overhead crane wire rope inspection for sale

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.

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.

Based in St. Louis, Missouri, Tri-State Rigging Equipment is your one stop shop for all local crane, rigging, and fall protection repair, service and inspection. We employ 19 full time service techs who are experts at inspecting and repairing cranes, hoists and rigging equipment. Since we also fabricate and install cranes, our service techs have a wholistic knowledge of how cranes and rigging equipment function together.

Tri-State Rigging Equipment not only provides service and repair for overhead cranes, rigging equipment, and fall protection, but we are also a Master Parts Distributor for all overhead cranes and rigging equipment. We have been in the material handling industry for over 55 years and have gained extensive knowledge on the functionality of overhead cranes, rigging equipment and fall protection. We have also developed valuable relationships with many manufacturers so that we can offer our customers the best service possible. Some of the services we provide are:

Tri-State Rigging Equipment is the premier overhead crane, rigging equipment and fall protection service provider near you. We have a 24-hour emergency service hotline to always keep you up and running. Top tier customer service is what we have built our company on so give our service team a call for any and all questions regarding, crane inspections, crane repair, hoist repair, rigging inspections, and more.

For overhead cranes you must comply with OSHA 1910.179. OSHA requires that all top running overhead cranes be inspected every month, including the hook, wire rope and chains. These monthly inspections are required to have documentation with a certification record.

Underrunning cranes on the other hand need to be inspected for safety purposes but do not require documentation. Per OSHA and ASME standards all our inspectors are “qualified persons” and have the knowledge and training to properly conduct an OSHA overhead crane inspection.

Since we also fabricate overhead cranes, our 19 crane service techs can look beyond the failed component to identify issues others would miss. They know how the systems are installed, inspected, and fabricated, making them experts at solving both simple, and the most complex crane issues.

All rigging equipment must go through three different types of inspections to satisfy OSHA and ASME standards. These inspections are first, an Initial Inspection (prior to first use), second a Frequent Inspection (daily or before use), and third a Periodic Inspection (minimum every 12 months).

There are a lot of reasons it is important to use a third-party rigging inspection service. First, a fresh set of eyes will always help identify potential hazards that workers wouldn’t notice because they see it every day. Second, it allows employers to shift some of the responsibility and liability away from themselves and onto the third-party inspection service provider. Lastly, here at Tri-State Rigging Equipment our rigging inspectors are experts when it comes to OSHA and ASME standards. We can save you time and money by implementing a lifting and rigging compliance program, including reminding you when an inspection deadline is approaching.

It is important to note that the purpose of rigging inspections is not to get you in trouble, but rather to keep you out of trouble. The cost of an accident can quickly get out of control if you do not have the proper rigging and lifting compliance program in place. Lastly and most importantly, rigging inspections are meant to keep you and your coworkers safe.

Wire ropes are complex machines with a great many moving parts. They require attention, skilled operators, careful maintenance, inspection and lubrication.

In spite of their vital importance, wire ropes are frequently treated as and considered low-tech commodities. Failures are frequently accepted as “inevitable.”

With the appropriate inspections, wire rope failures can be predicted, and expenses and losses reduced. Consider that the price tag of rope failures can easily be in the seven or even eight digit range, and the cost of an inspection is marginal.

Much more dependable than visual inspections, magnetic rope testing (MRT) is a reliable non-destructive evaluation/examination (NDE) procedure used for the in-service inspection of wire ropes. NDE methods allow the detection and evaluation of external as well as internal rope deterioration. This allows the inspection of a rope’s entire cross-section to the core. MRT drastically increases wire rope safety. At the same time, it promises significant annual savings.

Ropes usually degrade internally with no visible indications. Internal deterioration modes include inter-strand nicking that will eventually develop into clusters of internal broken wires and corrosion including corrosion pitting.

External deterioration includes winding-on-drum damage. Urgently needed, suitable inspection equipment and procedures are now available – especially for the quantitative characterization of internal rope deterioration.

Ensure that you have the right lift equipment for your worksite or warehouse by relying on the team at ProTek Crane Solutions. We provide complete crane sales, repairs, and inspections to our various clients throughout the area. Whether you are looking for bridge cranes, chain hoists, rigging equipment, or control equipment, our sales team will help you find the products that you need for your business.

Once you have your crane equipment set up, our crane inspection experts will ensure that your machinery complies with OSHA codes and standards and that it is safe to operate. And if there are any issues with your equipment, our skilled technicians will efficiently handle any repairs to get your crane up and running again. Contact us today to learn more about our sales, inspections, and repairs or to discuss your company"s equipment needs with our team.

