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  Return to Wire Rope Main Page and Detailed Wire Rope Data  
    Technical Information  
  Use and Care of Wire Rope  
  Wire Rope is a Machine  
    Installation of Wire Rope:  
  Foreword, Measuring the rope diameter  
  If you have to cut a rope  
  Unreeling the rope  
  Connecting the old rope to the new rope  
  Rope lay direction versus Drum Grooving  
  Winding on to the drum  
  Installation of Wedge Sockets  
  Using your rope for the first time  
  Efficiency ratings of end terminations  
    Inspection of Wire Rope:  
  How to inspect Wire Rope  
  Crown- and Valley Wire Breaks  
  Number of broken Wire Discard Tables  
  Reduction of diameter, Rope Wear  
  Rope Stretch, Core Wire breaks  
  Mechanical damages  
  Corrosion, Rope Removal and Cause  
  Inspection of Sheaves and Drums, Dimensions of Groove Radius  
  Cut and Slip Procedure, Lubrication  
    Rope Properties & Data:  
  Tensile Strength and Fill Factor  
  Strand- and Swage Compaction  
  Rotation Resistant and Non-Rotating Wire Rope  
  Sheave and Drum Dimensions  
  Relative Service Life, Loss of Strength over Pins, Why Multistrand Ropes  
Technical Information – Inspection of Wire Rope
  to Technical Information Main Page

It is essential to maintain a well planed program of periodic inspections. In most cases there are statutory and/or regulatory agencies whose requirements must be adhered to.

Whether or not such requirements exist in your specific environment, you can be guided by the suggested procedures that follows.

Abrasion, Bending and Crushing represent the ABC's of wire rope abuse, and it is the primary goal of good inspection practice to discover such conditions with minimum effort. When any degradation indicates a loss of original rope strength, a decision must be made quickly to allow the rope to remain in service. Such a decision can only be made by an experienced inspector. His determination will be based on:

1)   Details of the equipment's operation
2)   Frequency of inspection
3)   Maintenance history
4)   Consequences of failure
5)   Historical records of similar equipment
  Broken Wires

Shortly after installation

The occasional premature failure of a single wire may be found early in the rope life and in most cases it should not constitute a basis for rope removal. Note the area and watch carefully for any further wire breaks. Remove the broken ends by bending the wire backwards and forwards. In this way the wire is more likely to break inside the rope where the ends are left tucked away between the strands. These infrequent premature wire breaks are not caused by fatigue of the wire material.

During wire rope service (Fatigue Breaks)

The rope must be replaced if a certain number of broken wires are found which indicate that the rope has reached its finite fatigue life span. See Broken Wire Discard Tables.
Areas to examine
(Based on ISO 4309)

Examine termination of the rope.

Examine for defective coiling, which causes deformation (flattened portions) and wear, which can be severe at cross-over positions. (cross-overs only if multiple layer drums).

Examine for wire breaks.

Examine for corrosion.

Look for deformations caused by snatch loading.

Examine portion which winds over sheave for wire breaks and wear.
Check section of rope on equalizer sheave (or compensating pulley) by lifting up the rope to look at the underside.

Look for deformation.

Check rope diameter against original wire rope diameter. Keep record of rope diameter measured after break in period. Note that shortly after installation rope diameter will slightly decrease.

Examine carefully length which runs through lower sheave block, particularly that section which is in contact with the pulley when the crane is in a loaded condition.

Examine for wire breaks or surface wear.
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