wire rope inspection requirements supplier

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.

Original equipment wire rope and replacement wire rope must be selected and installed in accordance with the requirements of this section. Selection of replacement wire rope must be in accordance with the recommendations of the wire rope manufacturer, the equipment manufacturer, or a qualified person.

Wire rope design criteria: Wire rope (other than rotation resistant rope) must comply with either Option (1) or Option (2) of this section, as follows:

Option (1). Wire rope must comply with section 5-1.7.1 of ASME B30.5-2004 (incorporated by reference, see § 1926.6) except that section"s paragraph (c) must not apply.

Option (2). Wire rope must be designed to have, in relation to the equipment"s rated capacity, a sufficient minimum breaking force and design factor so that compliance with the applicable inspection provisions in § 1926.1413 will be an effective means of preventing sudden rope failure.

Type I rotation resistant wire rope ("Type I"). Type I rotation resistant rope is stranded rope constructed to have little or no tendency to rotate or, if guided, transmits little or no torque. It has at least 15 outer strands and comprises an assembly of at least three layers of strands laid helically over a center in two operations. The direction of lay of the outer strands is opposite to that of the underlying layer.

Type II rotation resistant wire rope ("Type II"). Type II rotation resistant rope is stranded rope constructed to have significant resistance to rotation. It has at least 10 outer strands and comprises an assembly of two or more layers of strands laid helically over a center in two or three operations. The direction of lay of the outer strands is opposite to that of the underlying layer.

Type III rotation resistant wire rope ("Type III"). Type III rotation resistant rope is stranded rope constructed to have limited resistance to rotation. It has no more than nine outer strands, and comprises an assembly of two layers of strands laid helically over a center in two operations. The direction of lay of the outer strands is opposite to that of the underlying layer.

Type I must have an operating design factor of no less than 5, except where the wire rope manufacturer and the equipment manufacturer approves the design factor, in writing.

When Types II and III with an operating design factor of less than 5 are used (for non-duty cycle, non-repetitive lifts), the following requirements must be met for each lifting operation:

A qualified person must inspect the rope in accordance with § 1926.1413(a). The rope must be used only if the qualified person determines that there are no deficiencies constituting a hazard. In making this determination, more than one broken wire in any one rope lay must be considered a hazard.

Each lift made under § 1926.1414(e)(3) must be recorded in the monthly and annual inspection documents. Such prior uses must be considered by the qualified person in determining whether to use the rope again.

Rotation resistant ropes may be used as boom hoist reeving when load hoists are used as boom hoists for attachments such as luffing attachments or boom and mast attachment systems. Under these conditions, all of the following requirements must be met:

The requirements in ASME B30.5-2004 sections 5-1.3.2(a), (a)(2) through (a)(4), (b) and (d) (incorporated by reference, see § 1926.6) except that the minimum pitch diameter for sheaves used in multiple rope reeving is 18 times the nominal diameter of the rope used (instead of the value of 16 specified in section 5-1.3.2(d)).

The operating design factor for these ropes must be the total minimum breaking force of all parts of rope in the system divided by the load imposed on the rope system when supporting the static weights of the structure and the load within the equipment"s rated capacity.

Wire rope clips used in conjunction with wedge sockets must be attached to the unloaded dead end of the rope only, except that the use of devices specifically designed for dead-ending rope in a wedge socket is permitted.

Prior to cutting a wire rope, seizings must be placed on each side of the point to be cut. The length and number of seizings must be in accordance with the wire rope manufacturer"s instructions.

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.

(1) Cable laid and 6 x 19 and 6 x 37 slings shall have a minimum clear length of wire rope 10 times the component rope diameter between splices, sleeves or end fittings.

(c) Safe Operating Temperatures. Fiber core wire rope slings of all grades shall be permanently removed from service if they are exposed to temperatures in excess of 200o F. When nonfiber core wire rope slings of any grade are used at temperatures above 400o F, or below minus 60o F, the sling manufacturer"s recommendations shall be followed.

(3) Where rope clip attachments are used, they shall be made with U-bolts on the dead or short end of the rope and the saddle on the live end. The minimum number of clips for end attachments shall be not less than indicated in manufacturer"s tables, but in no case shall be less than three for any permanent installation. Clips shall be drop-forged steel. The clips shall be spaced at a distance equal to at least six times the diameter of the rope. All clip or clamp bolts shall be kept tight after tightening while rope is under tension.