ProTek Crane Solutions is a team of dedicated professionals that strive daily to find new and innovative technology and best practices to improve the safety, reliability and productivity in the overhead crane industry. Our promise to continually improve shall never waiver as we strive to be the service provider the industry has to offer!

ProTek Crane Solutions is dedicated to excellence in the service we provide. Ensuringthe safety of your equipment with a prompt and reliable response is our guarantee.

ProTek Crane Solutions is dedicated to excellence in the service we provide. Ensuring the safety of your equipment with a prompt and reliable response is our guarantee.

“Running rope in service shall be visually inspected daily, unless a qualified person determines it should be performed more frequently. The visual inspection shall consist of observation of all rope that can reasonably be expected to be in use during the day’s operations. The inspector should focus on discovering gross damage that may be an immediate hazard.”

For more than 65 years, Mazzella has provided ideal lifting solutions to customers in all types of industries. Mazzella supports construction, mining, manufacturing, automotive, steel, and energy companies with all of their rigging, wire rope, and overhead lifting needs. We offer all styles of slings, rigging hardware, wire rope, overhead cranes, overhead crane service, hoists, and engineered lifting devices. We also provide training, in-field inspection, and repair services that support our products.

Mazzella supports Atlanta and Northern Georgia from three of our Southeast locations (Charlotte, NC; Chattanooga, TN; and Birmingham, AL)—all within 3-hours and available to ship stocked standard wire rope, lifting slings, and rigging hardware same day. The Mazzella name is synonymous with quality slings—from the customer favorite Mazzella 7-Part™ to the high performance synthetic Twin-Path® product line. We can manufacture any sling to meet your needs, including:Welded and Mechanical Alloy Chain

Additionally, we stock well over 26 million feet of wire rope for making assemblies—both large and small—for bridge cables, crane cables, steel mill cables, and OEM assemblies.

With construction, precast, and manufacturing continuing to drive much of the economic growth in the Atlanta, Columbus, and Macon markets, Georgia business owners understand they have to continue to invest in reliable equipment that will help drive production and continue to grow their business. Partnering with Mazzella provides you with a single-source for your overhead lifting needs. Whether you need replacement wire rope or cables for your construction cranes, an overhead crane or rigging inspection to satisfy OSHA requirements, or crane operator and rigging training for your employees, Mazzella can help keep your projects on schedule, your production up and running, and help to keep you OSHA/ASME compliant.

We offer competitive pricing and have a large inventory of domestic and import wire rope and rigging equipment from all of the major players, including:Crosby

We also engineer and fabricate overhead cranes and custom lifting devices for complicated or challenging lifts. We have dedicated technicians that offer inspections and repairs for most of the overhead lifting and rigging products we sell. If you have a crane, hoist, or rigging equipment in your facility, we can get you replacement parts, inspect your equipment to satisfy industry requirements, and train your employees on best practices for how to properly use it.

Mazzella FHSoperates out of Duluth, GA and provides scheduled or emergency overhead crane service to all of Georgia—including Macon, Augusta, Columbus, LaGrange, Dalton, and Atlanta. We offer our customers the following services:Crane and hoist maintenance

Our service technicians are independently trained and certified for expert maintenance and repair to keep your overhead crane equipment running. Our techs specialize in solving complex problems in emergency situations. We strive to minimize your downtime and our technicians are available 24 hours a day, 7 days a week.

Mazzella FHS sets the standard in inspection documentation management. Our online reporting system continuously archives your OSHA inspection reports and allows you to instantly access them through our website. Our Inspection Division works daily to keep your investment safe.

As a stocking parts distributor for most major hoist manufacturers, Mazzella FHS can quickly respond to your needs. Our Parts Department Service Representatives are on hand and ready to serve you with a high sense of urgency. We understand the importance of keeping your production flowing so we service and stock replacement parts for all makes and models of cranes and hoists.

Additionally, we stock wire rope and high-performance crane ropes at our various locations in sizes from 1/4″ to 3″ diameter and 9mm to 52mm diameter. We stock both domestic and non-domestic rope products ready for same or next day shipment from one of our many southeastern service centers.

We also employ certified technicians who can perform an in-field poured socket replacement for your high-performance crane rope. We come to you with all of the tools and equipment necessary and will get your crane up and running in no time!

We offer replacement high-performance crane ropes and cables for mobile cranes, crawler cranes, tower cranes, and overhead cranes. We partner with the premier rope manufacturers in the industry, including:Bridon

For custom and critical heavy-lift applications, Mazzella can design and fabricate a custom below-the-hook lifting device specific for your overhead lifting project. We supply spreader beams, lifting beams, lifting baskets, coil hooks, vacuum lifters, magnetic lifters and other custom lifters.

