture (e.g., wire rope shows signs of pitting). A fibre core rope will dry out and break at temperatures above 120°C (250°F).

Kinks from the improper installation of new rope, the sudden release of a load or knots made to shorten a rope. A kink cannot be removed without creating a weak section. Discarding kinked rope is best.

Wire rope is extremely sturdy and can be used in many different applications. In order to withstand harsh conditions, wire rope has basic guidelines of inspection it must meet. Continue reading to find out the guidelines of inspection for wire rope.

Abrasion damage is usually caused by the rope making contact with an abrasive surface. It can also be caused by simply passing over the drum and sheaves during regular, continued use. To minimize this risk, all components should be in proper working condition and be of appropriate diameter for the rope. Badly worn sheaves or drums will cause serious damage to a new rope and will greatly diminish the integrity of the rope quickly.

Corrosion is hard to assess but is more problematic than abrasion. Corrosion is usually the result of the lack of lubrication. It will most likely take place internally before there are any apparent signs on the rope’s surface. One telltale sign of corrosion is a slight discoloration, which is generally the result of rusting. This discoloration indicates a need for lubrication which should be dealt with as soon as possible. Failure to attend to this situation will lead to severe corrosion which will cause premature fatigue failures in the wires and strands. If this occurs, the rope will need to be removed immediately.

Diameter reduction is an extremely serious deterioration factor and can occur for several reasons. The most common reasons for diameter reduction are excessive abrasion of the outside wires, loss of core diameter/support, internal or external corrosion damage, or inner wire failure.

Examining and documenting a new rope’s actual diameter when under normal load conditions is critical. During the life of the rope, the actual diameter of the rope should be regularly measured at the same location under similar loading conditions. If this protocol is followed correctly, it should divulge a routine rope characteristic—after an initial reduction, the overall diameter will stabilize, then gradually decrease in diameter during the course of the rope’s life. This occurrence is completely natural, but if diameter reduction is confined to a single area or happens quickly, the inspector must quickly identify the source of the diameter loss and make the necessary changes if possible. Otherwise, the rope should be replaced as soon as possible.

Crushing or flattening of wire rope strands can happen for many reasons. These issues usually arise on multilayer spooling conditions but can also develop just by using the wrong wire rope for the specific application. Incorrect installation is the most common cause of premature crushing/flattening. Quite often, failure to secure a tight first layer, which is known as the foundation, will cause loose or “gappy” conditions in the wire rope which will result in accelerated deterioration. Failure to appropriately break-in the new rope, or even worse, to have no break-in protocol whatsoever, will also result in poor spooling conditions. The inspector must understand how to correctly inspect the wire rope, in addition to knowing how that rope was initially installed.

Another potential cause for the replacement of the rope is shock loading (also known as bird-caging). Shock loading is caused by the abrupt release of tension on the wire rope and its rebound culminating from being overloaded. The damage that ensues can never be amended and the rope needs to be replaced immediately.

There are several different instances that might result in high stranding. Some of these instances include the inability to correctly seize the rope prior to installation or the inability to maintain seizing during wedge socket installation. Sometimes wavy rope occurs due to kinks or very tight grooving issues. Another possible problem arises from introducing torque or twist into a new rope during poor installation methods. In this situation, the inspector must assess the continued use of the rope or conduct inspections more often.

There are a lot of guidelines for troubleshooting wire rope. At Silver State Wire Rope and Rigging, Inc., we take these guidelines seriously, and so should you. All of our products are tested and guaranteed to be the best fit for your specific needs. We can also help you with your troubleshooting needs. Contact us today!

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.

A specific procedure for sling inspection is the best safeguard against injury, death and property damage. It is important that you employ a three stage level of inspection to ensure that slings are inspected with appropriate frequency. It is also important that all inspections must be done by trained and qualified personnel.

To detect possible damage, you should perform a visual inspection of the entire sling by making all parts of the sling readily visible. If necessary, remove dirt and grime so wires and components are visible. Look for any of the conditions listed in the Removal from Service Criteria. The following example depict some of the types of damage, but note that they are relatively extreme examples provided for illustration purposes only.

If you identify ANY of these types of damage, remove slings from service immediately, even if the damage you see is not as extensive as shown. Slings that are removed from service must be destroyed and rendered completely unusable. Never ignore sling damage or attempt to perform temporary field repairs of damaged slings. It is very important that slings are regularly and properly inspected. If you are not sure whether or not a sling is damaged, DO NOT USE IT.

Your crane"s wire rope works hard. (Almost as hard as you do.) It can deteriorate more quickly than you might think, posing a real danger for you and your crew. In this article, we"ll answer the following questions.

Before we get into that, let"s take a brief moment to go over the proper wire terminology. Understanding the make-up of the wire rope allows you to have a clear understanding of when the rope needs to be replaced.

Flexible steel wire rope is made up of individual wires that make up a strand; these strands are then wrapped around a central core to make up a rope.

