wire rope inspection standard quotation

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.

Lifting slings are one of the most versatile rigging and lifting equipment. While slings have been around for centuries, their industrial use began only a few decades ago. Today, industrial slings are made from synthetic fibers like polyester, nylon, or high-performance materials. You will also see wire rope slings made from high-grade steel or iron.

Slings play a critical role in handling and transporting heavy loads. That’s why, when it comes to lifting slings, safety needs to be the topmost concern. You can’t ensure safe material handling without sling inspection before use. Moreover, these inspections should meet or exceed the prescribed standards.

The American Society of Mechanical Engineers or ASME has set standards for industrial lifting and rigging equipment of all shapes and sizes. The ASME B30.9 standard specifically deals with load-handling lifting slings. It covers everything about lifting slings, including:Attachment

The standard applies to everyone, including manufacturers, suppliers, owners, and users. If you are one of them, you will also want to confer to this standard. ASME keeps updating the standard every few years.

Adhering to the ASME B30.9 standard brings you several benefits. When it comes to buying, using, and maintaining lifting slings, this standard is a must. And here’s why.

For example, the ASME B30.9 standard clearly states that if a sling meets the following conditions, you should remove it from service immediately.Bird Caging

The standard also talks about manufacturing, assembling, and fabrication guidelines for lifting slings. In other words, AMSE lifting slings are thoroughly vetted. They also meet the quality and safety standards prescribed by the B30.9 code.

This standard also talks about maintaining lifting slings in excellent condition. Maintenance is necessary to ensure safety and long shelf life. While synthetic web or round slings are not expensive, large wire rope slings cost hundreds of thousands.

As mentioned before, ASME keeps updating all of its standards periodically. For ASME B30.9, the latest changes came into effect in 2021. That said, Holloway Houston prides itself in conferring to these latest revisions. Here’s a short synopsis of the latest changes made to the ASME B30.9 – 2021.

Taking the compliance of ASME B30.9 for granted is a mistake. ASME standards, B30.9 included, are not mandatory. ASME cannot force any manufacturer, inspector, or installer to follow ASME standards.

As you can see, standards like ASME B30.9 play a critical role in ensuring the safety, quality, and maintenance of lifting slings. When you are out shopping for these industrial lifting devices, you have to make sure to understand what this standard means, how it works, and why you need to consider it. Hopefully, this short post will shed some light in this regard.

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 rope. Insert a marlin spike beneath two strands and rotate to lift strands and open 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 improper installation of new rope, 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 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 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.

Specific inspection intervals and procedures are required by the Occupational Safety and Health Act (OSHA) and by ANSI B30.9 Regulations, and the responsibility for performance of inspections is placed squarely upon the sling user by Federal Legislation.

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

But because 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 single-part slings. 10 randomly distributed broken wires in one rope lay, or five broken wires in one strand on one rope lay. For multi-part slings these same criteria apply to each of the component ropes.For the inspection, a broken wire shall only be counted once; that is, each break should have two ends.

Metal Loss: Wear or scraping of one-third the original diameter of outside individual wires. This is quite difficult to determine on slings and experience should be gained by the inspector by taking apart old slings and actually measuring wire diameters.

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. Slight bends in a rope where wires or strands are still relatively in their original positions would not be considered serious damage. But good judgement is indicated.

Metal 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 rusting usually does not affect strength of a sling, however. In addition to these seven conditions specified by OSHA, the following are also important:

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.

Disposition of Retired Slings: the best inspection program available is of no value if slings which are worn out and have been retired are not disposed of properly. When it is determined by the inspector that a sling is worn out or damaged beyond use, it should be tagged immediately DONOTUSE. This sling should then be destroyed as soon as possible by cutting the eye and fittings from the rope with a torch. This will help assure that an employee will not mistakenly use a sling which has been retired from service.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire. On shipping docks, rigging, and load bearing equipment, wire rope is attached to swivels, shackles, or hooks to lift a load in a controlled, even, and efficient manner.

The uses for wire rope include adding support to suspension bridges, lifting elevators, and serving as additional reinforcement for towers. The design of wire rope, with its multiple strands wrapped around a stable core, provides strength, flexibility, and ease of handling for applications that have bending stress.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of lifting or supportive applications.

The term wire rope encompasses a wide range of mechanical tools that are made to perform heavy and extreme lifting jobs. Wire rope is a complicated and complex tool with multiple moving parts capable of moving in unison. A 6 by 25 wire rope has 150 outer strands that move as one in an intricate pattern supported by a flexible core.