With three locations in Birmingham, Charlotte, and Chattanooga, and a distribution center in Memphis, Mazzella has one of the largest inventories of wire rope, slings, hoists, hoist parts, pullers, rigging hardware, and tiedown / load securement products to support North Georgia. Mazzella offers competitive pricing and excellent service for all of our product offerings and we ship our stock items within 24 hours of your order.

Mazzella employs certified inspectors that can provide documented rigging inspections that meet or exceed government requirements (OSHA and ASME). We also provide personal fall protection inspections, inspections of below-the-hook lifting devices, and basic level NDT inspections to support our visual inspections.

If your employees require specific training programs for OSHA compliance for overhead cranes, slings, hoists, or rigging hardware, we can assist in creating a safe and reliable workplace. Our trainers are accredited through Industrial Training International, Inc. (ITI) and train to OSHA and ASME standards.

It’s useful to understand where you’ve been before deciding where you want to go. Our history has served as a foundation of who we are, what we believe and what we value. Back in 1954, James Mazzella formed a business in Cleveland, Ohio by providing the most basic of lifting devices; wire rope slings that were braided by hand. It wasn’t the cleanest and certainly not the easiest job around – but it was fundamental to the industry. This gut-level standard of performance defined the company in 1954 and it defines the company to this day.

Some of our capabilities include:In-house engineering and fabrication of light-duty to heavy-duty overhead crane systems and custom below-the-hook lifting devices

Over 2 million feet of wire inventory—complete with reels of ropes in all sizes and configurations—from every major manufacturer—for any overhead crane, hoist, mobile crane, or specialty application

We stock a large variety of rigging gear and hardware. Our in-house services include inspection, test, and certifying of slings and rigging gear. We also offer on-site inspection of rigging, of rolex replica slings and rigging gear, on-site inspection of rigging, and pickup and delivery. We can have any of our experienced sales staff go on-site and assist with determining the best way to handle your lifting needs. We also offer an on site class on proper rigging gear inspection.

Harrington Hoists is recognized as an innovator and market leader in the hoist and crane industry. Harrington Hoists and Cranes manufactures revolutionary manual, electric, and air chain hoists, wire rope hoists and overhead crane products. TSOC is a Harrington wire rope Hoist distributor and we carry a full line of world class Harrington Wire Rope Hoists, including the RH, RH-Advantage and RY models, available in capacities ranging from 2 Ton to 20 Ton.

Harrington"s RH-Advantage electric wire rope trolley hoists have a space saving design and are built for quality. The RH-Advantage has an ultra-low headroom configuration which provides the lowest headroom possible.

Tri-State Overhead Crane is your reliable Harrington Hoist distributor. TSOC sells, services and provides parts for Harrington wire rope hoists; serving clients from coast to coast, Canada, Mexico and especially focused in Missouri, Illinois, Indiana, Iowa, Kansas, Nebraska, Arkansas, Mississippi, Tennessee, Kentucky, South Carolina, Florida, and Oklahoma.

(1) 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.

(A) 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.

(1) 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.

(2) In rotation resistant ropes: Two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters.

(3) 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.

(i) 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:

(B) 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.

(ii) 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:

(A) 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),

(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 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.

(B) 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.

(iv) 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.

(2) 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.

(3) 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.

(1) 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).

(ii) 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:

(iii) 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.

(B) 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.

(ii) 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.

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

Mid-America Rigging has an online asset tracking system for your purchases. This is a great way to manage your slings and products by being able to remotely access proof testing certificates, inspection results, certificates of compliance, as well as easy reordering.

As the name suggests Electric Wire Rope Hoist utilizes Electricity to lift heavy workloads which are beyond human capacity. The Phenomenon lift loads by wrapping a cable around a grooved drum and then the load is attached to a hoist by the means of a lifting hook.

Electric Wire Rope Hoist is an invaluable asset for lifting and lowering a high amount of weight and reducing the efforts no matter what its unit is it can payback many times the investment made on it due to its efficiency for lifting purposes.

Electric Wire Rope Hoists are commonly seen at manufacturing units, large-scale factories, and construction sites. It gives workers a helping hand and makes their work hassle-free.

Electric Wire Rope Hoists shortens the Amount of work time for a certain period which takes hours and days to complete. They are simple and easy to use solution which will increase the productivity in your operation.

Electric Wire rope hoist is a fast speed lifting equipment in comparison to Electric Chain hoist. The lifting mechanism of the Electric Wire rope hoist is driven by a motor to complete the lifting action of the wire rope drum.

