wire rope inspection requirements quotation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In the rigging businesses, there are ample protocols and procedures for cable rigging hardware that are designed to ensure safety. One protocol that is crucial to follow is the inspection of wire ropes. Below, we have provided information on who should inspect the wire ropes, how to inspect them, and when to stop using them. Continue reading for our wire rope inspection checklist.

To ensure the wire ropes are safe, you shouldn’t let just anybody conduct the inspections. Riggers train professionally and have to keep up to date with their knowledge and expertise. Therefore, those professionals and experts are the only ones who should conduct the inspections. Keep in mind that an individual who uses the wire rope frequently should not be the one to also inspect the wire rope. Getting a new set of eyes on the wire rope will ensure nothing is overlooked.

Not only should you inspect the wire ropes every day at the start of each shift, but you should also inspect them before every use. It is crucial that you note and document this inspection and keep track of the records pertaining to the condition of the wire rope. Communication is crucial in this regard.

Rag-and-Visual: This allows you to look for external damage to the wire rope. All you must do is grab the rope lightly and move a cotton cloth or rag slowly down the wire. If the rag snags on any part of the wire, inspect that area to see how extreme the broken wire is.

Visually Assess: Just taking the time to look over the entire wire rope will help you catch breaks and other problems that you might not have noticed with the rag. These might be abrasions, corrosions, and lubrication inside the rope.

Measure Rope Diameter: Once you measure the rope’s current diameter, compare it to the rope’s original diameter. If the measures are not the same, there is likely a problem. The issue is most likely an internal or external rope issue.

Make sure to complete each of these steps thoroughly to ensure the safety and security of the individuals using the ropes. Not completing a step or overlooking an area can be extremely dangerous and harmful.

If you complete an inspection and find that a rope does not meet expectations, you should not use that rope until it has been repaired or replaced. Whether you can tell that the rope has heat damage, has been stretched and overused, or has been kinked or crushed, you should stop using it immediately. If you are unsure whether an issue is large enough to stop using the item, ask someone. Don’t just assume it is safe!

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

All running ropes in service should be visually inspected, at least, once each working day. A visual inspection shall consist of observation of all rope which can reasonably be expected to be in use during the day’s operations.

A – Distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core protrusion. Loss of rope diameter in a short rope length or unevenness of outer strands should provide evidence that the rope must be replaced.

Inspect the entire length of the rope. Some areas of the wire rope such as around the core are more difficult to inspect. To inspect the core, examine the rope as it passes over the sheaves. The strands have a tendency to open up slightly which will give the inspector a better view of the core. Also regularly inspect for any reduction in diameter and lengthening of rope lay as both conditions indicate core damage.

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.

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.

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.

But on one particular day in early May of 2009, it wasn’t a boom reaching toward the big Texas sky that was causing people to stop and stare; it was one that was lying in a heap just beside the water, lattice sections bent and lacings twisted into mess of mangled steel and frayed wire rope. “I got the call to investigate the cause of loss on a Manitowoc 888 that was being used to drive underwater pilings at a dock in Port Isabel,” says JR Bristow, of Bristow Truck and Equipment Specialists, an organization based in Ridgewood, NJ that provides failure analysis and appraisals, among other things, for heavy equipment. “The operator was hoisting the boom when it just sort of gave out and crashed to the ground. No one was hurt, but the boom was in bad shape. The initial reserve was set at $500,000.”

Though a half million dollars wasn’t a total loss – the crane was valued at $1.5 million – it was a pretty hefty price to pay for something that, as it turned out, could have been avoided. On lattice-type cranes, booms are raised and lowered using boom hoist wire rope, and when that wire rope shows surface wear or corrosion, or worse, has broken wires within the rope strand, it can fail. It’s usually just a matter of time.

The subsequent investigation that followed revealed that the wire rope used to hoist the boom of the Model 888 had been in an out-of-service condition for quite some time, due to lack of proper lubrication.