An essential part of the design of wire rope is the required clearance between the strands to give each stand the freedom to move and adjust when the rope bends. It is this unique feature that differentiates wire rope from solid wire and other forms of cable.

The basic element of wire rope is wire that is used to configure, shape, and form the rope. Typically, steel, stainless steel, and galvanized wires are the first choice with aluminum, nickel alloy, bronze, copper, and titanium being second possibilities. The choice of wire is dependent on the type of work the wire is going to be used to perform with strength, flexibility, and abrasion resistance being the major determining factors.

Stainless steel wire rope has all of the basic qualities of galvanized and general wire rope with the added benefits of corrosion and rust resistance; this makes it the ideal choice for harsh and stressful conditions.

Steel wire rope is classified as general purpose wire rope and comes in a wide variety of sizes, diameters, and strengths. It is the most common type of wire rope and is used for several industrial, manufacturing, and construction applications.

Before going further into the discussion of how wire rope is made, it is important to understand the numbers used to describe each type. All wire ropes have a core around which wires are wound. The various styles of cores vary according to the construction and design of the requirements of the wire rope that is being produced.

Wire rope is classified by the number of strands it has as well as the number of wires in each strand. The most common classification is a seven wire rope that has one strand in the center and six around its circumference. This type of wire rope is lightweight with a very simple construction. The majority of wire ropes are more complex and intricate with multiple intertwining strands and wires.

What must be understood about wire rope is that it has a complicated configuration. It is actually wires wrapped around wires to form bundles that are wrapped around other bundles. In the case of a seven wire wire rope, the core has bundles of wires wound around it; this can be seen in the image below.

The first step in wire rope creation is the production of wire strands where wires are wound around a single core wire. The number of wires included in the strand is dependent on the specified strength, flexibility, and size requirements of the rope. Once the strand is completed, it is straightened before being moved to wire rope construction.

Like wire ropes, strands have different patterns; patterns are the arrangements of the wires and their diameters. Though most strands have a core, there are strand patterns that have three or four wires without a core that are referred to as centerless strands. The design of each strand pattern is meant to enhance the strength of the wire rope and improve its performance.

For a multiple layer strand, the layers of wire are placed over one another in successive order. The placement of the wires on top of each other must be such that they fit smoothly and evenly.

The Warrington pattern is like the multiple layer pattern with one variation. Like the multiple layer pattern, the inner wires and the core are the same and have the same diameter. The difference is in the outer layer, which has wires of alternating sizes of large and small with larger diameter wires laying in the valleys of the inner wires.

All of the wires of a filler pattern are the same size. What makes this pattern unique is the insertion of small wires in the valleys of the inner wires to fill the gap between the inner and outer layer.

The flattened strand pattern is also known as the triangular strand, which can be triangular or oval. Three round wires form the core. The outer flattened surface has a greater sectional metallic area; this makes this pattern stronger and longer lasting.

The core of a wire rope runs through the center of the rope and can be composed of a variety of materials, which include synthetic fibers, natural fibers, a single strand, or another wire rope. The core supports the wound strands, helps maintain their position, is an effective lubricant carrier, and provides support.

Wire ropes with fiber cores are restricted to light loads and are not used in severe, harsh, or stressful conditions. Polypropylene and nylon are types of synthetic fiber cores and can be used in conditions where there is exposure to chemicals.

Cores made of wire are classified as independent wire cores. The core of a wire rope with a wire core is actually a wire rope with another wire rope serving as the core, as can be seen in the diagram below. These types of wire ropes are used where the rope will be exposed to exceptional resistance and crushing.

A strand, or wire strand core, is exactly like the rest of the strands of the wire rope with wires of the same diameter and size as the other strands.

The choice of core and creation of the strands are the simplest yet most essential parts of wire rope construction. Wire rope lays, the method used to wind the strands, is more complex and involves several choices.

Lay is a term used to describe three of the main characteristics of wire rope: direction, relationship, and linear distance. The strands can be wrapped around the core going right or left. Right or left refers to the direction of the strands wrapped around the core and the wires within the strands. The linear distance is how far a strand moves when it is making a revolution around the core.

In a regular lay, the wires and strands spiral in opposite directions. With a right hand regular lay, the wires spiral to the left and the strands to the right. In the left hand regular lay, the wires spiral to the right and the strands to the left. This type of lay is easy to handle but wears out quickly because the crown wires are in contact with the bearing surface.

In the Lang, or Albert, lay, the wires and strands spiral in the same direction with right hand lay being the most common. The wires in a Lang lay appear to run parallel to the center line of the rope. The difficulty with Lang lay wire ropes is handling since they tend to kink, twist, and crush.

