wire rope inspection requirements in stock

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.

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.

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.

Wire rope is extremely sturdy and can be used in many different applications. In order to withstand harsh conditions, wire rope has basic guidelines of inspection it must meet. Continue reading to find out the guidelines of inspection for wire rope.

Abrasion damage is usually caused by the rope making contact with an abrasive surface. It can also be caused by simply passing over the drum and sheaves during regular, continued use. To minimize this risk, all components should be in proper working condition and be of appropriate diameter for the rope. Badly worn sheaves or drums will cause serious damage to a new rope and will greatly diminish the integrity of the rope quickly.

Corrosion is hard to assess but is more problematic than abrasion. Corrosion is usually the result of the lack of lubrication. It will most likely take place internally before there are any apparent signs on the rope’s surface. One telltale sign of corrosion is a slight discoloration, which is generally the result of rusting. This discoloration indicates a need for lubrication which should be dealt with as soon as possible. Failure to attend to this situation will lead to severe corrosion which will cause premature fatigue failures in the wires and strands. If this occurs, the rope will need to be removed immediately.

Diameter reduction is an extremely serious deterioration factor and can occur for several reasons. The most common reasons for diameter reduction are excessive abrasion of the outside wires, loss of core diameter/support, internal or external corrosion damage, or inner wire failure.

Examining and documenting a new rope’s actual diameter when under normal load conditions is critical. During the life of the rope, the actual diameter of the rope should be regularly measured at the same location under similar loading conditions. If this protocol is followed correctly, it should divulge a routine rope characteristic—after an initial reduction, the overall diameter will stabilize, then gradually decrease in diameter during the course of the rope’s life. This occurrence is completely natural, but if diameter reduction is confined to a single area or happens quickly, the inspector must quickly identify the source of the diameter loss and make the necessary changes if possible. Otherwise, the rope should be replaced as soon as possible.

Crushing or flattening of wire rope strands can happen for many reasons. These issues usually arise on multilayer spooling conditions but can also develop just by using the wrong wire rope for the specific application. Incorrect installation is the most common cause of premature crushing/flattening. Quite often, failure to secure a tight first layer, which is known as the foundation, will cause loose or “gappy” conditions in the wire rope which will result in accelerated deterioration. Failure to appropriately break-in the new rope, or even worse, to have no break-in protocol whatsoever, will also result in poor spooling conditions. The inspector must understand how to correctly inspect the wire rope, in addition to knowing how that rope was initially installed.

Another potential cause for the replacement of the rope is shock loading (also known as bird-caging). Shock loading is caused by the abrupt release of tension on the wire rope and its rebound culminating from being overloaded. The damage that ensues can never be amended and the rope needs to be replaced immediately.

There are several different instances that might result in high stranding. Some of these instances include the inability to correctly seize the rope prior to installation or the inability to maintain seizing during wedge socket installation. Sometimes wavy rope occurs due to kinks or very tight grooving issues. Another possible problem arises from introducing torque or twist into a new rope during poor installation methods. In this situation, the inspector must assess the continued use of the rope or conduct inspections more often.

There are a lot of guidelines for troubleshooting wire rope. At Silver State Wire Rope and Rigging, Inc., we take these guidelines seriously, and so should you. All of our products are tested and guaranteed to be the best fit for your specific needs. We can also help you with your troubleshooting needs. Contact us today!

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.

A specific procedure for sling inspection is the best safeguard against injury, death and property damage. It is important that you employ a three stage level of inspection to ensure that slings are inspected with appropriate frequency. It is also important that all inspections must be done by trained and qualified personnel.

To detect possible damage, you should perform a visual inspection of the entire sling by making all parts of the sling readily visible. If necessary, remove dirt and grime so wires and components are visible. Look for any of the conditions listed in the Removal from Service Criteria. The following example depict some of the types of damage, but note that they are relatively extreme examples provided for illustration purposes only.

