wire rope inspection requirements for sale

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.

The occasional premature failure of a single wire may be found early in the rope life and in most cases it should not constitute a basis for rope removal. Note the area and watch carefully for any further wire breaks. Remove the broken ends by bending the wire backwards and forwards. In this way the wire is more likely to break inside the rope where the ends are left tucked away between the strands. These infrequent premature wire breaks are not caused by fatigue of the wire material.

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.

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

Guidelines for inspecting a wire rope system or installation are now available in a new 12-page brochure from the Wire Rope Technical board. The publication provides a clear and concise approach to assisting wire rope user’s needs to comply with industry and governmental regulations that require inspection of individual ropes, fittings and attachments, as well as entire operating systems at regularly scheduled intervals. 12 pages, 8.5″ x 11″ Softbound.

A thorough inspection of all ropes shall be made at least once a month and a certification record which includes 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.

Using wire rope slings is one of the most reliable ways to secure a load to lifting equipment. Wire rope slings are light, strong, and durable, and they can be used in a variety of ways for many different kinds of lifts.

Because crane operators rely on wire rope slings for so many lifting operations, they must be kept in good condition for safe operation, and they should be inspected routinely for any damage or excessive wear. To ensure that all wire rope slings are properly inspected, it is important to know who should perform the inspections, how frequently inspections should be performed, and what criteria should be examined to pass an inspection. OSHA and ASME provide inspection requirements and guidelines that can be used to ensure that all wire rope slings are inspected correctly and safe for material handling operations.

How often wire rope slings are inspected depends largely on how frequently those slings are used. However, there are a few universal rules for when to inspect all slings. First, every wire rope sling should be inspected upon receipt from the manufacturer. Check slings for any manufacturing flaws and that the sling received is the correct sling and meets your application’s requirements.

Next, all wire rope slings should also be inspected before using. Regardless of how frequently a sling is used, it should always be inspected prior to use, as damage to the sling could have occurred during the previous use or in the time between uses. Inspecting a sling before every use ensures that a sling that has been damaged isn’t used if the damage wasn’t noticed or reported at the time.

In addition to these universal guidelines, wire rope slings should also be inspected routinely by a Qualified Person based on how frequently and how severely they are used. ASME guidelines require periodic sling inspections by a Qualified Person yearly for normal, occasional use and monthly to quarterly for severe, frequent use. ASME B30.9 also requires these periodic inspections to be documented and kept on-record.

The person inspecting the wire rope sling will be different depending on the circumstances of the inspection. Wire rope slings must be inspected prior to every use, and this inspection should be done by the operator in preparation for the lift. The operator should be a competent person, as defined by OSHA, with the necessary knowledge to perform inspections. For monthly to yearly inspections, a professional service provider or Qualified Person, as defined by OSHA, should conduct the inspection.

The inspection process is not specifically defined by OSHA or ASME, so it is the responsibility of the inspector to know and understand how to inspect the sling properly and what to look for. First, the sling should be laid out so that the entire sling is visible and easily accessible. Then the sling should be cleaned with a rag or wire brush to make the wires and fittings more visible.

Next, the sling should be inspected thoroughly along its full length, with special attention given to fittings and end attachments. Identify any points with significant wear and determine if the sling is still suitable for service. If the sling is not suitable for service, it should be removed immediately. Label slings that have been inspected and keep records of inspection dates and sling conditions.

There are several factors that should be examined when inspecting a wire rope sling. OSHA 1910.184(f)(5) describes several conditions that require a sling to be removed from service if they are identified. These conditions include:

OSHA 1910.184(f)(2) also states that wire rope slings must have “permanently affixed and legible identification markings.” These markings provide information regarding the maximum safe working load at various angles for different types of hitches, the size of the sling, and the manufacturer. If the identification markings on a sling are missing or illegible during inspection, the sling should be removed from service.

ASME B30.9 provides several inspection standards in addition to OSHA requirements. If eye splices show evidence of slipping or if tucked strands have moved, the sling should be removed from service. Any cracked, bent, or broken end fittings also indicate that a sling is not suitable for use. Any severe corrosion of the rope or end attachments that cause the wires to bind will require a sling to be removed from service, but light surface rust will not substantially affect a sling’s strength.

Properly inspecting wire rope slings and removing unsafe slings from service helps keep material handling operations safe. If a sling fails during operation, equipment can be damaged, leading to long downtime and costly repairs, and workers can be put at high risk of serious injury or even death. Routinely inspecting and maintaining wire rope slings is a simple, effective way to ensure that all material handling operations are completed safely.

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

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

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

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

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

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

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

Wire ropes are designed to be extremely strong and durable to safely lift and secure heavy items. Wire ropes are commonly used with overhead lifting and rigging equipment to hoist loads – so when things go wrong, it can be extremely dangerous.

