when to replace wire rope on crane factory

Your crane"s wire rope works hard. (Almost as hard as you do.) It can deteriorate more quickly than you might think, posing a real danger for you and your crew. In this article, we"ll answer the following questions.

Before we get into that, let"s take a brief moment to go over the proper wire terminology. Understanding the make-up of the wire rope allows you to have a clear understanding of when the rope needs to be replaced.

Flexible steel wire rope is made up of individual wires that make up a strand; these strands are then wrapped around a central core to make up a rope.

Understanding the difference between a wire and a strand is critical. If a strand (grouping of wires) in the rope breaks, the crane wire would need to be replaced. However, if a single wire in the strand breaks, the rope itself may still be usable.

Rag & Visual Inspections: In this method, you use a rag in your inspection, pulling it slowly across the strand, stopping for a closer and more detailed inspection wherever the rag gets caught on a wire.

The Diameter Measurement Method: This method involves comparing the diameter of your rope at various intervals with the rope"s official diameter per the manufacturer"s guidelines. A variation in the rope"s diameter can alert you to potential interior damage that a visual inspection would miss.

Localized Flaw Inspections (LF) vs. Loss of Metallic Area Inspections (LMA) - Both methods use electromagnetics to search for a wire rope"s internal damage.

According to OSHA"s safety regulations, you"re required to inspect your crane"s wire ropes at least every 12 months by qualified professionals. However, OSHA and other experts also recommend inspecting your wire ropes more frequently, such as after every initial installation or repair, or daily before each shift to ensure a safe work environment.

As discussed at the very beginning of this article, we can break down wire rope into three parts. First, wires, which make up strands, and then the strands wrapped around the central core make the rope. Of your total number of wires, you never want more than 10% to be damaged before you need to look into crane wire rope replacement.

According to OSHA, only "trained personnel should carry out inspections," and according to the Crane Manufacturers Association of America, a certified crane inspector should get 2,000+ hours of field experience and training.

We at Americrane & Hoist Corporation are just the experts you need, qualified to offer OSHA inspections and provide operator safety training classes to your employees. Contact us today!

Buying new crane ropes is a detailed and thorough process. While it may be time-consuming, wire rope replacement prioritizes safety for your workers, minimizes downtime on a jobsite, maximizes the lifespan of the crane and avoids the costly and time-consuming process of getting correct rope onsite and respooling your crane.

Sometimes, it can seem like the wire rope buying process is overly complicated. This is done on purpose to avoid as many issues as possible when the new rope is installed. The reason for that is so buyers avoid putting the wrong types of ropes on cranes and unnecessarily increasing the risk of injuries to workers or damage to loads being lifted. The processes are to make sure to prevent that added risk and put the correct rope on the correct machine, per Original Equipment Manufacturer (OEM) specifications.

Wire rope specialists ask these questions to understand your circumstances and what your needs are. With this information, they are better prepared to get the absolute correct rope.

Most of the time, the customer should have access to their crane’s operations manual that will show what rope diameter and length is specified. The customer may have to measure or come up with his own calculations on length. The crane manufacturer is going to make a specific drum for that specific type of wire rope.

The rope has to be specific to the lagging of the drum for that machine, which is why there are multiple variations for each size of wire rope because each kind is specific to the type of crane, and it shouldn’t be substituted. Mazzella will only install the rope that is the correct brand and tolerance on a particular crane.

Ordering the correct crane rope will prevent crane rope damage. The wrong rope could cause damage to the equipment, and at worst, boom failure. On the less severe side, you will have bad performance or it might not work at all. You could have twist and/or spooling issues. That could lead to the crane failing altogether, which creates downtime as you wait for the correct wire rope to be ordered/delivered and installed.

Many crane owners are working for somebody else when they’re doing jobs, so if the rope doesn’t work, they’re paying for work that is not getting done and falling behind schedule.

On the more severe side, you could total your crane and/or irreparably damage the load being lifted if you use the wrong wire rope. In the worst-case scenario, using the incorrect rope could result in severe injury and/or the loss of life.