Wire rope is an exceptionally strong tool that has been configured and designed to withstand the stress placed upon it through rigorous and continual use. In most applications, wire rope has to endure extreme stress and strain. It is for these reasons that coatings have been developed to protect wire rope from abrasions, corrosion, UV rays, and harmful and damaging chemicals.

Three main types of coatings are used to protect wire rope: polyvinyl chloride (PVC), polypropylene, and nylon. Of the three types, PVC is the most popular.

In cases where there are severe and hazardous working conditions, polypropylene is the recommended choice since it is capable of protecting wire rope against corrosion and chemical leaching. Additionally, it is resistant to impact damage and abrasion. Polypropylene is a tough, rigid, and crystalline thermoplastic that is made from a propene monomer and is resilient as well as inexpensive.

Braided wires are electrical conductors made up of small wires that are braided together to form a round tubular braid. The braiding and configuration of braided wire makes them very sturdy such that they do not break when flexed or bent. Braided wires are widely used as conductors, are commonly made from copper due to copper"s exceptional conductivity, and can be bare or coated depending on the application.

Braided wire can be round and tubular or flat. Round tubular braids fit in most spaces where flat braided wire will not. Flat braided wire begins as round braided wire which is flattened on a capstan. They are exceptionally strong and designed for medical and aircraft applications.

Metals used to make wire rope are various grades of stainless steel, bright steel, and galvanized steel. Though the majority of wire rope manufacturers use these three metals, other metals such as copper, aluminum, bronze, and monel are also used on a limited basis.

The most important aspect of wire rope is the wire and the metal from which it is made. The strength and resilience of wire rope is highly dependent on the quality of metal used to make it, and these are essential factors to be considered when purchasing it.

Bright steel wire does not have a coating and is rotation resistant, (designed to not rotate when lifting a load). It is drawn from hot rolled rods that are put through a die to match its specific dimensional tolerances, mechanical properties, and finish. Bright wire is used as a single line in conditions that require a rope that will resist cabling.

Galvanized steel has a zinc coating for corrosion resistance and has the same strength and durability as bright steel. Environmental conditions determine the use of galvanized steel. In mildly severe and slightly harsh conditions, galvanized steel wire is an economical replacement for stainless steel.

In the manufacturing process, galvanized wire goes through the process of galvanization, a method of coating steel wire with a protective and rust resistant metal. Galvanized wire is exceptionally strong, rust resistant, and flexible enough to meet the needs of a variety of applications.

Wire rope made from copper is mostly used for electrical applications due to its exceptional electrical characteristics. The benefits of copper wire rope are its durability, flexibility, and resilience compared to standard copper wire. The strength of copper wire rope is seen in its use in applications where there are vibrations and shaking.

The wire rope lubrication process begins during its fabrication and continues during its use. Lubrication of wire rope is designed to lower the amount of friction it endures and provide corrosion protection. Continued lubrication increases the lifespan of wire rope by preventing it from drying up, rusting, and breaking.

The types of lubricants for wire rope are penetrating or coating with coatings covering and sealing the outside of the rope. Penetrating lubricants go deep into the rope and seep into the core where they evaporate to form a thick coating or film.

The application of the lubricant is dependent on the type of core. Fiber cores absorb the lubricant and serve as a reservoir that retains the lubricant for an extended period of time. With metal cores, the lubricant is applied as the wire is twisted into strands to give complete saturation and coverage of the wires.

There are several types of greases that are used as wire rope lubricating agents and are made up of oil, a thickener, and additives. The essential components are the base oil and additives, which influence the behavior of the grease. The thickener holds the base oil and additives together. The amount of base oil in a grease is between 70% and 95% with an additive of 10%.

The additive in grease enhances the positive properties of the oil and suppresses the negative properties. Common additives are oxidation and rust inhibitors as well as pressure, wear, and friction reducing agents.

Of the many choices for lubricants, vegetable oil is the easiest to use and penetrates the deepest. The design of the additives for vegetable oils gives them the necessary qualities required to penetrate deep into a wire rope. The exceptional penetration provides protection against wear and corrosion. Since vegetable oil is a fluid, it helps in washing the wire rope to remove external abrasive contaminants.

Wire rope is widely used in machines, structures, and varied lifting applications. Its type, size, and requirements are determined by how it will be used. Regardless of its use, wire rope guarantees exceptional strength and provides high quality and excellent performance.