Understanding the difference between a wire and a strand is critical. If a strand (grouping of wires) in the rope breaks, the crane wire would need to be replaced. However, if a single wire in the strand breaks, the rope itself may still be usable.

Rag & Visual Inspections: In this method, you use a rag in your inspection, pulling it slowly across the strand, stopping for a closer and more detailed inspection wherever the rag gets caught on a wire.

The Diameter Measurement Method: This method involves comparing the diameter of your rope at various intervals with the rope"s official diameter per the manufacturer"s guidelines. A variation in the rope"s diameter can alert you to potential interior damage that a visual inspection would miss.

Localized Flaw Inspections (LF) vs. Loss of Metallic Area Inspections (LMA) - Both methods use electromagnetics to search for a wire rope"s internal damage.

According to OSHA"s safety regulations, you"re required to inspect your crane"s wire ropes at least every 12 months by qualified professionals. However, OSHA and other experts also recommend inspecting your wire ropes more frequently, such as after every initial installation or repair, or daily before each shift to ensure a safe work environment.

As discussed at the very beginning of this article, we can break down wire rope into three parts. First, wires, which make up strands, and then the strands wrapped around the central core make the rope. Of your total number of wires, you never want more than 10% to be damaged before you need to look into crane wire rope replacement.

According to OSHA, only "trained personnel should carry out inspections," and according to the Crane Manufacturers Association of America, a certified crane inspector should get 2,000+ hours of field experience and training.

We at Americrane & Hoist Corporation are just the experts you need, qualified to offer OSHA inspections and provide operator safety training classes to your employees. Contact us today!

Abrasion damage may occur when the rope contacts an abrasive medium or simply when it passes over the drum and sheaves. Therefore it is vital that all components be in proper working order and of the appropriate diameter for the rope. A badly corrugated or worn sheave or drum will seriously damage a new rope, resulting in premature rope replacement.

Corrosion is very difficult to evaluate but is a more serious cause of degradation than abrasion. Usually signifying a lack of lubrication, corrosion will often occur internally before there is any visible external evidence on the rope’s surface. A slight discoloration caused by rusting usually indicates a need for lubrication which should be tended to immediately. If this condition persists, it will lead to severe corrosion which promotes premature fatigue failures in the wires and strands, necessitating the rope’s immediate removal from service.

The table below shows the number of allowable wire breaks per crane type. The inspector must know the ASME standard for the equipment being inspected. The number of broken wires on the outside of the wire rope is an indication of its general condition and whether or not it must be considered for replacement. The inspector may use a type of spike to gently probe the strands for any wire breaks that do not protrude. Check as the rope runs at a slow speed over the sheaves, where crown (surface) wire breaks may be easier to see. Also examine the rope near the end connections. Keeping a detailed inspection record of the wire breaks and other types of damage will help the inspector determine the elapsed time between breaks. Note the area of the breaks and carefully inspect these areas in the future. Replace the rope when the wire breaks reach the total number allowable by ASME or other applicable specifications.

Valley breaks, or breaks in between strands, must be taken very seriously at all times!When two or more valley breaks are found in one lay-length, immediately replace the rope. Valley breaks are difficult to see; however, if you see one you can be assured that there are a few more hidden in the same area. Crown breaks are signs of normal deterioration, but valley breaks indicate an abnormal condition such as fatigue or breakage of other wires such as those in the core.

Once crown and valley breaks appear, their number will steadily and quickly increase as time goes on. The broken wires should be removed as soon as possible by bending the broken ends back and forth with a pair of pliers. In this way the wire is more likely to break inside the rope where the ends will be tucked away. If the broken wires are not removed they may cause further damage. The inspector must obey the broken wire standard; pushing the rope for more life will create a dangerous situation.

It is important to check and record a new rope’s actual diameter when under normal load conditions. During the life of the rope the inspector should periodically measure the actual diameter of the rope at the same location under equivalent loading conditions. If followed carefully, this procedure reveals a common rope characteristic—after an initial reduction, the overall diameter will stabilize and slowly decrease in diameter during the course of the rope’s life. This condition is normal. However, if diameter reduction is isolated to one area or happens quickly, the inspector must immediately determine (and correct, if necessary) the cause of the diameter loss, and schedule the rope for replacement.

Crushing or flattening of the strands can be caused by a number of different factors. These problems usually occur on multilayer spooling conditions but can occur by simply using the wrong wire rope construction. Most premature crushing and/or flattening conditions occur because of improper installation of the wire rope. In many cases failure to obtain a very tight first layer (the foundation) will cause loose or “gappy” conditions in the wire rope which will cause rapid deterioration. Failure to properly break-in the new rope, or worse, to have no break-in procedure at all, will cause similar poor spooling conditions. Therefore, it is imperative that the inspector knows how to inspect the wire rope as well as how that rope was installed.