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 must be inspected as part of the shift, monthly, and annual inspections required by. The shift and monthly inspections must evaluate all rope that is visible during the shift in which the inspection is conducted. The annual inspection must include the entire length of the rope. The shift and monthly inspections must pay particular attention to the following:

You must take certain action if an inspection reveals a defect in the rope. Some defects require either that the rope be removed from service or the damaged section be severed. For others, the inspector must evaluate whether the defect constitutes a safety hazard, with the corrective action depending on the outcome of the evaluation. Note that, if a wire rope must be repaired or replaced, either the equipment (as a whole) or the hoist with that wire rope must be tagged-out during the repair/replacement process.

Where severing the rope is permitted, the section that is damaged must be discarded. Two undamaged sections may not be spliced to make a longer rope. If the undamaged part that remains is too short for the drum to have two full wraps of rope when the load and/or boom is in its lowest position, the rope cannot be used and must be replaced.

Wire rope that has made electrical contact with a power line (either by the rope, the equipment, or the load contacting the line) must be immediately removed from service even if no damage is visible. The rope may have suffered internal damage that cannot be repaired.

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, or more than one broken wire in a rope lay located at an end connection

Exception:If the wire rope manufacturer has approved different criteria for visible broken wires or diameter reduction, you may follow those criteria instead of those above.

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

If they are not found to be an immediate hazard:You may continue to use the rope. However, if such a defect is identified during an annual inspection, you must check it during each monthly inspection. Note that this may require a more complete monthly inspection than would otherwise be required because the annual inspection must cover the entire rope and may reveal a defect in a part of the rope that would not normally be visible during a shift or monthly inspection.

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.

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.

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.

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(a) Original crane/derrick wire rope and replacement wire rope must be selected and installed in accordance with the requirements of this section. Selection of replacement wire rope must be in accordance with the recommendations of the wire rope manufacturer, the crane/derrick manufacturer, or a qualified person.

(b) Wire rope design criteria: Wire rope (other than rotation resistant rope) must comply with either Option (1) or Option (2) of this section, as follows:

(ii) Option (2). Wire rope must be designed to have, in relation to the crane"s/derrick"s rated capacity, a sufficient minimum breaking force and design factor so that compliance with the applicable inspection provisions in this section will be an effective means of preventing sudden rope failure.

Type I rotation resistant wire rope (Type I). Type I rotation resistant rope is stranded rope constructed to have little or no tendency to rotate or, if guided, transmits little or no torque. It has at least 15 outer strands and comprises an assembly of at least 3 layers of strands laid helically over a center in two operations. The direction of lay of the outer strands is opposite to that of the underlying layer.

Type II rotation resistant wire rope (Type II). Type II rotation resistant rope is stranded rope constructed to have resistance to rotation. It has at least 10 outer strands and comprises an assembly of two or more layers of strands laid helically over a center in two or 3 operations. The direction of lay of the outer strands is opposite to that of the underlying layer.

Type III rotation resistant wire rope (Type III). Type III rotation resistant rope is stranded rope constructed to have limited resistance to rotation. It has no more than 9 outer strands, and comprises an assembly of two layers of strands laid helically over a center in two operations. The direction of lay of the outer strands is opposite to that of the underlying layer.

(C) Type I must have an operating design factor of no less than 5, except where the wire rope manufacturer and the crane/derrick manufacturer approves the design factor, in writing.

(iii) When Types II and III with an operation design factor of less than 5 are used (for nonduty cycle, nonrepetitive lifts), the following requirements must be met for each lifting operation:

(A) A qualified person must inspect the rope in accordance with subsection (2)(a) of this section. The rope must be used only if the qualified person determines that there are no deficiencies constituting a hazard. In making this determination, more than one broken wire in any one rope lay must be considered a hazard.

(C) Each lift made under these provisions must be recorded in the monthly and annual inspection documents. Such prior uses must be considered by the qualified person in determining whether to use the rope again.

(B) Rotation resistant ropes may be used as boom hoist reeving when load hoists are used as boom hoists for attachments such as luffing attachments or boom and mast attachment systems. Under these conditions, all of the following requirements must be met:

(III) The requirements of ANSI/ASME B30.5-2007, Section 5-1.3.2(a), (a)(2) through (a)(4), (b) and (d), except that the minimum pitch diameter for sheaves used in multiple rope reeving is 18 times the nominal diameter of the rope used instead of the value of 16 specified in Section 5-1.3.2(d).