The lifting of heavy loads for centuries involved the use of hemp rope or chains, neither of which was a guaranteed or substantial method. Early in the 18th Century, between 1824 and 1838, Wilhelm Albert, a German mining engineer, combined the twisting of hemp and strength of chains to create today‘s wire rope.

The most common use of wire rope is as a part of a crane hoist wherein it is attached to the hook of the hoist and wrapped around a grooved drum. The tensile strength and durability of wire rope makes an ideal tool for lifting and keeping loads secure. Though it is used in several industries, it is very popular for production environments wherein materials need to be lifted quickly and efficiently.

In addition to its many lifting applications, the strength and stability of wire rope is useful in other applications, especially in the aerospace industry. Pedals, levers, and connectors in the cockpit of an aircraft are connected with wire rope. The wires provide for the passage of power between systems and mechanisms; this allows control of the aircraft. Wire rope is used to control propeller pitch, cowl flaps, and the throttle. It also assists in lowering and minimizing vibrations.

Tires are reinforced with wire rope to increase their durability and strength. All automotive production environments make use of wire ropes for supplying materials, moving heaving loads, and positioning equipment. Wire rope can be found in the production of steering wheels, cables, exhausts, springs, sunroofs, doors, and seating components.

As surprising as it may seem, the place that wire rope has the greatest use is in the home, where its strength, long life, endurance, and resilience provide guaranteed protection and performance. The main reason wire ropes are so popular for home use is cost.

Inexpensive, easy to obtain, easy to install, and easy to maintain, wire ropes provide an additional method for performing home repairs and structural support. Their excellent flexibility and sturdiness combined with their invisibility has made wire rope an ideal solution to several home maintenance issues. It is used to support staircases, fences, decks, and hang plants.

The search and production of crude oil has relied on wire ropes for centuries to lift drill bits, insert shafts, and support oil rigs on land and the water. When equipment, machinery, and tools have to be lowered into the depths of the earth and sea, wire ropes are the tool that the oil industry relies on to do the job.

Many of the tasks of oil production require tools that are capable of enduring severe and harsh conditions. Wire ropes have to withstand enormous pressure, extraordinary stress, and a wide range of temperatures. The use of wire rope includes maintaining oil rig stability and moorings for offshore rigs.

Wire rope has long been a standard component for the transportation industry, from the cable cars of San Francisco to the lift chairs for ski resorts. For many years, cable cars have relied on heavy duty cables (wire ropes) to be pulled by a central motor from multiple locations. It is a method of transportation that has existed for centuries.

In Europe, funiculars use cables that hang from a support to move cars up and down a mountain with cables moving in opposite directions. The word funicular is from the French word funiculaire, meaning railway by cable. The terms wire rope and cable are used interchangeably when discussed by professionals. The first part of funicular, or funiculaire, is from the Latin word "funis," meaning rope.

The major use for wire ropes in the food and beverage industries is as a means for lifting and moving heavy loads. Wine barrels and containers full of ingredients are lifted and placed through use of cranes and wire ropes. They are also part of conveyor systems that move products from one station to another.

From the beginnings of amusement rides up to the present, wire ropes have been an essential part of attraction construction and safety. They pull cars on roller coasters, hold cabins that swing, and move carriages through haunted houses. The main concern of amusement parks is safety. The strength, stability, and guaranteed performance of wire ropes ensures that people who attend amusement parks will have a good time and stay safe.

The rigging used to complete the stunts in modern movies depends on wire rope for safety. Much like in amusement rides, wire ropes protect performers from injury and harm as they hang above a scene or carry out an impossible move.

The live theater industry uses wire ropes to raise and lower curtains, support overhead rigging, and hold backdrops and scenery pieces. During a production, rapid and efficient movement is a necessity that is facilitated by the use of wire ropes.

Wire rope is a tool that we tend to envision as indestructible, unable to succumb to any form of damage. Though it is exceptionally sturdy and strong as well as capable of enduring constant use, it is just as susceptible to breakdown as any other tool.

To avoid serious harm and damage, wire ropes should be scheduled for regular inspections. There are situations that can damage or break a wire rope; these should be understood prior to the problem arising.

Guide rollers have the potential to damage and cause abrasions on wire rope if they become rough and uneven. Of the various elements of a crane and lift, guide rollers have the greatest contact with the mechanism‘s wire rope. Regular inspection of guide rollers will ensure they are not damaging the rope or causing abrasions.

Bending is normally a regular part of wire rope usage; this occurs repetitively as the rope passes through a sheave. As a wire rope traverses the sheave, it is continually bent and develops cracks or breaks. The cracking and breaking are exacerbated by movement on and off the groove of the drum. Normally, the breakage happens on the surface and is visible. Once it appears, it accelerates to the core of the rope.