If you identify ANY of these types of damage, remove slings from service immediately, even if the damage you see is not as extensive as shown. Slings that are removed from service must be destroyed and rendered completely unusable. Never ignore sling damage or attempt to perform temporary field repairs of damaged slings. It is very important that slings are regularly and properly inspected. If you are not sure whether or not a sling is damaged, DO NOT USE IT.

Wire ropes undergo constant stress and wear through daily use. So, wire rope requires monthly inspection in accordance with this section to reduce the risk of failure and potential resulting injury or property damage. In addition, this section covers criteria to use in determining when to replace rope, and requires inspection of rope on equipment that has been idle for a month or more, before the rope and equipment can be returned to service.

A thorough inspection of all ropes shall be made at least once a month and a certification record which included the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes which were inspected shall be kept on file where readily available to appointed personnel. Any deterioration, resulting in appreciable loss of original strength, shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following:

All rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. This inspection shall be for all types of deterioration and shall be performed by an appointed person whose approval shall be required for further use of the rope. A certification record shall be available for inspection which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the rope which was inspected.

Wear and damage to wire rope can’t always be seen on the surface. Konecranes RopeQ Magnetic Rope Inspection pairs visual inspection with non-destructive testing to detect internal broken wires that may escape detection through traditional inspection methods.

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

Guidelines for inspecting a wire rope system or installation are 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 results of regular inspections for permanent, written fires required by many regulations.

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

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

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

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

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

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

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

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

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

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

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

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

Cranes must meet periodic inspection criteria as defined in the OSHA standard.  All cranes must also meet the design, construction, and testing criteria as set forth in 29 CFR 1926.1433 through 1926.1441. If a manufacturer’s inspection criteria exceed the requirements as defined in the OSHA standard, the crane must be inspected to meet the criteria of the manufacturer.  Prior to beginning work on the site, the crane subcontractor must verify the following inspections:

Periodic Monthly Inspections by a competent person.  If equipment has been idle for 3 months or greater, a monthly inspection must be conducted by a competent person prior to use on the site.

Deficiencies identified in any wire rope inspection must be documented, categorized, and corrected as indicated in the standard before any work can begin.

The most important test a trained professional will conduct is a spot check. This means that they will give a visual inspection of the whole sling. All parts of the sling must be inspected (this means hard to see areas). It is important to clean your sling prior inspection so that dirt and dust do not make a visual inspection more difficult.

If any of the above are encountered, a sling must be promptly removed from service and destroyed. Even if there is only minimal damage, a sling should be taken out of service and destroyed. Never underestimate the importance of inspecting and maintaining perfectly working wire rope slings.

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

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

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

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

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

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

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

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

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

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

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

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

A wire rope consists of hundreds of components that must move and interact in unison to bend and support massive weights. Wire rope is often likened to a “machine,” and like any other machine, a good maintenance program will yield significantly longer life. Although the subject is much broader and longer than a short magazine article will allow, touching on some of the key points of wire rope maintenance is at least a good start.

A significant part of good wire rope maintenance is ensuring that the equipment it works with is also in good order. For the wire rope, that mainly means checking the sheaves. Sheaves must move freely to avoid undue abrasion and run true without wobbles to avoid vibrations that can fatigue the rope. Next, the groove must be suitable for the rope being used. It is recommended that the groove be 1 percent larger than the maximum rope diameter including its allowable tolerance. That means for a typical wire rope with 0 to +5 percent tolerance, the groove should be nominal rope diameter +6 percent.

Worn and undersized sheaves lead to deformations from forced twist while larger tolerances can lead to damage caused by a lack of support. Corrugation in the groove will both twist and wear the rope. Finally, inspection of rollers must be regarded to be as important as inspection of the sheaves. They also need to be free of corrugation, wear and stuck or worn bearings.

As a manufacturer and distributor of wire rope, wire rope slings, chain slings, synthetic slings and rigging hardware, we often see customers confused about what is involved in the inspection of their rigging equipment.Our goal is to help you understand what is required for your wire rope slings to meet ASME standards, which 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. A good working knowledge of wire rope design and construction is 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.