Electric Wire rope hoists use wire to lift which is wrapped around a grooved drum they move load slightly laterally and not precise or accurate in lifting. Although the lateral movement is negligible.

These hoists are made to carry heavy objects in a variety of conditions like heat, furnaces, and over the burners. These hoists can lift ranging from pounds to tones. But at the same time, it is required to maintain proper safety measures to ensure the safety of the Hoist, load, and the operator.

Electric Wire Rope Hoists are made using strands and wires which assures the spreading of pressure, stress, and weight on the overall length rather than being distributed on a single strand alone which decreases the chances of breaking factor.

Even if one of the strands breaks, there are chances that the lifting work will be completed without any problems. But a professional would suggest not to use the wire rope which has suffered any such issue but still the current operation can be completed irrespective of the broken strand. So always consider the rope material, wire, and strand structure as they go through more wear and tear than they are subjected to.

Electric Wire Rope hoists come with an instruction guide where you will have all the operating information. There are a few checks which are suggested to perform you put Electric Wire Rope hoist into use.

Wire Rope: – 6×37 construction which is a special flexible steel wire rope, having a safety factor of 6 for class-II and 7 for class-II duty cycle is provided on the hoist.

Rope Drum: – Main component is the rope drum which is made of sturdy seamless pipe or fabricated from steel plated and is grooved to take the full lift without over-winding.

Limit Switch: – To avoid over winding of wire rope, limit switches are provided with each hoist, which ensures the highest and lowest position of the load hook.

If you do not pay attention to the inspection and maintenance of the wire rope when using the crane in normal times, it is easy to cause the wire rope to break due to negligence and cause catastrophe. In daily use, attention should be paid to damages such as broken wires, abrasion, and deformation of the wire rope. Our editor will share with you the requirements and standards for wire rope inspections and the scrap standards for hoisting wire ropes.

Broken wire: Broken wires are divided into inner broken wires and outer broken wires. The steel wire that admits that the cracks or scars have reached half the diameter of the steel wire shall be regarded as broken wires.

Corrosion: Check the degree of rust, pitting, and curium corrosion. It is difficult to check the appearance of internal corrosion. When the steel wire is severely slack, it should be regarded as internal corrosion.

Rope end fastening parts: check the defects of the pressure block, cracks, and deformation of the rope end to see if some of the fixed rope ends are pulled out or slipped.

The number of broken wires in a lay length (referring to the axial interval in which any wire rope strand is coiled for one week) of the twisted wire rope reaches 10% of the total wire number of the rope.

For steel wire ropes for lifting hot metal or dangerous goods, the number of scrapped wires and broken wires is half of that of ordinary cranes. For example, the broken wires will occur in some places, or the broken wires will occur in one strand within six times the diameter of the wire rope. , Should be voided according to half of the rule in item 1.

There are cracks or slipping deformation at the joint between the steel wire rope and the aluminum alloy; the insertion part of the inserted braided steel wire rope has severe withdrawal; the casting wire rope anchorage and the connection part of the wire rope have displacement, causing the phenomenon of withdrawal.

There is abrasion or corrosion on the surface of the wire rope, and there are a certain number of broken wires. The number of broken wires should be multiplied by the reduction factor in the rules of item 1 or 2 to determine: when the wear or corrosion rate is 10%, 15 %, 20%, 30%-40%, the reduction factor corresponds to 85%, 75%, 70%, 60%, 50%.

The wire rope bumps, jumps out of the pulley, entangled messy, etc. will cause damage to the wire rope. Be sure to pay attention to inspection when using it.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire. On shipping docks, rigging, and load bearing equipment, wire rope is attached to swivels, shackles, or hooks to lift a load in a controlled, even, and efficient manner.

The uses for wire rope include adding support to suspension bridges, lifting elevators, and serving as additional reinforcement for towers. The design of wire rope, with its multiple strands wrapped around a stable core, provides strength, flexibility, and ease of handling for applications that have bending stress.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of lifting or supportive applications.

The term wire rope encompasses a wide range of mechanical tools that are made to perform heavy and extreme lifting jobs. Wire rope is a complicated and complex tool with multiple moving parts capable of moving in unison. A 6 by 25 wire rope has 150 outer strands that move as one in an intricate pattern supported by a flexible core.

An essential part of the design of wire rope is the required clearance between the strands to give each stand the freedom to move and adjust when the rope bends. It is this unique feature that differentiates wire rope from solid wire and other forms of cable.