A bird cage is caused by a sudden release of tension and a rebound of the rope. This type of break requires that the rope be replaced since the place of the break will not return to its normal condition.

Wire ropes are multi-layered; this makes them flexible and torque balanced. The layering inside and outside creates flexibility and wear resistance. Relative motion between the wires causes wear over time, which leads to internal breakage. The detection of these breaks can be indicated by an electromagnetic inspection that calculates the diameter of the rope.

Kinked wire rope is caused by pulling a loop on a slack line during installation or operation; this causes a distortion in the strands and wires. This is a serious condition that necessitates rope replacement.

Corrosion damage is the most difficult cause of wire rope damage to identify, which makes it the most dangerous. The main reason for corrosion is poor lubrication that can be seen in the pitted surface of the rope.

The types of damage and problems listed here are only a small portion of the problems that can be caused if a wire rope is not regularly lubricated and inspected. Various regulatory agencies require that wire ropes be inspected weekly or monthly and provide a list of factors to examine.

As with any type of heavy duty equipment, wire rope is required to adhere to a set of regulations or standards that monitor and control its use for safety and quality reasons. The two organizations that provide guidelines for wire rope use are the American Society of Mechanical Engineers (ASME) and the Occupational Safety and Health Administration (OSHA).

All wire rope manufacturers and users closely follow the standards and guidelines established by OSHA and ASME. In the majority of cases, they will identify the specific standards they are following in regard to their products.

OSHA‘s regulations regarding wire rope fall under sections 1910, 1915, and 1926, with the majority of the stipulations listed in 1926 under material handling, storage, use, and disposal.

"Running rope in service shall be visually inspected daily, unless a qualified person determines it should be performed more frequently. The visual inspection shall consist of observation of all rope that can reasonably be expected to be in use during the day‘s operations. The inspector should focus on discovering gross damage that may be an immediate hazard."

"The inspection frequency shall be based on such factors as rope life on the particular installation or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. Close visual inspection of the entire rope length shall be made to evaluate inspection and removal criteria."

ASTM A1023 covers the requirements for steel wire ropes with specifications for various grades and constructions from ¼ in. (6 mm) to 31/2 in. (89 mm) manufactured from uncoated or metallic coated wire. Included are cord products from 1/32 in. (0.8 mm) to 3/8 in. (10 mm) made from metallic coated wire.

United States Federal Spec RR W 410 covers wire ropes and wire seizing strands but does not include all types, classes, constructions, and sizes of wire rope and strands that are available. The purpose of Spec RR W 410 is to cover more common types, classes, constructions, and sizes suitable for federal government use.

Wire rope and wire seizing strand covered by United States Federal Spec RR W 410 are intended for use in general hauling, hoisting, lifting, transporting, well drilling, in passenger and freight elevators, and for marine mooring, towing, trawling, and similar work, none of which are for use with aircraft.

API 9A lists the minimum standards required for use of wire rope for the petroleum and natural gas industries. The types of applications include tubing lines, rod hanger lines, sand lines, cable-tool drilling and clean out lines, cable tool casing lines, rotary drilling lines, winch lines, horse head pumping unit lines, torpedo lines, mast-raising lines, guideline tensioner lines, riser tensioner lines, and mooring and anchor lines. Well serving wire ropes such as lifting slings and well measuring are also included in API 9A.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of a lifting or supportive task.

We stock a large variety of rigging gear and hardware. Our in-house services include inspection, test, and certifying of slings and rigging gear. We also offer on-site inspection of rigging, of rolex replica slings and rigging gear, on-site inspection of rigging, and pickup and delivery. We can have any of our experienced sales staff go on-site and assist with determining the best way to handle your lifting needs. We also offer an on site class on proper rigging gear inspection.

All wire ropes should be thorougly inspected at regular intervals. The longer it has been in service or the more severe the service, the more thoroughly and frequently it should be inspected. Be sure to maintain records of each inspection.

Inspections should be carried out by a person who has learned through special training or practical experience what to look for and who knows how to judge the importance of any abnormal conditions they may discover. It is the inspector’s responsibility to obtain and follow the proper inspection criteria for each application inspected.

Ropes in rope drives are open gears which are exposed to external influences but also have common signs of wear. Above all however, the service life of a rope is limited. Once the rope has reached its discard criterion, it has also reached the end of its service life. The rope’s discard state must be detected early enough to avoid accidents such as a rope break. This detection requires regular rope inspections, which document the percentage of rope life left before it is ready to be discarded.

