wire rope inspection requirements brands

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.

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The following is a fairly comprehensive listing of critical inspection factors. It is not, however, presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted standards by which wire ropes must be judged. Use the outline to skip to specific sections:

Rope abrades when it moves through an abrasive medium or over drums and sheaves. Most standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original outer wire diameter. This is not easy to determine, and discovery relies upon the experience gained by the inspector in measuring wire diameters of discarded ropes.

All ropes will stretch when loads are initially applied. As a rope degrades from wear, fatigue, etc. (excluding accidental damage), continued application of a load of constant magnitude will produce incorrect varying amounts of rope stretch.

Initial stretch, during the early (beginning) period of rope service, caused by the rope adjustments to operating conditions (constructional stretch).

Following break-in, there is a long period—the greatest part of the rope’s service life—during which a slight increase in stretch takes place over an extended time. This results from normal wear, fatigue, etc.

Thereafter, the stretch occurs at a quicker rate. This means that the rope has reached the point of rapid degradation: a result of prolonged subjection to abrasive wear, fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon be removed.

In the past, whether or not a rope was allowed to remain in service depended to a great extent on the rope’s diameter at the time of inspection. Currently, this practice has undergone significant modification.

Previously, a decrease in the rope’s diameter was compared with published standards of minimum diameters. The amount of change in diameter is, of course, useful in assessing a rope’s condition. But, comparing this figure with a fixed set of values can be misleading.

As a matter of fact, all ropes will show a significant reduction in diameter when a load is applied. Therefore, a rope manufactured close to its nominal size may, when it is subjected to loading, be reduced to a smaller diameter than that stipulated in the minimum diameter table. Yet under these circumstances, the rope would be declared unsafe although it may, in actuality, be safe.

As an example of the possible error at the other extreme, we can take the case of a rope manufactured near the upper limits of allowable size. If the diameter has reached a reduction to nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps, be removed.

Today, evaluations of the rope diameter are first predicated on a comparison of the original diameter—when new and subjected to a known load—with the current reading under like circumstances. Periodically, throughout the life of the rope, the actual diameter should be recorded when the rope is under equivalent loading and in the same operating section. This procedure, if followed carefully, reveals a common rope characteristic: after an initial reduction, the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter throughout its life.

Deciding whether or not a rope is safe is not always a simple matter. A number of different but interrelated conditions must be evaluated. It would be dangerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimum arbitrarily established in a table if, at the same time, other observations lead to an opposite conclusion.

Corrosion, while difficult to evaluate, is a more serious cause of degradation than abrasion. Usually, it signifies a lack of lubrication. Corrosion will often occur internally before there is any visible external evidence on the rope surface.

Pitting of wires is a cause for immediate rope removal. Not only does it attack the metal wires, but it also prevents the rope’s component parts from moving smoothly as it is flexed. Usually, a slight discoloration because of rusting merely indicates a need for lubrication.

Severe rusting, on the other hand, leads to premature fatigue failures in the wires necessitating the rope’s immediate removal from service. When a rope shows more than one wire failure adjacent to a terminal fitting, it should be removed immediately. To retard corrosive deterioration, the rope should be kept well lubricated with a clear wire rope lube that can penetrate between strands. In situations where extreme corrosive action can occur, it may be necessary to use galvanized wire rope.

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

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

Bird caging results from torsional imbalance that comes about because of mistreatment, such as sudden stops, the rope being pulled through tight sheaves, or wound on too small a drum. This is cause for rope replacement unless the affected section can be removed.

Particular attention must be paid to wear at the equalizing sheaves. During normal operations, this wear is not visible. Excessive vibration or whip can cause abrasion and/or fatigue. Drum cross-over and flange point areas must be carefully evaluated. All end fittings, including splices, should be examined for worn or broken wires, loose or damaged strands, cracked fittings, worn or distorted thimbles and tucks of strands.

After a fire or the presence of elevated temperatures, there may be metal discoloration or an apparent loss of internal lubrication. Fiber core ropes are particularly vulnerable. Under these circumstances the rope should be replaced.

Continuous pounding is one of the causes of peening. This can happen when the rope strikes against an object, such as some structural part of the machine, or it beats against a roller or it hits itself. Often, this can be avoided by placing protectors between the rope and the object it is striking.

Another common cause of peening is continuous working-under high loads—over a sheave or drum. Where peening action cannot be controlled, it is necessary to have more frequent inspections and to be ready for earlier rope replacement.

Below are plain views and cross-sections show effects of abrasion and peening on wire rope. Note that a crack has formed as a result of heavy peening.

Scrubbing refers to the displacement of wires and strands as a result of rubbing against itself or another object. This, in turn, causes wear and displacement of wires and strands along one side of the rope. Corrective measures should be taken as soon as this condition is observed.

Wires that break with square ends and show little surface wear have usually failed as a result of fatigue. Such fractures can occur on the crown of the strands or in the valleys between the strands where adjacent strand contact exists. In almost all cases, these failures are related to bending stresses or vibration.