The basic element of wire rope is wire that is used to configure, shape, and form the rope. Typically, steel, stainless steel, and galvanized wires are the first choice with aluminum, nickel alloy, bronze, copper, and titanium being second possibilities. The choice of wire is dependent on the type of work the wire is going to be used to perform with strength, flexibility, and abrasion resistance being the major determining factors.

Stainless steel wire rope has all of the basic qualities of galvanized and general wire rope with the added benefits of corrosion and rust resistance; this makes it the ideal choice for harsh and stressful conditions.

Steel wire rope is classified as general purpose wire rope and comes in a wide variety of sizes, diameters, and strengths. It is the most common type of wire rope and is used for several industrial, manufacturing, and construction applications.

Before going further into the discussion of how wire rope is made, it is important to understand the numbers used to describe each type. All wire ropes have a core around which wires are wound. The various styles of cores vary according to the construction and design of the requirements of the wire rope that is being produced.

Wire rope is classified by the number of strands it has as well as the number of wires in each strand. The most common classification is a seven wire rope that has one strand in the center and six around its circumference. This type of wire rope is lightweight with a very simple construction. The majority of wire ropes are more complex and intricate with multiple intertwining strands and wires.

What must be understood about wire rope is that it has a complicated configuration. It is actually wires wrapped around wires to form bundles that are wrapped around other bundles. In the case of a seven wire wire rope, the core has bundles of wires wound around it; this can be seen in the image below.

The first step in wire rope creation is the production of wire strands where wires are wound around a single core wire. The number of wires included in the strand is dependent on the specified strength, flexibility, and size requirements of the rope. Once the strand is completed, it is straightened before being moved to wire rope construction.

Like wire ropes, strands have different patterns; patterns are the arrangements of the wires and their diameters. Though most strands have a core, there are strand patterns that have three or four wires without a core that are referred to as centerless strands. The design of each strand pattern is meant to enhance the strength of the wire rope and improve its performance.

For a multiple layer strand, the layers of wire are placed over one another in successive order. The placement of the wires on top of each other must be such that they fit smoothly and evenly.

The Warrington pattern is like the multiple layer pattern with one variation. Like the multiple layer pattern, the inner wires and the core are the same and have the same diameter. The difference is in the outer layer, which has wires of alternating sizes of large and small with larger diameter wires laying in the valleys of the inner wires.

All of the wires of a filler pattern are the same size. What makes this pattern unique is the insertion of small wires in the valleys of the inner wires to fill the gap between the inner and outer layer.

The flattened strand pattern is also known as the triangular strand, which can be triangular or oval. Three round wires form the core. The outer flattened surface has a greater sectional metallic area; this makes this pattern stronger and longer lasting.

The core of a wire rope runs through the center of the rope and can be composed of a variety of materials, which include synthetic fibers, natural fibers, a single strand, or another wire rope. The core supports the wound strands, helps maintain their position, is an effective lubricant carrier, and provides support.

Wire ropes with fiber cores are restricted to light loads and are not used in severe, harsh, or stressful conditions. Polypropylene and nylon are types of synthetic fiber cores and can be used in conditions where there is exposure to chemicals.

Cores made of wire are classified as independent wire cores. The core of a wire rope with a wire core is actually a wire rope with another wire rope serving as the core, as can be seen in the diagram below. These types of wire ropes are used where the rope will be exposed to exceptional resistance and crushing.

A strand, or wire strand core, is exactly like the rest of the strands of the wire rope with wires of the same diameter and size as the other strands.

The choice of core and creation of the strands are the simplest yet most essential parts of wire rope construction. Wire rope lays, the method used to wind the strands, is more complex and involves several choices.

Lay is a term used to describe three of the main characteristics of wire rope: direction, relationship, and linear distance. The strands can be wrapped around the core going right or left. Right or left refers to the direction of the strands wrapped around the core and the wires within the strands. The linear distance is how far a strand moves when it is making a revolution around the core.

In a regular lay, the wires and strands spiral in opposite directions. With a right hand regular lay, the wires spiral to the left and the strands to the right. In the left hand regular lay, the wires spiral to the right and the strands to the left. This type of lay is easy to handle but wears out quickly because the crown wires are in contact with the bearing surface.

In the Lang, or Albert, lay, the wires and strands spiral in the same direction with right hand lay being the most common. The wires in a Lang lay appear to run parallel to the center line of the rope. The difficulty with Lang lay wire ropes is handling since they tend to kink, twist, and crush.

Wire rope is an exceptionally strong tool that has been configured and designed to withstand the stress placed upon it through rigorous and continual use. In most applications, wire rope has to endure extreme stress and strain. It is for these reasons that coatings have been developed to protect wire rope from abrasions, corrosion, UV rays, and harmful and damaging chemicals.