Shock loading (bird-caging) of the rope is another reason for replacement of the rope. Shock loading is caused by the sudden release of tension on the wire rope and its resultant rebound from being overloaded. The damage that occurs can never be corrected and the rope must be replaced.

High stranding may occur for a number of reasons such as failure to properly seize the rope prior to installation or maintain seizing during wedge socket installation. Sometimes wavy rope occurs due to kinks or a very tight grooving problem. Another possibility is simply introducing torque or twist into a new rope during poor installation procedures. This condition requires the inspector to evaluate the continued use of the rope or increase the frequency of inspection.

Dear Suresh Dharman; I have done several inspections. It"s necesary to know the aplication of the wire rope. Technical data of the rope regarding construction. Normally ASME B 30 will do. There are considerations regarding number of wires in certain length, let"s say 6 in a lay length. Also reduction in diameter around 10 % or 5%. It depends in the aplication. And regarding remaining life, it"s quite difficult to predict. Around 50,000 cycles is considered a normal usefull life. There are investigations regarding this subject, but not concluded yet. Too many things to consider. Send me an Email to correo@manuelhaces.com. Regards.

Hi Suresh! Intron Plus www.intron-plus.com is a leading company for magnetic rope testing (MRT). One of the latest standard ISO 4309:2017, recognises MRT as sufficient mean to provide rope safety. We can comment your questions in regard to MRT equipment, training, inspection, etc. Drop me a message with your questions.

As mentioned before, go to ASME B 30 Series. Replacement criterion will move from 10 down to 5% in reduction of diameter, not yet but check this. Also, common practice is to discard this type of rope at 7 years interval, due to fatigue. Send email and I"ll make more recomendations if you like. Regards

I have never heard about practice to discard guyed rope every 7 years. We have carried number of such inspections, using winch or self propelled climber https://www.youtube.com/watch?v=9DFNZZKVi90. Most of ropes were much older 7 years and were extended after NDT. Our in-house developed software enables assessment of rope residual breaking strength. Data from at least 2 sequential inspections of the same rope allow us assessment of residual rope life as well.

It was found from other people that after 7 years ropes with no movement in cranes like pendants or flare stack wires that due to wind and other causes, start to develop fatigue cracks. And also as they are present, they will grow in number and size, very rapid, with out proportion of time or plain related to time. So its recomended, that inspection will increase in time moving to shorter elapsed times. And yes, it is possible to extend the usefull life of the rope doing inspection, we have done that for different companies were due to regulations they will change the rope after some cycles or time. If you are sure that after inspection the rope is fine, then carry on with the use. But as soon as you discover fatigue, do another inspection in a short period of time, in order to take carefully actions.

Infrastructure Inspection services and Bridge Inspections Go Robotic with the latest in robotic bridge inspection technology. Infrastructure Preservation Corporation spent 5 years designing and testing the latest infrastructure and bridge inspection robotic. Developing services to exceed AASHTO and FHWA (Federal Highway Administration) inspection protocols. https://www.infrastructurepc.com/robotic-wire-rope-inspection-service-for-bridge-inspections-crane-and-hoist-inspections/

In addition to guidance on storage, handling, installation and maintenance, this document provides discard criteria for those running ropes which are subjected to multi-layer spooling, where both field experience and testing demonstrate that deterioration is significantly greater at the crossover zones on the drum than at any other section of rope in the system.

It also provides more realistic discard criteria covering decreases in rope diameter and corrosion, and gives a method for assessing the combined effect of deterioration at any position in the rope.

ISO 4309:2017 applies to rope on cranes, winches and hoists used for hook, grabbing, magnet, ladle, excavator or stacking duties, whether operated manually, electrically or hydraulically.

NOTE In view of the fact that the exclusive use of synthetic sheaves or metal sheaves incorporating synthetic linings is not recommended when single-layer spooling at the drum, due to the inevitability of wire breaks occurring internally in large numbers before there is any visible evidence of any wire breaks or signs of substantial wear on the periphery of the rope, no discard criteria are given for this combination.

A specific procedure for sling inspection is the best safeguard against injury, death and property damage. It is important that you employ a three stage level of inspection to ensure that slings are inspected with appropriate frequency. It is also important that all inspections must be done by trained and qualified personnel.

To detect possible damage, you should perform a visual inspection of the entire sling by making all parts of the sling readily visible. If necessary, remove dirt and grime so wires and components are visible. Look for any of the conditions listed in the Removal from Service Criteria. The following example depict some of the types of damage, but note that they are relatively extreme examples provided for illustration purposes only.

If you identify ANY of these types of damage, remove slings from service immediately, even if the damage you see is not as extensive as shown. Slings that are removed from service must be destroyed and rendered completely unusable. Never ignore sling damage or attempt to perform temporary field repairs of damaged slings. It is very important that slings are regularly and properly inspected. If you are not sure whether or not a sling is damaged, DO NOT USE IT.