If diameter of the sheaves, rollers or drum cannot be increased, a more flexible rope should be used. But, if the rope in use is already of maximum flexibility, the only remaining course that will help prolong its service life is to move the rope through the system by cutting off the dead end. By moving the rope through the system, the fatigued sections are moved to less fatiguing areas of the reeving.

The number of broken wires on the outside of a wire rope are an index of its general condition, and whether or not it must be considered for replacement. Frequent inspection will help determine the elapsed time between breaks. Ropes should be replaced as soon as the wire breakage reaches the numbers given in the chart below. Such action must be taken without regard to the type of fracture.

* All ropes in the above applications—one outer wire broken at the point of contact with the core that has worked its way out of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required.

Rope that has either been in contact with a live power line or been used as “ground” in an electric welding circuit, will have wires that are fused, discolored and/or annealed and must be removed.

On occasion, a single wire will break shortly after installation. However, if no other wires break at that time, there is no need for concern. On the other hand, should more wires break, the cause should be carefully investigated.

On any application, valley breaks—where the wire fractures between strands—should be given serious attention. When two or more such fractures are found, the rope should be replaced immediately. (Note, however, that no valley breaks are permitted in elevator ropes.)

It is good to remember that once broken wires appear—in a rope operating under normal conditions—a good many more will show up within a relatively short period. Attempting to squeeze the last measure of service from a rope beyond the allowable number of broken wires (refer to table on the next page) will create an intolerably hazardous situation.

Recommended retirement criteria for all Rotation Resistant Ropes are 2 broken wires in 6 rope diameters or 4 broken wires in 30 rope diameters (i.e. 6 rope diameters for a 1″ diameter rope = 6″).

Distortion of Rotation Resistant Ropes, as shown below, can be caused by shock load / sudden load release and/or induced torque, and is the reason for immediate removal from service.

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

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

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

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

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

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

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

Wire 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.

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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.

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.

Wire rope slings are essential pieces of rigging hardware, especially for industrial sites, and designed to lift and hoist heavy objects. The lifting device remains connected to those slings with several different configurations. While these slings are generally durable, proper inspection and maintenance are required to keep up their integrity. Damages from wear and tear are likely without detailed inspection. According to ASME and OSHA standards, users must inspect wire rope slings regularly and correctly to operate them safely. Continue reading for more information regarding the inspection of wire rope slings.

According to OSHA guidelines, inspections on wire rope slings should be conducted at a regular interval. The frequency of the inspections will largely depend on the frequency of use. However, you should stick to these general recommendations when it comes to wire rope sling inspections:Inspect slings immediately after receiving them from the manufacturers

Before using your wire rope slings, it’s essential to inspect them properly. An inspection will allow you to detect the damage that may have been caused during your previous use. Be sure to take appropriate steps to solve the issues if you come across them.

Visual inspections should be conducted daily. An inspection can be as simple as the person who is using the sling to identify any signs of deterioration. Even the most minor of damage can potentially weaken the wire rope sling. The user should attempt to identify defective wires, crushing potentials, corrosion, and faulty attachments.

It is also imperative to conduct an annual inspection. This inspection should include every part of the sling, including the fittings, end attachments, and splices.

A certified and qualified person should be conducting the inspections on your wire rope slings. If you’re only using the slings occasionally, a yearly inspection may suffice. However, for severe use, a quarterly inspection would be optimal. Consider contracting an inspection service.

The inspector will look for the damaged and worn-out parts of the wire rope sling. The inspector will also label the parts that were already inspected.

You may find some signs of damages after the inspection. However, that doesn’t mean it’ll be easy to decide between repair and replacement of the damaged slings. This is a guide that might help you determine when it’s time to replace those damaged slings.Deteriorated wires: Five damaged wires in a strand indicate that it’s time for a replacement if you are using single-part slings. If you’re using a multi-part sling, ten randomly damaged wires in a rope lay should warrant replacement.

Metal loss: The loss of metal may be indicated by the outer diameters of wires showing wear and tear signs. In this case, you should strongly consider replacing the sling.

Severe rope corrosion is a sign that you should replace your slings. However, light rusting will only reduce the strength of your slings. In this case, whether you replace them or not is entirely up to you.

You need to cut the fittings and eye of the sling first. Then label them properly to avoid accidentally using them. It is imperative that you do not use those slings at all.

Remember that proper inspections will prevent you from using damaged wire rope slings. It’s strongly recommended that you hire professionals to inspect your slings. Checking and maintaining wire rope slings throughout the year can help you avoid costly repairs.

Proper maintenance and upkeep will help make sure you get the most out of your wire rope slings. It’s also imperative to understand the correct ways to store your slings while they aren’t in use. As a general rule, you should keep slings away from heat, liquids, sprays, and corrosion. With proper maintenance and care, you can easily use your wire rope slings for several years.

AtSilver State Wire Rope and Rigging, we know everything there is to know about wire ropes and rigging. If you have any questions about wire rope slings, inspections, or anything else regarding wire ropes, feel free tocontactone of our professional staff members.

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

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

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

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

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