Sometimes, customers assume that there’s a one-size-fits-all replacement, that if it’s a non-rotating rope, it should work on every application. There’s a lot of misinformation on what will work and what won’t work. With our experience and access to all brands of wire rope, Mazzella guarantees we can get you the right rope for your cranes. If Mazzella isn’t comfortable with the project, we won’t supply the wire rope.

If the wrong wire rope is ordered and delivered, it could be hours or days before the correct rope is on location. Especially with a lot of the larger cranes, manufacturers are shipping model-specific ropes all over the country, and depending on location and money, that could cause delays on your jobsite.

With our large inventory of rope, Mazzella can have a new spool of wire on a truck and out for delivery in a matter of hours. Avoid the pitfalls of ordering the wrong crane rope and you’ll have a new spool of wire rope on its way. Once the order process is done, what can your company do to prepare for delivery and installation?

As much as Mazzella can be prepared on our end, the customer needs to be ready for installation so the process can go as smoothly and safely as possible.

You have to make sure the technicians have the requisite space to perform their duties. The easier it is for the installers to get on-site, get to work and finish their responsibilities, the faster your company can get back up and running.

It is a good idea to give management the proper notice of when the installer will be on-site, have the necessary technicians on-site to help the installer with the rope replacement and make sure the installer/technicians have a clear working space.

There’s a lot of downtime associated with making a mistake in the preparation process, so the more prepared you can be for the install, the better. You don’t want a situation where your crane is inactive because of an oversight or completely avoidable situation.

Also, Mazzella recommends you measure your sheaves with a sheave gauge. A sheave gauge will help you measure the wear of the root, the amount of wear on the groove wall and the diameter of the wire rope.

After ordering the correct rope and having the requisite space and approval for installation, how long will it take to remove and replace the old rope when the technician, assistants and supplies arrive onsite? For some small cranes, the timeframe could be as little as 45 minutes, but for larger cranes, removing the old rope and installing the new one could be a several-hour process.

There’s a lot of factors that go into a successful crane rope installation. The most important thing is the quicker your supplier responds to your order and gets a rope on location, the quicker that rope gets installed properly, saving time and money. Downtime is the key, and it could cost companies tens of thousands of dollars per day if their crane(s) are inoperable.

Once a new crane rope is installed, a break-in period or tension period is recommended to make sure everything is performing correctly, and help you avoid shock-loading the newly installed wire rope. The break-in period is recommended because installation and spooling equipment are not going to put adequate tension on the rope. A break-in period consists of putting a low percentage of the working load limit weight on the rope for several lift cycles, and running the blocks up to the boom length (working height) and back down. For the most specific guidelines on the breaking-in process for your new wire rope, refer to the manufacturer’s recommendations.

If a brand-new wire rope on a crane is not broken in properly before lifting a large load, it potentially could damage the rope and render useless the equipment that was just installed on your machine.

When Mazzella fulfills a crane ropes order, it is not just about the sale and the bottom line. While we’re in the business of selling crane ropes, we’re also in the business of building relationships and trust. We are committed to making sure you get the correct products for the right applications.

Crane rope issues don’t just happen 9-to-5 during the normal work week. They happen Friday nights, holidays, weekends and early mornings. They’re always on the clock, and it is just about being honest with the customer and letting them know, they type of rope that is required. That honesty and trust is of utmost importance for the safety of your workers and the proper maintenance of your cranes.

Mazzella has one of the largest crane ropes inventories in the United States. The company provides wire rope assemblies and manufactures bridge cables, crane cables, steel mill cables and thousands of OEM assemblies in sizes from ¼ to 3-inch diameter and 9 to 52 millimeter diameter, domestic and non-domestic and in stock and ready for same or next-day shipment.

Mazzella Companies can also manufacture assemblies with standard or custom end fittings. Special testing and tolerance requirements are also available when necessary.

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 a deficiency is identified, an immediate determination must be made by the qualified person as to whether the deficiency constitutes a safety hazard.