What are the basic inspection criteria for wire rope slings? 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. ASME B30.9 standards specify that a wire rope sling shall be removed from service if any of the following conditions are present:

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:

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.

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.

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.

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.

Among the most misunderstood aspects of crane rope maintenance is lubrication. When a wire rope is bent the individual wires and strands have to slide relative to each other and the rope itself glides within the sheave. Without proper lubrication, friction increases and the rope life is drastically reduced. Checking the lubrication and periodically applying a thin coating of maintenance lubricant is key to any maintenance program. As a rule of thumb, ropes require maintenancelubrication every six to 12 months.

When it comes to maintenance lubrication there are a few lesser-known things to keep in mind. First, the lubricant must be compatible with the original lubricant. Otherwise, through intermixing, the two products can form a totally different lubricant with different technical properties. Second, a lubricant designed only for wire rope is a must. Wire rope lubrication performs a very specific function with very specific properties which generally cannot be met by multi-use products such as a typical gear, chain and rope lubricant. Third, the lubricant must be able to penetrate inside of the strands to cover each component uniformly. A product that just sits on the outside does not help the wire rope life, plus it can inhibit inspection.

A common wear area of running ropes on construction cranes is at the drum. Since the rope is wound in multiple layers it is subjected to abrasion and crushing at crossover points between rope wraps and change in layers. To get optimal life from the rope it must be sufficiently tensioned on the drum to 5 to 10 percent of working load limit during installation. When a wire rope is sufficiently tensioned it tightens and gains lateral stability wires pushed out of position due to non-tensioned drum wraps, enabling it to resist crushing from the incoming loaded rope. When it is not tensioned it will crush much more easily. It is important to note that tensioning is not a one-time event. Over time, unused lower wraps and layers slowly lose this tension and therefore ropes need to be routinely tensioned as part of the crane maintenance program.

The new Super Reeve Connector Swivel Socket (SCS-SW) from RopeBlock is the result of further development of the company’s patented Super Reeve Connector Socket (SCS). The new design adds an integral swivel. The Super Reeve Connector Swivel Socket utilizes a poured button that achieves an efficiency of 100 percent of the wire rope breaking strength, RopeBlock said.

The shorter length optimizes the hoisting height. Integrating a swivel increases safety as the torsional forces are reduced in comparison to situations where only a socket is used, the company said. RopeBlock engineers have designed the SCS-SW as a universal product that can be relatively easily adapted to all types of cranes. The SCS-SW is available for wire rope sizes from 7/16 inches to 2 1/8 inches (11mm - 54mm).

Another method to extend the lifetime of wire rope is by cutting a length equal to 1-1/4 drum wraps from the drum end to move the wear points. For this method to be effective it must be done at intervals that occur prior to these sections showing more wear than the rest of the rope. Three or more times over the rope’s lifetime is recommended.

For tower cranes the problem is usually compounded. The crane starts at a base height and climbs during the job leaving lots of unused rope in the lower layers on the drum, not to be used until the crane is climbed to its final working height.

These lower layers at the start of the job cannot be practically re-tensioned or shortened until the rope climbs high enough to fully spool the rope off. Unfortunately, by the time the rope at these lower layers is needed it may already be damaged. The solution is to plan to use a different length of rope for each stage of the job. This ensures that there aren’t any unused, low tension layers becoming damaged before seeing any useful life and in most cases the ropes can be used again at the next job.

WireCo WorldGroup has introduced a new product that will replace Apex for extend and retract assemblies on cranes. Following an analysis conducted by its technical and engineering specialists, Wireco WorldGroup is now offering Betalift SP.

“Betalift SP can be directly substituted into the application the Apex product is currently used, with equal breaking strength and even more benefits to our customers,” said WireCo WorldGroup. “Manufactured to the industry’s highest standards, Betalift SP is constructed with drawn galvanized wires that provide excellent corrosion resistance. In addition, extensive testing has shown Betalift SP provides 25 to 50 percent improvement in fatigue life.”

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