Such inspections must be carried out on a regular basis. The intervals of the different tasks mentioned above may vary. A visual inspection should be carried out daily, but the diameter for example should be measured monthly or quarterly, depending on the load and frequency of use.

With a general visual inspection, obvious damage such as cracked strands or errors in the reeving should be detected at an early stage and, if possible, repaired before the start of operation.

In this case, places near the end connection or places that could get into contact with the crane must be inspected with increased attention. This inspection should be carried out carefully by the crane operator.

Measuring the diameter of a wire rope during operation provides information on the wear and the diameter reduction. However, an increased diameter may also occur to a structural change. The diameter of the rope should always be determined with the aid of suitable measurement equipment. Small calipers with wider measurement flanks are advantageous here. The following pictures display suitable measuring equipment.

A rope must always be measured at its widest point, i.e. from strand crown to strand crown. A complete measurement consists of two measurements in the X-direction and two measurements in the Y-direction, each approximately 1 m apart. The resulting average of the values describes the current rope diameter.

An indication of whether a rope has been twisted by force or has generally undergone an unnatural twist can be found in a resulting change of lay length. In order to measure the lay length, the following utensils are required. A negative of the rope surface is created with the help of a cash register roller and a wax crayon. In this process, a cash register paper must be placed on the rope surface while a wax crayon is moved across with downwards pressure. As a result, there is an impression of the rope strands on the paper.

In order to determine the lay length of the rope a certain number of impressions must be counted. Here the number of outer strands is decisive (in the picture above there are 8 outer strands). The distance from the beginning and end point gives the lay length in mm. It is recommended to count at least three measurements and divide the total length by three parts in order to reduce measuring errors (see picture).

A rope inspection includes not only the inspection of the rope itself, but also of the sheaves in which the rope runs. Special measuring equipment is required to measure the groove diameter: Groove gauges and a flashlight.

Such groove gauges are available upon request from verope®. The values indicated on the gauge are actual values and not, as is sometimes the case, target values. The flashlight serves as an aid to determine the exact measurement. Here the gauge in the groove is illuminated from behind. If light shines through on the sides between the gauge and the sheave, this indicates, that the used gauge is too large. If there is no light visible at the complete radius of the gauge, the correct groove size corresponds to the gauge size used.

According to ISO 16625, the groove depth should be no greater than 1.5 times the rope diameter and in addition, the bottom of the groove must be circular. The maximum permissible depth until the sheave has to be replaced due to wear must be specified by or obtained from the sheave manufacturer. This value must be observed at all times as disregarding it can result in serious accidents as a result of material failure.

Ropes usually have different strengths, tensile grades such as 1770 N/mm2, 1960 N/mm2 or 2160 N/mm2 are common. The diagram to the right shows the respective degree of hardness in HV (Vickers Hardness) for the corresponding strength class. The hardness of the sheaves and drum should be between 300 – 350 HV. This is due to the fact that rope sheaves that are too soft absorb the pure wear of the system and thus the discard criterion of the rope is more difficult to detect. If the used rope sheave or rope drum has a higher hardness value, this does no harm to the system, but involves higher hardening costs.

Wire breaks on the rope surface are caused by bending stress on the rope when running over sheaves. The number of wire breaks over a defined length must

The number of wire breaks over a defined length must not exceed a certain number corresponding to its design and subsequently to the RCN (Rope Category Number), otherwise it must be discarded immediately.

Some wire breaks may cause the wire to protrude from the rope. This wire can damage neighboring wires when it runs over the sheave again causing secondary wire breaks. With the help of pliers and continuous back and forth bending of the protruding wire, it can be removed and is no longer a danger to neighboring wires.

A single layer steel core rope with a nominal diameter of 22.00 mm has a reference diameter of 22.80 mm as in calculation example and a measured diameter of 21.90 mm.

With the following hints we would like to draw your attention to some essential points for correct selection, operation and maintenance of wire ropes. In addition to technical literature on wire ropes, national and international standards, the verope®team will be happy to assist you with all questions concerning wire ropes.Please contact us!