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

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

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

The importance of the wire rope that holds the hook and hoists together is often overlooked. This component is often replaced, and it is similar to why we replace car tires. Wire ropes are prone to wear as time goes on and how often they are used. The more they are used, and the heavier the load is, the faster they wear down. If the rope is maintained well, then it will last till the specified time.

If a wire rope isn’t installed correctly, it can be susceptible to damage from an external source or operated the wrong way. This is why it’s essential to

We recommend getting the wire rope or the details you need for the hoist from the original manufacturer to end up with a compatible one. Installing the new rope is also critical, as this ensures that the twists aren’t introduced and the optimal revving procedure is maintained.

When is wire rope replacement necessary? Corrosion:Corrosion is a more severe sign of damage as many stronger ropes are made from steel wires. This occurs when those wires have degraded badly and are usually the result of no lubrication care. Corrosion generally starts from the inside of the wires before it becomes visible on the outside. Rusting leads to a mild discolouration that can be resolved using lubricants and as quickly as possible. In some cases, this condition can persist and result in extreme corrosion and premature fatigue. The strands become weak, and that’s when you need to remove the rope.

Replacing the wire rope on a hoist, especially for an underhung hoist model, is essential and is determined during the load test requirements. Its manufacturer should have already tested out the rope being used on the hoist after producing it – this is a standard test carried out to ensure the quality of the completed wire rope.

Once you purchase it, the wire rope should be tested by the technician who evaluates the lowering function, lifting speed, limit switches and brake operation. These assessments are made without the lifting loads. Manufacturers may recommend this process for replacing a new wire rope. After the rope has been installed, start with a small load weight recommended by the manufacturer’s instructions. Next, run through all the lowering and lifting cycles that the rope intends to serve, then gradually move up to the full load capacity. This pattern lets the rope adjust and get seated on the hoist. After completing this break-in period, ensure that the hook block is secured. Then, disconnect the rope end for relaxing, correcting any twist or torque that may have crept in during the installation.

Wire ropes are mechanical devices that consist of moving parts working in sync to support a heavy load and move it to its desired direction. The rigging and lifting industry benefits largely from the utilities of the wire rope. Especially when they are used in overhead lifting equipment such as cranes and hoists. The wire rope is attached firmly to a hoist or crane, and the load is fitted using swivels, hooks, or shackles, facilitating controlled movement. It is used in many applications to support suspension towers or bridges and lower or lift elevators.

Wire ropes have become the preferred lifting device in many industrial applications. It has its fair share of reasons as well. Firstly, the unique design allows flexibility, strength, and the ability to handle bending stresses. Depending on the rope"s material, wire, and strand structure, it will provide different sets of benefits for the specific application it is used in.

Selecting the right wire rope for the right application is a process that involves careful thought. Thoughts involving proper analysis of the above aspects of the wire rope and the particular lifting application is required.

The following factors might prove to be impactful in damaging or breaking a wire rope. Wear and tear on areas that are directly in contact with drums and hoist sheaves.

Lack of proper lubrication and heat exposure leading to corrosion. At temp beyond 120 degrees Celsius, a fibre core wire rope will give way and break.

Improper installations are also a common issue that can cause the wire rope to break. Improper installation kinks create a weak section in the rope, which is exploited with prolonged use.

A finished wire rope is comprised of individual wires, make up individual strands, which are then laid in a helical pattern around a synthetic or steel core.

Wires are the smallest component of wire rope and they make up the individual strands in the rope. Wires can be made from a variety of metal materials including steel, iron, stainless steel, monel, and bronze. The wires can be manufactured in a variety of grades that relate to the strength, resistance to wear, fatigue resistance, corrosion resistance, and curve of the wire rope. Selecting the proper wire rope for your application is essential to long-lasting performance in a wire rope.

Strands of wire rope consist of two or more wires arranged and twisted in a specific arrangement. The individual strands are then laid in a helical pattern around the core of the rope. Strands made of larger diameter wires are more resistant to abrasion, while strands made of smaller diameter wires are more flexible.

The core of a wire rope runs through the center of the rope and supports the strands and helps to maintain their relative position under loading and bending stresses. Cores can be made from a number of different materials including natural or synthetic fibers and steel.