Wire rope hazards have caused hundreds of injuries and even fatalities on construction sites. According toone report, more than 60 people were killed over 15 years due to a wire rope breaking.

When wire rope is handled or stored incorrectly, it can tremendously increase the likelihood of a safety hazard. Some of the most common safety issues with this piece of industrial equipment include broken strands, corrosion, crushed wires, or fatigue that causes the rope to slip, stretch, or snap.

At Elite Sales, we have fulfilled lots of orders forwire ropesto replace broken or damaged equipment. So, take our advice with these tips to reduce wire rope hazards through proper handling.

OSHA requires that all overhead lifting and rigging equipment be carefully inspected before use. Certified crane operators are typically responsible for this task – but all workers interacting with wire ropes should know how to conduct an inspection.

First, the wire rope should be visually inspected to note any of the most common signs of wear and tear. This includes crown or valley breaks in the exterior strands or any kinks in the wire rope.

Any visible rusting, loose wires, kinking, or damaged fitting should be noted immediately. The wire rope should be replaced or repaired before it is used, as even a few broken wires could compromise its strength and durability.

Dryness or dust forming on the wire rope is an indication that hasn’t been recently lubricated. This can cause the wire rope to break far more easily, so this must be taken into consideration during the inspection as well.

Wire ropes are commonly damaged when they are being moved as the strands can get caught, broken, or bent. Correctwire rope installation and handlingare crucial for extending the life and use of this equipment. So, all employees who handle wire ropes should receive adequate training for proper handling.

Special care should be taken when the wire rope is unreeled or uncoiled. The strands can easily get kinked or crushed during this process. The best practice is to pull the wire rope in a straight line off of the reel or mount it on a revolving stand to ensure that the rope does not look or kink.

All wire ropes should be routinely re-lubricated as well. This helps to reduce wear from friction and movement and also protects the wires from corrosion.

Additionally, all handlers should be aware of practices that can damage wire ropes and avoid them at all costs. For instance, battening down the wire rope sling to secure it can crush and break the strands. This is unfortunately a fairly common practice on construction sites – so supervisors should strictly enforce correct handling.

Wire rope can get damaged during storage, too. All wire ropes must be completely dried and stored in a cool, temperature-controlled space. It is also best to avoid stacked coiled wire rope directly on the ground and instead stack it on cement or metal.

As an industrial hardware supplier, we understand that it is not just the way that these materials are handled – but also the quality of the equipment that lowers safety risk.  Cheap wire rope will rust or wear down quickly, which increases the likelihood of it breaking.

First, be sure that you only purchase wire rope made with improved plow steel (IPS), extra improved plow steel (EIPS), or even extra-extra improved plow steel (EEIPS). This means that the wire rope is made of stronger steel than mild plow steel (MPS).

You should always double-check that you are using the correct wire rope for your application. There are many different styles, constructions, and patterns available which are optimized for certain uses.

For example, some are designed to berotation resistantwhich is best for overhead lifting. The central core of the wire rope is also an important factor to consider. A fiber core is best for applications where elasticity and stretch are needed – but it is not ideal for high heat or heavy loads. Wire strand cores on the other hand are best when additional stability is needed for securement.

Working with a trusted and experienced industrial wire rope supplier can be extremely beneficial here. Not only will this give you access to a wide range of wire rope options, but you can receive advice and guidance from professionals.

Here at Elite Sales, we’ve worked with construction companies and industrial manufacturers for years to provide top-rated equipment. We carry a great selection of wire rope in many styles, lengths, diameters, and constructions to meet nearly all applications. Plus, our team of experts is just a phone call away.

Reducing the risk of wire rope hazards on the job site needs to be a top priority. Any mistakes with wire rope installation, transportation, or storage can lead to major safety issues. One of the easiest ways to do this is enforcing proper handling of top-quality wire rope equipment throughout the organization.

If you are looking to purchase high-quality wire rope for your business, be sure to check out our selection. Elite Sales is proud to carry top-rated industrial hardware. Our team is available to answer any questions and direct you to the exact types you need for any application.

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.

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

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

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. .

In this full length handbook, learn the basics of wire rope including how to choose and measure wire rope. Additionally, you will understand the fundamental mechanics behind our most popular rope constructions and classifications. Finally, you will learn the proper way to care for and use your wire rope, including end treatments, inspection, and removal criteria.

Twisted hoist lines can bring a construction project to a sudden halt, resulting in downtime. But the good news is that you can minimize block rotation through proper installation, handling and corrective measures. In this reference document, you will better understand torque and gain tips on how to reduce block rotation.

Our galvanized strand products meet or exceed ASTM specifications A475 and ASTM A363. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn what the strands are tested for. Additionally, a chart detailing the physical properties of zinc-coated steel wire strand is included.

Our industry has its fair share of terminology and phrases. In this reference document (an excerpt from the Wire Rope Users Handbook), you will be provided a comprehensive glossary of all Wire Rope words. From “Abrasion” to “Warrington”, your questions are answered here.