Wire ropes and their end fittings are not fatigue resistant endlessly and must therefore be controlled periodically for safe operation. Wire ropes and the end fittings must be discarded before reaching a unsafe condition.Note please refer to the respective valid international or national standards (e.g. ISO 4309, EN 12385 and EN 13411) and the technical literature for expert inspection as well as for the correct determination of the discard maturity of wire ropes and their end fittings. During installation of ropes which are provided with an end fitting it must be ensured that these have been carried out in accordance with the operating instructions at the designated place and can be installed in the correct position. For end fittings, which can be dismantled, e.g. wedge end clamps, it is absolutely necessary to remove the rope or end fitting according to manufacturer specifications. For questions, ambiguities or problems, please contact the customer service of the verope®technical department: TCS @ verope.com

It’s a rather complex machine, actually. Its primary function is to move, which in turn is where it obtains its source of strength. And because it is such a complex piece of machinery, no precise rules have been given to determine exactly when a wire rope sling has passed it’s service or expiration date. There are guidelines, though, one should follow to know whether the sling they possess is suitable for continued use or needs replacement.

The reason we should inspect wire rope slings prior to use is to identify potential hazards or damage that may be present and if it’s suitable for continued use. The Occupational Safety and Health Administration (OSHA) and ASME B30.9 standards also dictate that inspection intervals and procedures must be performed and that the inspections are executed by the sling user. Since all wire rope that has been fabricated into slings applies to the same work practices as all “working” wire rope, it’s essential that the sling inspector has a good working knowledge of wire rope design and construction before conducting an inspection of the wire rope sling.

As with most types of wire rope, a number of multi-wired strands are laid or helically bent around what is essentially called a core member. Typically, there are two types of cores that are used in the process of manufacturing wire rope: fiber cores and IWRC cores (nonfiber). IWRC is a steel core whilst a fiber core is comprised of synthetic fibers. For this particular article, we will be focusing mainly on IWRC cores, which is the more commonly-used type of wire rope cores. (Klinke, 24)

When it comes to how the eye of a wire rope sling is spliced, there are again two preferred methods: Hand and Mechanical. A hand splicing method offers a narrower profile and therefore can fit through tighter spaces. Because no metal sleeve is required to secure the eye in a hand-sliced sling, it offers more flexibility to the user, but less in carrying capacity. A mechanical splicing is fabricated by unlaying the rope body into two parts, one containing half the number of strands and the other having the remaining strands and core. The rope is then unlayed far enough back to allow the eye to be formed by looping one part in one direction and the other part in the opposite direction and laying the rope back together. The strands are rolled back around the rope body and a metal sleeve is slipped over the ends and pressed to secure the ends to the sling body. This option is more economical, offers the highest of rated capacities, and is the most preferred option amongst wire rope users. (Klinke, 24)

According to the Wire Rope Technical Board, a proper inspection should follow a systemic procedure. The following numerical list below was provided by the Wire Rope Technical Board’s Wire Rope Sling Users Manual, 3rd Edition and as it stands the most up-to-date and current method of inspecting wire rope slings.

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

Ideally, other systems of ensuring the quality of your slings should be installed in your warehouse or facility’s inspection procedures. For example, Lifting Gear Hire is completing the final stages of adopting a brand new, streamlined RFID tracking system to record when equipment was inspected, who inspected it, if and when the equipment was damaged, as well. This new system will help speed up LGH’s intensive testing and inspecting processes.

It’s also advisable to find quality training resources or learning institutes that teach courses on how to properly inspect wire rope slings; preferably ones that can teach you how and also provide you a Rigging Gear Inspector certification, too.

A sling’s service life can be extended substantially should it receive a fair amount of care and maintenance. This includes the type of storage its housed within, the temperature in which its kept at, and how often/well it’s lubricated on a consistent basis. Proper storage commands that slings be housed in an environment free of exposure to water, extreme heat, corrosion, liquids, sprays, kinks, etc.

As with most machines, wire rope is lubricated at the time of its own manufacture. No supplementary lubrication is generally required if the sling has been used under typical conditions, but if a sling was stored outside or in any environment that could cause corrosion, it is advisable to apply additional lubrication to prevent the onset of rusting or corroding. If in the event the wire rope needs to be re-lubricated, the same type of lubrication during manufacture must be applied.

The temperature of its storage also plays an important role in preserving the lifespan of a sling. It’s generally accepted and agreed that steel cored slings shouldn’t be used at temperatures above 400 deg. F or below minus 40 deg. F. Although it’s not always easy to see when a sling has been damaged by temperature-related causes, a general rule of thumb is that if there are any suspicions that a sling’s integrity may have been compromised, it should be taken out of service right away or at the very least the manufacturer should be consulted. (Wire Rope Sling Users Manual, 134)

Cable laid and 6×19 and 6×37 slings shall have a minimum clear length of wire rope 10 times the component rope diameter between splices, sleeves, and end fittings. If you have a one-inch sling, then you have to have 10 diameter lengths in between the splices so you have to have a minimum 10 inches between the knuckles.