Lubrication is applied during the manufacturing process and penetrates all the way to the core. Wire rope lubrication has two primary benefits:Reduces friction as the individual wires and strands move over each other,

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Rope diameter is specified by the user and is generally given in the equipment manufacturer’s instruction manual accompanying the machine on which the rope is to be used.

Rope diameters are determined by measuring the circle that just touches the extreme outer limits of the strands— that is, the greatest dimension that can be measured with a pair of parallel-jawed calipers or machinist’s caliper square. A mistake could be made by measuring the smaller dimension.

The right way to unreel.To unreel wire rope from a heavy reel, place a shaft through the center and jack up the reel far enough to clear the floor and revolve easily. One person holds the end of the rope and walks a straight line away from the reel, taking the wire rope off the top of the reel. A second person regulates the speed of the turning reel by holding a wood block against the flange as a brake, taking care to keep slack from developing on the reel, as this can easily cause a kink in the rope. Lightweight reels can be properly unreeled using a vertical shaft; the same care should be taken to keep the rope taut.

The wrong way to unreel.If a reel of wire rope is laid on its flange with its axis vertical to the floor and the rope unreeled by throwing off the turns, spirals will occur and kinks are likely to form in the rope. Wire rope always should be handled in a way that neither twists nor unlays it. If handled in a careless manner, reverse bends and kinks can easily occur.

The right way to uncoil.There is only one correct way to uncoil wire rope. One person must hold the end of the rope while a second person rolls the coil along the floor, backing away. The rope is allowed to uncoil naturally with the lay, without spiraling or twisting. Always uncoil wire rope as shown.

The wrong way to uncoil.If a coil of wire rope is laid flat on the floor and uncoiled by pulling it straight off, spirals will occur and kinking is likely. Torsions are put into the rope by every loop that is pulled off, and the rope becomes twisted and unmanageable. Also, wire rope cannot be uncoiled like hemp rope. Pulling one end through the middle of the coil will only result in kinking.

Great stress has been placed on the care that should be taken to avoid kinks in wire rope. Kinks are places where the rope has been unintentionally bent to a permanent set. This happens where loops are pulled through by tension on the rope until the diameter of the loop is only a few inches. They also are caused by bending a rope around a sheave having too severe a radius. Wires in the strands at the kink are permanently damagedand will not give normal service, even after apparent “re-straightening.”

When wire rope is wound onto a sheave or drum, it should bend in the manner in which it was originally wound. This will avoid causing a reverse bend in the rope. Always wind wire rope from the top of the one reel onto the top of the other.Also acceptable, but less so, is re-reeling from the bottom of one reel to the bottom of another. Re-reeling also may be done with reels having their shafts vertical, but extreme care must be taken to ensure that the rope always remains taut. It should never be allowed to drop below the lower flange of the reel. A reel resting on the floor with its axis horizontal may also be rolled along the floor to unreel the rope.

Wire rope should be attached at the correct location on a flat or smooth-faced drum, so that the rope will spool evenly, with the turns lying snugly against each other in even layers. If wire rope is wound on a smooth-face drum in the wrong direction, the turns in the first layer of rope will tend to spread apart on the drum. This results in the second layer of rope wedging between the open coils, crushing and flattening the rope as successive layers are spooled.

A simple method of determining how a wire rope should be started on a drum. The observer stands behind the drum, with the rope coming towards him. Using the right hand for right-lay wire rope, and the left hand for left lay wire rope, the clenched fist denotes the drum, the extended index finger the oncoming rope.

Clips are usually spaced about six wire rope diameters apart to give adequate holding power. They should be tightened before the rope is placed under tension. After the load is placed on the rope, tighten the clips again to take care of any lessening in rope diameter caused by tension of the load. A wire rope thimble should be used in the eye of the loop to prevent kinking.

U-bolt Clips.There is only one correct method for attaching U-bolt clips to wire rope ends, as shown in TheRightWayimage below. The base of the clip bears on the live end of the rope; the “U” of the bolt bears on the dead end.