How long will your rope last? While there is not a simple answer, there are several factors involved. In this reference document (an excerpt from the Wire Rope Users Handbook), you will the factors affecting the longevity of your ropes life. Additionally, information regarding the cleaning and lubrication of your ropes is included.

There is a correct methodology behind measuring of wire rope diameter. Learn this methodology in this reference document (an excerpt from the Wire Rope Users Handbook). Also, the definition of design factor is available. And finally, detailed information regarding metric conversion and equivalents is included.

Yes, there is a RIGHT way to unreel, uncoil and store a wire rope. Learn the proper steps in this reference document (an excerpt from the Wire Rope Users Handbook). Additionally, the three stages of kinking are vividly displayed.

Wires are the basic building blocks of a wire rope. And, a rope core will greatly impact the performance of your rope. Learn how the number of wire strands and construction determine a wire rope classification. In this reference document (an excerpt from the Wire Rope Users Handbook), you will become familiar with the standard rope classifications and special rope constructions.

The types of wire, lay and performing greatly affect wire rope performance and operation. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the basic types of wire used in ropes, the common grades of wire rope and the meaning of “lay”.

In this Product Bulletin, you will learn about the new rope description format that WireCo WorldGroup will follow in all of our product descriptions. This format will adopt symbols and designations that are part of ISO, ASTM, and other industry standards and specifications.

Rotation-resistant ropes can frequently provide the best and most economical service in specific applications, when you choose, handle and use them properly. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the difference between Category 1, Category 2 and Category 3 Rotation-Resistant Rope.

Previously known as “aircraft” cable, and now known as “utility cable, these small diameter specialty ropes are used in a variety of applications, including control cables, window and door closures, different kind of remote control systems and boat riggings. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn how Union specialty small ropes are engineered and fabricated, and the special lubrication and testing they require. Additionally, a minimum breaking force and weights for 7x7, and 7x19 utility cable is included.

Our industry has its fair share of abbreviations. In this reference document (an excerpt from the Wire Rope Users Handbook), you will be provided a comprehensive glossary of all Wire Rope words. From “PRF” (preformed) to “XIP®” (Extra improved plow steel), your questions are answered here.

Swaged ropes and “Double-Swaged” ropes provide excellent strength for some specific applications. In this reference document (an excerpt from the Wire Rope Users Handbook), you will find the definition of swaged and PowerFlex (aka double-swaged) ropes. Minimum breaking force and weights charts for 6x19, 6x36, PowerFlex, 3x19 and 3x36 ropes are included.

Our most popular Tech Report, this Wire Rope Inspection Tech Report explains why periodic inspection of wire ropes are necessary. Learn how to properly inspect wire rope, what tools are necessary for inspection, and how to use inspection forms. Additionally, you will learn how often you should inspect your wire rope, what your ‘critical’ points are, how to inspect your end attachments, how to make an internal rope examination, how to inspect sheaves, and how to evaluate drums. Finally, you will understand how to properly measure rope diameter and rope lay.

In applications where a specific length is critical, the constructional stretch can be minimized by prestretching the rope prior to installation, HOWEVER, learn why WireCo WorldGroup advises against prestretching Tuf-Kote/PFV rope. After reading this product bulletin, you will understand the rationale behind WireCo WorldGroup’s recommendation against prestretching Tuf-Kote/PFV Rope.

Engineering and producing wire rope slings for your application is a highly specialized field - with exacting standards that we gladly live by. In this marketing flier, learn the different Union Wire Rope Sling constructions. Additionally learn more about Union Spelter Sockets (both open and closed). There are capacity and diameter charts associated with each product.

In this Product Bulletin, learn the various definition of "US made wire rope" including references to the Buy American Act and the Buy America Requirement. Additionally, learn how Union wire rope meets these definitions.

Most ropes are shipped with the ends seized as they are prepared for cutting, however, in some cases, the rope requires special end preparations. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the two chosen methods for seizing cut ends of your wire ropes. Illustrations and step-by-step instructions are included.

All wire ropes will wear out eventually and gradually lose work capability throughout their service life. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn why periodic inspections are critical. The purposes for inspection, guidelines around timing and choosing the right person to inspect are included. Additionally, illustrations regarding “what to look for” in a wire rope is available.

There is obvious evidence of wire rope wear and abuse, and specific criteria regarding removal of your wire rope. In this reference document (an excerpt from the Wire Rope Users Handbook), you will learn the various types of wear and abuse (illustrations included) and the exact removal criteria. A chart on when to replace your wire rope – based on number of broken wires is included.

In this product bulletin, learn why WireCo WorldGroup refers to XLT4 as a low-torque rope and not a rotation-resistant rope. Also included are the definitions of ASTM A1023 and ASME B30.5.

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.