Three main types of coatings are used to protect wire rope: polyvinyl chloride (PVC), polypropylene, and nylon. Of the three types, PVC is the most popular.

In cases where there are severe and hazardous working conditions, polypropylene is the recommended choice since it is capable of protecting wire rope against corrosion and chemical leaching. Additionally, it is resistant to impact damage and abrasion. Polypropylene is a tough, rigid, and crystalline thermoplastic that is made from a propene monomer and is resilient as well as inexpensive.

Braided wires are electrical conductors made up of small wires that are braided together to form a round tubular braid. The braiding and configuration of braided wire makes them very sturdy such that they do not break when flexed or bent. Braided wires are widely used as conductors, are commonly made from copper due to copper"s exceptional conductivity, and can be bare or coated depending on the application.

Braided wire can be round and tubular or flat. Round tubular braids fit in most spaces where flat braided wire will not. Flat braided wire begins as round braided wire which is flattened on a capstan. They are exceptionally strong and designed for medical and aircraft applications.

Metals used to make wire rope are various grades of stainless steel, bright steel, and galvanized steel. Though the majority of wire rope manufacturers use these three metals, other metals such as copper, aluminum, bronze, and monel are also used on a limited basis.

The most important aspect of wire rope is the wire and the metal from which it is made. The strength and resilience of wire rope is highly dependent on the quality of metal used to make it, and these are essential factors to be considered when purchasing it.

Bright steel wire does not have a coating and is rotation resistant, (designed to not rotate when lifting a load). It is drawn from hot rolled rods that are put through a die to match its specific dimensional tolerances, mechanical properties, and finish. Bright wire is used as a single line in conditions that require a rope that will resist cabling.

Galvanized steel has a zinc coating for corrosion resistance and has the same strength and durability as bright steel. Environmental conditions determine the use of galvanized steel. In mildly severe and slightly harsh conditions, galvanized steel wire is an economical replacement for stainless steel.

In the manufacturing process, galvanized wire goes through the process of galvanization, a method of coating steel wire with a protective and rust resistant metal. Galvanized wire is exceptionally strong, rust resistant, and flexible enough to meet the needs of a variety of applications.

Wire rope made from copper is mostly used for electrical applications due to its exceptional electrical characteristics. The benefits of copper wire rope are its durability, flexibility, and resilience compared to standard copper wire. The strength of copper wire rope is seen in its use in applications where there are vibrations and shaking.

The wire rope lubrication process begins during its fabrication and continues during its use. Lubrication of wire rope is designed to lower the amount of friction it endures and provide corrosion protection. Continued lubrication increases the lifespan of wire rope by preventing it from drying up, rusting, and breaking.

The types of lubricants for wire rope are penetrating or coating with coatings covering and sealing the outside of the rope. Penetrating lubricants go deep into the rope and seep into the core where they evaporate to form a thick coating or film.

The application of the lubricant is dependent on the type of core. Fiber cores absorb the lubricant and serve as a reservoir that retains the lubricant for an extended period of time. With metal cores, the lubricant is applied as the wire is twisted into strands to give complete saturation and coverage of the wires.

There are several types of greases that are used as wire rope lubricating agents and are made up of oil, a thickener, and additives. The essential components are the base oil and additives, which influence the behavior of the grease. The thickener holds the base oil and additives together. The amount of base oil in a grease is between 70% and 95% with an additive of 10%.

The additive in grease enhances the positive properties of the oil and suppresses the negative properties. Common additives are oxidation and rust inhibitors as well as pressure, wear, and friction reducing agents.

Of the many choices for lubricants, vegetable oil is the easiest to use and penetrates the deepest. The design of the additives for vegetable oils gives them the necessary qualities required to penetrate deep into a wire rope. The exceptional penetration provides protection against wear and corrosion. Since vegetable oil is a fluid, it helps in washing the wire rope to remove external abrasive contaminants.

Wire rope is widely used in machines, structures, and varied lifting applications. Its type, size, and requirements are determined by how it will be used. Regardless of its use, wire rope guarantees exceptional strength and provides high quality and excellent performance.

The lifting of heavy loads for centuries involved the use of hemp rope or chains, neither of which was a guaranteed or substantial method. Early in the 18th Century, between 1824 and 1838, Wilhelm Albert, a German mining engineer, combined the twisting of hemp and strength of chains to create today‘s wire rope.