(IV) All sheaves used in the boom hoist reeving system must have a rope pitch diameter of not less than 18 times the nominal diameter of the rope used.

(VI) The operating design factor for these ropes must be the total minimum breaking force of all parts of rope in the system divided by the load imposed on the rope system when supporting the static weights of the structure and the load within the crane"s/derrick"s rated capacity.

(f) Wire rope clips used in conjunction with wedge sockets must be attached to the unloaded dead end of the rope only, except that the use of devices specifically designed for dead-ending rope in a wedge socket is permitted.

(h) Prior to cutting a wire rope, seizings must be placed on each side of the point to be cut. The length and number of seizings must be in accordance with the wire rope manufacturer"s instructions.

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

(I) Distortion of the wire rope structure such as kinking, crushing, unstranding, birdcaging, signs of core failure or steel core protrusion between the outer strands.

(I) Visibly broken wires in running wire ropes: 6 randomly distributed broken wires in one rope lay or 3 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;

(II) Visibly broken wires in rotation resistant ropes: Two randomly distributed broken wires in 6 rope diameters or 4 randomly distributed broken wires in 30 rope diameters;

(III) Visibly broken wires 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 at an end connection; and

(A) If a deficiency in Category I 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:

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

(I) You comply 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;

(C) 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 subsection, you 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 III is identified, operations involving use of the wire rope in question must be prohibited until:

(II) 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 subsection, you must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

(D) Where a wire rope is required to be removed from service under this section, either the crane/derrick (as a whole) or the hoist with that wire rope must be tagged-out, in accordance with WAC 296-155-53400(67), until the wire rope is repaired or replaced.

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

(iii) Wire ropes on a crane/derrick must not be used until an inspection under this subsection demonstrates that no corrective action under (a)(iii) of this subsection is required.

(i) At least every 12 months, wire ropes in use on the crane/derrick must be inspected by a qualified person in accordance with (a) of this subsection (shift inspection).

(B) 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:

(C) Exception: In the event an inspection under (c)(ii) of this subsection is not feasible due to existing set-up and configuration of the crane/derrick (such as where an assist crane is needed) or due to site conditions (such as a dense urban setting). The inspection must consist of observation of the working range plus 3 additional wraps (running and standing) prior to use.

(II) 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 subsection, you must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

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

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

All wire ropes will wear out eventually and gradually lose work capability throughout their service life. That"s why periodic inspections are critical. Applicable industry standards such as ASME B30.2 for overhead and gantry cranes or federal regulations such as OSHA refer to specific inspection criteria for varied applications.

You should thoroughly inspect all wire ropes at regular intervals. The longer it has been in service or, the more severe the service, the more thoroughly and frequently it should be inspected. Be sure to maintain records of each inspection.

Inspections should be carried out by a person who has learned through specialized training or practical experience of what to look for and who knows how to judge the importance of any abnormal conditions they may discover. It is the inspector"s responsibility to obtain and follow the proper inspection criteria for each application inspected.

Figure 1is what happens when a wire breaks under tensile load exceeding its strength. It"s typically recognized by the "cup and cone" appearance at the point of failure. The necking down of the wire at the point of failure to form the cup and cone indicates failure has occurred while the wire retained its ductility (the ability to change form without breaking).

Figure 2is a wire with a clear fatigue break. It is identified by the square end perpendicular to the wire. This break was produced by a torsion machine that"s used to measure the ductility. This break is similar to wire failures in the field caused by fatigue.

Figure 3 is a wire rope that has been subjected to repeated bending over sheaves under typical loads. This fatigue results in breaks in individual wires - these breaks are square and usually in the crown of the strands.

Figure 4 is an example of fatigue failure of a wire rope subjected to heavy loads over small sheaves. The breaks in the valleys of the strands are caused by "strand nicking." There may be crown breaks, too.

Figure 5 is a single strand removed from a wire rope subjected to "strand nicking." This condition is a result of adjacent strands rubbing against one another. While this is normal in a rope"s operation, the nicking can be accentuated by high loads, small sheaves or loss of core support. The ultimate result will be individual wire breaks in the valleys of the strands.