wire rope inspection standard pricelist

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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

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

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

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

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

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

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

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

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

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

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

If possible, maintain a detailed record of all your sling inspections. Well-kept records make it easier to identify slings that are nearing the end of their service life or are damaged.

Sling tag identification is the most critical step in sling inspection. These tags help you identify the usage specifications of the slings. So, make sure to maintain the tags in excellent condition throughout the lifespan of the slings. If the tag is damaged or illegible, remove the sling from use immediately.

If you come across any of the following scenarios during your sling inspection, you will need to remove the slings immediately. Furthermore, if you are unsure of the potential damage, discontinue the use of slings.

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

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

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

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

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

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

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

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

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

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

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

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

The system assesses the residual bearing capacity and service life of the tested wire ropes in-service, through quantitative testing to the effective cross-sectional area loss percentage of the actual load-bearing metals caused by various internal and external wire breakage, abrasion, fatigue and other damages. Hence, providing users with scientific basis for safe use and reasonable replacement in accordance with standards and specifications. This assessment will help to prevent effectively wire rope breaking accidents and safety issue, also reasonably reducing the cost of ropes and scientifically improving wire rope operating efficiency.

Wire ropes are complex machines with a great many moving parts. They require attention, skilled operators, careful maintenance, inspection and lubrication.

In spite of their vital importance, wire ropes are frequently treated as and considered low-tech commodities. Failures are frequently accepted as “inevitable.”

With the appropriate inspections, wire rope failures can be predicted, and expenses and losses reduced. Consider that the price tag of rope failures can easily be in the seven or even eight digit range, and the cost of an inspection is marginal.

Much more dependable than visual inspections, magnetic rope testing (MRT) is a reliable non-destructive evaluation/examination (NDE) procedure used for the in-service inspection of wire ropes. NDE methods allow the detection and evaluation of external as well as internal rope deterioration. This allows the inspection of a rope’s entire cross-section to the core. MRT drastically increases wire rope safety. At the same time, it promises significant annual savings.

Ropes usually degrade internally with no visible indications. Internal deterioration modes include inter-strand nicking that will eventually develop into clusters of internal broken wires and corrosion including corrosion pitting.

External deterioration includes winding-on-drum damage. Urgently needed, suitable inspection equipment and procedures are now available – especially for the quantitative characterization of internal rope deterioration.

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

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

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

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

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

However as there are no formal NDT rejection criteria, all rejection criteria standards are taken from the widely used visual inspection standards. We offer the best service in Wire rope Management.

We provide a full detailed inspection report outlining the condition of the inspected rope, fully detailed the rope type, settings, and calibration results.

With heavy investment on our wire rope inspection services, our technology services make it possible to inspect qualitatively, not just external flaws, but most importantly internal flaws or wire ropes.

Wire rope isa type of cablewhich is made up of several strands of metal wirelaid or twisted into a braid or helix.Do you know how often your wire rope needs to be inspected? Wire rope inspections are vital to industries that use wire rope.

One of the most important purposes of carrying out wire rope inspections or testing is to oversee the process of depreciation in the wire rope. When any depreciation or deterioration is identified these wire ropes can cease to be used immediatelybefore it becomes a hazard. A great advantage of conducting these examinations is to analyse and identify if there is unexpected corrosion and destruction.

Commonly, there is a constant increase rate in the amount of wire rope breaks, during the lifespan of that wire rope. Wire ropes need to be inspected and tested as they have a limited life, like all consumable products. Early in the life of the wire rope (when it is starting to be used), the wires and strands of the rope settle into position and the breaking strength increases. Once it has hit its maximum, the breaking strength then decreases rapidly.

Wire rope inspections should only be carried out by highly trained professionals. There are 2 ways that these inspections are carried out on crane wire rope: Visual and Non-Destructive. Visual and no-destructive examinations are equally as important but a non-destructive wire rope test is a lot less frequent than a visual wire rope inspection. Destructive testing only takes place when specifically required by a company to find out what type of wire rope something is that has not been labelled and is not common practice in the general testing/inspections.