The most common use of wire rope is as a part of a crane hoist wherein it is attached to the hook of the hoist and wrapped around a grooved drum. The tensile strength and durability of wire rope makes an ideal tool for lifting and keeping loads secure. Though it is used in several industries, it is very popular for production environments wherein materials need to be lifted quickly and efficiently.

In addition to its many lifting applications, the strength and stability of wire rope is useful in other applications, especially in the aerospace industry. Pedals, levers, and connectors in the cockpit of an aircraft are connected with wire rope. The wires provide for the passage of power between systems and mechanisms; this allows control of the aircraft. Wire rope is used to control propeller pitch, cowl flaps, and the throttle. It also assists in lowering and minimizing vibrations.

Tires are reinforced with wire rope to increase their durability and strength. All automotive production environments make use of wire ropes for supplying materials, moving heaving loads, and positioning equipment. Wire rope can be found in the production of steering wheels, cables, exhausts, springs, sunroofs, doors, and seating components.

As surprising as it may seem, the place that wire rope has the greatest use is in the home, where its strength, long life, endurance, and resilience provide guaranteed protection and performance. The main reason wire ropes are so popular for home use is cost.

Inexpensive, easy to obtain, easy to install, and easy to maintain, wire ropes provide an additional method for performing home repairs and structural support. Their excellent flexibility and sturdiness combined with their invisibility has made wire rope an ideal solution to several home maintenance issues. It is used to support staircases, fences, decks, and hang plants.

The search and production of crude oil has relied on wire ropes for centuries to lift drill bits, insert shafts, and support oil rigs on land and the water. When equipment, machinery, and tools have to be lowered into the depths of the earth and sea, wire ropes are the tool that the oil industry relies on to do the job.

Many of the tasks of oil production require tools that are capable of enduring severe and harsh conditions. Wire ropes have to withstand enormous pressure, extraordinary stress, and a wide range of temperatures. The use of wire rope includes maintaining oil rig stability and moorings for offshore rigs.

Wire rope has long been a standard component for the transportation industry, from the cable cars of San Francisco to the lift chairs for ski resorts. For many years, cable cars have relied on heavy duty cables (wire ropes) to be pulled by a central motor from multiple locations. It is a method of transportation that has existed for centuries.

In Europe, funiculars use cables that hang from a support to move cars up and down a mountain with cables moving in opposite directions. The word funicular is from the French word funiculaire, meaning railway by cable. The terms wire rope and cable are used interchangeably when discussed by professionals. The first part of funicular, or funiculaire, is from the Latin word "funis," meaning rope.

The major use for wire ropes in the food and beverage industries is as a means for lifting and moving heavy loads. Wine barrels and containers full of ingredients are lifted and placed through use of cranes and wire ropes. They are also part of conveyor systems that move products from one station to another.

From the beginnings of amusement rides up to the present, wire ropes have been an essential part of attraction construction and safety. They pull cars on roller coasters, hold cabins that swing, and move carriages through haunted houses. The main concern of amusement parks is safety. The strength, stability, and guaranteed performance of wire ropes ensures that people who attend amusement parks will have a good time and stay safe.

The rigging used to complete the stunts in modern movies depends on wire rope for safety. Much like in amusement rides, wire ropes protect performers from injury and harm as they hang above a scene or carry out an impossible move.

The live theater industry uses wire ropes to raise and lower curtains, support overhead rigging, and hold backdrops and scenery pieces. During a production, rapid and efficient movement is a necessity that is facilitated by the use of wire ropes.

Wire rope is a tool that we tend to envision as indestructible, unable to succumb to any form of damage. Though it is exceptionally sturdy and strong as well as capable of enduring constant use, it is just as susceptible to breakdown as any other tool.

To avoid serious harm and damage, wire ropes should be scheduled for regular inspections. There are situations that can damage or break a wire rope; these should be understood prior to the problem arising.

Guide rollers have the potential to damage and cause abrasions on wire rope if they become rough and uneven. Of the various elements of a crane and lift, guide rollers have the greatest contact with the mechanism‘s wire rope. Regular inspection of guide rollers will ensure they are not damaging the rope or causing abrasions.

Bending is normally a regular part of wire rope usage; this occurs repetitively as the rope passes through a sheave. As a wire rope traverses the sheave, it is continually bent and develops cracks or breaks. The cracking and breaking are exacerbated by movement on and off the groove of the drum. Normally, the breakage happens on the surface and is visible. Once it appears, it accelerates to the core of the rope.

A bird cage is caused by a sudden release of tension and a rebound of the rope. This type of break requires that the rope be replaced since the place of the break will not return to its normal condition.