Compare this with the incorrect methods. Five of the six clips shown are incorrectly attached—only the center clip in the top view is correct. When the “U” of the clip bears on the live end of the rope, there is a possibility of the rope being cut or kinked, with subsequent failure.

Proper seizing and cutting operations are not difficult to perform, and they ensure that the wire rope will meet the user’s performance expectations. Proper seizings must be applied on both sides of the place where the cut is to be made. In a wire rope, carelessly or inadequately seized ends may become distorted and flattened, and the strands may loosen. Subsequently, when the rope is operated, there may be an uneven distribution of loads to the strands; a condition that will significantly shorten the life of the rope.

Either of the following seizing methods is acceptable. Method No. 1 is usually used on wire ropes over one inch in diameter. Method No. 2 applies to ropes one inch and under.

Method No. 1: Place one end of the seizing wire in the valley between two strands. Then turn its long end at right angles to the rope and closely and tightly wind the wire back over itself and the rope until the proper length of seizing has been applied. Twist the two ends of the wire together, and by alternately pulling and twisting, draw the seizing tight.

The Seizing Wire. The seizing wire should be soft or annealed wire or strand. Seizing wire diameter and the length of the seize will depend on the diameter of the wire rope. The length of the seizing should never be less than the diameter of the rope being seized.

Proper end seizing while cutting and installing, particularly on rotation-resistant ropes, is critical. Failure to adhere to simple precautionary measures may cause core slippage and loose strands, resulting in serious rope damage. Refer to the table below ("Suggested Seizing Wire Diameters") for established guidelines. If core protrusion occurs beyond the outer strands, or core retraction within the outer strands, cut the rope flush to allow for proper seizing of both the core and outer strands.

The majority of wire rope problems occurring during operation actually begin during installation, when the rope is at its greatest risk of being damaged. Proper installation procedures are vital in the protection and performance of wire rope products.

Until the rope is installed it should be stored on a rack, pallet or reel stand in a dry, well-ventilated storage shed or building. Tightly sealed and unheated structures should be avoided as condensation between rope strands may occur and cause corrosion problems. If site conditions demand outside storage, cover the rope with waterproof material and place the reel or coil on a support platform to keep it from coming directly in contact with the ground.

While lubrication is applied during the manufacturing process, the wire rope must still be protected by additional lubrication once it is installed. Lubricants will dry out over a period of time and corrosion from the elements will occur unless measures are taken to prevent this from happening. When the machine becomes idle for a period of time, apply a protective coating of lubricant to the wire rope. Moisture (dew, rain, and snow) trapped between strands and wires will create corrosion if the rope is unprotected. Also apply lubricant to each layer of wire rope on a drum because moisture trapped between layers will increase the likelihood of corrosion.

Always use the nominal diameter as specified by the equipment manufacturer. Using a smaller diameter rope will cause increased stresses on the rope and the probability of a critical failure is increased if the rated breaking strength does not match that of the specified diameter. Using a larger diameter rope leads to shorter service life as the rope is pinched in the sheave and drum grooves which were originally designed for a smaller diameter rope. Just as using a different diameter rope can create performance problems, so can the use of an excessively undersized or oversized rope.

Measure the wire rope using a parallel-jawed caliper as discussed in Measuring Rope Diameter at the top of this page. If the rope is the wrong size or outside the recommended tolerance, return the rope to the wire rope supplier. It is never recommended nor permitted by federal standards to operate cranes with the incorrect rope diameter. Doing so will affect the safety factor or reduce service life and damage the sheaves and drum. Note that in a grooved drum application, the pitch of the groove may be designed for the rope’s nominal diameter and not the actual diameter as permitted by federal standards.

Wire rope can be permanently damaged by improper unreeling or uncoiling practices. The majority of wire rope performance problems start here.Improper unreeling practices lead to premature rope replacement, hoisting problems and rope failure.

