rotation resistant wire rope inspection pricelist

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.

Wire rope is a preferred lifting device for many reasons. Its unique design consists of multiple steel wires that form individual strands laid in a helical pattern around a core. Wire rope comes in a variety of strand patterns including single layer, filler wire, seale, warrington, and combination. Wire rope strands can be laid around the core in different configurations including regular lay wire rope, lang lay wire rope, and alternate lay wire rope. There also many types of grades of wire rope, including: improved plow steel (IPS), extra improved plow steel (EIPS), and extra extra improved plow steel (EEIPS). Some types of wire rope is preferred over others due to the unique properties, including: rotation resistant wire rope, compacted strand wire rope, swaged wire rope, plastic coated wire rope, plastic impregnated (PI) wire rope.

Using the rope to its maximum fatigue life will cause the rope to deteriorate from the inside out. Sudden rope failures may be the result. For this reason we do not recommend this construction for tower cranes. There have been fatal and catastrophic accidents involving this rope construction because of undetected inner rope fatigue.

However, mobile and truck mounted cranes are operated on a much less severe duty cycle and it is not expected that 19x7 has to be replaced because of inner rope fatigue but because of other mechanical damages. Keep in mind that this statement covers normal mobile crane use. If you use a mobile crane like a production crane you WILL experience the above mentioned danger situations.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

19x7 wire rope is recommended for hoisting unguided loads with a single-part line. The rotation-resistant properties of this rope are superior to those of the 8x19 class wire ropes, and are secured by two layers of strands. The inner strands are left lay, while the 12 outer strands are right lay, which enables one layer to counteract the other layer’s rotation.

Galvanized wire rope (steel) features a compressed zinc coating for providing excellent corrosion resistance. With a higher break strength, yet lower price than stainless steel wire rope, galvanized steel wire rope is widely used in general engineering applications such as winches and security ropes.

The bright class of industrial wire rope is produced without a surface treatment—making the rope less likely to untwist or kink while giving it a stronger crush resistance than lay ropes. Generally, they are fully lubricated to protect the rope from rust and corrosion. Also available in USA-made.

There are a variety of cables and wires that are used for various purposes. They can either be hidden underground or pass overhead. Crane Cable is one such cable wire rope made out of several strands of metal wires that are twisted together into a helix form to make them into a single rope. Initially, wrought iron was used to make these Crane Cables however, these days steel is the primary material used. Apart from this high carbon steel and galvanized steel are also used in manufacturing these cables. Dents or flaws in the ordinary link chain can lead to severe failure whereas, damage in these EOT Crane Cablecan be easily covered up. Ther are ideally used for lifting elevators, in the transmission of mechanical power, and in cranes.

Crane Lifting Cables are resistant to corrosion and have excellent ductility for optimal fatigue. They have a high breaking strength compared to steel crane wire rope. The radially elastic rope structure absorbs the dynamic force thus giving it high impact resistance. Crane Cable Wires are said to be cost-effective as a strong and durable structure helps in reducing maintenance costs and downtime. They can be coated with bright phosphate or galvanized depending upon the customers’ requirements.

Crane Electrical Cable is available in rotating, rotation, compact, or non-compact structures. Most of the wire ropes have the tendency of developing torque and are thus prone to rotation. However, non-rotation wires are designed in a way that their outer rotation naturally counteracts the inner strands rotation. Crane Hoist Cable can be used in tower crane ropes or offshore crane ropes.

Overhead Crane Cable reel should be capable of winding it automatically. The drive torque of the crane cable should not be less than the max winding torque of the winding crane cable. The cable conductor should be as small as possible when the Crane Rope laying acts on the traction force.

The Crane Wire Rope does not have a reinforcement core, the maximum tension allowed on the copper conductor cross-section is 20N/mm2. We at Bhuwal Insulation Cable Pvt. Ltd. not only provide you the best quality Tower Crane Cable but also the parts required to assemble them. Our long-standing reputation in providing the best quality product at a competent price has made us one of the leading Crane Cable manufacturers in India.

Cables or cords are the wire ropes which have diameters smaller than 3/8 inches, While wire ropes have diameters greater than 3/8 inches. if there are two or more wire concentrically laid then it is known as strand

Warrington: Two layers of wires around a center with one diameter of wire in the inner layer and two diameters of wire alternating large and small in the outer later

6 by 19 is a type of wire rope which can withstand fatigue resistance, abrasion and prevents crushing on drums. it is available in diatmeter range of 3mm to 6 mm. While 7 by 19 are wire rope which has diameters ranging between 3 mm to 16 mm which can be use in different applications.

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.