Wire ropes are multi-layered; this makes them flexible and torque balanced. The layering inside and outside creates flexibility and wear resistance. Relative motion between the wires causes wear over time, which leads to internal breakage. The detection of these breaks can be indicated by an electromagnetic inspection that calculates the diameter of the rope.

Kinked wire rope is caused by pulling a loop on a slack line during installation or operation; this causes a distortion in the strands and wires. This is a serious condition that necessitates rope replacement.

Corrosion damage is the most difficult cause of wire rope damage to identify, which makes it the most dangerous. The main reason for corrosion is poor lubrication that can be seen in the pitted surface of the rope.

The types of damage and problems listed here are only a small portion of the problems that can be caused if a wire rope is not regularly lubricated and inspected. Various regulatory agencies require that wire ropes be inspected weekly or monthly and provide a list of factors to examine.

As with any type of heavy duty equipment, wire rope is required to adhere to a set of regulations or standards that monitor and control its use for safety and quality reasons. The two organizations that provide guidelines for wire rope use are the American Society of Mechanical Engineers (ASME) and the Occupational Safety and Health Administration (OSHA).

All wire rope manufacturers and users closely follow the standards and guidelines established by OSHA and ASME. In the majority of cases, they will identify the specific standards they are following in regard to their products.

OSHA‘s regulations regarding wire rope fall under sections 1910, 1915, and 1926, with the majority of the stipulations listed in 1926 under material handling, storage, use, and disposal.

"Running rope in service shall be visually inspected daily, unless a qualified person determines it should be performed more frequently. The visual inspection shall consist of observation of all rope that can reasonably be expected to be in use during the day‘s operations. The inspector should focus on discovering gross damage that may be an immediate hazard."

"The inspection frequency shall be based on such factors as rope life on the particular installation or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. Close visual inspection of the entire rope length shall be made to evaluate inspection and removal criteria."

ASTM A1023 covers the requirements for steel wire ropes with specifications for various grades and constructions from ¼ in. (6 mm) to 31/2 in. (89 mm) manufactured from uncoated or metallic coated wire. Included are cord products from 1/32 in. (0.8 mm) to 3/8 in. (10 mm) made from metallic coated wire.

United States Federal Spec RR W 410 covers wire ropes and wire seizing strands but does not include all types, classes, constructions, and sizes of wire rope and strands that are available. The purpose of Spec RR W 410 is to cover more common types, classes, constructions, and sizes suitable for federal government use.

Wire rope and wire seizing strand covered by United States Federal Spec RR W 410 are intended for use in general hauling, hoisting, lifting, transporting, well drilling, in passenger and freight elevators, and for marine mooring, towing, trawling, and similar work, none of which are for use with aircraft.

API 9A lists the minimum standards required for use of wire rope for the petroleum and natural gas industries. The types of applications include tubing lines, rod hanger lines, sand lines, cable-tool drilling and clean out lines, cable tool casing lines, rotary drilling lines, winch lines, horse head pumping unit lines, torpedo lines, mast-raising lines, guideline tensioner lines, riser tensioner lines, and mooring and anchor lines. Well serving wire ropes such as lifting slings and well measuring are also included in API 9A.

Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire.

Individual designs of wire rope involve different materials, wire, and strand configurations as a means for supporting and assisting in the completion of a lifting or supportive task.

Cranes which are operated at least once per month, otherwise known as cranes in regular service, need to be inspected on a regular basis at intervals that depend on a few factors. Overhead crane inspection is done either at “frequent” intervals or “periodic” intervals based on the integral components, the degree of the crane’s exposure to wear and tear, and how many malfunctions the crane is subject to. crane inspections are required to be done by a qualified person who must then ascertain if any deficiencies seen are safety hazards. “Frequent” overhead crane inspections pertain to the operating mechanisms, hydraulic systems, hooks, and hoist chains. They can be inspected visually and OSHA recommends doing so daily, before every shift. Hoist equipment in particular needs to be inspected by a certified overhead crane inspector and must keep a written record. Periodic inspections cover bolts, sheaves, locking devices, braking systems, load indicators, power-plants, and electrical wiring. Periodic inspections should be conducted yearly for normal or heavily used cranes. Cranes with severe service should be inspected quarterly.

An overhead crane that is used infrequently or which has been idle for a period of one month or more but less than one year, shall be inspected before being placed in service using the guidelines outlined in Frequent Inspection.

Wire rope installed on a crane should not be left unused for more than 1 month at a time without being inspected again before use. A qualified person must inspect the wire rope and certify it’s inspection with his/her signature. The qualified person should check the wire rope for a reduction in rope diameter, broken or worn outside wires, corroded wire, and kinked or crushed wire.