overhead crane wire rope inspection in stock

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.

“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.”

Any wire rope in use should be inspected on a regular basis. You have too much at stake in lives and equipment to ignore thorough examination of the rope at prescribed intervals.

The purpose of inspection is to accurately estimate the service life and strength remaining in a rope so that maximum service can be had within the limits of safety. Results of the inspection should be recorded to provide a history of rope performance on a particular job.

On most jobs wire rope must be replaced before there is any risk of failure. A rope broken in service can destroy machinery and curtail production. It can also kill.

Because of the great responsibility involved in ensuring safe rigging on equipment, the person assigned to inspect should know wire rope and its operation thoroughly. Inspections should be made periodically and before each use, and the results recorded.

When inspecting the rope, the condition of the drum, sheaves, guards, cable clamps and other end fittings should be noted. The condition of these parts affects rope wear: any defects detected should be repaired.

To ensure rope soundness between inspections, all workers should participate. The operator can be most helpful by watching the ropes under his control. If any accident involving the ropes occurs, the operator should immediately shut down his equipment and report the accident to his supervisor. The equipment should be inspected before resuming operation.

The Occupational Safety and Health Act has made periodic inspection mandatory for most wire rope applications. If you need help locating the regulations that apply to your application, please give our rigging experts a call.

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!

Maintain a record for each rope that includes the date of inspection, type of inspection, the name of the person who performed the inspection, and inspection results.

Use the "rag-and-visual" method to check for external damage. Grab the rope lightly and with a rag or cotton cloth, move the rag slowly along the wire. Broken wires will often "porcupine" (stick out) and these broken wires will snag on the rag. If the cloth catches, stop and visually assess the rope. It is also important to visually inspect the wire (without a rag). Some wire breaks will not porcupine.

Measure the rope diameter. Compare the rope diameter measurements with the original diameter. If the measurements are different, this change indicates external and/or internal rope damage.

Visually check for abrasions, corrosion, pitting, and lubrication inside the rope. Insert a marlin spike beneath two strands and rotate to lift strands and open rope.

Assess the condition of the rope at the section showing the most wear. Discard a wire rope if you find any of the following conditions:In running ropes (wound on drums or passed over sheaves), 6 or more broken wires in one rope lay length; 3 or more broken wires in one strand in one rope lay. (One rope lay is the distance necessary to complete one turn of the strand around the diameter of the rope.)

Corrosion from lack of lubrication and exposure to heat or moisture (e.g., wire rope shows signs of pitting). A fibre core rope will dry out and break at temperatures above 120°C (250°F).

Kinks from the improper installation of new rope, the sudden release of a load or knots made to shorten a rope. A kink cannot be removed without creating a weak section. Discarding kinked rope is best.

A 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.

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.

The most common repair made on Overhead Cranes is the replacement of wire rope. Though a consumable item, wire rope is very often misused, says Cliff Dickinson of CIS. It’s spooled incorrectly on drums and in so doing, gets damaged. The cause is often incorrect operation, Such as side loading.  Training can help with that, he says. CIS offers training for proper overhead crane operation, and crane inspections, maintenance, and repair services.

Manufacturing facilities, utility plants, military bases, or military providers all utilize overhead cranes, and the machines require regular inspections to make sure they’re in proper working order. “We do monthly inspections as part of a normal safety routine, unless they’ve had an incident that requires inspection in between scheduled times. We supply documentation, as well, for the monthly inspections,” he says.

Repairs are done at the crane’s location by CIS staff. If, for example, a bar system or wire rope needs to be replaced, a CIS techician will go out to the site and take measurements, determine what replacement components are needed, and order components for the customer. Once parts are in, it’s a matter of removing old components and installing new.

The largest part of the CIS overhead crane service involves preventive maintenance on a contract basis. ”CIS has offered overhead crane services since 2008, and the work is always done in accordance with accepted industry ASME standards, OSHA regulations, and manufacturers recommendations.” says Cliff Dickinson.

When clients need it, CIS will also assess safety or productivity issues as they relate to overhead crane operation. That includes training. Personnel turnover may be part of the problem with decreased overhead crane life, says Cliff Dickinson. Operators who know how to operate an overhead crane correctly are safer and have better productivity.  “We will do training for operators and rigging crews, and typically that’s one in the same in a lot of facilities,” explains Debbie Dickinson, CEO of CIS. “We do the consulting for their training, teaching employees to use machines the efficiently to keep them in good working order and to use the overhead cranes with skill.”

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.

Wire Rope Inspection Services in the oil and gas industry with the use ofLRM®XXI Diagnostic System allows to get information about the technical condition of wire rope in full cross section and in full available length of wire rope in the fastest way.

With regular periodic wire rope inspection combined with data utilization of crane the it is possible to estimate the remaining lifetime of crane wires.

Due to cooperation with Laboratory LRM-NDE with success offshore companies has implemented inspections of cranes wire ropes with the use of LRM®XXI Diagnostic System according to MRT Examination procedure and international standards for offshore fleet.

In reasonable notice can be predicted and scheduled necessary activities in crane maintenance, it allows to increase operation safety and fleet availability during project.

Long-term cooperation with offshore companies has allowed Laboratory LRM-NDE to achieve the knowledge and necessary competence to design wire rope diagnostic system equipment that can meet the harsh environmental conditions at sea.

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.