“An examination of the failed boom hoist wire rope revealed that the wire rope had gone without the proper lubrication, which was the responsibility of the insured per the attached lease agreement,” Bristow remembers. “I also noted significant broken wires within the rope strands at an average of six to 12 per strand lay. Clearly, if the insured had performed a daily inspection of the boom hoist wire rope as required, that incident would not have happened.”

The broken strand condition that Bristow observed was caused by load cycles that occurred during boom up and boom down functions that were part of the daily operation of the crane. Simultaneous compression and expansion of the wire rope usually occurs as it travels over the hoist sheaves, and that causes the gradual deterioration of the strand wires.

Like many other segments of the crane and rigging industry, the nuances of wire rope are complicated and varied. Considerable time, money and resources have been invested in new technology, new inspection suggestions and new manufacturers. And rightly so. As was the case in Bristow’s example earlier, there’s quite a bit at stake in terms of both human capital and equipment cost.

Python High Performance wire rope, a wire rope manufacturer that has produced a number of resources to assist people in understanding and ultimately purchasing wire rope, clarifies the structure of wire rope on its website www.pythonrope.com.

Python’s site explains that a typical wire rope can contain hundreds of individual wires. These wires are fabricated and formed to operate at close bearing tolerances to one another. When a wire rope bends, each of its many wires slides and adjusts in the bend to accommodate the difference in length between the inside and the outside bend. The sharper the bend, the greater the movement, and the greater capacity for stress on the wire rope.

While manufacturers of wire rope are many and varied, each of the wire ropes they produce have three basic components:The wires, which form the strands and collectively provide the rope strength

According to Python’s site, the greatest differences in wire ropes are found in the number of strands, the construction of strands, the size of the core and the lay direction of the strand versus the core. But what does that mean for the layperson? What should he or she look for when purchasing wire rope?

Tony Fastuca, vice president Python America & High Performance Products, says that most people buy rope based on four ideal standards. “Abrasion resistance, fatigue resistance, flexibility and strength. Those four typical standards often weigh into a purchase decision: he says. “A buyer sometimes has to give a little in one area to get a bit more in another, but a lot of buyers are looking for a good balance of those four standards.”

Whereas other products usually come with an expected lifespan, wire ropes don’t really have an average operational life. “There are records that exist of wire ropes getting two to three years of use, sometimes longer,” says Fastuca. ”But it’s about the level of wear on the rope, not the length of time it’s been in service.”

Just as the crane itself needs to undergo frequent and period inspections, the wire rope does, too. Fastuca talks of the so called “A,B,Cs” of wire rope abuse – abrasion, bending, crushing.

The principle goal of a wire rope inspection is to find potential problems before they manifest into incidents or serious accidents. Inspections should be performed slowly and methodically, with a keen eye for corrosion or broken wires or sections of rope that look questionable. Because the reality of wire rope is that it will fail if it becomes worn out, overloaded, damaged, misused or improperly maintained. It can lead to huge headaches for companies that try to take shortcuts or don’t properly maintain it – a risk that just isn’t worth taking.

Wire rope lifting slings, bridles and assemblies provide great durability and high tensile strength for lifting heavy loads. In addition, wire rope lifting slings are lighter in weight and more cost efficient than chain slings. Wire rope slings, sometimes referred to as wire slings, or cable lifting slings, are constructed using a variety of different styles and sizes of steel wire rope. Every style and size of wire rope offers different properties and benefits such as:

Each type of wire rope has benefits and drawbacks. What all wire ropes have in common however, is that they are made up of steel wires which form individual stands. These strands are laid in a helical pattern around a fiber or steel IWRC (independent wire rope core) core.

Wire rope lifting slings, bridles and assemblies are highly customizable, so if you are unable to find what you are looking for, or if you don’t know exactly what you need, call or email our sales team to speak with a rigging product specialist.

The durability of steel cable lifting slings is also put to the test in the harsh environments seen in steel mills and forging facilities. Every steel wire rope configuration will offer different properties and will be better equipped to handle certain applications. Generally, a smaller number of large outer wires will provide more wear, corrosion and abrasion resistance. Conversely, a larger number of smaller outer wires will provide better flexibility and fatigue resistance.