Visual inspection of wire ropeThe visual method is a simple yet effective method to check for external damage to a crane wire rope. Visually inspecting the entire length of rope is very important. The rope should be inspected 2 to 3 feet at a time and examined carefully at each stop. Whilst inspecting the wire rope it also cleaned with Lanotec and a wire brush.

Although tedious, it can determine many visual signs of wire rope damage, such as; kinks, bird caging, cutting, knots, flattening, crushing & heat damage (burn marks, discolouration of the metal). Wearing heavy duty gloves, an inspector will grab the rope and lightly move a rag slowly along the length of rope. Broken wires will often stick out (porcupine) and will therefore snag on the rag. Should the rag snag on a wire, the inspector should the stop and visually assess the rope condition. Broken wires do not always ‘porcupine’. Visual inspections should not be the only method relied on for inspecting crane wire ropes.

Due to the composition of a wire rope, the outer layer only represents approximately 40% of the metallic cross section of the rope and only approximately half of this is visible due to the strand twisting inside and out. That means you are only able to visually examine approximately 20% of the entire rope composition. You can only assume that the other 80% is in good condition.

Although the external 20% may look in good condition it may be concealing a great number of wire breaks and internal damage. Wire ropes with internal damage that have no signs of external damage can be extremely dangerous. This is why an internal wire rope inspection should also be completed. Internal deterioration is the primary cause of many rope failures, mainly due to corrosion and the normal progress of fatigue. Single-layer stranded ropes may be opened up slightly to allow an assessment of their internal condition, provided that they are at zero tension; though, some restrictions occur with large rope sizes. Permanent damage can be caused to multi-layer wire ropes if they are opened.

Internal inspection should always be carried out by a capable person. The method of inspection consists of firmly attaching two clamping jaws of appropriate size at a suitable distance apart to the rope. During the inspection of sections of rope adjacent to terminations, it is adequate to use a single clamping jaw, since the end anchorage system, or a bar suitably located through the end portion of the termination, may be used as the second clamp.

By the application of a force to the clamping jaws in the opposite direction to the rope lay, the outer strands separate and move away from the core. Care should be taken during the opening process to ensure that the clamping jaws do not slip about the outside of the rope. The strands should not be displaced excessively. When a limited opening is achieved, a small probe, such as a screwdriver, may be used to remove grease or debris that could obstruct observation of the interior of the rope. The crucial points that should be observed are as follows:

After inspection, a service dressing should be introduced into the opened part and the clamping jaws rotated with moderate force to ensure correct replacement of the strands around the core. After removal of the jaws, the outer surface of the rope should be greased. Since it is impossible to inspect the interior of the wire rope over the whole of its length, suitable sections shall be selected.

For wire ropes that wind onto a drum, or pass over pulleys or rollers, it is recommended that the lengths that engage the pulley grooves when the appliance is in a loaded condition be inspected. Those localised lengths in which shock forces are arrested (i.e., adjacent to drum and jib head pulleys) and those lengths that are particularly exposed to the weather for long periods should be inspected. Attention should be given to the length of rope close to its termination, and this is particularly important for fixed ropes, such as stays or pendants. This is where a visual inspection is complimented by a non-destructive test. .

Hi Holger, I would argue that for plastic infill ropes, in certain circumstances, MRT is essential. Whilst it is true that plastic infill reduces inter-strand contact pressure along with other benefits, the plastic also makes local internal visual inspection more difficult. We carried out MRT on a plastic infill rope and found that the core had completely parted without any external visual indications (the outside of the rope was in good condition with no local loss in diameter). Without MRT, the owner would have been unaware of the true condition of his rope and it is likely that the rope would have failed before the next Thorough Examination. Regards, Barrie.

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