Place the payout reel as far away from the boom tip as is practical, moving away from the crane chassis. Never place the payout reel closer to the crane chassis than the boom point sheave. Doing so may introduce a reverse bend into the rope and cause spooling problems. Follow the guidelines highlighted under Unreeling and Uncoiling and Drum Winding. Take care to determine whether the wire rope will wind over or under the drum before proceeding. If the wire rope supplier secured the end of the rope to the reel by driving a nail through the strands, ask that in the future a U-bolt or other nondestructive tie-down method be used; nails used in this manner damage the rope.

Take extra precaution when installing lang lay, rotation-resistant, flattened strand or compacted ropes. Loss of twist must be avoided to prevent the strands from becoming loosened, causing looped wire problems.

The end of the rope must be securely and evenly attached to the drum anchorage point by the method recommended by the equipment manufacturer. Depending on the crane’s regulatory requirements, at least two to three wraps must remain on the drum as dead wraps when the rope is unwound during normal operations. Locate the dead end rope anchorage point on the drum in relation to the direction of the lay of the rope. Do not use an anchorage point that does not correspond with the rope lay. Mismatching rope lay and anchorage point will cause the wraps to spread apart from each other and allow the rope to cross over on the drum. Very gappy winding will occur resulting in crushing damage in multilayer applications.

Back tension must be continually applied to the payout reel and the crewman installing the rope must proceed at a slow and steady pace whether the drum is smooth or grooved.Regardless of the benefits of a grooved drum, tension must be applied to ensure proper spooling. An improperly installed rope on a grooved drum will wear just as quickly as an improperly installed rope on a smooth drum. If a wire rope is poorly wound and as a result jumps the grooves, it will be crushed and cut under operating load conditions where it crosses the grooves.

Every wrap on the first or foundation layer must be installed very tightly and be without gaps. Careless winding results in poor spooling and will eventually lead to short service life. The following layers of rope must lay in the grooves formed between adjacent turns of the preceding layer of rope. If any type of overwind or cross-winding occurs at this stage of installation and is not corrected immediately, poor spooling and crushing damage will occur.

On a multilayer spooling drum be sure that the last layer remains at least two rope diameters below the drum flange top. Do not use a longer length than is required because the excess wire rope will cause unnecessary crushing and may jump the flange. Loose wraps that occur at any time must be corrected immediately to prevent catastrophic rope failure.

The use of a mallet is acceptable to ensure tight wraps, however a steel-faced mallet should be covered with plastic or rubber to prevent damage to the rope wires and strands.

Rotation-resistant ropes of all constructions require extra care in handling to prevent rope damage during installation. The lay length of a rotation-resistant rope must not be disturbed during the various stages of installation. By introducing twist or torque into the rope, core slippage may occur—the outer strands become shorter in length, the core slips and protrudes from the rope. In this condition the outer strands become over- loaded because the core is no longer taking its designed share of the load. Conversely, when torque is removed from a rotation-resistant rope core slippage can also occur. The outer strands become longer and the inner layers or core become overloaded, reducing service life and causing rope failure.

The plain end of a wire rope must be properly secured. If the entire cross section of the rope is not firmly secured, core slippage may occur, causing the core to pull inside the rope’s end and allowing it to protrude elsewhere, either through the outer strands (popped core) or out the other end of the line. The outer layer of the outside strands may also become overloaded as there is no complete core-to-strand support.

Secure the ends of the rope with either seizing or welding methods as recommended under Seizing Wire Rope. It is imperative that the ends be held together tightly and uniformly throughout the entire installation procedure, including attaching the end through the wedge socket and the drum dead end wedge

When installing a new line, connect the old line to the new line by using a swivel-equipped cable snake or Chinese finger securely attached to the rope ends. The connection between the ropes during change-out must be very strong and prevent torque from the old rope being transferred into the new rope.Welding ropes together or using a cable snake without the benefit of a swivel increases the likelihood of introducing torque into the new rope. A swivel-equipped cable snake is not as easy as welding the ropes, but this procedure can be mastered with a little patience and practice.

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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.

Although every effort is made to ensure the accuracy, currency and completeness of the information, CCOHS does not guarantee, warrant, represent or undertake that the information provided is correct, accurate or current. CCOHS is not liable for any loss, claim, or demand arising directly or indirectly from any use or reliance upon the information.