Braided slings shall have a minimum clear length of wire rope 40 times the component rope diameter between the loops or end fittings. Cable laid grommets, strand laid grommets, and endless slings shall have a minimum circumferential length of 96 times their body diameter. (Rigging Gear Inspector Levels I & II, 42)

When steel-cored wire rope slings of any grade are used at temperatures above 400 deg. F or below minus 60 deg. F, recommendations of the sling manufacturer regarding use at that temperature shall be followed. This is because the metallurgy of the steel start to realign above those temperatures. If something has been used in or is planning to be used above those temperatures, consult the manufacturer of the sling to prevent degradation. (Rigging Gear Inspector Levels I & II, 42)

Corrosion of the rope or end attachments. Only extreme corrosion is necessary to reject a sling. Light corrosion does not substantially affect the strength of a sling. (Rigging Gear Inspector Levels I & II, 42)

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.

Should a sling be determined as worn out or damaged beyond use because of any of the aforementioned reasons, the inspector should immediately tag the sling as Do Not Use. Afterwards, the sling should realistically be destroyed as soon as possible by cutting the eye and fittings from the rope with a torch. Cutting the body of the sling is also appropriate. This method of destruction should deter another employee from mistakenly using a sling that has been formally retired from service. Any inspection program, however thorough, is of no value if the slings that have been rejected or retired are not disposed of properly. (ASME B30.9-2014, 15)

According to ASME B30.9, should a sling become damaged and be eligible for repair, a restoration should only be conducted by the manufacturer itself or a qualifying individual with the appropriate experience and certifications. For example, if an end fitting such as a hook becomes bent beyond guidelines, you would need to send that back to the manufacturer regardless if the wire rope sling is in tact and undamaged.

All repairs conducted on wire rope slings will require marks, tags, or some kind of proof of its restoration and parts that need replacement can only be substituted for the same original parts that were used in its manufacturing.

Should the wire rope used to craft the sling itself become damaged, it is not to be repaired under any circumstances. For example, if one of the wires is damaged by weld splatter or heat damage, it is simply not possible to remove the one strand of wire and replace it. It’s also not necessarily cost-effective for that matter either. Repairs such as these could be more expensive than what the sling is even worth at that point. When a vehicle is involved in an accident, if the price of repair outweighs the total value of the vehicle, it’s considered totaled. Same principles apply to equipment such as wire rope slings. When repairs are worth more than the equipment itself, it’s time to scrap the wire rope sling. (ASME B30.9-2014, 15)

Moreover, if a repair is warranted and completed, a proof test of its structural integrity should be conducted. With wire rope slings, the proof test is a 200% load test.

When and how often you should inspect a wire rope sling are often the subjects of debate. The amount of usage the wire rope sling receives should equate to an appropriate number of inspections it receives every year. A wire rope sling that’s used a few times a year does not require the same number of inspections as a wire rope sling that’s used more frequently, for longer periods of time, and in compromising environments. A general rule of thumb when it comes to how often you should inspect a wire rope sling, at bare minimum, is once a year. However, if the wire rope sling is used frequently or in severe atmospheres where it could be exposed to extreme temperatures where the sling’s integrity can become challenged, then it’s advisable to inspect the wire rope every month or quarterly at least.

It’s also necessary to keep written records of when the wire rope was last inspected, so you can have proof of it’s inspection and rest assured when using it. If there was an accident or cause for concern, people will want to see those records. As long as those records match what you’ve been doing, you can protect yourself. It’ll also prevent someone from sending out a wire rope sling that’s unsafe or hasn’t been inspected. Because after all, the most important thing on a jobsite is maintaining safety. Safety must always come first.

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: 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).

Removal criteria for wire rope, wire rope slings, synthetic web/round slings, chain slings, rigging hardware, and below-the-hook lifting devices is the focus here. Personnel qualification is available.

American Wire Rope & Sling wants to make sure your training needs go beyond the canned versions that most companies offer. All of our Rigging Trainers are Crosby-Certified to conduct any level of rigging training you might need. We work with your company to learn how you are using your rigging, and then we create a custom training plan that not only educates your people on general rigging requirements, but also dives deeper into the things your employees use the most at your facility. We offer training in one-hour increments and up to four-hour full scope rigging trainings. We offer trainings at our rigging service centers or at your facility, jobsite or corporate office. If you want the best rigging training in the business, it only comes from one place: American Wire Rope & Sling.