After you decide what construction and size of wire rope fits your application, you must configure the entire sling. Wire rope bridles and assemblies are available in single-leg, double-leg, triple-leg, and quadruple-leg configurations. They most commonly have 2 eyes and are constructed using a mechanical flemish splice. Wire rope lifting slings can be used in vertical, choker and basket hitches. They can also be equipped with a variety of attachments and fittings to accommodate almost any overhead lifting application.

Although wire rope sling fittings and attachment can be reused, the wire rope itself is not repairable. If a wire rope sling fails an inspection, it is to be properly destroyed and disposed of

It is important to inspect wire rope slings regularly and to keep a record of all sling inspections. At Tri-State Rigging Equipment we offer a full range of rigging inspection and repair services. The standards that govern wire rope sling inspection are OSHA 1910.184 and ASME B30.9. It is recommended that wire rope rigging slings first undergo an initial inspection when you receive the lifting sling from the manufacturer. The purpose of this initial inspection is to:

Wire rope slings, bridles and assemblies should also be inspected by a designated and qualified individual every day before use to make sure that the sling is in working condition and will lift its rated capacity. The person performing the inspection should examine all the wire rope, fastenings and attachments on the wire rope sling. The inspector is looking for visual indications of any defects, deformities and general damage that might affect the integrity of the sling.

Depending on your application, it may be recommended that you perform these visual inspections more than once a day. If the wire rope sling is used many times throughout the day, by multiple individuals, across multiple shifts, it is imperative that the sling be inspected before every shift change and before any change in lifting application.

ASME standards further require a thorough periodic inspection to be performed at least once a year by either a professional service provider, or by a Qualified Person. In addition, written records must be kept until the next periodic inspection. The rejection criteria for periodic wire rope sling inspections are as follows:

10 or more randomly distributed broken wires in one rope lay, or 5 or more broken wires in one strand in one rope lay, for strand-laid grommets and single part slings.

If your wire rope sling shows any of the rejection criteria above, you must remove the sling from service, and it must be destroyed. Properly destroying rigging equipment is imperative because you can be held accountable for damage done by people who find and use your discarded slings. Therefore, lifting slings deemed not suitable for service must be destroyed beyond use and beyond repair. The process for destroying a wire rope sling is as follows:

The purpose of daily and periodic wire rope sling inspections is not to get anyone in trouble but rather to gain knowledge of the frequency of use, severity of conditions, and nature of lifts, and consider how all these factors affect your wire rope sling. The most important reason to perform daily and periodic wire rope sling inspections, however, is to keep you and your coworkers safe.

Tri-State Rigging Equipment is a custom manufacturer, service provider and distributor for all wire rope lifting slings serving clients from coast to coast, Canada, Mexico and especially focused in the states of Missouri, Illinois, Indiana, Iowa, Kansas, Nebraska, Arkansas, Mississippi, Tennessee, Kentucky, South Carolina, Florida, and Oklahoma.

Guidelines for inspecting a wire rope system or installation are available in this brochure. The publication provides a clear and concise approach to assisting wire rope users" needs to comply with industry and governmental regulations that require inspections of individual ropes, fittings and attachments, as well as entire operating systems at regularly scheduled intervals. In addition to information and criteria, the brochure includes a blank Inspection Form, which may be copied for recording

Wire Rope Inspection Services in the oil and gas industry with the use ofLRM®XXI Diagnostic System allows to get information about the technical condition of wire rope in full cross section and in full available length of wire rope in the fastest way.

With regular periodic wire rope inspection combined with data utilization of crane the it is possible to estimate the remaining lifetime of crane wires.

Due to cooperation with Laboratory LRM-NDE with success offshore companies has implemented inspections of cranes wire ropes with the use of LRM®XXI Diagnostic System according to MRT Examination procedure and international standards for offshore fleet.

Long-term cooperation with offshore companies has allowed Laboratory LRM-NDE to achieve the knowledge and necessary competence to design wire rope diagnostic system equipment that can meet the harsh environmental conditions at sea.

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