Sheaves facilitate the smooth and safe operation of overhead crane hoists. Damaged sheaves can wear ropes prematurely and cause other dangerous hazards, such as binding wire rope. Konecranes technicians are trained to identify and correct problems with sheaves and other parts of hoisting equipment.

Sheaves carrying ropes which can be momentarily unloaded shall be provided with close-fitting guards or other suitable devices to guide the rope back into the groove when the load is applied again.

The sheaves in the bottom block shall be equipped with close-fitting guards that will prevent ropes from becoming fouled when the block is lying on the ground with ropes loose.

In using hoisting ropes, the crane manufacturer"s recommendation shall be followed. The rated load divided by the number of parts of rope shall not exceed 20 percent of the nominal breaking strength of the rope.

Rope clips attached with U-bolts shall have the U-bolts on the dead or short end of the rope. Spacing and number of all types of clips shall be in accordance with the clip manufacturer"s recommendation. Clips shall be drop-forged steel in all sizes manufactured commercially. When a newly installed rope has been in operation for an hour, all nuts on the clip bolts shall be retightened.

Wherever exposed to temperatures, at which fiber cores would be damaged, rope having an independent wirerope or wire-strand core, or other temperature-damage resistant core shall be used.

Replacement rope shall be the same size, grade, and construction as the original rope furnished by the crane manufacturer, unless otherwise recommended by a wire rope manufacturer due to actual working condition requirements.

Konecranes wire rope inspections can help crane users extend the life of hoist ropes. Ropes, sheaves and other reeving system components are inspected for compliance with crane standards, and to determine if they have flaws that could hinder safe operation. Contact us today to schedule an assessment.

*The foregoing OSHA regulations are not intended to be a comprehensive overview of all applicable regulations pertaining to the designated topic. State laws may mandate different safety and maintenance standards. Accordingly, please consult applicable state laws as well as original equipment manufacturer specifications for further guidance. The statements and descriptions contained herein constitute the opinion/recommendation of the seller and are not intended to create any express warranties.

They can be compared to tires on a car. Wire ropes are prone to wear and tear over time and with continued use. The more often they’re used and the heavier their loads, the sooner they wear. They should last their full expected life if they are properly maintained. However, it’s important to note that wire ropes are susceptible to being ruined due to improper installation or external damage caused by improper operation. Continue reading to find out more about replacing hoist wire ropes.

Using a generic wire rope to replace a damaged or worn rope can be dangerous because the rope being replaced may already be the wrong size or type if it isn’t the original rope. It’s also important to mention that identifying the correct type, size, and length of wire rope needed can be tricky.

Replacement wire ropes should be purchased or sourced from the original manufacturer to ensure that the correct rope is being used for the hoist. The installation of the wire rope is a crucial task. Whoever installs the new wire rope needs to be sure no twists are introduced into the rope while maintaining the hoist’s proper reeving.

Load test requirements are excluded when it comes to the replacement of wire rope or chain for underhung hoists. This is because the manufacturer should have already tested the wire rope or chain during the production process. To properly check lifting and lowering function, brake operation, and to check limiting devices, the technician should perform a test without a load attached. Breaking in the rope beforehand is recommended by some wire rope manufacturers. Once the rope has been installed, and a light load has been attached (following manufacturer’s recommendations), it’s recommended that you run through 20-25 lifting and lowering cycles at a reduced speed, gradually increasing the weight up to full capacity if possible. Doing this will allow the rope to adjust and properly seat itself. After this procedure is followed to break in the wire rope, secure the hook block and disconnect the rope end to relax or correct any possible torque or twists that may have developed during the new installation and break-in.

Replacing hoist wire ropes can be a daunting task, from selecting the correct type, size, and length of wire rope, to the actual installation process. However, it doesn’t have to be.Silver State Wire Rope and Riggingis here to provide you and your company with comprehensive wire rope and rigging solutions. Our professional and knowledgeable staff can help you with the entire process of replacing hoist wire ropes.Contact ustoday.